Yamaha R1 2004 ServiceManual
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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 mkg, 8.7 ftlb)
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. Check: water pump housing cover 1 water pump housing 2 impeller 3 rubber damper 4 rubber damper holder 5 water pump seals oil seal Cracks / damage / wear Replace. 2. Check: bearing Rough movement Replace. 3. Check: water pump outlet pipe Cracks / damage / wear Replace.
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 No.1215 or Quick Gasket 2 to the water pump housing 3. Mechanical seal installer 4 90890-04078, YM-33221 Middle driven shaft bearing driver 5 90890-04058, YM-04058 Yamaha bond #1215 90890-85505 Quick gasket ACC-11001-05-01 APush down. 3. Install: rubber damper New 2 rubber damper holder New 1 Before installing the rubber damper, apply tap water or coolant onto its outer surface.
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 position sensor FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM
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 position sensor 33Intake air pressure sensor 34Atmospheric pressure sensor 35Cylinder identification sensor 36Lean angle cut-off switch 43Multi function meter 53Engine stop switch 73Fuse (ignition)
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 warning light to alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is stored in the memory of the ECU. To inform the rider that the fuel injection system is not functioning, the engine trouble warning light flashes when the start switch is being pushed to start the engine. If a malfunction is detected in the system by the self-diagnostic function, this mode provides an ap- propriate substitute characteristic operation, and alerts the rider of the detected malfunction by illumi- nating an engine trouble warning light. After the engine has been stopped, the fault code number appears from the lowest value in order of precedence on the LCD meter. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is deleted. EAS00900 Engine trouble warning light indication and FI system operating condition Warning light indication ECU’s operationFI operationVehicle operation Flashing*Warning provided when unable to start engineOperation stoppedUnable Remains ONMalfunction detectedOperated with substitute characteristics in accordance with the description of the malfunctionAble / Unable depend- ing on the self-diag- nostic fault code * The warning light flashes when any one of the conditions listed below is present and the start switch is pushed. 11: Cylinder identification sensor 12: Crankshaft position sensor 19: Sidestand switch (open circuit in wire to ECU) EAS00901 Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned “ON” and when the start switch is being pushed. If the warning light does not come on under these condi- tions, the warning light bulb may be defective.
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 alternate operating instructions that enable the engine to continue to operate or stop operating, depending on the conditions. The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value, and the other in which the ECU directly operates an actuator. Details on the fail-safe actions are given in the table below. FAIL-SAFE ACTIONS TABLE Fault Code No.ItemSymptomFail-safe actionAble / unable to startAble / unable to drive 11 Cylinder identification sensorNo normal signals are received from the cylinder identification sensor.Continues to operate the engine based on the results of the cylinder identification that existed up to that point. UnableAble 12Crankshaft position sensorNo normal signals are received from the crankshaft position sensor.Stops the engine (by stopping the injection and ignition).UnableUnable 13 14Intake air pressure sensor (open or short circuit) (pipe system)Intake air pressure sensor-open or short circuit detected. Faulty intake air pressure sensor system.Fixes the intake air pressure to 101.3 kpa. AbleAble 15 16Throttle position sensor (open or short circuit) (stuck)Throttle position sensor-open or short circuit detected.Fixes the throttle position sensor to fully open.AbleAble 17EXUP servo motor potention (open or short circuit)EXUP servo motor potention-open or short circuit detected.Turn the EXUP servo motor toward the open side for 3 seconds and then stop it.AbleAble 18 EXUP servo motor (lock)A lock of the EXUP servo motor is detected.Perform the preventive control against motor locking. Perform the lock release operation twice every 100 seconds. AbleAble 19Sidestand switch (open circuit in wire to ECU)Open circuit in the input line of ECU No.15 terminal is detected when the start switch is pressed.-- (No start)UnableUnable 20Intake air pressure Atmospheric pressureDefective values are detected due to the internal malfunctionFixes the intake air pressure and atmospheric pressure to 101.3 kpa.AbleAble 21Coolant temperature sensorCoolant temperature sensor-open or short circuit detected.Fixes the coolant temperature to 60C.AbleAble 22Intake temperature sensorIntake temperature sensor-open or short circuit detected.Fixes the intake temperature to 20C.AbleAble 23Atmospheric pressure sensorAtmospheric pressure sensor-open or short circuit detected.Fixes the atmospheric pressure to 101.3 kpa.AbleAble 33 34 35 36 Faulty ignitionOpen circuit detected in the primary lead of the ignition coil.Cut the injection of other cylinder in the same group with the cylinder that the error is detected. (Example: when the #1 cylinder is detective, cut the injection of #1 and #4 cylinders, when the #2 cylinder is detective, cut the injection of #2 and #3 cylinders). Turn on the power to the air induction solenoid to always cut-off the air. Able (depending on the num- ber of faulty cylinders)Able (depending on the num- ber of faulty cylinders) 30 41Lean angle cut-off switch (latch up detected) (open or short circuit)Lean angle cut-off switch-open or short circuit detected.Turns OFF the fuel injection system relay of the fuel system. UnableUnable 42Speed sensor, neutral switchNo normal signals are received from the speed sensor; or, an open or short circuit is detected in the neutral switch.Fixes the gear to the top gear.AbleAble 43Fuel system voltage (monitor voltage)The ECU is unable to monitor the battery voltage (an open circuit in the line to the ECU).Fixes the battery voltage to 12 V.AbleAble 44 Error in writing the amount of CO adjustment on EEPROMAn error is detected while reading or writing on EEPROM (CO adjustment value).-- AbleAble
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 motor is detected.Perform the preventative control against motor locking. (Perform the lock release operation twice every 100 seconds.) AbleAble 50ECU internal malfunction (memory check error)Faulty ECU memory. When this malfunction is detected, the code number might not appear on the meter.--UnableUnable — Start unable warningRelay is not turned ON even if the crank signal is input while the start switch is turned ON. When the start switch is turned ON while an error is detected with the fault code of No.11, 12, 19, 30, 41 or 50.Engine trouble warning light flashes when the start switch is turned ON. UnableUnable Communication error with the meter Fault Code No.ItemSymptomFail-safe actionAble / unable to startAble / unable to drive Er-1ECU internal malfunction (output signal error)No signals are received from the ECU.–UnableUnable Er-2ECU internal malfunction (output signal error)No signals are received from the ECU within the specified duration.–UnableUnable Er-3ECU internal malfunction (output signal error)Data from the ECU cannot be received correctly.–UnableUnable Er-4ECU internal malfunction (input signal error)Non-registered data has been received from the meter.–UnableUnable