2004 YAMAHA YZF-R1S check engine

3-41
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
NOTE:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.

Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.

If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.

Do not mix different types of antifreeze.
13. Install:

radiator cap
14. Fill:

coolant reservoir tank
(with the recommended coolant to the maxi-
mum level mark
a)
15. Install:

coolant reservoir cap
16. Start the engine, warm it up for several min-
utes, and then stop it.
17. Check:

coolant level
Refer to “CHECKING THE COOLANT LEV-
EL”.
Before checking the coolant level, wait a few
minutes until the coolant has settled.
18. Install:

rider seat
Refer to “SEATS”.

bottom cowlings

side cowlings
Refer to “COWLINGS”.
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3-49
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
NOTE:
CAUTION:
WARNING
NOTE:
EAS00140
ADJUSTING THE DRIVE CHAIN SLACK
The drive chain slack must be checked at the
tightest point on the chain.
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swin-
garm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Spin the rear wheel several times and find
the tightest position of drive chain.
3. Check:

drive chain slack
a
Out of specification
Adjust.
Drive chain slack
25
35 mm (0.98
1.38 in)
4. Adjust:

drive chain slack
a. Loosen the wheel axle nut
1.
b. Loosen both locknuts
2.
c. Turn both adjusting bolts
3 in direction a or
b until the specified drive chain slack is ob-
tained.
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3-61
CHECKING AND LUBRICATING THE CABLES /
LUBRICATING THE LEVERS AND PEDALS /
LUBRICATING THE SIDESTAND / LUBRICATING THE REAR SUSPENSIONCHK
ADJ
WARNING
NOTE:
EAS00170
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the in-
ner and outer cables.
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
1. Check:

outer cable
Damage
Replace.
2. Check:

cable operation
Rough movement
Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.
EAS00171
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Recommended lubricant
Lithium-soap-based grease
EAS00172
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
Lithium-soap-based grease
EAS00174
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.
Recommended lubricant
Molybdenum-disulfide grease
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4-74
SWINGARM AND DRIVE CHAINCHAS
CAUTION:
2. Check:

drive chain
Stiffness
Clean and lubricate or replace.
3. Clean:

drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
This motorcycle has a drive chain with small
rubber O-rings
1 between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean the
drive chain. High-pressure methods could
force dirt or water into the drive chain’s in-
ternals, and solvents will deteriorate the O-
rings. A coarse brush can also damage the
O-rings. Therefore, use only kerosene to
clean the drive chain. Don’t soak drive chain
in kerosine more them ten minutes. O-ring is
damage by kerosine.
4. Check:

O-rings
1
Damage
Replace the drive chain.

drive chain rollers
2
Damage / wear
Replace the drive chain.

drive chain side plates
3
Damage / wear
Replace the drive chain.
Cracks
Replace the drive chain and make
sure the battery breather hose is properly
routed away from the drive chain and below
the swingarm.
5. Lubricate:

drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
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5-18
CAMSHAFTENG
NOTE:
NOTE:
NOTE:
3. Install:

timing chain tensioner spring

timing chain tension rod
1
Prior to installing the timing chain tensioner rod,
drain the engine oil from the timing chain ten-
sioner housing.
a. Install the timing chain tensioner spring and
timing chain tensioner rod
1.
b. Squeeze the timing chain tensioner clip
2
and push the timing chain tensioner rod 3.
When the timing chain tensioner rod
3 is
pushed while holding the grip of the timing chain
tensioner clip
2, make sure not to release the
timing chain tensioner rod
3 before releasing
the timing chain tensioner clip
2. (Otherwise,
the timing chain tensioner rod
3 may run off.)
c. Hook the clip
4 to the timing chain tensioner
rod
3.
Hook the timing chain tensioner rod pin
5 to the
center of the clip
4. After the installation, check
that the clip
4 can come off by its own weight by
pushing the timing chain tensioner rod
3 at the
position of installation.
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5-24
CYLINDER HEADENG
8 Nm (0.8 m
kg, 5.8 ft
lb)
NOTE:
NOTE:
19 Nm (1.9 m
kg, 14 ft
lb)
67 Nm (6.7 m
kg, 48 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
NOTE:
EAS00233
INSTALLING THE CYLINDER HEAD
1. Check:

cylinder head bolts
1
Retighten the cylinder head bolts to specifica-
tion, before installing the cylinder head.
2. Install:

gasket
New
1

dowel pins
3. Install:

cylinder head
Pass the timing chain through the timing chain
cavity.
4. Tighten:

cylinder head nuts
1
10
1st
2nd

cylinder head bolts
11 12

First, tighten the nuts 1
10 to approximate-
ly 19 Nm (1.9 m
kg, 14 ft
lb) with a torque
wrench, and then tighten the 67 Nm (6.7 m
kg,
48 ft
lb).

Lubricate the cylinder head nuts with engine
oil.

Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.
5. Install:

exhaust camshaft

intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”.
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5-41
STARTER CLUTCH AND GENERATORENG
NOTE:
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
INSTALLING THE STARTER CLUTCH
1. Install:

generator rotor
1

damper 2

driven gear 3

The hole side of the damper is installed to the
generator side.

Lubricate the engine oil
4.
2. Install:

starter clutch drive gear
1

collar 2

washer 3
Refer to “CHECKING THE STARTER
CLUTCH”.
3. Install:

washer
1

O-ring 2 New

spacer
3
Lubricate the engine oil to O-ring.
INSTALLING THE GENERATOR
1. Install:

idle gear shaft

idle gear
1

washer

idle gear shaft bolt
2
LOCTITE
2. Install:

generator rotor and starter clutch assembly
1
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5-54
CLUTCHENG
NOTE:
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:

pressure plate
1
Cracks / damage
Replace.

bearing
2
Damage / wear
Replace.
EAS00287
CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:

pull lever shaft pinion gear teeth
1

pull rod teeth 2
Damage / wear
Replace the pull rod and
pull lever shaft pinion gear as a set.
2. Check:

pull rod bearing
Damage / wear
Replace.
INSTALLING THE CLUTCH
1. Install:

clutch damper spring seat
1

clutch damper spring 2
2. Install:

friction plate 3
1

clutch plate 2 2
Lubricate the engine oil.
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