Yamaha YZF-R1S Service Manual

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[Page 1] Yamaha YZF-R1S

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[Page 2] Yamaha YZF-R1S

EAS00010 YZF-R1S/YZF-R1SC SERVICE MANUAL 2003 by Yamaha Motor Corporation, U.S.A. First edition, December 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressl...

[Page 3] Yamaha YZF-R1S

NOTE: WARNING CAUTION: EAS00030 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- al. Theref...

[Page 4] Yamaha YZF-R1S

12 4 8 3 5 6 7 EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out ...

[Page 5] Yamaha YZF-R1S

22 1 3 5 7 9 2 4 8 6 24 25 2321 19 2018 16 1715 1413 11 12 10 GEN INFO SPEC ENG FI ELEC COOL 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. 1 G...

[Page 6] Yamaha YZF-R1S

GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 3 ENG 4 COOL 5 FI 6 CHAS 7 ELEC 8 TRBL SHTG 9 CHK ADJ EAS00012 TABLE OF CONTEN...

[Page 7] Yamaha YZF-R1S

CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1-1. . . . . . . . . . . . . . . . ....

[Page 8] Yamaha YZF-R1S

LUBRICATION DIAGRAMS 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE ROUTING 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INT...

[Page 9] Yamaha YZF-R1S

CHASSIS 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE 3-43. . . . . . . . . ....

[Page 10] Yamaha YZF-R1S

FRONT AND REAR BRAKES 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE PADS 4-16. . . . . . . . . . . . . . . . . . ....

[Page 11] Yamaha YZF-R1S

REAR SHOCK ABSORBER ASSEMBLY 4-65. . . . . . . . . . . . . . . . . . . . . . . . HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPOSING OF A REAR SHOCK ...

[Page 12] Yamaha YZF-R1S

STARTER CLUTCH AND GENERATOR 5-35. . . . . . . . . . . . . . . . . . . . . . . . . STATOR COIL ASSEMBLY 5-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER CLUTCH 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . ....

[Page 13] Yamaha YZF-R1S

CRANKCASE 5-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CRANKCASE 5-74. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKCASE 5-75. . . . . . . . . . . . . . . ....

[Page 14] Yamaha YZF-R1S

CHECKING THE WATER PUMP 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE WATER PUMP 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 7-1. . . . . . . . . . . ....

[Page 15] Yamaha YZF-R1S

CHECKING THE CONDITION OF THE BULB SOCKETS 8-6. . . . . . . CHECKING THE LEDs 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION SYSTEM 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

[Page 16] Yamaha YZF-R1S

ELECTRICAL SYSTEMS 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INCORRECT ENGINE IDLING SPEED 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

[Page 17] Yamaha YZF-R1S

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 ...

[Page 18] Yamaha YZF-R1S

1-2 1 1 Clock 2 Speedometer 3 “SELECT” button 4 “RESET” button 5 Tachometer 6 Coolant temperature display/air intake temperature display 7 Odometer/tripmeters/fuel reserve tripme- ter/stopwatch 8 Shift timing indicator light 1 Clock 2 Speedom...

[Page 19] Yamaha YZF-R1S

1-3 FEATURES GEN INFO 1 Coolant temperature display/air intake temperature display 2 Odometer/tripmeters/fuel reserve tripme- ter/stopwatch 3 Shift timing indicator light NOTE: NOTE: Odometer, tripmeter, and stopwatch modes Push the “SELECT” butt...

[Page 20] Yamaha YZF-R1S

1-4 FEATURES GEN INFO NOTE: Self-diagnosis devices The model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the engine trouble warning light will come on, and then the right display w...

[Page 21] Yamaha YZF-R1S

1-5 FEATURES GEN INFO NOTE: NOTE: To set the shift timing indicator light activation function The shift timing indicator light activation function can be set between 7000 r/min and 15000 r/m. From 7000 r/min to 12000 r/min, the indicator light can be...

[Page 22] Yamaha YZF-R1S

1-6 spring lip oil grease lip IMPORTANT INFORMATION GEN INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, eliminate all dirt, mud, dust and foreign material. 2. Use only the proper tools a...

[Page 23] Yamaha YZF-R1S

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 ...

