2004 YAMAHA YZF-R1S light

4-27
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
NOTE:
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Disconnect:

brake light switch connector
1
(from the brake light switch)
2. Remove:

union bolt
2

copper washers 3

brake hose 4
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
3. Remove :

brake master cylinder bracket

brake master cylinder assembly
4. Remove :

dust boot

circlip
EAS00589
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:

union bolt
1

copper washers 2

brake hose 3
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
2. Remove :

brake master cylinder assembly
3. Remove :

dust boot

circlip
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4-29
FRONT AND REAR BRAKESCHAS
WARNING
13 Nm (1.3 m
kg, 9.4 ft
lb)
NOTE:
30 Nm (3.0 m
kg, 22 ft
lb)
WARNING
EAS00607
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER

Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.

Never use solvents on internal brake com-
ponents.
Recommended brake fluid
DOT 4
1. Install :

brake master cylinder kit

circlip
New

dust boot
2. Install:

brake master cylinder
1

Install the brake master cylinder holder with
the “UP” mark
a facing up.

Align the end of the brake master cylinder
holder with the punch mark
b on the right han-
dlebar.

First, tighten the upper bolt, then the lower bolt.
There should be 2
2.5 mm (0.08
0.10 in)
for clearance between the right handlebar
switch and the brake master cylinder holder.
3. Install:

copper washers
New

brake hose

union bolt

brake light switch coupler
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
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4-32
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:

brake fluid level
Below the minimum level mark
a
Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Adjust:

rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
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4-56
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15Removing the handlebars
Front cowling and side cowling
Left grip end
Handlebar grip
Clutch switch connector
Left handlebar switch
Clutch cable
Clutch lever
Right grip end
Throttle cable housing
Throttle cable
Throttle grip
Front brake light switch connector
Right handlebar switch
Clutch cable holder
Brake fluid reservoir tank
Brake master cylinder bracket1
1
2
1
1
1
1
1
2
1
2
1
1
1
1Remove the parts in the order listed.
Refer to “COWLINGS” in chapter 3.
Disconnect.
Disconnect.
113 Nm (11.3 m
kg, 82 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
11 Nm (1.1 m
kg, 8.0 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)3.8 Nm (0.38 m
kg, 2.7 ft
lb)
3.8 Nm (0.38 m
kg, 2.7 ft
lb)
3.8 Nm (0.38 m
kg, 2.7 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
26 Nm (2.6 m
kg, 19 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
HANDLEBARSCHAS
EAS00665
HANDLEBARS
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5-31
VALVES AND VALVE SPRINGSENG
CAUTION:
NOTE:
a. Apply a coarse lapping compound a to the
valve face.
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hands.
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) onto
the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width
a again. If the
valve seat width is out of specification, reface
and lap the valve seat.
EAS00241
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:

valve spring free length
a
Out of specification
Replace the valve
spring.
Valve spring free length
Intake valve spring
39.3 mm (1.55 in)
: 37.3 mm (1.47 in)
Exhaust valve spring
39.3 mm (1.55 in)
: 37.3 mm (1.47 in)
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5-34
VALVES AND VALVE SPRINGSENG
CAUTION:
NOTE: 5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
Hitting the valve tip with excessive force
could damage the valve.
6. Install:

valve pad
1

valve lifter 2

Lubricate the valve lifter and valve pad with
molybdenum disulfide oil.

The valve lifter must move smoothly when ro-
tated with a finger.

Each valve lifter and valve pad must be rein-
stalled in its original position.
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7-1
FUEL INJECTION SYSTEMFI
19Atmospheric pressure
sensor
20Fuel injection system
relay
21Engine trouble warning
light
22Lean angle cut-off
switch
23Air cut-off valve
13Coolant temperature
sensor
14Spark plug
15Cylinder identification
sensor
16Pressure regulator
17Battery
18ECU
1Ignition coil
2Air filter case
3Intake temperature
sensor
4Fuel delivery hose
5Fuel tank
6Fuel pump
7Fuel return hose
8Intake air presure sen-
sor
9Throttle position sen-
sor
10Fuel injector
11Catalytic converter
12Crankshaft position
sensor
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
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7-4
30: Lean angle cut-off switch
(latch up detected)
41: Lean angle cut-off switch
(open or short circuit)
50: ECU internal malfunction
(memory check error)
FUEL INJECTION SYSTEMFI
EAS00899
ECU’S SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is
stored in the memory of the ECU.

To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes when the start switch is being pushed to start the engine.

If a malfunction is detected in the system by the self-diagnostic function, this mode provides an ap-
propriate substitute characteristic operation, and alerts the rider of the detected malfunction by illumi-
nating an engine trouble warning light.

After the engine has been stopped, the fault code number appears from the lowest value in order of
precedence on the LCD meter. Once a fault code has been displayed, it remains stored in the memory
of the ECU until it is deleted.
EAS00900
Engine trouble warning light indication and FI system operating condition
Warning light
indication
ECU’s operationFI operationVehicle operation
Flashing*Warning provided
when unable to start
engineOperation stoppedUnable
Remains ONMalfunction detectedOperated with
substitute
characteristics
in accordance with the
description of the
malfunctionAble / Unable depend-
ing on the self-diag-
nostic fault code
* The warning light flashes when any one of the conditions listed below is present and the start switch is
pushed.
11: Cylinder identification sensor
12: Crankshaft position sensor
19: Sidestand switch
(open circuit in wire to ECU)
EAS00901
Checking for a defective engine trouble warning light bulb
The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned “ON”
and when the start switch is being pushed. If the warning light does not come on under these condi-
tions, the warning light bulb may be defective.
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