Yamaha R1 2004 ServiceManual

6-13
WATER PUMPCOOL
Order Job / Part Q’ty Remarks
5
6
7
8Water pump seal
Oil seal
Bearing
O-ring1
1
1
1
For installation, reverse the removal 
procedure.
12 Nm (1.2 m
kg, 8.7 ft
lb) 

6-14
WATER PUMPCOOL
NOTE:
NOTE:
NOTE:
EAS00471
DISASSEMBLING THE WATER PUMP
1. Remove:

water pump seal 
1
Tap out the water pump seal from the inside of
the water pump housing.
2Water pump housing
2. Remove:

oil seal 
1

bearing 2
Tap out the bearing and oil seal from the outside
of the water pump housing.
3Water pump housing
3. Remove:

rubber damper holder 
1

rubber damper 2
(from the impeller, with a thin, flat-head
screwdriver)
Do not scratch the impeller shaft.
EAS00473
CHECKING THE WATER PUMP
1....

6-15
WATER PUMPCOOL
NOTE:
CAUTION:
NOTE:
NOTE:
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:

oil seal 
New 1
(into the water pump housing 2)

Before installing the oil seal, apply tap water or
coolant onto its out surface.

Install the oil seal with a socket that matches its
outside diameter.
2. Install:

water pump seal 
New 1
Never lubricate the water pump seal surface
with oil or grease.

Install the water pump seal with the special
tools.

Before installing the water pump seal, apply
Yamaha bond...

6-16
WATER PUMPCOOL
CAUTION:
4. Measure:

impeller shaft tilt
Out of specification 
 Repeat steps (3) and
(4).
Make sure the rubber damper and rubber
damper holder are flush with the impeller.
Impeller shaft tilt limit
0.15 mm (0.006 in)
1Straightedge
2Impeller 

7-1
FUEL INJECTION SYSTEMFI
19Atmospheric pressure
sensor
20Fuel injection system
relay
21Engine trouble warning
light
22Lean angle cut-off
switch
23Air cut-off valve
13Coolant temperature
sensor
14Spark plug
15Cylinder identification
sensor
16Pressure regulator
17Battery
18ECU
1Ignition coil
2Air filter case
3Intake temperature
sensor
4Fuel delivery hose
5Fuel tank
6Fuel pump
7Fuel return hose
8Intake air presure sen-
sor
9Throttle position sen-
sor
10Fuel injector
11Catalytic converter
12Crankshaft...

7-2
FUEL INJECTION SYSTEMFI
7
WIRING DIAGRAM 

7-3
FUEL INJECTION SYSTEMFI
1Main switch
4Fuse (main)
5Fuse (backup)
6Battery
7Fuse (fuel injection)
10Starting circuit cut-off relay
11Neutral switch
12Sidestand switch
13Fuel pump
14E.C.U.
15Ignition coil #1
16Ignition coil #2
17Ignition coil #3
18Ignition coil #4
19Spark plug
20Injector #1
21Injector #2
22Injector #3
23Injector #4
25Sub-throttle position sensor
26EXUP servo motor
27Speed sensor
28Coolant temperature sensor
29Intake air temperature sensor
31Crankshaft position sensor
32Throttle...

7-4
30: Lean angle cut-off switch
(latch up detected)
41: Lean angle cut-off switch
(open or short circuit)
50: ECU internal malfunction
(memory check error)
FUEL INJECTION SYSTEMFI
EAS00899
ECU’S SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble...

7-5
FUEL INJECTION SYSTEMFI
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION)
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions
that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with...

7-6
FUEL INJECTION SYSTEMFI
Fault
Code No.ItemSymptomFail-safe actionAble / unable
to startAble / unable
to drive
46Vehicle system power
supply (Monitor voltage)Power supply to the FI system is not
normal.--AbleAble
47Sub-throttle servo motor
potention (open or short
circuit)sub-throttle servo motor potention-
open or short circuit detected.
Turn the sub-throttle servo motor
toward the close side for 4 seconds
and then stop it.AbleAble
48
Sub-throttle servo motor
(lock)A lock of the sub-throttle servo...