Yamaha R1 2004 ServiceManual
Have a look at the manual Yamaha R1 2004 ServiceManual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 255 Yamaha manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
8-8 IGNITION SYSTEMELEC EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM
8-9 IGNITION SYSTEMELEC 1Main switch 4Fuse (main) 6Battery 10Starting circuit cut-off relay 11Neutral switch 12Sidestand switch 14E.C.U. 15Ignition coil #1 16Ignition coil #2 17Ignition coil #3 18Ignition coil #4 19Spark plug 31Crankshaft position sensor 35Cylinder identification sensor 36Lean angle cut-off switch 53Engine stop switch 59Clutch switch 73Fuse (ignition)
8-10 YESNO 2. Battery Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20C (68F) Is the battery OK? Clean the battery terminals. Recharge or re- place the battery. EAS00739 YESNO EAS00741 3. Spark plugs The following procedure applies to all of the spark plugs. Check the condition of the spark plug. Check the spark plug type. Measure the spark plug gap. Refer to “CHECKING THE SPARK PLUGS” in chapter 3. Standard spark plug CR9EK (NGK) Spark plug gap 0.6 0.7 mm (0.0236 0.0276 in) Is the spark plug in good condition, is it of the correct type, and is its gap within specifica- tion? Re-gap or replace the spark plug. IGNITION SYSTEMELEC NOTE: YESNO 1. Main and ignition fuses Check the main and ignition fuses for conti- nuity. Refer to “CHECKING THE FUSES” in chap- ter 3. Are the main and ignition fuses OK? Replace the fuse(s). EAS00737 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Check: 1. main and ignition fuses 2. battery 3. spark plugs 4. ignition spark gap 5. ignition coil resistance 6. crankshaft position sensor 7. main switch 8. engine stop switch 9. neutral switch 10. sidestand switch 11. clutch switch 12. starting circuit cut-off relay (diode) 13. lean angle cut-off switch 14. wiring connections (of the entire ignition system) Before troubleshooting, remove the following part(s): 1. seat 2. fuel tank 3. side cowlings Troubleshoot with the following special tool(s). Ignition checker 90890-06754 Dynamic spark tester YM-34487 Pocket tester 90890-03112, YU-3112 EAS00738
8-11 IGNITION SYSTEMELEC NOYES 1 a 2 4. Ignition spark gap The following procedure applies to all of the spark plugs. Disconnect the spark plug cap from the spark plug. Connect the ignition checker and spark plug cap as shown. Set the main switch to “ON”. Measure the ignition spark gap . Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs. Minimum ignition spark gap 6 mm (0.24 in) Is there a spark and is the spark gap within specification? The ignition system is OK. 5. Ignition coil resistance The following procedure applies to all of the ignition coils. Disconnect the ignition coil leads from the wire harness. Connect the pocket tester (Ω 1) to the ignition coil as shown. EAS00747 Positive tester probe ignition coil terminal Negative tester probe ignition coil terminal Connect the pocket tester (Ω 1k) to the ignition coil as shown. Measure the primary coil resistance. Primary coil resistance 1.19 1.61 Ω at 20C Negative tester probe ignition coil terminal Positive tester probe spark plug terminal 1 2 Measure the secondary coil resistance. Secondary coil resistance 8.5 11.5 kΩ at 20C Is the ignition coil OK? YESNO Replace the ignition coil. EAS00743
8-12 IGNITION SYSTEMELEC 6. Crankshaft position sensor resistance Disconnect the crankshaft position sensor coupler from the wire harness. Connect the pocket tester (Ω 100) to the crankshaft position sensor coupler as shown. Positive tester probe gray Negative tester probe black 1 2 Measure the crankshaft position sensor resistance. Crankshaft position sensor resistance 336 504 Ω at 20C (between gray and black) Is the crankshaft position sensor OK? YESNO Replace the crankshaft position sensor. EAS00749 7. Main switch Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the main switch OK? YESNO Replace the main switch. EAS00748EAS00750 8. Engine stop switch Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the engine stop switch OK? YESNO Replace the right handlebar switch. EAS00751 9. Neutral switch Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the neutral switch OK? YESNO Replace the neutral switch. EAS00752 10. Sidestand switch Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the sidestand switch OK? YESNO Replace the side- stand switch. EAS00763 11. Clutch switch Check the clutch switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the clutch switch OK? YESNO Replace the clutch switch.