[Page 24] Yamaha YZF-R1S

1-8 CHECKING THE CONNECTIONS GEN INFO NOTE: NOTE: NOTE: EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead S coupler S connector 2. Check: S lead S coupler S connector Mo...

[Page 25] Yamaha YZF-R1S

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 inappropria...

[Page 26] Yamaha YZF-R1S

1-10 SPECIAL TOOLS GEN INFO Tool No. Tool name/Function Illustration 90890-01441 YM-01441 Fork spring compressor This tool is used to disassemble or assemble the front fork legs. 90890-01442 YM-01442 Fork seal driver This tool is used to install the...

[Page 27] Yamaha YZF-R1S

1-11 SPECIAL TOOLS GEN INFO Tool No. Tool name/Function Illustration 90890-04113 YM-04113 90890-04118 YM-4118 Valve guide reamer This tool is used to rebore the new valve guides. 90890-06754 YM-34487 Ignition checker This tool is used to check the ig...

[Page 28] Yamaha YZF-R1S

1-12 SPECIAL TOOLS GEN INFO Tool No. Tool name/Function Illustration 90890-04101 Valve lapper This tool is needed to remove and install the valve lifter. 90890-03176 YM-03176 Fuel pressure adapter This tool is needed to measure fuel pres- sure. 90890...

[Page 29] Yamaha YZF-R1S

2-1 GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5VY4 (USA), 5VY5 (CAL) SSS Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radi...

[Page 30] Yamaha YZF-R1S

2-2 ENGINE SPECIFICATIONS SPEC 2 ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Displacement Cylinder arrangement Bore stroke Compression ratio Engine idling speed Vacuum pressure at engine idling speed Standard compression pressure (...

[Page 31] Yamaha YZF-R1S

2-3 ENGINE SPECIFICATIONS SPEC Item Standard Limit Oil filter Oil filter type Bypass valve opening pressure Paper 80 X 120 kPa (0.8 X 1.2 kg/cm 2 , 0.8 X 1.2 bar, 11.6 X 17.4 psi) SSS SSS Oil pump Oil pump type Inner-rotor-to-outer-rotor-tip clearanc...

[Page 32] Yamaha YZF-R1S

2-4 ENGINE SPECIFICATIONS SPEC Item Standard Limit Camshafts Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaft- cap clearance Intake camshaft lobe dimensions Measurement A Measurement B Exhaust camshaft ...

[Page 33] Yamaha YZF-R1S

2-5 ENGINE SPECIFICATIONS SPEC Head Diameter Face Width Seat Width Margin Thickness Item Standard Limit Timing chain Model/number of links Tensioning system RH2020/122 Automatic SSS SSS Valves, valve seats, valve guides Valve clearance (cold) Intake ...

[Page 34] Yamaha YZF-R1S

2-6 ENGINE SPECIFICATIONS SPEC Item Standard Limit Valve springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt Intake Exhaust Winding direction (top view) Inta...

[Page 35] Yamaha YZF-R1S

2-7 ENGINE SPECIFICATIONS SPEC Item Standard Limit 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 ri...

[Page 36] Yamaha YZF-R1S

2-8 ENGINE SPECIFICATIONS SPEC Item Standard Limit Connecting rods Crankshaft-pin-to-big-end-bearing clearance Bearing color code 0.034 X 0.058 mm (0.0013 X 0.0023 in) 1 = Blue 2 = Black 3 = Brown 4 = Green 0.09 mm (0.0035 in) SSS Crankshaft Width A ...

[Page 37] Yamaha YZF-R1S

2-9 ENGINE SPECIFICATIONS SPEC Item Standard Limit Clutch Clutch type Clutch release method Clutch release method operation Operation Clutch cable free play (at the end of the clutch lever) Friction plates Color code Thickness Plate quantity Color co...

[Page 38] Yamaha YZF-R1S

2-10 ENGINE SPECIFICATIONS SPEC Item Standard Limit 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 gea...

[Page 39] Yamaha YZF-R1S

2-11 CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Caster angle Trail Diamond 24_ 97 mm (3.82 in) SSS SSS SSS Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. l...

