turn signal YAMAHA YZF-R1SC 2004 Service Manual

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2-15
ELECTRICAL SPECIFICATIONSSPEC
ELECTRICAL SPECIFICATIONS
ItemStandardLimit
System voltage12 V



Ignition system
Ignition system type
Ignition timing
Crankshaft position sensor
resistance / color
T.C.I. unit model (manufacturer)
DC. T.C.I.
5 BTDC at 1,050 r / min
336  504 Ω at 20C (68F) / Gy-B
F8T822 (MITSUBISHI) (USA)
F8T823 (MITSUBISHI) (CAL)



















Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
F6T558 (MITSUBISHI)
6 mm (0.24 in)
1.19  1.61 Ω at 20C (68F)
8.5  11.5 kΩ at 20C (68F)















Charging system
System type
Model (manufacturer)
Normal output
Stator coil resistance / color
A.C. magneto
F4T850 (MITSUBISHI)
14 V / 560 W at 5,000 r / min
0.14  0.18 Ω at 20C (68F) / W-W















Rectifier / regulator
Regulator type
Model (manufacture)
Semi conductor short circuit
FH011AA (SHINDENGEN)







()
No-load regulated voltage
Rectifier capacity
Withstand voltage
()
14.3  15.1 V
50 A
100 V











Battery
Battery type
Battery voltage / capacity
Specific gravity
Manufacturer
Ten hour rate amperage
YTZ10S
12 V / 8.6 Ah
1.310
YUASA
0.8 A



















Headlight typeHalogen bulb
Bulbs (voltage / wattage
quantity)
Headlight
Auxiliary light
Tail / brake light
Front turn signal light / position light
Rear turn signal light
Licence plate light
Meter light
12 V 55 W
4
12 V 5 W
2
LED
1
12 V 21 W / 5 W
2
12 V 21 W
2
12 V 5 W
1
LED
1



























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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)



