Yamaha YZF-R1S - Service Manual

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Specifications5
- Table of Contents6
Default Chapter3
- Important Manual Information3
- How to Use this Manual4
Periodic Checks and Adjustments5
Chassis5
Engine5
Cooling System5
Fuel Injection System5
Electrical System5
Troubleshooting15
Chapter 1 General Information17
Motorcycle Identification17
- Vehicle Identification Number17
- Model Label17
Gen Info17
Features18
- Instrument Functions18
Important Information22
- Preparation for Removal and Disassembly22
- Replacement Parts22
- Gaskets, Oil Seals and O-Rings22
- Lock Washers/Plates and Cotter Pins23
- Bearings and Oil Seals23
- Circlips23
Checking the Connections24
Special Tools25
Chapter 2 Specifications29
Spec29
General Specifications29
Engine Specifications30
Chassis Specifications39
Electrical Specifications43
Conversion Table46
General Tightening Torque Specifications46
Tightening Torques47
- Engine Tightening Torques47
- Chassis Tightening Torques51
Lubrication Points and Lubricant Types53
- Engine53
- Chassis54
Cooling System Diagrams55
Engine Oil Lubrication Chart57
Lubrication Diagrams58
Cable Routing63
Chapter 3 Periodic Checks and Adjustments78
Introduction78
Periodic Maintenance Chart for the Emission Control System78
General Maintenance and Lubrication Chart78
- Air Filter79
Chk Adj78
Seats80
Fuel Tank81
- Removing the Fuel Tank82
- Removing the Fuel Pump82
- Installing the Fuel Pump83
- Installing the Fuel Tank83
Cowlings84
- Front Cowling and Side Cowlings84
- Rear Cowling85
- Removal86
- Installation86
Air Filter Case87
Engine88
- Adjusting the Valve Clearance88
- Synchronizing the Throttle Bodies94
- Adjusting the Exhaust Gas Volume96
- Adjusting the Engine Idling Speed98
- Adjusting the Throttle Cable Free Play99
- Checking the Spark Plugs100
- Measuring the Compression Pressure101
- Checking the Engine Oil Level103
- Changing the Engine Oil105
- Measuring the Engine Oil Pressure106
- Adjusting the Clutch Cable Free Play108
- Replacing the Air Filter Element109
- Checking the Fuel and Breather Hoses110
- Checking the Crankcase Breather Hose111
- Checking the Exhaust System112
- Adjusting the Exup Cables113
- Checking the Coolant Level114
- Checking the Cooling System115
- Changing the Coolant116
Chassis119
- Adjusting the Front Brake119
- Adjusting the Rear Brake120
- Checking the Brake Fluid Level121
- Adjusting the Rear Brake Light Switch122
- Checking the Front and Rear Brake Pads122
- Checking the Front and Rear Brake Hoses123
- Bleeding the Hydraulic Brake System124
- Adjusting the Shift Pedal125
- Adjusting the Drive Chain Slack126
- Lubricating the Drive Chain127
- Checking and Adjusting the Steering Head128
- Checking the Front Fork130
- Adjusting the Front Fork Legs131
- Adjusting the Rear Shock Absorber Assembly133
- Checking the Tires135
- Checking the Wheels137
- Checking and Lubricating the Cables138
- Lubricating the Levers and Pedals138
- Lubricating the Sidestand138
- Lubricating the Rear Suspension138
Electrical System139
- Checking and Charging the Battery139
- Checking the Fuses144
- Replacing the Headlight Bulbs146
- Adjusting the Headlight Beams147
Chapter 4 Chassis148
Chas148
Front Wheel and Brake Discs148
- Removing the Front Wheel150
- Checking the Front Wheel150
- Checking the Brake Discs152
- Installing the Front Wheel153
- Adjusting the Front Wheel Static Balance154
- Rear Wheel and Brake Disc156
Rear Wheel and Brake Disc Rear Wheel156
- Rear Brake Disc and Rear Wheel Sprocket157
- Removing the Rear Wheel159
- Checking the Rear Wheel160
- Checking the Rear Wheel Drive Hub160
- Checking and Replacing the Rear Wheel Sprocket160
- Installing the Rear Wheel161
- Adjusting the Rear Wheel Static Balance161
