Yamaha Yzf R1 2007 Manual
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ELECTRICAL COMPONENTS 8-92 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the ignition coil from the spark plug. b. Connect the ignition checker/dynamic spark tester “2” as shown. c. Set the main switch to “ON”. d. Measure the ignition spark gap “a”. e. Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1. Disconnect: Crankshaft position sensor coupler (from the wire harness) 2. Check: Crankshaft position sensor resistance Out of specification → Replace the crank- shaft position sensor. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 100) to the crankshaft position sensor coupler as shown.b. Measure the crankshaft position sensor resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28130 CHECKING THE LEAN ANGLE SENSOR 1. Remove: Lean angle sensor (from the bracket.) 2. Check: Lean angle sensor out put voltage Out of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the lean angle sensor coupler to the wire harness. b. Connect the pocket tester (DC 20 V) to the lean angle sensor coupler as shown. Minimum ignition spark gap 6.0 mm (0.24 in) Ignition checker 90890-06754 Opama pet-4000 spark checker YM-34487 1. Ignition coil Crankshaft position sensor resistance 336–504 Ω at 20°C (68°F) Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Gray “1” Negative tester probe Black “2” Lean angle sensor out put volt- age Less than 65°: 0.4–1.4 V More than 65°: 3.7–4.4 V Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Yellow/Green “1” Negative tester probe Black/Blue “2”
ELECTRICAL COMPONENTS 8-93 c. When turn the lean angle sensor to 65°. d. Measure the lean angle sensor out put volt- age. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4C81020 CHECKING THE STARTER MOTOR OPERA- TION 1. Check: Starter motor operation Does not operate → Perform the electric starting system troubleshooting, starting with step 4. Refer to TROUBLESHOOTING on page 8-9. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the positive battery terminal “1” and starter motor lead “2” with a jumper lead “3”. WARNING EWA13810 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. b. Check the starter motor operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28150 CHECKING THE STATOR COIL 1. Disconnect: Stator coil coupler (from the rectifier/regulator) 2. Check: Stator coil resistance Out of specification → Replace the stator coil. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1) to the stator coil coupler as shown. b. Measure the stator coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28170 CHECKING THE RECTIFIER/REGULATOR 1. Check: Charging voltage Out of specification → Replace the rectifier/ regulator. Stator coil resistance 0.14–0.18 Ω at 20°C (68°F) Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe White “1” Negative tester probe White “2” Positive tester probe White “1” Negative tester probe White “3” Positive tester probe White “2” Negative tester probe White “3”
ELECTRICAL COMPONENTS 8-94 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachometer to the ignition coil of cylinder #1. b. Connect the pocket tester (AC 20 V) to the rectifier/regulator coupler as shown. c. Start the engine and let it run at approxi- mately 5000 r/min. d. Measure the charging voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28180 CHECKING THE HORN 1. Check: Horn resistance Out of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the horn leads from the horn terminals. b. Connect the pocket tester (Ω × 1) to the horn terminals.c. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: Horn sound Faulty sound → Adjust or replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a battery (12 V) to the horn. b. Turn the adjusting screw in direction “a” or “b” until the specified horn sound is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28190 CHECKING THE OIL LEVEL SWITCH 1. Drain: Engine oil 2. Remove: Oil level switch (from the oil pan) 3. Check: Oil level switch resistance Charging voltage 14 V at 5000 r/min Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Red “1” Negative tester probe Black “2” Horn resistance 1.15–1.25 Ω at 20°C (68°F) Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Horn terminal “1” Negative tester probe Horn terminal “2”
ELECTRICAL COMPONENTS 8-95 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 100) to the oil level switch terminal as shown. b. Measure the pickup coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28230 CHECKING THE FUEL SENDER 1. Disconnect: Fuel pump coupler Fuel sender coupler (from the wire harness) 2. Remove: Fuel tank 3. Remove: Fuel pump (from the fuel tank)4. Check: Fuel sender resistance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1) to the fuel sender terminal as shown. b. Measure the fuel sender resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28240 CHECKING THE SPEED SENSOR 1. Check: Speed sensor output voltage Out of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness side) as shown. Oil level switch Maximum level position resis- tance 484–536 Ω at 20°C (68°F) Minimum level position resis- tance 114–126 Ω at 20°C (68°F) Pocket tester 90890-03112 Analog pocket tester YU-03112-C Maximum level position “A” Positive tester probe Connector (white) “1” Negative tester probe Body earth “2” Minimum level position “B” Positive tester probe Connector (white) “1” Negative tester probe Body earth “2” Fuel sender resistance 19–141Ω at 20°C (68°F) Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Green/white “1” Negative tester probe Black “2” Output voltage reading cycle 0.6 V to 4.8 V to 0.6 V to 4.8 V Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe White/Yellow “1” Negative tester probe Black/Blue “2”
