2004 YAMAHA YZF-R1S oil type
[x] Cancel search: oil typePage 5 of 457
22
1
3
5
7
9
2
4
8
6
2425
2321
192018
161715
1413
1112
10
GEN
INFOSPEC
ENG
FI ELECCOOL CHK
ADJ
TRBL
SHTG
CHAS
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols
1 to 9 indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Fuel injection system
8Electrical system
9Troubleshooting
Symbols 10 to 17 indicate the following.
10Serviceable with engine mounted
11Filling fluid
12Lubricant
13Special tool
14Tightening torque
15Wear limit, clearance
16Engine speed
17Electrical data
Symbols 18 to 23 in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
18Engine oil
19Gear oil
20Molybdenum-disulfide oil
21Wheel-bearing grease
22Lithium-soap- based grease
23Molybdenum-disulfide grease
Symbols 24 to 25 in the exploded diagrams indi-
cate the following.
24Apply locking agent (LOCTITE)
25Replace the part
ProCarManuals.com
Page 7 of 457
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . .
MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEATURES1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT FUNCTIONS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY 1-6. . . . . . . . .
REPLACEMENT PARTS 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS 1-6. . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS / PLATES AND COTTER PINS 1-7. . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONNECTIONS1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS SPECIFICATIONS2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS2-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONVERSION TABLE2-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TIGHTENING TORQUE SPECIFICATIONS2-18 . . . . . . . . . . . .
TIGHTENING TORQUES2-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS TIGHTENING TORQUES 2-23. . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINTS AND LUBRICANT TYPES2-25 . . . . . . . . . . . . . . .
ENGINE 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM DIAGRAMS2-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL LUBRICATION CHART2-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 35 of 457
2-7
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Piston
Piston-to-cylinder clearance
Diameter D
Height H
Piston pin bore (in the piston)
Diameter
Offset
Offset direction
Piston pins
Outside diameter
Piston-pin-to-piston-pin-bore
clearance
Piston rings
Top ring
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
2nd ring
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
Oil ring
Dimensions (B T)
End gap (installed)
0.010 0.035 mm (0.0004 0.0014 in)
76.975 76.990 mm (3.0305 3.0311 in)
5 mm (0.20 in)
17.002 17.013 mm
(0.6694 0.6698 in)
0.5 mm (0.0197 in)
Intake side
16.991 17.000 mm
(0.6689 0.6693 in)
0.002 0.022 mm (0.0001 0.0009 in)
Barrel
0.90 2.75 mm (0.04 0.11 in)
0.15 0.25 mm (0.0059 0.0098 in)
0.030 0.065 mm (0.0012 0.0026 in)
Taper
0.80 2.75 mm (0.03 0.11 in)
0.30 0.45 mm (0.0118 0.0177 in)
0.020 0.055 mm (0.0008 0.0022 in)
1.50 2.25 mm (0.06 0.09 in)
0.10 0.40 mm (0.0039 0.0158 in)0.120 mm
(0.0047 in)
17.043 mm
(0.6710 in)
16.971 mm
(0.6682 in)
0.072 mm
(0.0028 in)
0.50 mm
(0.0197 in)
0.115 mm
(0.0045 in)
0.80 mm
(0.0315 in)
0.115 mm
(0.0045 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
ProCarManuals.com
Page 41 of 457
2-13
CHASSIS SPECIFICATIONSSPEC
ItemStandardLimit
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
Spacer length
Installed length
Spring rate (K1)
Spring stroke (K1)
Inner tube outer diameter
Inner tube bending limit
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the outer
tube, with the outer tube fully
compressed, and without the
fork spring)
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
Telescopic fork
Coil spring / oil damper
120 mm (4.72 in)
236.5 mm (9.31 in)
100 mm (3.937 in)
222.5 mm (8.76 in)
8.83 N / mm (0.90 kg / mm, 50.42 lb / in)
0 120 mm (0 4.7244 in)
43 mm (1.69 in)
No
Suspension oil “01”
0.53 L (0.47 Imp qt, 0.56 US qt)
76 mm (2.99 in)
8
4.5
1
26
10
1
25
10
1
231.8 mm
(9.13 in)
0.2 mm
(0.01 in)
ProCarManuals.com
Page 42 of 457
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