charging YAMAHA YZF-R1S 2004 Service Manual

CHASSIS3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL 3-44. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-45. . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE PADS 3-45. . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE HOSES 3-46. . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-47. . . . . . . . . . . . . . .
ADJUSTING THE SHIFT PEDAL 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE DRIVE CHAIN SLACK 3-49. . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE DRIVE CHAIN 3-50. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD 3-51. . . . . . . . .
CHECKING THE FRONT FORK 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT FORK LEGS 3-54. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-56. . . . .
CHECKING THE TIRES 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WHEELS 3-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND LUBRICATING THE CABLES 3-61. . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS 3-61. . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND 3-61. . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION 3-61. . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM3-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CHARGING THE BATTERY 3-62. . . . . . . . . . . . . . . . .
CHECKING THE FUSES 3-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS 3-69. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAMS 3-70. . . . . . . . . . . . . . . . . . . . . .
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISCS 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7. . . . . . . . .
REAR WHEEL AND BRAKE DISC4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE DISC AND REAR WHEEL SPROCKET 4-10. . . . . . . . .
REMOVING THE REAR WHEEL 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL DRIVE HUB 4-13. . . . . . . . . . . . . . . . .
CHECKING AND REPLACING THE REAR WHEEL
SPROCKET 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR WHEEL 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR WHEEL STATIC BALANCE 4-14. . . . . . . . . . .
ProCarManuals.com

CHECKING THE CONDITION OF THE BULB SOCKETS 8-6. . . . . . .
CHECKING THE LEDs 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM8-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC STARTING SYSTEM8-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 8-15. . . . . . . . .
TROUBLESHOOTING 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER MOTOR8-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STARTER MOTOR 8-21. . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE STARTER MOTOR 8-22. . . . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM8-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM8-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE LIGHTING SYSTEM 8-31. . . . . . . . . . . . . . . . . . . . . . . .
SIGNALING SYSTEM8-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SIGNALING SYSTEM 8-36. . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM8-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP SYSTEM8-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP SYSTEM 8-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP 8-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELF-DIAGNOSIS8-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURES9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ProCarManuals.com

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



























ProCarManuals.com

3-62
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
WARNING
CAUTION:
EAS00178
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:

Wear protective eye gear when handling or
working near batteries.

Charge batteries in a well-ventilated area.

Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).

DO NOT SMOKE when charging or han-
dling batteries.

KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.

Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL

Skin – Wash with water.

Eyes – Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL

Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.

This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery per-
formance will deteriorate.

Charging time, charging amperage and
charging voltage for an MF battery are dif-
ferent from those of conventional batter-
ies. The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
ProCarManuals.com

3-63
Relationship between the open-circuit voltage
and the charging time at 20C
Open-circuit voltage (V)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level. 13.0
12.5
12.0
11.5
5 6.5 10
Charging time (hours)
Ambient
temperature
20C
Open-circuit voltage (V)
Charging condition of the battery (%)
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
CAUTION:
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:

rider seat
Refer to “SEATS”.
2. Disconnect:

battery leads
(from the battery terminals)
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
3. Remove:

battery
4. Check:

battery charge
a. Connect a pocket tester to the battery termi-
nals.
Pocket tester
90890-03112, YU-3112
Positive tester probe

positive battery terminal
Negative tester probe

negative battery terminal

The charge state of an MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive battery ter-
minal is disconnected).

No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20
30%
ProCarManuals.com

3-64
Charging
Ambient temperature 20C
Open-circuit voltage (V)
Check the open-circuit
voltage.Time (minutes)
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
WARNING
CAUTION:
5. Charge:

battery
(refer to the appropriate charging method il-
lustration)
Do not quick charge a battery.

Never remove the MF battery sealing caps.

Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause bat-
tery overheating and battery plate damage.

If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.

When charging a battery, be sure to remove
it from the motorcycle. (If charging has to
be done with the battery mounted on the
motorcycle, disconnect the negative bat-
tery lead from the battery terminal.)

To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.

Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.

Make sure the battery charger lead clips
are in full contact with the battery terminal
and that they are not shorted. A corroded
battery charger lead clip may generate heat
in the contact area and a weak clip spring
may cause sparks.

If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot batter-
ies can explode!

As shown in the following illustration, the
open-circuit voltage of an MF battery stabi-
lizes about 30 minutes after charging has
been completed. Therefore, wait 30 min-
utes after charging is completed before
measuring the open-circuit voltage.
ProCarManuals.com

