charging YAMAHA YZF-R1S 2004 User Guide

7-31
FUEL INJECTION SYSTEMFI
Fault code No.44SymptomError is detected while reading or writing on EEP-ROM
(CO adjustment value).
Used diagnostic No. 60 (EEP-ROM improper cylinder indication)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Malfunction in ECUExecute diagnostic code 60
1. Check the faulty cylinder. (If there are multiple
cylinders, the number of the faulty cylinders
appear alternately at 2-second intervals.)
2. Readjust the CO of the displayed cylinder.
Refer to “ADJUSTING THE EXHAUST GAS
VALUME” in chapter 3.
Replace ECU if defective.Reinstated by
turning the
main switch
ON.
Fault code No.46SymptomPower supply to the FI system relay is not normal.
Used diagnostic code No. – –
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
ECU coupler.Reinstated by
starting the
engine and
operating it at
idle.
2Faulty batteryReplace or change the battery
Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
3The malfunction of the rectifier / regula-
tor.Replace if defective.
Refer to “CHARGING SYSTEM” in chapter 8.
4Open or short circuit in wiring harness.Repair or replace if there is an open or short
circuit.

Between battery and main switch
red – red

Between main switch and fuse (ignition)
brown/blue – brown/blue

Between fuse (ignition) and ECU
red/white – red/white
ProCarManuals.com

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
ProCarManuals.com

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
ProCarManuals.com

8-24
2A.C. magneto
3Rectifier / regulator
4Fuse (main)
6Battery
CHARGING SYSTEMELEC
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
ProCarManuals.com

8-25
NOYES
3. Charging voltage

Set the engine tachometer to the ignition coil
of cylinder #1.

Connect the pocket tester (DC 20 V) to the
battery as shown.
The charging circuit
is OK. Positive tester probe

positive battery terminal
Negative tester probe

negative battery terminal

Start the engine and let it run at approxi-
mately 5,000 r / min.

Measure the charging voltage.
Charging voltage
14 V at 5,000 r / min

Is the charging voltage within specification?
EAS00775
YESNO

Clean the battery
terminals.

Recharge or re-
place the battery.
Make sure the battery is fully charged.
NOTE:
Minimum open-circuit voltage
12.8 V or more at 20C (68F)

Is the battery OK?
CHARGING SYSTEMELEC
NOTE:
YESNO
1. Main fuse

Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3.

Is the main fuse OK?
Replace the fuse.
2. Battery

Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
EAS00739 EAS00774
TROUBLESHOOTING
The battery is not being charged.
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil lead
5. stator coil resistance
6. wiring connections
(of the entire charging system)

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
EAS00738
ProCarManuals.com

8-26
CHARGING SYSTEMELEC
YESNO 5. Stator coil resistance

Remove the generator cover.

Connect the pocket tester (Ω
1) to the sta-
tor coils as shown.
Replace the stator
coil assembly.
EAS00776
Positive tester probe
white
Negative tester probe
white
Positive tester probe
white
Negative tester probe
white1
1
2
3

Measure the stator coil resistances.
Stator coil resistance
0.14  0.18 Ω at 20C (68F)

Is the stator coil OK?
YESNO 6. Wiring

Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.

Is the charging system’s wiring properly con-
nected and without defects?
Properly connect or
repair the charging
system’s wiring.
EAS00779
Replace the rectifi-
er / regulator.
4. Stator coil lead

Disconnect stator coil lead coupler.

Connect the pocket tester (Ω
1) to the sta-
tor coil lead coupler as shown.
Positive tester probe

white
Negative tester probe

ground
3
Positive tester probe

white
Negative tester probe

ground
1
Positive tester probe

white
Negative tester probe

groundNo
continuity
2
YESNO
Replace the stator
coil lead.
Are the tester readings correct?
ProCarManuals.com

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
ProCarManuals.com

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
ProCarManuals.com

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
ProCarManuals.com

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
ProCarManuals.com