Yamaha R1 2004 ServiceManual
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8-28 LIGHTING SYSTEMELEC 1Main switch 4Fuse (main) 6Battery 14E.C.U. 46Hi beam indicator light 49Meter light 57Dimmer switch 62Front turn signal/position light (left) 63Front turn signal/position light (right) 66Headlight 67Auxiliary light 68License plate light 69Rear brake light switch 70Tail/brake light 71Headlight relay (on / off) 72Headlight relay (dimmer) 74Fuse (signal) 75Fuse (headlight)
8-29 YESNO Clean the battery terminals. Recharge or re- place the battery. EAS00749 3. Main switch Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the main switch OK? YESNO Replace the main switch. EAS00784 YESNO 4. Dimmer switch Check the dimmer switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the dimmer switch OK? The dimmer switch is faulty. Replace the left handlebar switch. Minimum open-circuit voltage 12.8 V or more at 20C (68F) Is the battery OK? LIGHTING SYSTEMELEC NOTE: YESNO 1. Main, turn and headlight fuses Check the main, turn and headlight fuses for continuity. Refer to “CHECKING THE FUSES” in chap- ter 3. Are the main, turn and headlight fuses OK? Replace the fuse(s). 2. Battery Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. EAS00739EAS00781 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, licence light or meter light. Check: 1. main, turn and headlight fuses 2. battery 3. main switch 4. dimmer switch 5. pass switch 6. headlight relay (on / off) 7. headlight relay (dimmer) 8. wiring connections (of the entire lighting system) Before troubleshooting, remove the following part(s): 1. seat 2. fuel tank 3. side cowlings Troubleshoot with the following special tool(s). Pocket tester 90890-03112, YU-3112 EAS00738
8-30 Does the Headlight relay (dimmer) have continuity between red / yellow and black / green ? NOYES Replace the dimmer relay. Positive tester probe red / yellow Negative tester probe black / green 1 2 3 4 5. Headlight relay (on / off) Disconnect the headlight relay (on / off) from the coupler. Connect the pocket tester (Ω 1) and bat- tery (12 V) to the headlight relay (on / off) as shown. Positive battery lead red / yellow Negative battery lead yellow / black EAS00787 YESNO 7. Wiring Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the lighting system’s wiring properly con- nected and without defects? Properly connect or repair the lighting system’s wiring. Check the condition of each of the lighting system’s circuits. Refer to “CHECK- ING THE LIGHTING SYSTEM”. Does the headlight relay (dimmer) have continuity between black / green and black / yellow ? Positive tester probe black / green Negative tester probe black / yellow 1 2 3 4 6. Headlight relay (dimmer) Disconnect the headlight relay (dimmer) from the coupler. Connect the pocket tester (Ω 1) and bat- tery (12 V) to the headlight relay (dimmer) as shown. Positive battery lead black Negative battery lead yellow 3 4 3 4 YESNO Replace the head- light relay (dimmer). LIGHTING SYSTEMELEC
8-31 High beam indicator light (LEDs) Positive tester probe black / yellow Negative tester probe black / white YESNO 1. Headlight bulb and socket Check the headlight bulb and socket for con- tinuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. Are the headlight bulb and socket OK? Replace the head- light bulb, socket or both. YESNO 2. Voltage Connect the pocket tester (DC 20 V) to the headlight and meter assembly couplers as shown. The wiring circuit from the main switch to the headlight cou- pler is faulty and must be repaired. When the dimmer switch is set to “ ” When the dimmer switch is set to “ ” Headlight coupler (wire harness side) Low beam Headlight Positive tester probe black Negative tester probe black / green 1 2 Meter assembly coupler (wire harness side) Turn the main switch to “ON”. Start the engine. Set the dimmer switch to “ ” or “ ”. Measure the voltage (DC 12 V) of black / green or black / yellow on the headlight coupler (wire harness side). Is the voltage within specification? 2 This circuit is OK. A B Headlight Positive tester probe black Negative tester probe black / yellow A Headlight coupler (wire harness side) High beam B 6 5 3 4 4 LIGHTING SYSTEMELEC EAS00788 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on.
8-32 LIGHTING SYSTEMELEC YESNO 1. License plate light bulb and socket Check the license plate light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. Are the license plate light bulb and socket OK? Replace the license plate light bulb, sock- et or both. EAS007922. The license plate light fails to come on. YESNO 2. Voltage Connect the pocket tester (DC 20 V) to the license plate light coupler (wire harness light side) as shown. The wiring circuit from the main switch to the license plate light coupler is faulty and must be re- paired. Positive tester probe blue / red Negative tester probe black 1 2 Turn the main switch to “ON”. Measure the voltage (DC 12 V) of blue / red on the license plate light coupler (wire harness side). Is the voltage within specification? 1 This circuit is OK. EAS00790 3. The tail / brake light fails to come on. YESNO 1. Voltage Connect the pocket tester (DC 20 V) to the tail / brake light coupler (wire harness side) as shown. Wiring circuit from the main switch to the tail / brake light coupler is faulty and must be repaired. Positive tester probe blue / red Negative tester probe black 1 2 Turn the main switch to “ON”. Measure the voltage (DC 12 V) of blue / red on the tail / brake light coupler (wire har- ness side). Is the voltage within specification? 1 This circuit is OK.
