horn YAMAHA YZF-R1SC 2004 Service Manual
Page 16 of 457
ELECTRICAL SYSTEMS 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INCORRECT ENGINE IDLING SPEED9-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE9-2 . . . . . . . . . . . . .
ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY GEAR SHIFTING9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFTING IS DIFFICULT 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT PEDAL DOES NOT MOVE 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUMPS OUT OF GEAR 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY CLUTCH9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH SLIPS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH DRAGS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHEATING9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERCOOLING9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR BRAKING PERFORMANCE9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY FRONT FORK LEGS9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAKING OIL 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MALFUNCTION 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNSTABLE HANDLING9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY LIGHTING OR SIGNALING SYSTEM9-6 . . . . . . . . . . . . . . . . . . . .
HEADLIGHT DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BULB BURNT OUT 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAIL / BRAKE LIGHT DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . .
TAIL / BRAKE LIGHT BULB BURNT OUT 9-6. . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS SLOWLY 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL REMAINS LIT 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS QUICKLY 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN DOES NOT SOUND 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ProCarManuals.com
Page 44 of 457
2-16
ELECTRICAL SPECIFICATIONSSPEC
ItemStandardLimit
Indicator light
(voltage / wattage quantity)
Neutral indicator light
High beam indicator light
Oil level warning light
Turn signal indicator light
Fuel level warning light
Coolant temparture indicator light
Engine trouble warning light
Shift timing indicator light
LED 1
LED 1
LED 1
LED 2
LED 1
LED 1
LED 1
LED 1
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Armature coil resistance
Commutator diameter
Mica undercut
Constant mesh
5VY (YAMAHA)
0.9 kW
10.8 mm (0.43 in)
5.28 7.92 N (538 808 g,
18.99 28.48 oz)
0.0090 0.0110 Ω at 20C (68F)
24.5 mm (0.96 in)
1.5 mm (0.06 in)
3.6 mm
(0.14 in)
23.5 mm
(0.93 in)
Starter relay
Model (manufacturer)
Amperage
Coil resistance
2768079-A (JIDECO)
180 A
4.18 4.62 Ω at 20C (68F)
Horn
Horn type
Model (manufacturer) quantity
Max. amperage
Performance
Coil resistance
Plane
YF-12 (NIKKO) 1
3 A
105 113 db / 2 m
1.15 1.25 Ω at 20C (68F)
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Full transistor
FE218BH (DENSO)
No
75 95 cycles / min.
21 W 2 + 3.4 W
Oil level switch
Model (manufacturer)
5VY (SOMIC ISHIKAWA)
EXUP servo motor
Model (manufacturer)
5VY (YAMAHA)
ProCarManuals.com
Page 51 of 457
2-23
TIGHTENING TORQUESSPEC
See NOTE 2 CHASSIS TIGHTENING TORQUES
ItemThreadTighteningRemarksItemsizeNmmkgftlbRemarks
Upper bracket and outer tubeM8262.619
Upper bracket and steering stem nutM2811 311.382
Handlebar and outer tubeM8171.712
Handlebar and upper bracketM6131.39
Steering shaft and ring nutM30181.813See NOTE 1
Outer tube and under bracketM8232.317
Main switch and upper bracketM8262.619
Front brake master cylinder cap stopperM41.20.120.9
Front brake hose union boltsM10303.022
Front brake master cylinder and bracketM6131.39
Meter assembly and front cowling stay—1.30.130.9
Headlight and front cowling stay—0.80.080.6
Front cowling and headlight assembly—1.50.151.1
Cover 7, 8 and frameM650.53.6
Under cowling and engineM650.53.6
Windshield and front cowlingM50.40.040.3
Duct and console panelM51.30.130.9
End grip and handlebarM640.42.9
Horn bracket and under bracketM640.42.9
Coolant reservoir tank and frameM650.53.6
Engine mount front (left and right)M10454.533
Engine mount rear upperM10515.137
Engine mount rear underM10515.137
Engine mount rear adjust boltM1670.75.1
Catalyst pipe stay and frameM10444.432
Clutch cable lock nut (engine side)M870.75.1
Main frame and rear frameM10414.130
Throttle cable adjust nut (throttle body side)M650.53.6
Cover 2 and plate—0.80.080.6
Pivot shaft and nutM1810510.576
Connecting rod and frameM10444.432
Relay arm and connecting rodM10444.432
Relay arm and swingarmM10444.432
Rear shock absorber and relay armM10444.432
Rear shock absorber and upper bracketM10444.432
Upper bracket and frameM14929.267
Seal guardM670.75.1
Drive chain caseM670.75.1
Chain puller adjust nutM8161.612
Fuel tank and fuel pump assemblyM540.42.9
Fuel tank stay (front side) and frameM670.75.1
Fuel tank and fuel tank stay (front side)M670.75.1
Fuel tank stay (rear side) and rear frameM670.75.1
Side cover and fuel tankM50.40.040.3
Rider seat and frameM670.75.1
Seat lock plate and rear frameM6101.07
Side cover (rear side) and frameM540.42.9
ProCarManuals.com
Page 65 of 457
2-37
F Clamp the leads inside the front
fork of the vehicle. Point the exit
of the horn lead to the left front
fork side.
G Two throttle cables should not
cross with each other.
Route two throttle cables behind
the brake hose, pass between
the inside of the under bracket’s
upper side front fork and guide
wire assembly, and then pass it
through the clamp that is in-
serted to the cover 3 under the
frame.A Route the clutch cable so as to
get along the front side of the
main switch after passing it
through the guide.
