2004 YAMAHA YZF-R1S Service Manual

1-9
SPECIAL TOOLS
GEN
INFO
NOTE:
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.

For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.

For others, use part number starting with “90890-”.
Tool No.
Tool name / FunctionIllustration
90890-01304
YU-01304
Piston pin puller
This tool is used to remove the piston pins.
Radiator cap tester
90890-01325
YU-24460-01
Adapter
90890-01352
YU-33984Radiator cap tester
Radiator cap tester adapter
These tools are used to check the cooling
system.
90890-01403
YU-33975
Steering nut wrench
This tool is used to loosen or tighten the
steering stem ring nuts.
90890-01423
YM-01423
Damper rod holder
This tool is used to hold the damper rod as-
sembly when loosening or tightening the
damper rod assembly bolt.
90890-01426
YU-38411
Oil filter wrench
This tool is needed to loosen or tighten the
oil filter cartridge.
90890-01434
YM-01434
Rod holder
This tool is used to support the damper ad-
justing rod.
Rod puller
90890-01437
YM-01437
Rod puller
attachment
90890-01436
YM-01436Rod puller
Rod puller attachment
These tools are used to pull up the front
fork damper rod.
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1-10
SPECIAL TOOLS
GEN
INFO
Tool No.Tool name / FunctionIllustration
90890-01441
YM-01441
Fork spring compressor
This tool is used to disassemble or
assemble the front fork legs.
90890-01442
YM-01442
Fork seal driver
This tool is used to install the front fork’s oil
seal and dust seal.
90890-03094
YU-08030
Vacuum gauge
This guide is used to synchronize the car-
buretors.
Compression
gauge
90890-03081
YU-33223
Adapter
90890-04136Compression gauge
Compression gauge adapter
These tools are used to measure engine
compression.
Valve spring compressor
90890-04019
YM-04019
Attachment
90890-04108
YM-01253
90890-04114
YM-4114Valve spring compressor
Valve spring compressor attachment
These tools are used to remove or install
the valve assemblies.
Middle driven shaft
bearing driver
90890-04058
YM-4058
Mechanical seal
installer
90890-04078
YM-33221Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the water
pump seal.
90890-04086
YM-91042
Clutch holding tool
This tool is used to hold the clutch boss
when removing or installing the clutch boss
nut.
90890-04111
90890-04116
YM-4116
Valve guide remover
This tool is used to remove or install the
valve guides.
90890-04112
90890-04117
YM-4117
Valve guide installer
This tool is used to install the valve guides.
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1-11
SPECIAL TOOLS
GEN
INFO
Tool No.Tool name / FunctionIllustration
90890-04113
YM-04113
90890-04118
YM-4118Valve guide reamer
This tool is used to rebore the new valve
guides.
90890-06754
YM-34487
Ignition checker
This tool is used to check the ignition sys-
tem components.
90890-85505
ACC-1109-0501
Yamaha bond No. 1215
This bond is used to seal two mating sur-
faces (e.g., crankcase mating surfaces).
90890-03174
Digital circuit tester
This tool is used to check the electrical sys-
tem.
Pivot shaft wrench
90890-01471
YM-01471
Pivot shaft wrench
adapter
90890-01476Pivot shaft wrench
Pivot shaft wrench adapter
This tool is need to loosen or tighten the
spacer bolt.
90890-03132
YU-3112
Pocket tester
This instrument is needed for checking the
engine oil temperature.
Oil pressure
gauge
90890-03153
YU-03153
Adapter
90890-03139Oil pressure gauge
Adapter
These tools are used to measure engine oil
pressure.
90890-06756
Vacuum/pressure pump gauge set
This tool used to measure the vacuum pres-
sure.
90793-80009
Engine tachometer
This tool is needed for observing engine
rpm.
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1-12
SPECIAL TOOLS
GEN
INFO
Tool No.Tool name / FunctionIllustration
90890-04101
Valve lapper
This tool is needed to remove and install
the valve lifter.
90890-03176
YM-03176
Fuel pressure adapter
This tool is needed to measure fuel pres-
sure.
90890-03153
YU-03153
Pressure gauge
This tool is used to measure fuel pressure.
90890-04143
YM-04143
Camshaft wrench
This tool is used to hold and rotate the cam-
shaft sprocket.
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2-1
GENERAL SPECIFICATIONSSPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
ItemStandardLimit
Model code5VY4 (USA), 5VY5 (CAL)



Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,065 mm (8.13 in)
720 mm (28.3 in)
1,105 mm (43.5 in)
835 mm (32.9 in)
1,395 mm (54.9 in)
135 mm (5.31 in)
3,400 mm (133.9 in)



























Weight
Wet (with oil and a full fuel tank)
Maximum load (except motorcycle)
193 kg (425 lb) (USA)
194 kg (428 lb) (CAL)
202 kg (445 lb) (USA)
201 kg (443 lb) (CAL)







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2-2
ENGINE SPECIFICATIONSSPEC
2
ENGINE SPECIFICATIONS
ItemStandardLimit
Engine
Engine type
Displacement
Cylinder arrangement
Bore
stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Liquid-cooled, 4-stroke, DOHC
998 cm3 (60.90 cu.in)
Forward-inclined parallel 4-cylinder
77.0
53.6 mm (3.03
2.11 in)
12.4 : 1
1,150  1,250 r / min
22 kPa (165 mmHg, 6.5 inHg)
1,480 kPa (14.80 kg / cm
2,14.80 bar,
210.5 psi) at 350 r / min
































Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Premium unleaded gasoline only
18 L (3.96 Imp gal, 4.76 US gal)
3.4 L (0.75 Imp gal, 0.90 US gal)











Engine oil
Lubrication system
Recommended oil
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure
Engine oil temperature
Relief valve opening pressure
Wet sump
At 5C (40F) or higher
Yamalube 4 (20W40) or SAE 20W40
type SE motor oil
At 15C (60F) or lower
Yamalube 4 (10W30) or SAE 10W30
type SE motor oil
3.8 L (3.35 Imp qt, 4.02 US qt)
2.9 L (2.55 Imp qt, 3.07 US qt)
3.1 L (2.73 Imp qt, 3.28 US qt)
230 kPa at 5,000 r / min
(2.3 kg / cm
2 at 5,000 r / min)
(2.3 bar at 5,000 r / min)
(32.7 psi at 5,000 r / min)
100C (212F)
600  680 kPa (6.0  6.8 kg / cm
2,
6.0  6.8 bar, 87.0  98.6 psi)
























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2-3
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Oil filter
Oil filter type
Bypass valve opening pressure
Paper
80  120 kPa (0.8  1.2 kg / cm2,
0.8  1.2 bar, 11.6  17.4 psi)








Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip
clearance
Outer-rotor-to-oil-pump-housing
clearance
Trochoid
0.01  0.10 mm
(0.0004  0.0039 in)
0.09  0.15 mm
(0.00035  0.0059 in)



0.18 mm
(0.0071 in)
0.22 mm
(0.0087 in)
Cooling system
Radiator capacity
Radiator cap opening pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity
Water pump
Water pump type
Reduction ratio
Max. impeller shaft tilt
2.51 L (2.21 Imp qt, 2.65 US qt)
108  137 kPa (1.08  1.37 kg / cm2,
1.0  1.3 bar, 15.6  19.9 psi)
380 mm (14.96 in)
258 mm (10.2 in)
24 mm (0.94 in)
0.25 L (0.22 Imp qt, 0.26 US qt)
Single suction centrifugal pump
65 / 43
25 / 32 (1.181)































0.15 mm
(0.006 in)
Starting system typeElectric starter
Spark plugs
Model (manufacturer)
quantity
Spark plug gap
CR9EK (NGK)
4
0.6  0.7 mm (0.0236  0.0276 in)







Cylinder head
Volume
Max. warpage
12.5  13.1 cm3 (0.76  0.80 cu.in)







0.10 mm
(0.0039 in)
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2-4
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-
cap clearance
Intake camshaft lobe dimensions
Measurement A
Measurement B
Exhaust camshaft lobe dimensions
Measurement A
Measurement B
Max. camshaft runout
Chain drive (right)
22.500  22.521 mm (0.8858  0.8867 in)
22.459  22.472 mm (0.8842  0.8847 in)
0.028  0.062 mm (0.0011  0.0024 in)
32.85  32.95 mm (1.293  1.297 in)
25.14  25.24 mm (0.990  0.994 in)
30.75  30.85 mm (1.211  1.215 in)
23.09  23.19 mm (0.909  0.913 in)















32.75 mm
(1.289 in)
25.04 mm
(0.986 in)
30.65 mm
(1.207 in)
22.99 mm
(0.905 in)
0.03 mm
(0.0012 in)
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