[Page 40] Yamaha YZF-R1S

2-12 CHASSIS SPECIFICATIONS SPEC Item Standard Limit Front brakes Brake type Operation Recommended fluid Brake lever free play Brake discs Diameter thickness Min. thickness Max. deflection Brake pad lining thickness (inner) Brake pad lining thickne...

[Page 41] Yamaha YZF-R1S

2-13 CHASSIS SPECIFICATIONS SPEC Item Standard Limit 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...

[Page 42] Yamaha YZF-R1S

2-14 CHASSIS SPECIFICATIONS SPEC Item Standard Limit Steering Steering bearing type Angular bearing SSS Lock to lock angle (left) Lock to lock angle (right) 27_ 27_ SSS SSS Rear suspension Suspension type Rear shock absorber assembly type Rear shock ...

[Page 43] Yamaha YZF-R1S

2-15 ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V SSS Ignition system Ignition system type Ignition timing Crankshaft position sensor resistance/color T.C.I. unit model (manufacturer) DC. T.C.I. 5_ ...

[Page 44] Yamaha YZF-R1S

2-16 ELECTRICAL SPECIFICATIONS SPEC Item Standard Limit Indicator light (voltage/wattage quantity) Neutral indicator light High beam indicator light Oil level warning light Turn signal indicator light Fuel level warning light Coolant temparture ind...

[Page 45] Yamaha YZF-R1S

2-17 ELECTRICAL SPECIFICATIONS SPEC Item Standard Limit Fuses (amperage quantity) Main fuse Fuel injection system fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan motor fuse Backup fuse (odometer and clock) Reserve fuse 50 A 1...

[Page 46] Yamaha YZF-R1S

2-18 EAS00030 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each ch...

[Page 47] Yamaha YZF-R1S

2-19 TIGHTENING TORQUES SPEC Use a lock washer TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Item Fastener Thread Q ’ ty Tightening torque Remarks Item Fastener size Qty Nm mSkg ftSlb Remarks Spark plugs — M10 4 13 1.3 9.4 Cylinder...

[Page 48] Yamaha YZF-R1S

2-20 TIGHTENING TORQUES SPEC Item Fastener Thread Q ’ ty Tightening torque Remarks Item Fastener size Qty Nm mSkg ftSlb Remarks Exhaust pipe and cylinder head Nut M8 8 20 2.0 14 Catalyst pipe assembly and muffler Bolt M8 2 20 2.0 14 ...

[Page 49] Yamaha YZF-R1S

2-21 TIGHTENING TORQUES SPEC NOTE 1: NOTE 2: Item Fastener Thread Q ’ ty Tightening torque Remarks Item Fastener size Qty Nm mSkg ftSlb Remarks Main axle bearing housing Bolt M6 3 12 1.2 8.7 Shift fork shaft stopper Bolt M6 2 10 1.0 ...

[Page 50] Yamaha YZF-R1S

2-22 TIGHTENING TORQUES SPEC Cylinder head tightening sequence: Crankcase tightening sequence. ...

[Page 51] Yamaha YZF-R1S

2-23 TIGHTENING TORQUES SPEC See NOTE 2 CHASSIS TIGHTENING TORQUES Item Thread Tightening Remarks Item size Nm mSkg ftSlb Remarks Upper bracket and outer tube M8 26 2.6 19 Upper bracket and steering stem nut M28 113 11.3 82 Handlebar and outer...

[Page 52] Yamaha YZF-R1S

2-24 TIGHTENING TORQUES SPEC NOTE 1: NOTE 2: NOTE 3: Item Thread Tightening Remarks Item size Nm mSkg ftSlb Remarks Battery box and frame M6 7 0.7 5.1 Atmospheric pressure sensor and battery box — 0.7 0.07 0.5 Lean angle cut-off switch and b...

[Page 53] Yamaha YZF-R1S

2-25 LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Crankshaft journals Camshaft lobes Camshaft...

[Page 54] Yamaha YZF-R1S

2-26 LUBRICATION POINTS AND LUBRICANT TYPES SPEC 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 pi...

[Page 55] Yamaha YZF-R1S

2-27 1 Radiator fan 2 Radiator 3 Water pump COOLING SYSTEM DIAGRAMS SPEC EAS00033 COOLING SYSTEM DIAGRAMS ...

