2004 YAMAHA YZF-R1S steering
[x] Cancel search: steeringPage 9 of 457
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. . . . . . . . . . .
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Page 10 of 457
FRONT AND REAR BRAKES4-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE PADS 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE FRONT BRAKE PADS 4-18. . . . . . . . . . . . . . . . . . . . .
REPLACING THE REAR BRAKE PADS 4-20. . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER 4-22. . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE MASTER CYLINDER 4-25. . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE MASTER
CYLINDER 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE REAR BRAKE MASTER
CYLINDER 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-31. . . . . . .
FRONT BRAKE CALIPERS 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE CALIPER 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE CALIPERS 4-37. . . . . . . . . . .
DISASSEMBLING THE REAR BRAKE CALIPER 4-38. . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE CALIPERS 4-39. . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPERS 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK4-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK LEGS 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT FORK LEGS 4-47. . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT FORK LEGS 4-48. . . . . . . . . . . . . . . . .
CHECKING THE FRONT FORK LEGS 4-49. . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT FORK LEGS 4-50. . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT FORK LEGS 4-55. . . . . . . . . . . . . . . . . . . . . .
HANDLEBARS4-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING DAMPER 4-60. . . . . . . . . . . . . . . . . . . . . . .
STEERING HEAD4-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDER BRACKET 4-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE UNDER BRACKET 4-63. . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING HEAD 4-63. . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STEERING HEAD 4-64. . . . . . . . . . . . . . . . . . . . . . . . .
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Page 17 of 457
1-1
MOTORCYCLE IDENTIFICATION
GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number
1 is stamped
into the right side of the steering head pipe.
EAS00018
MODEL LABEL
The model label
1 is affixed to the frame. This
information will be needed to order spare parts.
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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.
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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)
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Page 51 of 457
2-23
TIGHTENING TORQUESSPEC
See NOTE 2 CHASSIS TIGHTENING TORQUES
ItemThreadTighteningRemarksItemsizeNmmkgftlbRemarks
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
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Page 54 of 457
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
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Page 79 of 457
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.
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