8-33 LIGHTING SYSTEMELEC EAS00791 4. The auxiliary light fails to come on. YESNO 1. Auxiliary light and socket Check the auxiliary light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. Are the auxiliary light .bulb and socket OK? Replace the auxiliary light bulb, socket or both. YESNO 2. Voltage Connect the pocket tester (DC 20 V) to the auxiliary light coupler (auxiliary light side) as shown. The wiring circuit from the main switch to the auxiliary light coupler is faulty and must be repaired. Positive tester probe blue / red Negative tester probe black 1 Turn the main switch to “ON”. Measure the voltage (DC 12 V) of blue / red on the auxiliary light coupler (auxiliary light side). Is the voltage within specification? 2 This circuit is OK. 2 5. The turn signa l/ position light fails to come on. YESNO 1. Turn signal / position light and socket Check the turn signal / position light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. Are the turn signal / position light bulb and socket OK? Replace the turn sig- nal / position light bulb, socket or both. YESNO 2. Voltage Connect the pocket tester (DC 20 V) to the turn signal / position light coupler (wire har- ness side) as shown. The wiring circuit from the main switch to the turn signal / position light coupler is faulty and must be repaired. Turn the main switch to “ON”. Measure the voltage (DC 12 V) of blue or blue on the turn signal / position light cou- pler (wire harness side). Is the voltage within specification? 3 This circuit is OK. Left turn signal / position light Positive tester probe blue Negative tester probe black Right turn signal / position light Positive tester probe blue Negative tester probe black 1 2 A Left turn signal / position light Right turn signal / position light B A B 3 4 1
8-34 SIGNALING SYSTEMELEC EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM
8-35 SIGNALING SYSTEMELEC 1Main switch 4Fuse (main) 6Battery 10Starting circuit cut-off relay 11Neutral switch 13Fuel pump 14E.C.U. 27Speed sensor 38Fuel level warning light 39Oil level warning light 40Neutral indicator light 41Tachometer 42Shift timing indicator light 43Multi function meter 45Coolant temperature indicator light 47Turn signal indicator light (left) 48Turn signal indicator light (light) 55Turn signal relay 58Horn switch 60Turn signal switch 61Horn 62Front turn signal / position light (left) 63Front turn signal / position light (right) 64Rear turn signal light (left) 65Rear turn signal light (right) 73Fuse (ignition) 74Fuse (signal)
8-36 YESNO Clean the battery terminals. Recharge or re- place the battery. EAS00749 3. Main switch Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the main switch OK? YESNO Replace the main switch. YESNO 1. Horn switch Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the horn switch OK? Replace the left han- dlebar switch. EAS00796 CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. EAS00795 4. Wiring Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the signaling system’s wiring properly connected and without defects? YESNO Properly connect or repair the signaling system’s wiring. Check the condition of each of the signal- ing system’s circuits. Refer to “CHECK- ING THE LIGHTING SYSTEM”. SIGNALING SYSTEMELEC NOTE: YESNO 1. Backup, main, ignition, signal and park fuses Check the backup, main, ignition, signal and park fuses for continuity. Refer to “CHECKING THE FUSES” in chap- ter 3. Are the backup, main, ignition, signal and park fuses OK? Replace the fuse(s). 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? EAS00739EAS00794 TROUBLESHOOTING Any of the following fail to light: turn sig- nal light, brake light or an indicator light. The horn fails to sound. Check: 1. backup, main, ignition, signal, and park fuses 2. battery 3. main switch 4. wiring connections (of the entire signaling system) Before troubleshooting, remove the following part(s): 1. seat 2. fuel tank 3. side cowlings Troubleshoot with the following special tool(s). Pocket tester 90890-03112, YU-3112 EAS00738
8-37 SIGNALING SYSTEMELEC YESNO 1. Tail / brake light bulb and socket Check the tail / brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. Are the tail / brake light bulb and socket OK? Replace the tail / brake light bulb, socket or both. EAS007972. The tail / brake light fails to come on. YESNO 2. Brake light switches Check the brake light switches for continuity. Refer to “CHECKING THE SWITCHES”. Is the brake light switch OK? Replace the brake light switch. 3. Voltage Connect the pocket tester (DC 20 V) to the tail / brake light coupler (wire harness side) as shown. Positive tester probe yellow Negative tester probe black 1 2 Turn the main switch to “ON”. Pull in the brake lever or push down on the brake pedal. Measure the voltage (DC 12 V) of yellow on the tail / brake light coupler (wire harness side). Is the voltage within specification? 1 YESNO 2. Voltage Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown. The wiring circuit from the main switch to the horn connec- tor is faulty and must be repaired. Positive tester probe black / white Negative tester probe ground 1 Turn the main switch to “ON”. Push the horn switch. Measure the voltage (DC 12 V) of black / white at the horn terminal. Is the voltage within specification? NOYES 3. Horn Disconnect the black connector at the horn terminal. Connect a jumper lead to the horn termi- nal and ground the jumper lead. Turn the main switch to “ON”. Push the horn switch. Does the horn sound? The horn is OK. 1 Replace the horn.