coolant YAMAHA YZF-R1S 2004 Owner's Manual

6-8
Order Job / Part Q’ty Remarks
1
2
3
4
5Removing the thermostat assembly
Rider seat
Fuel tank
Air filter case
Coolant
Thermostat assembly outlet hose
Thermostat assembly breather hose
Thermostat assembly
Thermostat assembly inlet hose
Band1
1
1
1
2Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter3.
For installation, reverse the removal
procedure.
THERMOSTATCOOL
EAS00460
THERMOSTAT
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6-11
THERMOSTATCOOL
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
EAS00464
ASSEMBLING THE THERMOSTAT
ASSEMBLY
1. Install:

thermostat housing
1

thermostat 2

O-ring New 3

thermostat housing cover 4
Install the thermostat with its breather hole a
facing up.
EAS00466
INSTALLING THE THERMOSTAT
ASSEMBLY
1. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:

cooling system
Leaks
Repair or replace any faulty part.
3. Measure:

radiator cap opening pressure
Below the specified pressure
Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
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6-12
WATER PUMPCOOL
Order Job / Part Q’ty Remarks
1
2
3
4Removing the impeller shaft
Oil / water pump assembly and oil
pump rotor
Water pump cover
O-ring
Pin
Impeller shaft (along with the impeller)1
1
2
1
Remove the parts in the order listed.

The water pump and oil pump are com-
bined into one unit (oil / water pump as-
sembly).

It is not necessary to remove the impeller
shaft unless the coolant level is extreme-
ly low or coolant leaks from the oil pan.
Refer to “OIL PAN AND OIL PUMP” in
chapter 5.
12 Nm (1.2 m
kg, 8.7 ft
lb)
NOTE:
EAS00468
WATER PUMP
IMPELLER SHAFT
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6-15
WATER PUMPCOOL
NOTE:
CAUTION:
NOTE:
NOTE:
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:

oil seal
New 1
(into the water pump housing 2)

Before installing the oil seal, apply tap water or
coolant onto its out surface.

Install the oil seal with a socket that matches its
outside diameter.
2. Install:

water pump seal
New 1
Never lubricate the water pump seal surface
with oil or grease.

Install the water pump seal with the special
tools.

Before installing the water pump seal, apply
Yamaha bond No.1215 or Quick Gasket
2 to
the water pump housing
3.
Mechanical seal installer
4
90890-04078, YM-33221
Middle driven shaft bearing
driver
5
90890-04058, YM-04058
Yamaha bond #1215
90890-85505
Quick gasket
ACC-11001-05-01
APush down.
3. Install:

rubber damper
New 2

rubber damper holder New 1
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
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7-1
FUEL INJECTION SYSTEMFI
19Atmospheric pressure
sensor
20Fuel injection system
relay
21Engine trouble warning
light
22Lean angle cut-off
switch
23Air cut-off valve
13Coolant temperature
sensor
14Spark plug
15Cylinder identification
sensor
16Pressure regulator
17Battery
18ECU
1Ignition coil
2Air filter case
3Intake temperature
sensor
4Fuel delivery hose
5Fuel tank
6Fuel pump
7Fuel return hose
8Intake air presure sen-
sor
9Throttle position sen-
sor
10Fuel injector
11Catalytic converter
12Crankshaft position
sensor
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
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7-3
FUEL INJECTION SYSTEMFI
1Main switch
4Fuse (main)
5Fuse (backup)
6Battery
7Fuse (fuel injection)
10Starting circuit cut-off relay
11Neutral switch
12Sidestand switch
13Fuel pump
14E.C.U.
15Ignition coil #1
16Ignition coil #2
17Ignition coil #3
18Ignition coil #4
19Spark plug
20Injector #1
21Injector #2
22Injector #3
23Injector #4
25Sub-throttle position sensor
26EXUP servo motor
27Speed sensor
28Coolant temperature sensor
29Intake air temperature sensor
31Crankshaft position sensor
32Throttle position sensor
33Intake air pressure sensor
34Atmospheric pressure sensor
35Cylinder identification sensor
36Lean angle cut-off switch
43Multi function meter
53Engine stop switch
73Fuse (ignition)
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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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7-10
FUEL INJECTION SYSTEMFI
Diagnostic fault code table
Fault
code No.SymptomProbable cause of malfunctionDiagnostic
code
11
No normal signals are received from
the cylinder identification sensor.
Open or short circuit in wiring sub lead.

Open or short circuit in wiring harness.

Defective cylinder identification sensor.

Malfunction in ECU.

Improperly installed sensor.
—
12
No normal signals are received from
the crankshaft position sensor.
Open or short circuit in wiring harness.

Defective crankshaft position sensor.

Malfunction in pickup rotor.

Malfunction in ECU.

Improperly installed sensor.
—
13
Intake air pressure sensor-open or
short circuit detected.
Open or short circuit in wiring sub lead.

Open or short circuit in wiring harness.

Defective intake air pressure sensor.

Malfunction in ECU.
03
14
Faulty intake air pressure sensor hose
system; a hose is detached, causing
constant application of the
atmospheric pressure to the sensor;
or, the hose is clogged.
Intake air pressure sensor hose is detached, clogged,
kinked, or pinched.

