2004 YAMAHA YZF-R1S ABS

CHASSIS3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL 3-44. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-45. . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE PADS 3-45. . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE HOSES 3-46. . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-47. . . . . . . . . . . . . . .
ADJUSTING THE SHIFT PEDAL 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE DRIVE CHAIN SLACK 3-49. . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE DRIVE CHAIN 3-50. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD 3-51. . . . . . . . .
CHECKING THE FRONT FORK 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT FORK LEGS 3-54. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-56. . . . .
CHECKING THE TIRES 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WHEELS 3-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND LUBRICATING THE CABLES 3-61. . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS 3-61. . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND 3-61. . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION 3-61. . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM3-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CHARGING THE BATTERY 3-62. . . . . . . . . . . . . . . . .
CHECKING THE FUSES 3-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS 3-69. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAMS 3-70. . . . . . . . . . . . . . . . . . . . . .
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISCS 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7. . . . . . . . .
REAR WHEEL AND BRAKE DISC4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE DISC AND REAR WHEEL SPROCKET 4-10. . . . . . . . .
REMOVING THE REAR WHEEL 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL DRIVE HUB 4-13. . . . . . . . . . . . . . . . .
CHECKING AND REPLACING THE REAR WHEEL
SPROCKET 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR WHEEL 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR WHEEL STATIC BALANCE 4-14. . . . . . . . . . .
ProCarManuals.com

REAR SHOCK ABSORBER ASSEMBLY4-65 . . . . . . . . . . . . . . . . . . . . . . . .
HANDLING THE REAR SHOCK ABSORBER AND
GAS CYLINDER 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPOSING OF A REAR SHOCK ABSORBER AND
GAS CYLINDER 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4-67. . . . .
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-68. . . . . .
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-68. . . . .
SWINGARM AND DRIVE CHAIN4-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE SWINGARM 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE DRIVE CHAIN 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWINGARM 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DRIVE CHAIN 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SWINGARM 4-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 5
ENGINE
ENGINE5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SPROCKET 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST PIPE 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEADS AND HOSES 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE ENGINE 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT5-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVER 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFTS 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CAMSHAFTS 5-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CAMSHAFTS 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN TENSIONER 5-17. . . . . . . . . . . . . . . .
INSTALLING THE CAMSHAFTS 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD5-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CYLINDER HEAD 5-23. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER HEAD 5-23. . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CYLINDER HEAD 5-24. . . . . . . . . . . . . . . . . . . . . . . . .
VALVES AND VALVE SPRINGS5-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE VALVES 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVES AND VALVE GUIDES 5-28. . . . . . . . . . . . . . .
CHECKING THE VALVE SEATS 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVE SPRINGS 5-31. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVE LIFTERS 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE VALVES 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ProCarManuals.com

1-7
IMPORTANT INFORMATION
GEN
INFO
CAUTION:
EAS00023
LOCK WASHERS / PLATES AND COTTER
PINS
After removal, replace all lock washers / plates
1 and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
1Oil seal
Do not spin the bearing with compressed air
because this will damage the bearing sur-
faces.
1Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip
1, make sure the
sharp-edged corner
2 is positioned opposite
the thrust
3 that the circlip receives.
4Shaft
ProCarManuals.com

2-14
CHASSIS SPECIFICATIONSSPEC
ItemStandardLimit
Steering
Steering bearing type
Angular bearing



Lock to lock angle (left)
Lock to lock angle (right)27
27







Rear suspension
Suspension type
Rear shock absorber assembly
type
Rear shock absorber assembly
travel
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Standard spring preload gas / air
pressure
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
Swingarm (link suspension)
Coil spring / gas-oil damper
65 mm (2.56 in)
173.5 mm (6.83 in)
163.5 mm (6.44 in)
83.4 N / mm (8.50 kg / mm, 476.21 lb / in)
0  65 mm (0.00  2.56 in)
No
1,200 kPa (12 kg / cm
2, 12 bar, 171 psi)
1
4
9
20
17
1
20
12
1








































































Swingarm
Free play (at the end of the
swingarm)
Radial
Axial







1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
Drive chain
Model (manufacturer)
Link quantity
Drive chain slack
Maximum ten-link section
50VA8 (DAIDO)
11 6
25  35 mm (0.98  1.38 in)















150.1 mm
(5.91 in)
ProCarManuals.com

2-23
TIGHTENING TORQUESSPEC
See NOTE 2 CHASSIS TIGHTENING TORQUES
ItemThreadTighteningRemarksItemsizeNmm
kgft
lbRemarks
Upper bracket and outer tubeM8262.619
Upper bracket and steering stem nutM2811 311.382
Handlebar and outer tubeM8171.712
Handlebar and upper bracketM6131.39
Steering shaft and ring nutM30181.813See NOTE 1
Outer tube and under bracketM8232.317
Main switch and upper bracketM8262.619
Front brake master cylinder cap stopperM41.20.120.9
Front brake hose union boltsM10303.022
Front brake master cylinder and bracketM6131.39
Meter assembly and front cowling stay—1.30.130.9
Headlight and front cowling stay—0.80.080.6
Front cowling and headlight assembly—1.50.151.1
Cover 7, 8 and frameM650.53.6
Under cowling and engineM650.53.6
Windshield and front cowlingM50.40.040.3
Duct and console panelM51.30.130.9
End grip and handlebarM640.42.9
Horn bracket and under bracketM640.42.9
Coolant reservoir tank and frameM650.53.6
Engine mount front (left and right)M10454.533
Engine mount rear upperM10515.137
Engine mount rear underM10515.137
Engine mount rear adjust boltM1670.75.1
Catalyst pipe stay and frameM10444.432
Clutch cable lock nut (engine side)M870.75.1
Main frame and rear frameM10414.130
Throttle cable adjust nut (throttle body side)M650.53.6
Cover 2 and plate—0.80.080.6
Pivot shaft and nutM1810510.576
Connecting rod and frameM10444.432
Relay arm and connecting rodM10444.432
Relay arm and swingarmM10444.432
Rear shock absorber and relay armM10444.432
Rear shock absorber and upper bracketM10444.432
Upper bracket and frameM14929.267
Seal guardM670.75.1
Drive chain caseM670.75.1
Chain puller adjust nutM8161.612
Fuel tank and fuel pump assemblyM540.42.9
Fuel tank stay (front side) and frameM670.75.1
Fuel tank and fuel tank stay (front side)M670.75.1
Fuel tank stay (rear side) and rear frameM670.75.1
Side cover and fuel tankM50.40.040.3
Rider seat and frameM670.75.1
Seat lock plate and rear frameM6101.07
Side cover (rear side) and frameM540.42.9
ProCarManuals.com

