2004 YAMAHA YZF-R1S oil filter
[x] Cancel search: oil filterPage 8 of 457
LUBRICATION DIAGRAMS2-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING2-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL MAINTENANCE AND LUBRICATION CHART3-1 . . . . . . . . .
SEATS3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL TANK 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL PUMP 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL PUMP 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL TANK 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COWLINGS3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT COWLING AND SIDE COWLINGS 3-7. . . . . . . . . . . . . . . . . . .
REAR COWLING 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR FILTER CASE3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE3-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE VALVE CLEARANCE 3-11. . . . . . . . . . . . . . . . . . . . . .
SYNCHRONIZING THE THROTTLE BODIES 3-17. . . . . . . . . . . . . . . . .
ADJUSTING THE EXHAUST GAS VOLUME 3-19. . . . . . . . . . . . . . . . . .
ADJUSTING THE ENGINE IDLING SPEED 3-21. . . . . . . . . . . . . . . . . . .
ADJUSTING THE THROTTLE CABLE FREE PLAY 3-22. . . . . . . . . . . .
CHECKING THE SPARK PLUGS 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE COMPRESSION PRESSURE 3-24. . . . . . . . . . . . . .
CHECKING THE ENGINE OIL LEVEL 3-26. . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE ENGINE OIL 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE ENGINE OIL PRESSURE 3-29. . . . . . . . . . . . . . . . .
ADJUSTING THE CLUTCH CABLE FREE PLAY 3-31. . . . . . . . . . . . . . .
REPLACING THE AIR FILTER ELEMENT 3-32. . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL AND BREATHER HOSES 3-33. . . . . . . . . . . . .
CHECKING THE CRANKCASE BREATHER HOSE 3-34. . . . . . . . . . . .
CHECKING THE EXHAUST SYSTEM 3-35. . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE EXUP CABLES 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLANT LEVEL 3-37. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLING SYSTEM 3-38. . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE COOLANT 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ProCarManuals.com
Page 25 of 457
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.
ProCarManuals.com
Page 30 of 457
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)
ProCarManuals.com
Page 31 of 457
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)
ProCarManuals.com
Page 38 of 457
2-10
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4nd gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
Constant mesh, 6-speed
Spur gear
65 / 43 (1.512)
Chain drive
45 / 17 (2.647)
Left-foot operation
38 / 15 (2.533)
33 / 16 (2.063)
37 / 21 (1.762)
35 / 23 (1.522)
30 / 22 (1.364)
33 / 26 (1.269)
0.08 mm
(0.0032 in)
0.08 mm
(0.0032 in)
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Shift drum / Guide bar
0.10 mm
(0.0039 in)
Air filter typeOil coated paper element
Fuel pump
Pump type
Model (manufacturer)
Output pressure
Electrical
5PW (DENSO)
294 kPa (2.94 kg / cm
2, 2.94 bar, 42.6 psi)
Throttle position sensor
Resistance
Output voltage (at idle)
4.9 5.1 kΩ at 20C (68F)
0.63 0.73 V
Throttle bodies
Model (manufacturer) quantity
Intake vacuum pressure
Throttle cable free play (at the flange
45EIDW (MIKUNI) 2
22 kPa (165 mmHg, 6.4966 inHg)
3 5 mm (0.12 0.20 in)
of the throttle grip)
ID mark
Throttle valve size
5VY1 00 (USA)
5VY5 10 (CAL)
#100
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Page 47 of 457
2-19
TIGHTENING TORQUESSPEC
Use a lock
washer
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmmkgftlbRemarks
Spark plugs—M104131.39.4
Cylinder headNutM1010See NOTE 1
BoltM62121.28.7
Camshaft capsBoltM628101.07.2
Cylinder head coverBoltM66121.28.7
Cylinder head (exhaust pipe)Stud boltM88151.511
Air indication system capBoltM64101.07.2
Camshaft sprocketsBoltM74242.417
Cylinder head and throttle bodyClampM5430.32.2
Connecting rod capsBoltM8820+1502.0+15014+150
Generator rotorBoltM101606.043
Timing chain tensionerBoltM62101.07.2
Water pump outlet pipeBoltM61101.07.2
Water pump inlet pipeBoltM61101.07.2
(water pump side)
Water pump inlet pipe (front side)BoltM61101.07.2
Oil / water pump assembly
sprocketBoltM61151.511
Water pumpBoltM62121.28.7
Thermostat coverNutM62101.07.2
Thermostat inlet pipeBoltM61101.07.2
Oil coolerBoltM201636.346
Engine oil drain boltBoltM141434.331
Oil pipeBoltM62101.07.2
Oil strainerBoltM63101.07.2
Oil delivery pipeBoltM63101.07.2
Oil filter union boltBoltM201707.051
Oil filter—M201171.712
Oil panBoltM614121.28.7
Oil panBoltM61121.28.7
Air filter case coverScrewM5101.70.171.2
Throttle body and throttle body
jointClampM5430.32.2
Throttle body and funnelBoltM564.20.423.0
Throttle cableNutM614.50.453.3
Throttle cable adjusterBoltM614.50.453.3
Stator coilScrewM63141.410
Generator rotor cover and
bearing housingScrewM63101.07.2
Pull lever coverBoltM62101.07.2
Thermostat assembly stayBoltM62101.07.2
Starter clutch idler gearBoltM61101.07.2
Clutch bossNutM201959.569Stake
Clutch springBoltM66101.07.2
Drive sprocketNutM221858.561
ProCarManuals.com
Page 58 of 457
2-30
LUBRICATION DIAGRAMSSPEC
1Intake camshaft
2Exhaust camshaft
3Oil filter cartridge
4Oil level switch
EAS00034
LUBRICATION DIAGRAMS
ProCarManuals.com
Page 60 of 457
2-32
1Oil cooler
2Oil filter cartridge
3Oil level switch
4Oil strainer
5Oil pump
6Oil pipe
LUBRICATION DIAGRAMSSPEC
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