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+.
8-38 SIGNALING SYSTEMELEC NO YESNO The wiring circuit from the main switch to the tail / brake light coupler is faulty and must be repaired. This circuit is OK. YES 1. Turn signal indicator light (LEDs) Check the turn signal indicator light for conti- nuity. Refer to “CHECKING THE LEDs”. Are the turn signal indicator light OK? Replace the meter assembly. EAS00799 3. The turn signal / position light, turn signal in- dicator light or both fail to blink. YES 2. Turn signal switch Check the turn signal switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the turn signal switch OK? Replace the left han- dlebar switch. 3. Voltage Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. Positive tester probe brown Negative tester probe ground 1 Turn the main switch to “ON”. Measure the voltage (DC 12 V) on brown at the turn signal relay coupler (wire harness side). Is the voltage within specification? 1 YESNO The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be re- paired. YESNO 4. Voltage Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. The turn signal relay is faulty and must be replaced. Positive tester probe brown / white Negative tester probe ground 1 Turn the main switch to “ON”. Measure the voltage (DC 12 V) on brown / white at the turn signal relay cou- pler (wire harness side). Is the voltage within specification? 1 NO
8-39 SIGNALING SYSTEMELEC C YESNO The wiring circuit from the turn signal switch to the turn sig- nal light connector is faulty and must be repaired. Left turn signal / position light Positive tester probe chocolate Negative tester probe ground Right turn signal / position light Positive tester probe dark green Negative tester probe ground 1 2 Turn the main switch to “ON”. Set the turn signal switch to “ ” or “ ”. Measure the voltage (DC 12 V) of the choco- late or dark green at the turn signal light connector (wire harness side). Is the voltage within specification? 12 This circuit is OK. AB 1. Neutral indicator light (LEDs) Check the neutral indicator light for continu- ity. Refer to “CHECKING THE LEDs”. Are the neutral indicator light OK? EAS00801 4. The neutral indicator light fails to come on. YESNO Replace the meter assembly. YESNO 2. Neutral switch Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the neutral switch OK? Replace the neutral switch. 3. 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 Continuity Positive tester probe sky blue Negative tester probe blue / yellow No continuity 1 2 2 1 EAS00753 5. Voltage Connect the pocket tester (DC 20 V) to the turn signal light connector or meter assem- bly coupler (wire harness side) as shown. Left turn signal light Right turn signal light Turn signal indicator light A B C
8-40 SIGNALING SYSTEMELEC YESNO Replace the starting circuit cut-off relay. YESNO 4. Voltage Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. The wiring circuit from the main switch to the meter assem- bly coupler is faulty and must be re- paired. Positive tester probe brown Negative tester probe ground 1 Turn the main switch to “ON”. Measure the voltage (DC 12 V) of brown at the meter assembly coupler (wire harness side). Is the voltage within specification? This circuit is OK. Are the tester readings correct? YESNO 1. Oil level warning light (LEDs) Check the oil level warning light for continu- ity. When the main switch is turn to “ON”, the oil level warning light is come on. Are the oil level warning light OK? Replace the meter assembly. EAS00802 5. The oil level warning light fails to come on. YESNO 2. Oil level switch Drain the engine oil and remove the oil level switch from the oil pan. Connect the pocket tester (Ω 100) to the oil level switch as shown. Replace the oil level switch. Positive tester probe Connector (white) Negative tester probe Body ground 1 12 Measure the oil level switch resistance. Oil level switch resistance 114 126 Ω at 20C (68F) 484 536 Ω at 20C (68F) 1 2 Is the oil level switch OK? 2 When you switch the positive and negative tester probes, the readings in the above chart will be reversed. NOTE: 1
8-41 SIGNALING SYSTEMELEC 3. Voltage Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Positive tester probe black / red Negative tester probe black / white 1 2 Turn the main switch to “ON”. Measure the voltage (DC 12V) of black / red and black / white at the meter as- sembly coupler. Is the voltage within specification? 12 YESNO The wiring circuit from the main switch to the meter assem- bly is faulty and must be repaired. This circuit is OK. EAS00803 6. The fuel level warning light fails to come on. 1. Fuel sender Drain the fuel from the fuel tank and remove the fuel pump from the fuel tank. Disconnect the fuel sender coupler from the wire harness. Connect the pocket tester (Ω 10) to the fuel sender terminals as shown. Positive tester probe green / white Negative tester probe black 1 2 Fuel sender resistance Full position of the float 20 26 Ω at 20C (68F) Empty position of the float 134 140 Ω at 20C (68F) Is the fuel sender OK? Measure the resistances when the float arm is in contact with the full position and empty position of the stopper. NOTE: Measure the fuel sender resistances. YESNO Replace the fuel pump.
