ECU YAMAHA YZF-R1S 2004 Service Manual

CHECKING THE WATER PUMP 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE WATER PUMP 6-15. . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECU’S SELF-DIAGNOSTIC FUNCTION 7-4. . . . . . . . . . . . . . . . . . . . . .
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL
(FAIL-SAFE ACTION) 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAIL-SAFE ACTIONS TABLE 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING CHART 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC MODE 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING DETAILS 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE BODIES7-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INJECTORS 7-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE INJECTORS 7-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THROTTLE BODIES 7-39. . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THROTTLE BODY JOINTS 7-39. . . . . . . . . . . . . . . . . .
CHECKING THE PRESSURE REGULATOR 7-40. . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR
OPERATION 7-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR 7-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE SUB-THROTTLE POSITION
SENSOR 7-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE THERMO WAX 7-45. . . . . . . . . . . .
AIR INDUCTION SYSTEM7-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INJECTION 7-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CUT-OFF VALVE 7-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM DIAGRAMS 7-47. . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE AIR INDUCTION SYSTEM 7-48. . . . . . . . . . . . . . . . . .
CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING SWITCH CONTINUITY8-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWITCHES8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BULBS AND BULB SOCKETS8-5 . . . . . . . . . . . . . . . . .
TYPES OF BULBS 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULBS 8-5. . . . . . . . . . . . . . . .
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2-41
C Fold back the clamp and secure
it after passing the lead through
the clamp.
D To the EXUP servo motor
E Pass the coolant reservoir tank
drain hose and fuel tank drain
hose through the clamp from the
outer side of the water pump inlet
pipe after routing it behind the
water pump breather hose.
The lengths of two hose ends are
allowed to be random. Any direc-
tion of cut edges can be ac-
cepted. (Only for the fuel tank
drain hose)
F Clamp the fuel tank drain hose
and fuel tank breather hose.A Clamp the leads so that they are
positioned inner of the vehicle
than the washer position after
routing them between the frame
and radiator stay. Align the clamp
position with the taping sections
of leads. Point the tip of the clamp
(surplus section) to the down
front side of the vehicle.
What the clamp fastens at this
stage are the handlebar switch
and main switch leads.
B Pass the main switch lead and
left handlebar switch lead be-
tween the frame and the heat
protector.
CABLE ROUTINGSPEC
1Heat protector
2Main switch lead
3Left handlebar switch lead
4EXUP servo motor lead
5Coolant reservoir tank drain hose
6Fuel tank drain hose
7Coolant outlet pipe
8Sidestand switch lead
9Oil level switch lead
10A.C.magneto lead
11Fuse box stay
12Water hose
13Stay 1
14Chain case cover
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3-6
FUEL TANK
CHK
ADJ
4 Nm (0.4 m
kg, 2.9 ft
lb)
NOTE:
CAUTION:
INSTALLING THE FUEL PUMP
1. Install:

fuel pump

Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.

Always use a new fuel pump gasket.

Install the fuel pump as shown in the illustra-
tion.

Tighten the fuel pump bolts in stages in a criss-
cross pattern and to the specified torque.
INSTALLING THE FUEL TANK
1. Install:

fuel hose

fuel return hose

fuel hose connector cover
When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose holder is in the correct position,
otherwise the fuel hose will not be properly
installed.
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3-20
ADJUSTING THE EXHAUST GAS VOLUME
CHK
ADJ
NOTE:
NOTE: 3. Using the “SELECT” button, select either the
Co adjustment mode
1 (which appears as
“Co”) or the diagnosis mode (which appears
as “dIAG”).
4. After “Co” appears as a result of pressing the
“SELECT” button, simultaneously press the
“SELECT” and “RESET” buttons for 2 se-
conds or more to excute the selection.
5. Press the “SELECT” and “RESET” buttons to
select the cylinder
2.

