check oil YAMAHA YZF-R1S 2004 Repair Manual

8-6
CHECKING THE BULBS AND BULB SOCKETSELEC
CAUTION:
NOTE:

Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
the coupler.

Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb, and the luminous flux will be adverse-
ly affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Check:

bulb (for continuity)
(with the pocket tester)
No continuity
Replace.
Pocket tester
90890-03112, YU-3112
Before checking for continuity, set the pocket
tester to “0” and to the “Ω
1” range.
a. Connect the positive tester probe to terminal
1 and the negative tester probe to terminal
2, and check the continuity.
b. Connect the positive tester probe to terminal
1 and the negative tester probe to terminal
3, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:

bulb socket (for continuity)
(with the pocket tester)
No continuity
Replace.
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

8-11
IGNITION SYSTEMELEC
NOYES
1
a
2
4. Ignition spark gap
The following procedure applies to all of the
spark plugs.

Disconnect the spark plug cap from the
spark plug.

Connect the ignition checker and spark
plug cap as shown.

Set the main switch to “ON”.

Measure the ignition spark gap .

Crank the engine by pushing the starter
switch and gradually increase the spark gap
until a misfire occurs.
Minimum ignition spark gap
6 mm (0.24 in)

Is there a spark and is the spark gap within
specification?
The ignition system
is OK.
5. Ignition coil resistance
The following procedure applies to all of the
ignition coils.

Disconnect the ignition coil leads from the
wire harness.

Connect the pocket tester (Ω
1) to the
ignition coil as shown.
EAS00747
Positive tester probe

ignition coil terminal
Negative tester probe

ignition coil terminal

Connect the pocket tester (Ω
1k) to the
ignition coil as shown.
Measure the primary coil resistance.
Primary coil resistance
1.19  1.61 Ω at 20C
Negative tester probe

ignition coil terminal
Positive tester probe

spark plug terminal
1
2

Measure the secondary coil resistance.
Secondary coil resistance
8.5  11.5 kΩ at 20C

Is the ignition coil OK?
YESNO
Replace the ignition
coil.
EAS00743
ProCarManuals.com

8-21
STARTER MOTORELEC
NOTE:
EAS00770
CHECKING THE STARTER MOTOR
1. Check:

commutator
Dirt
Clean with 600 grit sandpaper.
2. Measure:

commutator diameter
a
Out of specification
Replace the starter
motor.
Commutator wear limit
24.5 mm (0.96 in)
3. Measure:

mica undercut
a
Out of specification
Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commuta-
tor.
Mica undercut
1.5 mm (0.06 in)
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
4. Measure:

armature assembly resistances (commuta-
tor and insulation)
Out of specification
Replace the starter
motor.
a. Measure the armature assembly resistances
with the pocket tester.
Pocket tester
90890-03112, YU-3112
Armature coil
Commutator resistance
1
0.0090  0.0110 Ω
at 20C (68F)
Insulation resistance
2
Above 1 MΩ at 20C (68F)
b. If any resistance is out of specification, re-
place the starter motor.
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

8-40
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
ProCarManuals.com

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
ProCarManuals.com

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
ProCarManuals.com

9-1
STARTING FAILURES
TRBL
SHTG
NOTE:
FUEL SYSTEM
Fuel tank
Empty 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
ProCarManuals.com