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2-35
CABLE ROUTINGSPEC
G Clamp the head light lead by
wrapping and insert it to the in-
take air grill hole. (only at the
right side.)
H Do not connect the wire to the
coupler with the plug for options.
I To the turn signal light
J To the wire harness
K Cut the tip of the clamp.A Insert to the rib of the head light.
(Either location of the right and
left relays is acceptable.)
B The lead should not stretch too
much.
C Make sure to insert the coupler
and boot to the stay 1 hole.
D The speedometer lead should
not be strained.
E To the stay 1 hole
F Connect after passing over the
upper side of the duct.1Ground lead
2Meter lead
3Stay 1
4Auxiliary light lead (right)
5Headlight lead
6Auxiliary light lead (left)
7Console panel 1
8Duct 1
9Console panel 2
10Duct 2
11Headlight lead (right)
12Headlight lead (left)
EAS00035
CABLE ROUTING
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2-43
33Throttle body side cap
34Mud guard
35Turn signal light lead
36License plate light lead
37Rear fender rib
38Speed sensor lead
39Rear brake light switch lead
40Rear frame
41Swingarm bracket
42Main fuse lead
43Starting circuit cut-off relay lead
44Turn signal light relay lead
45Starter relay lead
46Main fuse lead (To the battery
positive lead)
47Right handlebar switch lead
17Battery negative lead
18Starter motor lead
19A.C.magneto lead
20Oil level switch lead
21Sidestand switch lead
22Throttle body lead
23Coolant reservoir tank drain hose
24Fuel tank drain hose
25Cover 7
26Radiator fan motor lead (left)
27Radiator fan motor lead (right)
28Wire harness
29Pipe 3
30Frame
31Coolant reservoir tank hose
32Thermo stat assembly breather
hose
CABLE ROUTINGSPEC
1Heat protector
2Crankshaft position sensor lead
3Neutral switch lead
4Ground lead
5Coolant reservoir tank
6Battery positive lead
7Starter relay
8Turn signal relay
9Main fuse
10Lean angle cut-off switch
11Atmospheric pressure sensor
12Tail / brake light lead
13Rear fender
14Seat lock cable
15Anti safety alarm coupler
16Starting circuit cut-off relay
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2-45
W Point the tip of the clamp (sur-
plus section) to the rear side of
the vehicle. Fasten the starter
relay lead, turn signal relay lead,
main fuse lead, main fuse lead
(from the battery positive lead)
and starting circuit cut-off relay
lead with a clamp.
X Route each lead under the wire
harness.
Y Fasten the wire harness, battery
negative lead and starter motor
lead with a clamp. Point the tip of
the clamp (excessive part) to the
inside of the vehicle.P Pass the lead through inside of
the battery band.
Q Press on the tip of the clamp af-
ter passing the leads through it.
R Insert the tail / brake light lead to
the rear frame hole.
S Insert the clamp from the vehicle
front to the rear side and fasten
each lead, coupler and onion-
head to the fender rib, and then
point the tip of the clamp (exces-
sive part) to the upper side of the
vehicle.
T Hold down the clamp tips after
passing each lead.U Make sure to position the cou-
pler at the downmost position of
leads. However, the coupler
should be set in the rear frame so
that it is not caught by the seat
bottom, cover and other compo-
nents.
V Point the tip of the clamp (exces-
sive part) to the inside of the ve-
hicle. Fasten the wire harness
with a clamp.
CABLE ROUTINGSPEC
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3-7
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13Removing the front cowling and
side cowlings
Rider seat
Side cowling
Front turn signal light lead coupler
Side cowling inner panel
Bottom cowling
Bottom cowing front cover
Frame side cover
Frame side panel
Headlight panel
Front cowling
Rear view mirror
Windshield
Air intake duct
Air intake duck mount2
2
2
2
1
2
2
2
1
2
1
2
2Remove the parts in the order listed.
Refer to “SEATS”.
Disconnect.
For installation, reverse the removal
procedure.
7 Nm (0.7 m
kg, 5.1 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
16 Nm (1.6 m
kg, 12 ft
lb)
COWLINGS
CHK
ADJ
COWLINGS
FRONT COWLING AND SIDE COWLINGS
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3-8
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the rear cowling
Rider seat and passenger seat
Muffler
Rear cowling (upper)
Tail / brake light lead coupler
Rear turn signal light lead coupler
Tail / brake light
License plate bracket assembly
Rear cowling (lower)1
1
4
1
1
1Remove the parts in the order listed.
Refer to “SEATS”.
Refer to “EXHAUST PIPE” in chapter 5.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
4 Nm (0.4 m
kg, 2.9 ft
lb)10 Nm (1.0 m
kg, 7.2 ft
lb)
COWLINGS
CHK
ADJ
REAR COWLING
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7-5
FUEL INJECTION SYSTEMFI
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION)
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions
that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue to operate or stop operating, depending on the conditions.
The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value,
and the other in which the ECU directly operates an actuator. Details on the fail-safe actions are given