2-26
LUBRICATION POINTS AND LUBRICANT TYPESSPEC
EAS00032
CHASSIS
Lubrication point
Lubricant
Steering bearings and bearing races (upper and lower)
Throttle grip inner surface
Brake lever pivoting point and metal-to-metal moving parts
Clutch lever pivoting point and metal-to-metal moving parts
Engine mount bolts (rear upper and lower)
Relay arm, connecting rod and rear shock absorber collar
Pivot shaft
Swingarm pivot bearing
Swingarm head pipe end, oil seal and bush
Oil seal (relay arm, connecting arm and rear shock absorber)
Seat lock assembly moving parts
Sidestand pivoting pint and metal-to-metal moving parts
Link and sidestand switch contact point
Sidestand hook and spring
Shift shaft joint
Front wheel oil seal (right and left)
Front axle shaft
Rear wheel oil seal
Rear wheel drive hub oil seal
Rear wheel drive hub mating surface
ProCarManuals.com

3-2
NOTE:
GENERAL MAINTENANCE AND LUBRICATION CHART
CHK
ADJ
NOTE:
INITIALODOMETER READINGS
No.ITEMROUTINE600 mi
(1000 km)
or
1 month4000 mi
(7000 km)
or
6 months8000 mi
(13000 km)
or
12 months12000 mi
(19000 km)
or
18 months16000 mi
(25000 km)
or
24 months20000 mi
(31000 km)
or
30 months
9*Swingarm pivot
bearings
(See page 4-71)
Check bearing assemblies for looseness.
Moderately repack with lithium-soap-based
grease.
Repack.
10Drive chain
(See page 3-49, 50)
Check chain slack/alignment and condition.
Adjust and lubricate chain with a special O-
ring chain lubricant thoroughly.Every 600 mi (800 km) and after washing the motorcycle or riding in the rain
11*Steering bearings
(See page 3-51)
Check bearing assembly for looseness.
Moderately repack with lithium-soap-based
grease every 16000 mi (25000 km) or 24
months.



Repack.

12*Steering damper
(See page 4-60)
Check operation and for oil leakage.





13*Chassis fasteners
(See page 2-23)
Check all chassis fitting and fasteners.
Correct if necessary.





14Brake and clutch
lever pivot shafts
(See page 3-61)
Apply lithium-soap-based grease (all-purpose
grease) lightly.





15Sidestand pivot(See page 3-61)

Check operation.

Apply lithium-soap-based grease (all-pur-
pose grease) lightly.





16*Sidestand switch
(See page 3-61, 8-4)
Check operation and replace if necessary.






17*Front fork
(See page 3-53)
Check operation and for oil leakage.
Replace if necessary.





18*Shock absorber
assembly
(See page 3-56, 4-67)
Check operation and for oil leakage.
Replace if necessary.





19*Rear suspension
link pivots
(See page 4-71)
Check operation.
Correct if necessary.


20Engine oil
(See page 3-26, 28)
Change (warm engine before draining.)






21*Engine oil filter cartridge
(See page 3-28)
Replace.



22*Cooling system

Check hoses for cracks or damage.
Replace if necessary.





22*Cooling system(See page 3-37, 38, 39)
Change with ethylene glycol antifreeze cool-
ant every 24 months.Change.
23*EXUP system
(See page 3-36)
Check operation, cable free play and pulley
position.
Every 12000 mi (19000 km)
24*Control cables
(See page 3-61)
Apply Yamaha chain and cable lube or en-
gine oil SAE 10W-30 thoroughly.






25*Throttle grip housing
and cable
(See page 3-22)
Check operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.





* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
Air filter

This model’s air filter is equipped with a disposable oil-coated paper element, which must not be
cleaned with compressed air to avoid damaging it.

The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
Hydraulic brake service

After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.

Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.

Replace the brake hoses every four years and if cracked or damaged.
ProCarManuals.com

3-52
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
WARNING
NOTE:
NOTE: c. Loosen the lower ring nut
4 completely, then
tighten it to specification.
Do not overtighten the lower ring nut.
Lower ring nut
(final tightening torque)
18 Nm (1.8 m
kg, 13 ft
lb)
d. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the under bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” in chapter 4.
e. Install the rubber washer
3.
f. Install the upper ring nut
2.
g. Finger tighten the upper ring nut
2, then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
h. Install the lock washer
1.
Make sure the lock washer tabs
a sit correctly
in the ring nut slots
b.
5. Install:

upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
6. Measure:

steering head tension
Make sure all of the cables and wires are prop-
erly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie
1 loosely around
the end of the handlebar as shown.
c. Hook a spring gauge
2 onto the plastic lock-
ing tie.
d. Hold the spring gauge at a 90 angle from the
handlebar, pull the spring gauge, and then
record the measurement when the handle-
bar starts to run.
ProCarManuals.com