Malfunction in ECU.
03
15
Throttle position sensor-open or
short circuit detected.
Open or short circuit in wiring sub lead.

Open or short circuit in wiring harness.

Defective throttle position sensor.

Malfunction in ECU.

Improperly installed throttle position sensor.
01
16A stuck throttle position sensor is
detected.
Stuck throttle position sensor.

Malfunction in ECU.01
17EXUP servo motor potention
circuit-open or short circuit detected.
Open or short circuit in wiring sub lead.

Detective EXUP servo motor (potention circuit).53
18EXUP servo motor is stuck.
Open or short circuit in wiring sub lead.

Stuck EXUP servo motor (mechanism).

Stuck EXUP servo motor (motor).53
19Open circuit in the input line of ECU
No.15 terminal is detected when the
start switch is pressed.
Open circuit in wiring harness (ECU Coupler).

Malfunction in ECU.20
20
When the main switch is turned to ON,
the atmospheric sensor voltage and
intake air pressure sensor voltage
differ greatly.
Atmospheric pressure sensor hose is clogged.

Intake air pressure sensor hose is clogged, kinked, or pinched.

Malfunction of the atmospheric pressure sensor in the
intermediate electrical potential.

Malfunction of the intake air pressure sensor in the
intermediate electrical potential.

Malfunction in ECU.
03
02
21Coolant temperature sensor-open or
short circuit detected.
Open or short circuit in wiring harness.

Defective coolant temperature sensor.

Malfunction in ECU.06
22Intake temperature sensor-open or
short circuit detected.
Open or short circuit in wiring harness.

Defective intake temperature sensor.

Malfunction in ECU.05
23Atmospheric pressure sensor-open or
short circuit detected.
Open or short circuit in wiring sub lead.

Defective atmospheric pressure sensor.

Malfunction in ECU.02
30The motorcycle has overturned.
Overturned.

Malfunction in ECU.08
33
Open circuit is detected in the primary
lead of the ignition coil (#1).
Open or short circuit in wiring harness.

Malfunction in ignition coil.

Malfunction in ECU.

Malfunction in a component of ignition cut-off circuit system.
30
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7-12
FUEL INJECTION SYSTEMFI
NOTE: Diagnostic mode table
Switch the meter display from the regular mode to the diagnosis mode. To switch the display, refer to
“DIAGNOSTIC MODE”.

Check the intake air temperature and coolant temperature as close as possible to the intake air tem-
perature sensor and the coolant temperature sensor respectively.

If it is not possible to check it with an atmospheric pressure gauge, judge it by using 101.3 kPa as the
standard.

If it is not possible to check the intake air temperature, use the ambient temperature as reference.
Diagnostic
codeItemDescription of actionData displayed on meter
(reference value)
01
Throttle angleDisplays the throttle angle.

Check with throttle fully closed.

Check with throttle fully open.0
125 degrees

Fully closed position (15
18)

Fully open position (95
100)
02
Atmospheric
pressureDisplays the atmospheric pressure.
* Use an atmospheric pressure gauge to check the
atmospheric pressure.Compare it to the value
displayed on the meter.
03
Intake air pressureDisplays the intake air pressure.
Engine stop switch is on.
* Generate the pressure difference by cranking the engine
with the starter, without actually starting the engine.
Not cranking-atmospheric
pressure

Cranking-intake air pressure It
changes at the value whitch is
smaller than in the atomo-
spheric pressure.
05Intake temperatureDisplays the intake air temperature.
* Check the temperature in the air cleaner case.Compare it to the value
displayed on the meter.
06Coolant temperatureDisplays the coolant temperature.
* Check the temperature of the coolant.Compare it to the value
displayed on the meter.
07
Vehicle speed pulseDisplays the accumulation of the vehicle pulses that are
generated when the tire is spun.(0
999; resets to 0 after 999)
OK if the numbers appear on
the meter.
08Lean angle cut-off
switchDisplays the lean angle cut-off switch values.Upright: 0.4
1.4 V
Overturned: 3.7
4.4 V
09Fuel system voltage
(battery voltage)Displays the fuel system voltage (battery voltage).
Engine stop switch is on.0
18.7 V
Normally, approximately 12.0 V
20Sidestand switchDisplays that the switch is ON or OFF. (When the gear is in a
position other than neutral.)Stand retracted: ON
Stand extended: OFF
21Neutral switchDisplays that the switch is ON or OFF.Neutral: ON
In gear: OFF
30
Ignition coil #1After the engine stop switch has been turned from OFF to
ON, it actuates ignition coil #1 for five times every second
and illuminates the engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check that spark is generated,
5 times with the engine stop
switch ON.
31
Ignition coils #2After the engine stop switch has been turned from OFF to
ON, it actuates ignition coil #2 for five times every second
and illuminates the engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check that spark is generated,
5 times with the engine stop
switch ON.
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7-23
FUEL INJECTION SYSTEMFI
Fault code No.21SymptomOpen or short circuit is detected from the coolant temperature sensor.
Used diagnostic code No. 06 (coolant temperature sensor)
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.
Coolant temperature 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
Black / Blue – Black / Blue
Green / White – Green / White
3Defective coolant temperature sensor.Execute the diagnostic mode (Code No.06).
Replace if defective.
Refer to “COOLING SYSTEM” in chapter 8.
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