in the table below.
FAIL-SAFE ACTIONS TABLE
Fault
Code No.ItemSymptomFail-safe actionAble / unable
to startAble / unable
to drive
11
Cylinder identification
sensorNo normal signals are received from
the cylinder identification sensor.Continues to operate the engine based
on the results of the cylinder
identification that existed up to that
point.
UnableAble
12Crankshaft position
sensorNo normal signals are received from
the crankshaft position sensor.
Stops the engine (by stopping the
injection and ignition).UnableUnable
13
14Intake air pressure
sensor (open or short
circuit) (pipe system)Intake air pressure sensor-open or
short circuit detected.
Faulty intake air pressure sensor
system.
Fixes the intake air pressure to
101.3 kpa.
AbleAble
15
16Throttle position sensor
(open or short circuit)
(stuck)Throttle position sensor-open or short
circuit detected.
Fixes the throttle position sensor to
fully open.AbleAble
17EXUP servo motor
potention
(open or short circuit)EXUP servo motor potention-open or
short circuit detected.
Turn the EXUP servo motor toward
the open side for 3 seconds and then
stop it.AbleAble
18
EXUP servo motor (lock)A lock of the EXUP servo motor is
detected.
Perform the preventive control
against motor locking.
Perform the lock release operation
twice every 100 seconds.
AbleAble
19Sidestand switch (open
circuit in wire to ECU)Open circuit in the input line of ECU
No.15 terminal is detected when the
start switch is pressed.-- (No start)UnableUnable
20Intake air pressure
Atmospheric pressureDefective values are detected due to
the internal malfunction
Fixes the intake air pressure and
atmospheric pressure to 101.3 kpa.AbleAble
21Coolant temperature
sensorCoolant temperature sensor-open or
short circuit detected.
Fixes the coolant temperature to
60C.AbleAble
22Intake temperature
sensorIntake temperature sensor-open or
short circuit detected.
Fixes the intake temperature to 20C.AbleAble
23Atmospheric pressure
sensorAtmospheric pressure sensor-open or
short circuit detected.
Fixes the atmospheric pressure to
101.3 kpa.AbleAble
33
34
35
36
Faulty ignitionOpen circuit detected in the primary
lead of the ignition coil.
Cut the injection of other cylinder in
the same group with the cylinder that
the error is detected.
(Example: when the #1 cylinder is
detective, cut the injection of #1 and
#4 cylinders, when the #2 cylinder is
detective, cut the injection of #2 and
#3 cylinders).
Turn on the power to the air induction
solenoid to always cut-off the air.
Able
(depending
on the num-
ber of faulty
cylinders)Able
(depending
on the num-
ber of faulty
cylinders)
30
41Lean angle cut-off
switch (latch up
detected) (open or short
circuit)Lean angle cut-off switch-open or short
circuit detected.
Turns OFF the fuel injection system
relay of the fuel system.
UnableUnable
42Speed sensor, neutral
switchNo normal signals are received from the
speed sensor; or, an open or short
circuit is detected in the neutral switch.
Fixes the gear to the top gear.AbleAble
43Fuel system voltage
(monitor voltage)The ECU is unable to monitor the
battery voltage (an open circuit in the
line to the ECU).
Fixes the battery voltage to 12 V.AbleAble
44
Error in writing the
amount of CO
adjustment on
EEPROMAn error is detected while reading or
writing on EEPROM (CO adjustment
value).--
AbleAble
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7-6
FUEL INJECTION SYSTEMFI
Fault
Code No.ItemSymptomFail-safe actionAble / unable
to startAble / unable
to drive
46Vehicle system power
supply (Monitor voltage)Power supply to the FI system is not
normal.--AbleAble
47Sub-throttle servo motor
potention (open or short
circuit)sub-throttle servo motor potention-
open or short circuit detected.
Turn the sub-throttle servo motor
toward the close side for 4 seconds
and then stop it.AbleAble
48
Sub-throttle servo motor
(lock)A lock of the sub-throttle servo motor is
detected.
Perform the preventative control
against motor locking.
(Perform the lock release operation
twice every 100 seconds.)
AbleAble
50ECU internal
malfunction (memory
check error)Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the meter.--UnableUnable
—
Start unable warningRelay is not turned ON even if the crank
signal is input while the start switch is
turned ON.
When the start switch is turned ON
while an error is detected with the fault
code of No.11, 12, 19, 30, 41 or 50.Engine trouble warning light flashes
when the start switch is turned ON.
UnableUnable
Communication error with the meter
Fault
Code No.ItemSymptomFail-safe actionAble / unable
to startAble / unable
to drive
Er-1ECU internal malfunction
(output signal error)No signals are received from the ECU.–UnableUnable
Er-2ECU internal malfunction
(output signal error)No signals are received from the ECU
within the specified duration.–UnableUnable
Er-3ECU internal malfunction
(output signal error)Data from the ECU cannot be received
correctly.–UnableUnable
Er-4ECU internal malfunction
(input signal error)Non-registered data has been received
from the meter.–UnableUnable
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