YAMAHA YZF-R1SC 2004 Service Manual

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
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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.
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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
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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
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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.
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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
thermistor
Open-circuit

Short-circuit
The fuel level warning light indi-
cate the condition code.Refer to *1
Oil level switch
Open-circuit

Short-circuit
The oil level warning light indicate
the condition code.Refer to *2
*1Condition code
Fuel level warning light
*
2Condition code
Oil level warning light
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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
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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
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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
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9-2
9
Starting system
Faulty 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
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