Front and Rear Brakes162
- Front Brake Pads162
- Rear Brake Pads163
- Replacing the Front Brake Pads165
- Replacing the Rear Brake Pads167
- Front Brake Master Cylinder169
- Cylinder172
- Disassembling the Rear Brake Master173
- Cylinder173
- Checking the Front and Rear Brake Master175
- Cylinders175
- Assembling and Installing the Front Brake176
- Master Cylinder176
- Assembling the Rear Brake Master Cylinder178
- Front Brake Calipers180
- Rear Brake Caliper182
- Disassembling the Front Brake Calipers184
- Calipers184
- Assembling and Installing the Rear189
- Brake Caliper189
Front Fork191
- Front Fork Legs191
- Removing the Front Fork Legs194
- Disassembling the Front Fork Legs195
- Checking the Front Fork Legs196
- Assembling the Front Fork Legs197
- Installing the Front Fork Legs202
Handlebars203
- Removing the Handlebars205
- Checking the Handlebars205
- Installing the Handlebars205
- Checking the Steering Damper207
Steering Head208
- Under Bracket208
- Removing the under Bracket210
- Checking the Steering Head210
- Installing the Steering Head211
Rear Shock Absorber Assembly212
- Handling the Rear Shock Absorber and Gas Cylinder213
- Disposing of a Rear Shock Absorber and Gas Cylinder213
- Removing the Rear Shock Absorber Assembly214
- Checking the Rear Shock Absorber Assembly215
- Installing the Rear Shock Absorber Assembly215
Swingarm and Drive Chain216
- Removing the Swingarm218
- Removing the Drive Chain219
- Checking the Swingarm219
- Checking the Drive Chain220
- Installing the Swingarm222
Chapter 5 Engine223
- Drive Sprocket223
- Exhaust Pipe224
- Leads and Hoses227
- Engine227
- Installing the Engine231
Eng223
Camshaft233
- Cylinder Head Cover233
- Camshafts235
- Removing the Camshafts236
- Checking the Camshafts237
- Checking the Timing Chain, Camshaft Sprockets, and Timing Chain Guides239
- Checking the Timing Chain Tensioner239
- Installing the Camshafts241
Cylinder Head244
- Removing the Cylinder Head245
- Checking the Cylinder Head245
- Installing the Cylinder Head246
Valves and Valve Springs249
- Removing the Valves249
- Checking the Valves and Valve Guides250
- Checking the Valve Seats252
- Checking the Valve Springs253
- Checking the Valve Lifters254
- Installing the Valves254
Starter Clutch and Generator257
- Stator Coil Assembly257
- Starter Clutch259
- Removing the Generator260
- Checking the Damper261
- Checking the Starter Clutch262
- Installing the Starter Clutch263
- Installing the Generator263
Crankshaft Position Sensor265
- Removing the Crankshaft Position Sensor266
- Installing the Crankshaft Position Sensor266
Clutch268
- Clutch Cover268
- Pull Lever Shaft269
- Clutch269
- Removing the Clutch272
- Checking the Friction Plates274
- Checking the Clutch Plates274
- Checking the Clutch Springs275
- Checking the Clutch Housing275
- Checking the Clutch Boss275
- Checking the Pressure Plate276
- Checking the Pull Lever Shaft and Pull Rod276
- Installing the Clutch276
Shift Shaft280
- Shift Shaft and Stopper Lever280
- Removing the Shift Shaft282
- Checking the Shift Shaft283
- Checking the Stopper Lever283
- Installing the Shift Shaft283
Oil Pan and Oil Pump285
- Removing the Oil Pan288
- Checking the Sprocket and Chain288
- Checking the Oil Pump289
- Checking the Relief Valve289
- Checking the Oil Delivery Pipe and Oil Pipe290
- Checking the Oil Strainer290
- Checking the Oil Nozzles290
- Assembling the Oil Pump290
- Installing the Oil/Water Pump Assembly291
- Installing the Oil Pan293
Crankcase294
- Disassembling the Crankcase296
- Checking the Crankcase297
- Checking the Bearings and Oil Seals297
- Assembling the Crankcase297
Connecting Rods and Pistons299
- Removing the Connecting Rods and Pistons300
