lock YAMAHA YZF-R1S 2004 Manual PDF

7-33
FUEL INJECTION SYSTEMFI
To prevent damaging the sub-throttle ser-
vomotor, perform this test within a few se-
conds of connecting the battery. Positive battery terminal
yellow / red
Negative battery terminal
yellow / white
1
2
CAUTION:
Fault code No.48SymptomSub-throttle servo motor is stuck.
Used diagnostic code 56
OrderInspection operation item and probable
couseOperation 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
couplerIf there is a malfunction repair it and
connect it securely.
Sub-throttle servo motor coupler
Main wire harness ECU coupler.Reinstated by
turning the
main switch
ON.
It takes 120
2Open or short circuit in wire harness.Repair or replace if there is an open
or short circuit.
Between motor coupler and ECU coupler.
Yellow / Red – Yellow / Red
Yellow / White – Yellow / Whiteseconds at the
maximum
before the
original state
returns.
3Defective sub-throttle servo motor.Execute the diagnostic mode (Code No.56).
Replace if defective.
1. Disconnect the sub-throttle cables from the
Sub-throttle servomotor pulley.
2. Disconnect the sub-throttle servomotor coupler
from the wire harness.
3. Connect the battery leads to the sub-throttle
servomotor coupler as shown.
4. Check that the sub-throttle servomotor pulley
rotates several times.
5. Does the sub-throttle servomotor pulley turn?
Fault code No.50SymptomFaulty ECU memory. (When this malfunction is detected in the ECU, the fault
code number might not appear on the meter.)
Used diagnostic code No. – –
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Malfunction in ECUReplace the ECU.Reinstated by
turning the
main switch
ON.
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7-34
FUEL INJECTION SYSTEMFI
Fault code No.Er-1SymptomNo signal are received from the ECU.
Er-2SymptomNo signal are received from the ECU within the specified duration.
Er-3SymptomData from the ECU cannot be received correctly.
Er-4SymptomNon-registered data has been received from the meter.
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.
Cylinder identification sensor coupler
Main wiring harness ECU coupler
Sub-wire harness couplerReinstated by
turning the
main switch
ON.
2Open or short circuit in wiring harness
and / or sub lead.Repair or replace if there is an open or short
circuit.
Between sensor coupler and ECU coupler
Yellow / Blue – Yellow / Blue
Black / White – Black / White
3Malfunction in meterReplace the meter.
4Malfunction in ECUReplace the ECU.
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7-44
THROTTLE BODIESFI
2. Adjust:

sub-throttle position sensor full open angle
a. Turn the nut
1 of the worm shaft of the sub-
throttle counterclockwise until it contacts
with the full open stopper.
b. When the dimension of
a sections of the
throttle bodies #3 and #4 is measured with a
micrometer caliper, adjust with the adjuster
2 of the output shaft section of the sub-
throttle servo motor so that the dimension is
in a range from 24.2 to 24.6 mm (0.95 to 0.97
in).
AFront side
BRear side
Sub-throttle dimension a
24.2
24.6 mm (0.95
0.97 in)
c. After adjusting the dimension of
a sections
of the throttle bodies #3 and #4, measure the
dimension of
a sections of #1 and #2.
d. If the dimension of
a sections of the throttle
bodies #1 and #2 is different from the dimen-
sion of
a sections of the throttle bodies #3
and #4, adjust it to the same dimension as
the measurement value adjusted for the
throttle bodies #3 and #4, using the tuning
screw
3 located between the throttle bodies
#2 and #3.
3. Adjust:

primary opening
a. After performing the full open angle of the
sub-throttle position sensor, turn the nut of
the worm shaft clockwise, measure the di-
mension of
b section with a micrometer cali-
per or other device and adjust so that the di-
mension is in a range from 8.1 to 8.5 mm
(0.32 to 0.33 in).
AFront side
BRear side
Sub-throttle dimension b
8.1
8.5 mm (0.32
0.33 in)
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8-5
CHECKING THE BULBS AND BULB SOCKETSELEC
WARNING
EAS00732
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continu-
ity between the terminals.
Damage / wear
Repair or replace the bulb,
bulb socket or both.
Improperly connected
Properly connect.
No continuity
Repair or replace the bulb, bulb
socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown in
the illustration on the left.

Bulbs
A and B are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The ma-
jority of these types of bulbs can be removed
from their respective socket by turning them
counterclockwise.

Bulbs
C are used for turn signal and
tail / brake lights and can be removed from
the socket by pushing and turning the bulb
counterclockwise.
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:

bulb

Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.

When changing the tail / brake light bulb,
confirm that the frame has cooled accord-
ing to the warning label and change the
tail / brake light bulb.
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8-20
STARTER MOTORELEC
Order Job / Part Q’ty Remarks
Disassembling the starter motor
O-ring
Front cover
Lock washer
Washer
Starter motor yoke
Armature assembly
O-ring
Starter motor lead
Brush holder
Rear cover1
1
1
1
1
1
2
2
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
4
5
6
7
8
9
10
5 Nm (0.5 m
kg, 3.6 ft
lb)
5 Nm (0.5 m
kg, 3.6 ft
lb)
5 Nm (0.5 m
kg, 3.6 ft
lb)
EAS00768
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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 m
kg, 14 ft
lb)
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
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