[Page 56] Yamaha YZF-R1S

2-28 1 Thermostat 2 Radiator cap 3 Radiator 4 Oil cooler COOLING SYSTEM DIAGRAMS SPEC ...

[Page 57] Yamaha YZF-R1S

2-29 ENGINE OIL LUBRICATION CHART SPEC ENGINE OIL LUBRICATION CHART ...

[Page 58] Yamaha YZF-R1S

2-30 LUBRICATION DIAGRAMS SPEC 1 Intake camshaft 2 Exhaust camshaft 3 Oil filter cartridge 4 Oil level switch EAS00034 LUBRICATION DIAGRAMS ...

[Page 59] Yamaha YZF-R1S

2-31 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Oil pipe 6 Oil strainer 7 Oil pump 8 Relief valve LUBRICATION DIAGRAMS SPEC ...

[Page 60] Yamaha YZF-R1S

2-32 1 Oil cooler 2 Oil filter cartridge 3 Oil level switch 4 Oil strainer 5 Oil pump 6 Oil pipe LUBRICATION DIAGRAMS SPEC ...

[Page 61] Yamaha YZF-R1S

2-33 1 Main axle 2 Oil delivery pipe 3 Drive axle LUBRICATION DIAGRAMS SPEC ...

[Page 62] Yamaha YZF-R1S

2-34 1 Cylinder head 2 Crankshaft LUBRICATION DIAGRAMS SPEC ...

[Page 63] Yamaha YZF-R1S

2-35 CABLE ROUTING SPEC G Clamp the head light lead by wrapping and insert it to the in- take air grill hole. (only at the right side.) H Do not connect the wire to the coupler with the plug for options. I To the turn signal light J To the wire harne...

[Page 64] Yamaha YZF-R1S

2-36 CABLE ROUTING SPEC L Clamp the head light lead to the stay 1 at the positioning white tape section. There should be no slack when clamping. Point the tip of the clamp (excessive part) to the front side of the vehicle. Fasten the head light lead ...

[Page 65] Yamaha YZF-R1S

2-37 F Clamp the leads inside the front fork of the vehicle. Point the exit of the horn lead to the left front fork side. G Two throttle cables should not cross with each other. Route two throttle cables behind the brake hose, pass between the inside...

[Page 66] Yamaha YZF-R1S

2-38 CABLE ROUTING SPEC H Clamp the assembly of the clamp and guide wire to the front fork outer tube. Cut the tip of the clamp leaving 2 to 4 mm (0.08 X 0.16 in). Point the binding part to the external part of the vehicle. Clamp it to the outer tube...

[Page 67] Yamaha YZF-R1S

2-39 E Clamp the clamp upper end along the line of lower end of the hose clamp assembly. Point the tip of the clamp (surplus section) to the front side of the vehicle. Clutch cable is what the clamp fastens. F The clutch cable doesn’t project outsi...

[Page 68] Yamaha YZF-R1S

2-40 P To the air filter Q Route the fuel tank drain hose over the canister stay and be- tween the breather hose 2 and wire harness. On the front side of the canister stay, let though the bottom of the A.C.magneto lead and the wire harness. R Route b...

[Page 69] Yamaha YZF-R1S

2-41 C Fold back the clamp and secure it after passing the lead through the clamp. D To the EXUP servo motor E Pass the coolant reservoir tank drain hose and fuel tank drain hose through the clamp from the outer side of the water pump inlet pipe afte...

[Page 70] Yamaha YZF-R1S

2-42 R Arrange so as not for each hose to cross in the part between “BB” from the section “AA” which is in the illustration. G Route the lead by the inside of the water hose and water pipe. H Route the lead by the inside of the water hose and...

[Page 71] Yamaha YZF-R1S

2-43 33 Throttle body side cap 34 Mud guard 35 Turn signal light lead 36 License plate light lead 37 Rear fender rib 38 Speed sensor lead 39 Rear brake light switch lead 40 Rear frame 41 Swingarm bracket 42 Main fuse lead 43 Starting circuit cut-off ...

