Yamaha R1 2004 ServiceManual
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7-47 AIR INDUCTION SYSTEMFI A To cylinder #1 and #2 B To cylinder #3 and #41 Air cut-off valve 2 Plate 3 Reed valve assembly 4 Reed valve cap 5 To air filter case EAS00509 AIR INDUCTION SYSTEM DIAGRAMS
7-48 AIR INDUCTION SYSTEMFI EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: hoses Loose connection Connect properly. Cracks / damage Replace. pipes Cracks / damage Replace. 2. Check: reed valve 1 reed valve stopper reed valve seat Cracks / damage Replace the reed valve. 3. Measure: reed valve bending limit a Out of specification Replace the reed valve. Reed valve bending limit 0.4 mm (0.016 in) 1Surface plate 4. Check: air cut-off valve Cracks / damage Replace.
7-49 AIR INDUCTION SYSTEMFI 5. Check: Air induction system solenoid a. Remove the Air induction system solenoid coupler from the wire harness. b. Connect the pocket tester (Ω 1) to the Air induction system solenoid terminal as shown. Tester positive probe orange 1 Tester negative probe green 2 c. Measure the Air induction system solenoid resistance. Air induction system solenoid resistance 18 22 Ω at 20C (68F) d. Out of specification Replace.
8-1 8 ELECTRICAL COMPONENTSELEC 9Oil level switch 10Radiator fan motor 11Horn 12Ignition coil 1Main switch 2Front brake light switch 3Starter relay 4Battery 5Fuse box 6Rear brake light switch 7Neutral switch 8Sidestand switch EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS
8-2 9Radiator fan motor relay 10Turn signal relay 11Rectifier / regulator 12Throttle position sensor 13Sub-throttle position sensor 1Coolant temperature sensor 2Intake air temperature sensor 3Intake air pressure sensor 4Fuel pump 5ECU 6Lean angle cut-off switch 7Starting circuit cut-off relay 8Headlight relay (dimmer) ELECTRICAL COMPONENTSELEC
8-3 CHECKING SWITCH CONTINUITYELEC CAUTION: NOTE: NOTE: EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Never insert the tester probes into the cou- pler terminal slots. Always insert the probes from the opposite end of the coupler 1 tak- ing care not to loosen or damage the leads. Pocket tester 90890-03112, YU-3112 Before checking for continuity, set the pocket tester to “0” and to the “Ω 1” range. When checking for continuity, switch back and forth between the switch positions a few times. The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustration similar to the one on the left. The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration. “ ” indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the respective switch position). The example illustration on the left shows that: There is continuity between red and brown / red when the switch is set to “P”. There is continuity between red, brown / blue and brown / red when the switch is set to “ON”.
8-4 11Neutral switch 12Rear brake light switch 13Fuse box 1Main switch 2Horn switch 3Dimmer switch 4Turn signal switch 5Clutch switch 6Sidestand switch 7Engine stop switch 8Front brake light switch 9Start switch 10Oil level switch CHECKING THE SWITCHESELEC EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage / wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch.
8-5 CHECKING THE BULBS AND BULB SOCKETSELEC WARNING EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage / wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect. No continuity Repair or replace the bulb, bulb socket or both. TYPES OF BULBS The bulbs used on this motorcycle are shown in the illustration on the left. Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb. The ma- jority of these types of bulbs can be removed from their respective socket by turning them counterclockwise. Bulbs C are used for turn signal and tail / brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise. CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: bulb Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. When changing the tail / brake light bulb, confirm that the frame has cooled accord- ing to the warning label and change the tail / brake light bulb.
8-6 CHECKING THE BULBS AND BULB SOCKETSELEC CAUTION: NOTE: Be sure to hold the socket firmly when re- moving the bulb. Never pull the lead, other- wise it may be pulled out of the terminal in the coupler. Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adverse- ly affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 2. Check: bulb (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03112, YU-3112 Before checking for continuity, set the pocket tester to “0” and to the “Ω 1” range. a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2, and check the continuity. b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3, and check the continuity. c. If either of the readings indicate no continuity, replace the bulb. CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: bulb socket (for continuity) (with the pocket tester) No continuity Replace.
8-7 CHECKING THE BULBS AND BULB SOCKETSELEC NOTE: NOTE: WARNING Pocket tester 90890-03112, YU-3112 Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. a. Install a good bulb into the bulb socket. b. Connect the pocket tester probes to the re- spective leads of the bulb socket. c. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket. CHECKING THE LEDs The following procedures applies to all of the LEDs. 1. Check: LED (for proper operation) Improper operation Replace. a. Disconnect the meter assembly coupler (me- ter assembly side). b. Connect two jumper leads 1 from the bat- tery terminals to the respective coupler ter- minal. As for connecting with which coupler terminal, refer to “CABLE ROUTING” in chapter 2. A wire that is used as a jumper lead must have at least the same capacity of the bat- tery lead, otherwise the jumper lead may burn. This check is likely to produce sparks, therefore, make sure no flammable gas or fluid is in the vicinity. c. When the jumper leads are connected to the terminals the respective LED should illumi- nate. Does not light Replace the meter assem- bly.