- Removing the Crankshaft Assembly301
- Checking the Cylinder and Piston301
- Checking the Piston Rings302
- Checking the Piston Pins303
- Checking the Big End Bearings304
- Installing the Connecting Rod and Piston308
Crankshaft314
- Checking the Crankshaft315
- Checking the Crankshaft Drive Sprocket315
- Checking the Crankshaft Journal Bearings315
- Installing the Crankshaft318
Transmission319
- Transmission, Shift Drum Assembly and Shift Forks319
- Removing the Transmission325
- Checking the Shift Forks325
- Checking the Shift Drum Assembly326
- Checking the Transmission326
- Installing the Transmission327
Chapter 6 Cooling System329
Cool329
Radiator329
- Checking the Radiator331
- Installing the Radiator332
Oil Cooler333
- Checking the Oil Cooler335
- Installing the Oil Cooler335
Thermostat336
- Checking the Thermostat338
- Assembling the Thermostat Assembly339
- Installing the Thermostat Assembly339
Water Pump340
- Impeller Shaft340
- Disassembling the Water Pump342
- Checking the Water Pump342
Chapter 7 Fuel Injection System345
- Wiring Diagram346
- Ecu's Self-Diagnostic Function348
- Fail-Safe Action349
- Fail-Safe Actions Table349
- Troubleshooting Chart351
- Diagnostic Mode352
- Troubleshooting Details359
Throttle Bodies379
- Injectors381
- Checking the Injectors383
- Checking the Throttle Bodies383
- Checking the Throttle Body Joints383
- Checking the Pressure Regulator384
- Checking the Fuel Pump and Pressure Regulator Operation384
- Checking and Adjusting the Throttle Position Sensor385
- Checking and Adjusting the Sub-Throttle Position Sensor387
- Checking and Adjusting the Thermo Wax389
Air Induction System390
- Air Injection390
- Air Cut-Off Valve390
- Air Induction System Diagrams390
- Checking the Air Induction System392
Chapter 8 Electrical System394
Elec394
Electrical Components394
Checking Switch Continuity396
Checking the Switches397
Checking the Bulbs and Bulb Sockets398
- Types of Bulbs398
- Checking the Condition of the Bulbs398
- Checking the Condition of the Bulb Sockets399
- CHECKING the Leds400
Ignition System401
- Circuit Diagram401
- Troubleshooting403
Electric Starting System407
- Circuit Diagram407
- Starting Circuit Cut-Off System Operation408
- Troubleshooting409
Starter Motor412
- Checking the Starter Motor414
- Assembling the Starter Motor415
Charging System417
- Circuit Diagram417
- Troubleshooting418
Lighting System420
- Circuit Diagram420
- Troubleshooting422
- Checking the Lighting System424
Signaling System427
- Circuit Diagram427
- Troubleshooting429
- Checking the Signaling System429
Cooling System436
- Circuit Diagram436
- Troubleshooting438
Fuel Pump System441
- Circuit Diagram441
- Troubleshooting443
- Checking the Fuel Pump445
Self-Diagnosis446
- Troubleshooting449
Chapter 9449
- Engine449
- Fuel System449
- Electrical Systems449
Starting Failures449
Incorrect Engine Idling Speed450
- Engine450
- Fuel System450
- Electrical Systems450
Poor Medium-And-High-Speed Performance450
Trbl Shtg450
Faulty Gear Shifting451
- Shifting Is Difficult451
- Shift Pedal Does Not Move451
- Jumps out of Gear451
Faulty Clutch451
- Clutch Slips451
- Clutch Drags451
Overheating452
- Engine452
- Cooling System452
- Fuel System452
- Chassis452
- Electrical Systems452
Overcooling452
Poor Braking Performance452
Faulty Front Fork Legs453
- Leaking Oil453
- Malfunction453
Unstable Handling453
Faulty Lighting or Signaling System454
- Headlight Does Not Come on454
- Headlight Bulb Burnt out454
- Tail/Brake Light Does Not Come on454
- Tail/Brake Light Bulb Burnt out454
- Turn Signal Does Not Come on454
- Turn Signal Blinks Slowly454
- Turn Signal Remains Lit454
- Turn Signal Blinks Quickly454
- Horn Does Not Sound454

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