3-65
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Measure the open-circuit
voltage prior to charging.
Connect a charged and
AMP meter to the battery
and start charging.
Make sure that the current
is higher than the standard
charging current written on
the battery.
By turning the charging
voltage adjust dial, set the
charging voltage at 20
24 V.
Adjust the voltage so that the
current is at the standard
charging level.Monitor the amperage for
3
5 minutes to check if the
standard charging current is
reached.
Set the time according to the
charging time suitable for the
open-circuit voltage.
Refer to “Battery condition
checking steps”.If the current does not
exceed the standard
charging current after 5
minutes, replace the battery.
If charging requires more than 5 hours, it is advisable to check the
charging current after a lapse of 5 hours. If there is any change in the
amperage, readjust the voltage to obtain the standard charging
current.
Measure the battery open-circuit voltage after leaving the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.YES NO
YES
NONOTE:
Voltage should be measured 30
minutes after the machine is stopped.
NOTE:
Set the charging voltage at 16
17 V.
(If the setting is lower, charging will be
insufficient. If too high, the battery will
be over-charged.)
Charging method using a variable-current (voltage) charger
ProCarManuals.com

3-66
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Measure the open-circuit
voltage prior to charging.
Connect a charger and
AMP meter to the battery
and start charging.
Make sure that the current
is higher than the standard
charging current written on
the battery.
Charge the battery until the battery’s
charging voltage is 15 V.This type of battery charger cannot
charge the MF battery. A variable
voltage charger is recommended.
Measure the battery open-circuit
voltage after leaving the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is
complete.
12.7 V or less --- Recharging is
required.
Under 12.0 V --- Replace the battery.
Set the charging time at 20 hours
(maximum).
YES NO
NOTE:
Voltage should be measured 30
minutes after the machine is stopped.
NOTE:
Charging method using a constant voltage charger
ProCarManuals.com

3-67
CHECKING AND CHARGING THE BATTERY /
CHECKING THE FUSESCHK
ADJ
CAUTION:
CAUTION:
NOTE: 6. Install:

battery
7. Connect:

battery leads
(to the battery terminals)
First, connect the positive battery lead
1,
and then the negative battery lead
2.
8. Check:

battery terminals
Dirt
Clean with a wire brush.
Loose connection
Connect properly.
9. Lubricate:

battery terminals
Recommended lubricant
Dielectric grease
10. Install:

rider seat
Refer to “SEATS”.
EAS00181
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:

front cowling inner panel (left)
Refer to “COWLINGS”.

rider seat
Refer to “SEATS”.
2. Check:

fuse
a. Connect the pocket tester to the fuse and
check the continuity.
Set the pocket tester selector to “Ω  1”.
ProCarManuals.com

7-11
FUEL INJECTION SYSTEMFI
Fault
code No.SymptomProbable cause of malfunctionDiagnostic
code
34
Open circuit is detected in the primary
lead of the ignition coil (#2).
Open or short circuit in wiring harness.

Malfunction in ignition coil.

Malfunction in ECU.

Malfunction in a component of ignition cut-off circuit system.
31
35
Open circuit is detected in the primary
lead of the ignition coil (#3).
Open or short circuit in wiring harness.

Malfunction in ignition coil.

Malfunction in ECU.

Malfunction in a component of ignition cut-off circuit system.
32
36
Open circuit is detected in the primary
lead of the ignition coil (#4).
Open or short circuit in wiring harness.

Malfunction in ignition coil.

Malfunction in ECU.

Malfunction in a component of ignition cut-off circuit system.
33
41Lean angle cut-off switch-open or
short circuit detected.
Open or short circuit in wiring harness.

Defective lean angle cut-off switch.

Malfunction in ECU.08
42
No normal signals are received from
the speed sensor; or, an open or
short circuit is detected in the neutral
switch.
Open or short circuit in wiring harness.

Defective speed sensor.

Malfunction in vehicle speed sensor detected unit.

Defective neutral switch.

Malfunction in the engine side of the neutral switch.

Malfunction in ECU.
07
21
43The ECU is unable to monitor the
battery voltage (an open circuit in the
monitor line to the ECU).
Open circuit in wiring harness.

Malfunction in ECU.09
44An error is detected while reading or
writing on EEPROM.
Malfunction in ECU. (The CO adjustment value is not
properly written on or read from the internal memory).60
46Power supply to the FI system is not
normal.
Malfunction in “CHARGING SYSTEM”.—
47Sub-throttle servo motor potention cir-
cuit-open or short circuit detected.
Open or short circuit in wiring harness.

Detective Sub-throttle servo motor (potention circuit).56
48Sub-throttle servo motor is stuck.
Open or short circuit in wiring harness.

Stuck Sub-throttle servo motor (mechanism).

Stuck Sub-throttle servo motor (motor).56
50
Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the
meter.
Malfunction in ECU. (The program and data are not
properly written on or read from the internal memory.)
—
Er-1
No signal are received from the ECU.
Open or short circuit in wiring harness.

Malfunction in meter.

Malfunction in ECU.

Defective wire connection of the ECU coupler.
—
Er-2No signal are received from the ECU
within the specified duration.
Improper connection in wiring harness.

Malfunction in meter.

Malfunction in ECU.—
Er-3Data from the ECU can not be
received correctly.
Improper connection in wiring harness.

Malfunction in meter.

Malfunction in ECU.—
Er-4Non-registered data has been
received from the meter.
Improper connection in wiring harness.

Malfunction in meter.

Malfunction in ECU.—
ProCarManuals.com