[Page 72] Yamaha YZF-R1S

2-44 K Pass the water hose lower side of the thermostat, and between the ground lead and the neutral switch. L Install the leads so that the en- gine ground lead is positioned lower and the battery negative lead to be upper. Install the pro- trusion ...

[Page 73] Yamaha YZF-R1S

2-45 W Point the tip of the clamp (sur- plus section) to the rear side of the vehicle. Fasten the starter relay lead, turn signal relay lead, main fuse lead, main fuse lead (from the battery positive lead) and starting circuit cut-off relay lead with...

[Page 74] Yamaha YZF-R1S

2-46 DD Fasten the wire harness, A.C.magneto lead, and throttle body lead with a clamp. Point the tip of the clamp (cut the tip of the clamp leaving 2 to 4 mm (0.08 to 0.16 in).) to the inside of the ve- hicle. EE To the air filter FF To the throttle...

[Page 75] Yamaha YZF-R1S

2-47 PP Route the leads in random or- der. MM Route each lead lower than the frame plate. Leads should be routed in random order. Clamp can be inserted in any direction. NN Route each lead higher than the frame plate, pass it to the inside of the veh...

[Page 76] Yamaha YZF-R1S

2-48 a Fuel piping connector attach- ment directions. (fuel pump side) 1. Insert the connector until the click sound is heard and check that the connector does not come off. Make sure that no for- eign matter is caught in the seal- ing section. (It i...

[Page 77] Yamaha YZF-R1S

2-49 F Point the clip grip to the upper side of the vehicle. G Install the part pointing the yel- low paint mark to the front side of the vehicle. H Install the part pointing the yel- low paint mark to the left side of the vehicle. A Point the clip g...

[Page 78] Yamaha YZF-R1S

3-1 3 INTRODUCTION/PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM/GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommend...

[Page 79] Yamaha YZF-R1S

3-2 NOTE: GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ NOTE: INITIAL ODOMETER READINGS No. ITEM ROUTINE 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (13000 km) or 12 months 12000 mi (19000 km) or 18 months 16000 mi (25000 km...

[Page 80] Yamaha YZF-R1S

3-3 Order Job/Part Q’ty Remarks 1 2 Removing the seats Rider seat Passenger seat 1 1 Remove the parts in the order listed. For installation, reverse the removal procedure. 7 Nm (0.7 mSkg, 5.1 ftSlb) SEATS CHK ADJ EAS00039 SEATS ...

[Page 81] Yamaha YZF-R1S

3-4 Order Job/Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Removing the fuel tank Rider sear Fuel tank side cover Fuel hose connector cover Fuel hose Fuel return hose Fuel sender coupler Fuel pump coupler Fuel tank over flow hose Fuel tank breather ho...

[Page 82] Yamaha YZF-R1S

3-5 FUEL TANK CHK ADJ CAUTION: NOTE: NOTE: CAUTION: REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: S fuel hose connector cover S fuel return hose S fuel hose S fuel sender coupler S fuel ...

[Page 83] Yamaha YZF-R1S

3-6 FUEL TANK CHK ADJ 4 Nm (0.4 mSkg, 2.9 ftSlb) NOTE: CAUTION: INSTALLING THE FUEL PUMP 1. Install: S fuel pump S Do not damage the installation surfaces of the fuel tank when installing the fuel pump. S Always use a new fuel pump gasket. S Install ...

[Page 84] Yamaha YZF-R1S

3-7 Order Job/Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 Removing the front cowling and side cowlings Rider seat Side cowling Front turn signal light lead coupler Side cowling inner panel Bottom cowling Bottom cowing front cover Frame side cov...

[Page 85] Yamaha YZF-R1S

3-8 Order Job/Part Q’ty Remarks 1 2 3 4 5 6 Removing the rear cowling Rider seat and passenger seat Muffler Rear cowling (upper) Tail/brake light lead coupler Rear turn signal light lead coupler Tail/brake light License plate bracket assembly Rear ...

[Page 86] Yamaha YZF-R1S

3-9 COWLINGS CHK ADJ NOTE: NOTE: REMOVAL 1. Remove: S rear cowling S side cowlings To remove the quick fastener, push its center with a screwdriver, then pull the fastener out. INSTALLATION 1. Install: S side cowlings S rear cowling To install the qu...

