Yamaha R1 2004 ServiceManual
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8-48 1Main switch 4Fuse (main) 6Battery 7Fuse (fuel injection) 10Starting circuit cut-off relay 13Fuel pump 14E.C.U. 53Engine stop switch FUEL PUMP SYSTEMELEC EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM
8-49 FUEL PUMP SYSTEMELEC 1Battery 2Fuse (main) 3Main switch 4Fuse (ignition) 5Engine stop switch 6ECU 7Fuse (fuel injection) 8Starting circuit cut-off relay (fuel injection system relay) 9Fuel pump EAS00815 FUEL PUMP SYSTEM The ECU includes the control unit for the fuel pump.
8-50 FUEL PUMP SYSTEMELEC 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”. YESNO Replace the main switch. Is the main switch OK? EAS00750 4. Engine stop switch Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. YESNO Replace the right handlebar switch. Is the engine stop switch OK? NOTE: YESNO 1. Main, ignition and fuel injection system fuses Check the main, ignition and fuel system fuses for continuity. Refer to “CHECKING THE FUSES” in chap- ter 3. Replace the fuse(s). Are the main, ignition and fuel injection sys- tem fuses OK? EAS00816 TROUBLESHOOTING If the fuel pump fails to operate. Check: 1. main, ignition and fuel injection fuses 2. battery 3. main switch 4. engine stop switch 5. starting circuit cut-off relay (the fuel injection system relay) 6. fuel pump 7. wiring connections (the entire fuel 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
8-51 FUEL PUMP SYSTEMELEC YESNO 5. Starting circuit cut-off relay (fuel injection system 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. Replace the starting circuit cut-off relay. Positive battery lead red / black Negative battery lead blue / yellow 1 2 Positive tester probe red Negative tester probe red / blue3 4 Does the starting circuit cut-off relay have continuity between red and red / blue? YESNO 6. Fuel pump resistance Disconnect the fuel pump coupler from the wire harness. Connect the pocket tester (Ω 1) to the fuel pump coupler as shown. Properly connect or repair the fuel sys- tem’s wiring. 1 2 Positive tester probe red / blue Negative tester probe black EAS00817 YESNO Fuel pump resistance 0.2 3.0 Ω at 20C (68F) Is the fuel pump OK? Replace the fuel pump. Measure the fuel pump resistance. 7. Wiring Check the entire fuel pump system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the fuel system’s wiring properly con- nected and without defects? EAS00818 Replace the ECU. EAS00759
8-52 FUEL PUMP SYSTEMELEC WARNING EAS00819 CHECKING THE FUEL PUMP Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: Stop the engine before refueling. Do not smoke, and keep away from open flames, sparks, or any other source of fire. If you do accidentally spill gasoline, wipe it up immediately with dry rags. If gasoline touches the engine when it is hot, a fire may occur. Therefore, make sure the engine is completely cool before per- forming the following test. 1. Check: Fuel pump operation a. Insert the plug 1 to fuel return hose end. b. Fill the fuel tank. c. Put the end of the fuel hose into an open con- tainer. d. Connect the battery (DC 12 V) to the fuel pump coupler as shown. Positive battery lead red / blue 2 Negative battery lead black 3 e. If fuel flows out of the fuel hose, the fuel pump is OK. If fuel does not flow, replace the fuel pump.