The adjustment cylinder appears on the clock
LCD.
“RESET” button = decrement
“SELECT” button = increment
6. Excute the selection of the cylinder by simul-
taneously pressing the “SELECT” and “RE-
SET” buttons for approximately 2 seconds.
7. After selecting the adjustment cylinder,
change the “Co” adjustment volume by
pressing the “SELECT” and “RESET” but-
tons.
The Co adjustment volume appears on the trip
LCD.
“RESET” button = decrement
“SELECT” button = increment
8. The selection is executed upon releasing the
finger from the switch.
9. Simultaneously press the “SELECT” and
“RESET” buttons to return to the cylinder
selection. (step 5)
10. Cancel the mode by turning “OFF” the main
switch.
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3-49
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
NOTE:
CAUTION:
WARNING
NOTE:
EAS00140
ADJUSTING THE DRIVE CHAIN SLACK
The drive chain slack must be checked at the
tightest point on the chain.
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swin-
garm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Spin the rear wheel several times and find
the tightest position of drive chain.
3. Check:

drive chain slack
a
Out of specification
Adjust.
Drive chain slack
25
35 mm (0.98
1.38 in)
4. Adjust:

drive chain slack
a. Loosen the wheel axle nut
1.
b. Loosen both locknuts
2.
c. Turn both adjusting bolts
3 in direction a or
b until the specified drive chain slack is ob-
tained.
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3-51
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
WARNING
NOTE:
NOTE:
EAS00146
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Check:

steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding / looseness
Adjust the steering
head.
3. Remove:

upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
4. Adjust:

steering head
a. Remove the lock washer
1, the upper ring
nut
2, and the rubber washer 3.
b. Loosen the lower ring nut
4 and then tighten
it to specification with a steering nut wrench
5.
Set the torque wrench at a right angle to the
steering nut wrench.
Steering nut wrench
90890-01403, YU-33975
Lower ring nut (initial tightening
torque)
52 Nm (5.2 m
kg, 38 ft
lb)
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3-53
CHECKING AND ADJUSTING THE STEERING HEAD /
CHECKING THE FRONT FORKCHK
ADJ
WARNING
Steering head tension
200
500 g
e. Repeat the above procedure on the opposite
handlebar.
f. If the steering head tension is out of specifi-
cation (both handlebars should be within
specification), remove the upper bracket and
loosen or tighten the upper ring nut.
g. Reinstall the upper bracket and measure the
steering head tension again as described
above.
h. Repeat the above procedure until the steer-
ing head tension is within specification.
i. Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding / looseness
Adjust the steering
head.
EAS00150
CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Check:

inner tube
1
Damage / scratches
Replace.

oil seal
2
Oil leakage
Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:

front fork operation
Push down hard on the handlebars several
times and check if the front fork rebounds
smoothly.
Rough movement
Repair.
Refer to “FRONT FORK” in chapter 4.
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3-54
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
WARNING
CAUTION:
a
b
CAUTION:
EAS00155
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.

Always adjust both front fork legs evenly.
Uneven adjustment can result in poor han-
dling and loss of stability.

Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload

Grooves are provided to indicate the ad-
justment position.

Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:

spring preload
a. Turn the adjusting bolt
1 in direction a or
b.
Direction
Spring preload is
increased (suspension is
harder).
Direction
Spring preload is
decreased (suspension
is softer).
Adjusting positions
Minimum: 8
Standard: 4.5
Maximum: 1
Rebound damping
Never go beyond the maximum or minimum
adjustment positions.
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3-56
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
WARNING
CAUTION:
a
b
CAUTION:
EAS00158
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:

spring preload
a. Adjust the spring preload with the special
wrench and extension bar included in the
owner’s tool kit.
b. Turn the adjusting ring
1 in direction a or
b.
c. Align the desired position on the adjusting
ring with the stopper
2.
Direction
Spring preload is
increased (suspension is
harder).
Direction
Spring preload is
decreased (suspension
is softer).
Adjusting positions
Minimum: 1
Standard: 4
Maximum: 9
Rebound damping
Never go beyond the maximum or minimum
adjustment positions.
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3-69
A
A
B
B
B
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
WARNING
EAS00183
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
headlight bulbs.
1. Disconnect:

headlight bulb cover
1

headlight coupler 2
Ahigh beam
Blow beam
2. Remove:

headlight bulb holder
1
Ahigh beam
Blow beam
3. Remove:

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

headlight bulb
New
Secure the new headlight bulb with the head-
light bulb holder.
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