8-42 SIGNALING SYSTEMELEC YESNO 2. Voltage Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. The wiring circuit from the main switch to the meter assem- bly coupler is faulty and must be re- paired. Positive tester probe green / white Negative tester probe black / white 1 2 Turn the main switch to “ON”. Measure the voltage (DC 12 V) of green / white and black / white at the meter assembly coupler. Is the voltage within specification? This circuit is OK. 12 Replace the multi- function meter. NO 1. Multi-function meter bulb socket Check the multi-function meter bulb socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. Is the multi-function meter bulb socket OK? YES EAS008067. The speedometer fails to come on. 2. Speed sensor Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness side) as shown. Replace the speed sensor. NOYES Positive tester probe white / yellow Negative tester probe black / blue1 2 Set the main switch to “ON”. Elevate the rear wheel and slowly rotate it. Measure the voltage (DC 5 V) of white / yel- low and blue. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V. Does the voltage reading cycle correctly? This circuit is OK.
8-43 COOLING SYSTEMELEC EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM
8-44 1Main switch 4Fuse (main) 6Battery 14E.C.U. 28Coolant temperature sensor 73Fuse (ignition) 76Radiator fan motor relay 77Fuse (radiator fan motor left) 78Fuse (radiator fan motor right) 79Radiator fan motor 2 80Radiator fan motor 1 COOLING SYSTEMELEC
8-45 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 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. COOLING SYSTEMELEC NOTE: YESNO 1. Main, ignition and radiator fan motor fuses Check the main, ignition and radiator fan motor fuses for continuity. Refer to “CHECKING THE FUSES” in chap- ter 3. Are the main, ignition and radiator fan motor fuses OK? Replace the fuse(s). EAS00808 TROUBLESHOOTING The radiator fan motor fails to turn. The coolant temperature indicator light fails to light when the engine is warm. Check: 1. main, ignition, and radiator fan motor fuses 2. battery 3. main switch 4. radiator fan motor 5. radiator fan motor relay 6. coolant temperature sensor 7. wiring connections (the entire cooling 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
8-46 YESNO 4. Radiator fan motor Disconnect the radiator fan motor coupler from the wire harness. Connect the battery (DC 12 V) as shown. The radiator fan mo- tor is faulty and must be replaced. Positive battery lead blue Negative battery lead black1 2 Does the radiator fan motor turn? 5. Radiator fan motor relay Disconnect the radiator fan motor relay form the wire harness. Connect the pocket tester (Ω 1) and bat- tery (12 V) to the radiator fan motor terminal as shown. Check the radiator fan motor for continuity. Replace the radiator fan motor relay. NOYES Battery positive terminal red / white Battery negative terminal green / yellow 1 2 Does the radiator fan motor relay have conti- nuity between red and brown / green? Tester positive probe red Tester negative probe brown / green3 4 COOLING SYSTEMELEC EAS00809
8-47 COOLING SYSTEMELEC Remove the coolant temperature sensor. Connect the pocket tester (Ω 1k) to the coolant temperature sensor as shown. Immerse the coolant temperature sensor in a container filled with coolant . Make sure the coolant temperature sensor terminals do not get wet. Place a thermometer in the coolant. Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table. Check the coolant temperature sensor for continuity at the temperatures indicated in the table. EAS00812 1 Coolant temperature sensor resistance 0C (32F): 5.21 6.37 kΩ 80C (176F): 0.29 0.35 kΩ WARNING Handle the coolant temperature sensor with special care. Never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor is dropped, replace it. 6. Coolant temperature sensor Replace the coolant temperature sensor. NOYES Coolant temperature sensor 20 Nm (2.0 mkg, 14 ftlb) Three bond sealock 10 Does the coolant temperature sensor oper- ate properly? 7. Wiring Check the entire cooling system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the cooling system’s wiring properly con- nected and without defects? Properly connect or repair the cooling system’s wiring. NOYES This circuit is OK. EAS00813 2 NOTE: 3