8-53 SELF-DIAGNOSISELEC SELF-DIAGNOSIS The YZF-R1(S) features a self-diagnosing system for the following circuit(-s): Fuel pump thermistor Oil level switch If any of these circuits are defective, their respective condition codes will be displayed on the warning light when the main switch is turned “ON” (irrespective of whether the engine is running or not). Circuit Defect(-s)System responseCondition code Fuel pump thermistorOpen-circuit Short-circuitThe fuel level warning light indi- cate the condition code.Refer to *1 Oil level switchOpen-circuit Short-circuitThe oil level warning light indicate the condition code.Refer to *2 *1Condition code Fuel level warning light * 2Condition code Oil level warning light
8-54 SELF-DIAGNOSISELEC L/B B Lg B BG/W B R/L Y/LY/BR/G Sb/W W G/W G/W R/L B R/W LgLgB Sb/WSb/WA Br BrA R/G R/GBB/R B/RBY/B Y/BBY/L Y/LBG/W G/WA GY 14 3839 40 41 42 43 44 45 Repair or replace the wire harness. NO 1. Wire harness Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. Is the wire harness OK? YES NO 2. Fuel pump thermistor Check the fuel pump thermistor for continuity. Refer to “The fuel level warning light fails to come on”. Is the fuel pump thermistor OK? YES Replace the fuel pump.Replace the multi- function meter. NOTE: 14Fuel pump 45Multi-function meter TROUBLESHOOTING The warning light starts to indicate the self-diagnosis sequence. Check: 1. fuel pump thermistor 2. oil level switch Before troubleshooting, remove the following part(-s): 1. seat 2. fuel tank Troubleshoot with the following special tool(-s). Pocket tester 90890-03112, YU-3112 1. Fuel pump thermistor CIRCUIT DIAGRAM
8-55 SELF-DIAGNOSISELEC Replace the oil level switch. NO 2. Oil level switch Check the oil level switch for continuity. Refer to “The oil level warning light fails to come on”. Is the oil level switch OK? YES Repair or replace the wire harness. NO 1. Wire harness Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. Is the wire harness OK? YES Replace the multi- function meter. B/WWW Y/LY/BR/G Sb/W W WG/W R/WSb/WSb/WA Br BrA R/G R/GBB/R B/RBY/B Y/BBY/L Y/L Dg Ch BG/W G/WA B/W B/W GY B 40 41 42 43 44 45 46 47 48 49 50 51 52 45Multi-function meter 52Oil level switch 2. Oil level switch CIRCUIT DIAGRAM
9-1 STARTING FAILURES TRBL SHTG NOTE: FUEL SYSTEM Fuel tankEmpty fuel tank Clogged fuel filter Clogged fuel strainer Clogged fuel tank drain hose Deteriorated or contaminated fuel Fuel pump Faulty fuel pump Faulty fuel pump relay Throttle body (-ies) Deteriorated or contaminated fuel Sucked-in air Ignition coil(s) Cracked or broken ignition coil body Broken or shorted primary or secondary coils Ignition system Faulty ECU Faulty crankshaft position sensor EAS00844 TROUBLESHOOTING The following guide for troubleshooting does not cover all the possible \ causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure i\ n this manual for checks, adjustments, and replacement of parts. STARTING FAILURES ENGINE Cylinder(s) and cylinder head(s) Loose spark plug Loose cylinder head or cylinder Damaged cylinder head gasket Damaged cylinder gasket Worn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timing Faulty valve spring Seized valve Piston(s) and piston ring(s) Improperly installed piston ring Damaged, worn or fatigued piston ring Seized piston ring Seized or damaged piston Air filter Improperly installed air filter Clogged air filter element Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft ELECTRICAL SYSTEMS Battery Discharged battery Faulty battery Fuse(s) Blown, damaged or incorrect fuse Improperly installed fuse Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator
9-2 9 Starting systemFaulty starter motor Faulty starter relay Faulty starting circuit cut-off relay Faulty starter clutch STARTING FAILURES / INCORRECT ENGINE IDLING SPEED / POOR MEDIUM-AND-HIGH-SPEED PERFORMANCETRBL SHTG ELECTRICAL SYSTEMS Battery Discharged battery Faulty battery Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Ignition coil(s) Broken or shorted primary or secondary coils Cracked or broken ignition coil Ignition system Faulty ECU Faulty crankshaft position sensor Switches and wiring Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty start switch Faulty sidestand switch Faulty clutch switch Improperly grounded circuit Loose connections EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder(s) and cylinder head(s) Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Throttle body (-ies) Damaged or loose throttle body joint Improperly synchronized throttle bodies Improperly adjusted engine idling speed (idle adjusting screw) Improper throttle cable free play Flooded throttle body Faulty air induction system EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES”. ENGINE Air filter Clogged air filter element FUEL SYSTEM Fuel pump Faulty fuel pump