B Pass the main switch lead
through the guide wire.
C Pass the left handlebar switch
lead through the guide wire.
D Point the tip of the band (exces-
sive part) to the rear side of the
vehicle and cut the surplus sec-
tion. Clamp it to the outer tube.
E Clamp the section between 0
and 20 mm (0 and 0.79 in) from
the split of the under bracket.
CABLE ROUTINGSPEC
1Right handlebar switch lead
2Clutch cable
3Main switch lead
4Left handlebar switch lead
5Horn lead
6Horn
7Throttle cables
8Brake hose
9Throttle cable (return side)
10Throttle cable (pull side)
ProCarManuals.com
Page 394 of 457
8-1
8
ELECTRICAL COMPONENTSELEC
9Oil level switch
10Radiator fan motor
11Horn
12Ignition coil
1Main switch
2Front brake light switch
3Starter relay
4Battery
5Fuse box
6Rear brake light switch
7Neutral switch
8Sidestand switch
EAS00729
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
ProCarManuals.com
Page 397 of 457
8-4
11Neutral switch
12Rear brake light switch
13Fuse box
1Main switch
2Horn switch
3Dimmer switch
4Turn signal switch
5Clutch switch
6Sidestand switch
7Engine stop switch
8Front brake light switch
9Start switch
10Oil level switch
CHECKING THE SWITCHESELEC
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage / wear Repair or replace.
Improperly connected Properly connect.
Incorrect continuity reading Replace the switch.
ProCarManuals.com
Page 428 of 457
8-35
SIGNALING SYSTEMELEC
1Main switch
4Fuse (main)
6Battery
10Starting circuit cut-off relay
11Neutral switch
13Fuel pump
14E.C.U.
27Speed sensor
38Fuel level warning light
39Oil level warning light
40Neutral indicator light
41Tachometer
42Shift timing indicator light
43Multi function meter
45Coolant temperature indicator light
47Turn signal indicator light (left)
48Turn signal indicator light (light)
55Turn signal relay
58Horn switch
60Turn signal switch
61Horn
62Front turn signal / position light (left)
63Front turn signal / position light (right)
64Rear turn signal light (left)
65Rear turn signal light (right)
73Fuse (ignition)
74Fuse (signal)
ProCarManuals.com
Page 429 of 457
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
Page 430 of 457
8-37
SIGNALING SYSTEMELEC
YESNO 1. Tail / brake light bulb and socket
Check the tail / brake light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the tail / brake light bulb and socket OK?
Replace the tail /
brake light bulb,
socket or both.
EAS007972. The tail / brake light fails to come on.
YESNO 2. Brake light switches
Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the brake light switch OK?
Replace the brake
light switch.
3. Voltage
Connect the pocket tester (DC 20 V) to the
tail / brake light coupler (wire harness side)
as shown.
Positive tester probe yellow
Negative tester probe black
1
2
Turn the main switch to “ON”.
Pull in the brake lever or push down on the
brake pedal.
Measure the voltage (DC 12 V) of yellow
on the tail / brake light coupler (wire harness
side).
Is the voltage within specification?
1
YESNO 2. Voltage
Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
The wiring circuit
from the main switch
to the horn connec-
tor is faulty and must
be repaired. Positive tester probe black / white
Negative tester probe ground
1
Turn the main switch to “ON”.
Push the horn switch.
Measure the voltage (DC 12 V) of
black / white at the horn terminal.
Is the voltage within specification?
NOYES 3. Horn
Disconnect the black connector at the horn
terminal.
Connect a jumper lead to the horn termi-
nal and ground the jumper lead.
Turn the main switch to “ON”.
Push the horn switch.
Does the horn sound?
The horn is OK.
1
Replace the horn.
ProCarManuals.com
Page 454 of 457
9-6
FAULTY LIGHTING OR SIGNALING SYSTEM
TRBL
SHTG
TURN SIGNAL DOES NOT COME ON
Faulty turn signal switch
Faulty turn signal relay
Burnt-out turn signal bulb
Incorrect connection
Damaged or faulty wire harness
Improperly grounded circuit
Faulty battery
Blown, damaged or incorrect fuse
TURN SIGNAL BLINKS SLOWLY
Faulty turn signal relay
Faulty main switch
Faulty turn signal switch
Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT
Faulty turn signal relay
Burnt-out turn signal bulb
TURN SIGNAL BLINKS QUICKLY
Incorrect turn signal bulb
Faulty turn signal relay
Burnt-out turn signal bulb
HORN DOES NOT SOUND
Improperly adjusted horn
Damaged or faulty horn
Faulty main switch
Faulty horn switch
Faulty battery
Blown, damaged or incorrect fuse
Faulty wire harness
EAS00866
FAULTY LIGHTING OR SIGNALING SYSTEM
HEADLIGHT DOES NOT COME ON
Wrong headlight bulb
Too many electrical accessories
Hard charging
Incorrect connection
Improperly grounded circuit
Poor contacts (main or light switch)
Burnt-out headlight bulb
HEADLIGHT BULB BURNT OUT
Wrong headlight bulb
Faulty battery
Faulty rectifier / regulator
Improperly grounded circuit
Faulty main switch
Faulty light switch
Headlight bulb life expired
TAIL / BRAKE LIGHT DOES NOT COME ON
Too many electrical accessories
Incorrect connection
TAIL / BRAKE LIGHT BULB BURNT OUT
Faulty battery
Incorrectly adjusted rear brake light switch
ProCarManuals.com