8-13 IGNITION SYSTEMELEC 12. Starting circuit cut-off relay (diode) Disconnect the starting circuit cut-off relay coupler from the wire harness. Connect the pocket tester (Ω 1) to the starting circuit cut-off relay coupler as shown. Check the starting circuit cut-off relay for continuity. Positive tester probe blue / yellow Negative tester probe sky blue 1 2 EAS00753 Positive tester probe blue / yellow Negative tester probe blue / black Continuity 1 3 Positive tester probe sky blue Negative tester probe blue / yellow 2 1 Positive tester probe blue / black Negative tester probe blue / yellow No continuity 3 1 YESNO Replace the starting circuit cut-off relay. When you switch the positive and negative tester probes, the readings in the above chart will be reversed. Are the tester readings correct? NOTE: 13. Lean angle cut-off switch Check the lean angle cut-off switch. Refer to “FUEL INJECTION SYSTEM” in chapter 7. Is the lean angle cut-off switch OK? YESNO Replace the lean angle cut-off switch. EAS00754 14. Wiring Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the ignition system’s wiring properly con- nected and without defects? YESNO Properly connect or repair the ignition system’s wiring. Replace the ECU.
8-14 1Main switch 4Fuse (main) 6Battery 8Starter relay 9Starter motor 10Starting circuit cut-off relay 11Neutral switch 12Sidestand switch 53Engine stop switch 54Start switch 73Fuse (ignition) ELECTRIC STARTING SYSTEMELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM
8-15 ELECTRIC STARTING SYSTEMELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so cur- rent cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the starter switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1Battery 2Main fuse 3Main switch 4Ignition fuse 5Engine stop switch 6Starting circuit cut-off relay 7Diode 8Clutch switch 9Sidestand switch 10Neutral switch 11Start switch 12Starter relay 13Starter motor
8-16 YESNO 3. Starter motor Connect the positive battery terminal and starter motor lead with a jumper lead . Repair or replace the starter motor. A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, other- wise the jumper lead may burn. This check is likely to produce sparks, therefore make sure nothing flammable is in the vicinity. Does the starter motor turn? WARNING 1 23 EAS00758 YESNO 2. Battery Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20C (68F) Is the battery OK? Clean the battery terminals. Recharge or re- place the battery. EAS00739 ELECTRIC STARTING SYSTEMELEC NOTE: YESNO 1. Main and ignition fuses Check the main and ignition fuses for conti- nuity. Refer to “CHECKING THE FUSES” in chap- ter 3. Are the main and ignition fuses OK? Replace the fuse(s). EAS00757 TROUBLESHOOTING The starter motor fails to turn. Check: 1. main and ignition fuses 2. battery 3. starter motor 4. starting circuit cut-off relay 5. starter relay 6. main switch 7. engine stop switch 8. neutral switch 9. sidestand switch 10. clutch switch 11. start switch 12. wiring connections (of the entire starting system) Before troubleshooting, remove the following part(s): 1. seat 2. fuel tank 3. side cowlings 4. throttle body assembly Troubleshoot with the following special tool(s). Pocket tester 90890-03112, YU-3112 EAS00738
8-17 4. Starting circuit cut-off relay Disconnect the starting circuit cut-off relay coupler from the wire harness. Connect the pocket tester (Ω 1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown. YESNO Replace the starting circuit cut-off relay. Positive tester probe blue / white Negative tester probe blue / white Does the starting circuit cut-off relay have continuity between blue / white and blue / white ? 1 2 3 4 EAS00759 Positive battery terminal red / black Negative battery terminal black / yellow EAS00761 5. Starter relay Disconnect the starter relay coupler from the coupler. Connect the pocket tester (Ω 1) and battery (12 V) to the starter relay coupler as shown. YESNO Replace the starter relay. Positive battery terminal blue / white Negative battery terminal red / white Positive tester probe red Negative tester probe black 1 2 3 4 Does the starter relay have continuity be- tween red and black? EAS00749 6. Main switch Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the main switch OK? YESNO Replace the main switch. EAS00750 7. Engine stop switch Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the engine stop switch OK? YESNO Replace the right handlebar switch. EAS00751 8. Neutral switch Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the neutral switch OK? YESNO Replace the neutral switch. 3 4 ELECTRIC STARTING SYSTEMELEC