[Page 87] Yamaha YZF-R1S

3-10 Order Job/Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Removing the air filter case Rider sear Fuel tank Plug Air temperature sensor lead coupler Spacer Air temperature sensor Air filter case cover Air filter Funnel Air filter case Air induction sys...

[Page 88] Yamaha YZF-R1S

3-11 ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve c...

[Page 89] Yamaha YZF-R1S

3-12 ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: NOTE: 4. Measure: S valve clearance Out of specification ! Adjust. Valve clearance (cold) Intake valve 0.11 X 0.20 mm (0.0043 X 0.0079 in) Exhaust valve 0.21 X 0.25 mm (0.0083 X 0.0098 in) a. Turn th...

[Page 90] Yamaha YZF-R1S

3-13 ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: NOTE: NOTE: 5. Remove: S camshafts S Refer to “DISASSEMBLING THE ENGINE – CAMSHAFT AND CYLINDER HEAD” in chap- ter 5. S When removing the timing chain and cam- shafts, fasten the timing chain wit...

[Page 91] Yamaha YZF-R1S

3-14 ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: NOTE: c. Round off the original valve pad number ac- cording to the following table. Last digit Rounded value 0 or 2 0 5 5 8 10 EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm (0.058 in))...

[Page 92] Yamaha YZF-R1S

3-15 ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: S Refer to “ASSEMBLING AND ADJUSTING THE ENGINE – CYLINDER HEAD AND CAM- SHAFT” in chapter 5. S Lubricate the camshaft bearings, camshaft lobes and camshaft journals. S First, install the exhaust...

[Page 93] Yamaha YZF-R1S

3-16 ADJUSTING THE VALVE CLEARANCE CHK ADJ VALVE CLEARANCE (cold): 0.11 X 0.20 mm (0.0043 X 0.0079 in) Example: Installed is 175 Measured clearance is 0.27 mm (0.0106 in) Replace 175 pad with 185 pad Pad number: (example) Pad No.175 = 1.75 mm...

[Page 94] Yamaha YZF-R1S

3-17 ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE THROTTLE BODIES CHK ADJ NOTE: NOTE: NOTE: 7. Install: S all removed parts For installation, reverse the removal procedure. SYNCHRONIZING THE THROTTLE BODIES Prior to synchronizing the throttle bod...

[Page 95] Yamaha YZF-R1S

3-18 SYNCHRONIZING THE THROTTLE BODIES CHK ADJ NOTE: CAUTION: NOTE: 5. Install: S fuel tank Refer to “FUEL TANK”. 6. Start the engine and let it warm up for several minutes. 7. Measure: S engine idling speed Out of specification ! Adjust. Refer t...

[Page 96] Yamaha YZF-R1S

3-19 SYNCHRONIZING THE THROTTLE BODIES/ ADJUSTING THE EXHAUST GAS VOLUME CHK ADJ NOTE: NOTE: 9. Measure: S engine idling speed Out of specification ! Adjust. Make sure that the vacuum pressure is within specification. 10. Stop the engine and remove t...

[Page 97] Yamaha YZF-R1S

3-20 ADJUSTING THE EXHAUST GAS VOLUME CHK ADJ NOTE: NOTE: 3. Using the “SELECT” button, select either the Co adjustment mode 1 (which appears as “Co”) or the diagnosis mode (which appears as “dIAG”). 4. After “Co” appears as a resul...

[Page 98] Yamaha YZF-R1S

3-21 ADJUSTING THE ENGINE IDLING SPEED CHK ADJ NOTE: a b EAS00052 ADJUSTING THE ENGINE IDLING SPEED Prior to adjusting the engine idling speed, the throttle bodies synchronization should be ad- justed properly, and the engine should have ad- equate c...

[Page 99] Yamaha YZF-R1S

3-22 ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ NOTE: a b WARNING EAS00056 ADJUSTING THE THROTTLE CABLE FREE PLAY Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted proper- ly. 1. Check: S throttle cable ...

[Page 100] Yamaha YZF-R1S

3-23 CHECKING THE SPARK PLUGS CHK ADJ CAUTION: EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: S side cowlings S bottom cowlings Refer to “COWLINGS”. 2. Remove: S radiator upper bolts S radi...