ELECTRICAL COMPONENTS 8-96 b. Set the main switch to “ON”. c. Elevate the rear wheel and slowly rotate it. d. Measure the voltage (DC 5 V) of White/Yel- low and Black/Blue. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 V 4.8V to 0.6 V to 4.8 V. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4C81021 CHECKING THE RADIATOR FAN MOTORS 1. Check: Radiator fan motor Faulty/rough movement → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the radiator fan motor coupler from the wire harness. b. Connect the battery (DC 12 V) as shown. c. Measure the radiator fan motor movement. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28260 CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: Coolant temperature sensor WARNING EWA14130 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. 2. Check: Coolant temperature sensor resistance Out of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 100) to the coolant temperature sensor “1” as shown. b. Immerse the coolant temperature sensor in a container filled with coolant “2”. NOTE: Make sure the coolant temperature sensor ter- minals do not get wet. c. Place a thermometer “3” in the coolant. Positive tester probe Blue “1” Negative tester probe Black “2” Coolant temperature sensor resistance 0°C (32°F): 5.21–6.37 kΩ 80°C (176°F): 0.29–0.35 kΩ Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Coolant temperature sensor terminal Negative tester probe Coolant temperature sensor terminal
ELECTRICAL COMPONENTS 8-97 d. Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table. e. Check the coolant temperature sensor for continuity at the temperatures indicated in the table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4C81022 CHECKING THE THROTTLE POSITION SENSOR (FOR THROTTLE CABLE PUL- LEY) 1. Remove: Throttle position sensor (for throttle cable pulley) (from the throttle body) 2. Check: Throttle position sensor (for throttle cable pulley) maximum resistance Out of specification → Replace the throttle position sensor (for throttle cable pulley) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1k) to the throttle position sensor terminal as shown.b. Measure the throttle position sensor (for throttle cable pulley) maximum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: Throttle position sensor (for throttle cable pulley) NOTE: When installing the throttle position sensor (for throttle cable pulley), adjust its angle properly. Refer to ADJUSTING THE THROTTLE POSI- TION SENSOR (FOR THROTTLE CABLE PULLEY) on page 7-7. EAS28300 CHECKING THE THROTTLE POSITION SENSOR (FOR THROTTLE VALVES) 1. Remove: Throttle position sensor (for throttle valves) (from the throttle body) 2. Check: Throttle position sensor (for throttle valves) maximum resistance Out of specification → Replace the throttle position sensor (for throttle valves) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1k) to the throttle position sensor as shown. Resistance 2.0–3.0 kΩ Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester prove → White “1” Negative tester prove → Black “2” Resistance 2.0–3.0 kΩ Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester prove → White “1” Negative tester prove → Black “2”
ELECTRICAL COMPONENTS 8-98 b. Measure the throttle position sensor (for throttle valves) maximum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: Throttle position sensor (for throttle valves) NOTE: When installing the throttle position sensor (for throttle valves), adjust its angle properly. Refer to ADJUSTING THE THROTTLE POSITION SENSOR (FOR THROTTLE VALVES) on page 7-6. EAS28370 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1. Check: Air induction system solenoid resistance Out of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the air induction system sole- noid coupler from the air induction system solenoid. b. Connect the pocket tester (Ω × 1) to the air induction system solenoid terminal as shown.c. Measure the air induction system solenoid resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28380 CHECKING THE ATMOSPHERIC PRES- SURE SENSOR 1. Check: Atmospheric pressure sensor output volt- age Out of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the atmospheric pressure sensor coupler (wire harness side) as shown. b. Set the main switch to “ON”. c. Measure the atmospheric pressure sensor output voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Solenoid resistance 18–22 Ω at 20°C (68°F) Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Brown/Red “1” Negative tester probe Red/White “2” Atmospheric pressure sensor resistance 3.75–4.25 V Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Pink “1” Negative tester probe Black/Blue “2”
ELECTRICAL COMPONENTS 8-99 EAS28390 CHECKING THE CYLINDER IDENTIFICA- TION SENSOR 1. Check: Cylinder identification sensor output volt- age Out of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the cylinder identification sensor coupler (wire harness side) as shown. b. Set the main switch to “ON”. c. Rotate the crankshaft. d. Measure the voltage (DC 20 V) of White/ Black and Black/Blue. With each full rota- tion of the crankshaft, the voltage reading should cycle from 0.8 V to 4.8 V to 0.8 V to 4.8 V. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1. Check: Intake air pressure sensor output voltage Out of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the intake air pressure sensor coupler (wire harness side) as shown. b. Set the main switch to “ON”. c. Measure the intake air pressure sensor output voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28420 CHECKING THE INTAKE AIR TEMPERA- TURE SENSOR 1. Remove: Intake air temperature sensor (from the air filter case.) WARNING EWA14110 Handle the intake air temperature sensor with special care. Never subject the intake air temperature sensor to strong shocks. If the intake air temperature sensor is dropped, replace it. 2. Check: Intake air temperature sensor resistance Out of specification → Replace. Cylinder identification sensor output voltage When sensor is on 4.8 V or more When sensor is off 4.8 V or less Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe White/Black “1” Negative tester probe Black/Blue “2” Intake air pressure sensor out- put voltage 3.15–4.15 V Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Pink/White “1” Negative tester probe Black/Blue “2”
ELECTRICAL COMPONENTS 8-100 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 100) to the intake air temperature sensor terminal as shown. b. Measure the intake air temperature sensor resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: Intake air temperature sensor Intake air pressure sensor resistance 2.21–2.69 kΩ at 20°C (68°F) Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Brown/White “1” Negative tester probe Black/Blue “2” Intake air temperature sensor bolt 1.2 Nm (0.12 m·kg, 0.87 ft·lb)