fuel pump YAMAHA YZF-R1SC 2004 User Guide

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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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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7-8
FUEL INJECTION SYSTEMFI
NOTE:
NOTE:
EAS00905
DIAGNOSTIC MODE
It is possible to monitor the sensor output data
or check the activation of actuators without con-
necting the measurement equipment by simply
switching the meter indication from the normal
mode to the diagnostic monitoring mode.
Setting the diagnostic mode
1. Turn the main switch to “OFF” and set the en-
gine stop switch to “OFF”.
2. Disconnect the wire harness coupler from
the fuel pump.
3. Simultaneously press and hold the “SE-
LECT” and “RESET” buttons, turn the main
switch to “ON”, and continue to press the but-
tons for 8 seconds or more.

All displays on the meter disappear except the
clock and tripmeter displays.

“dIAG” appears on the LCD meter.
4. Press the “SELECT” button to select the CO
adjustment mode “Co” or the diagnostic
mode “dIAG”.
5. After selecting “dIAG”, simultaneously press
the “SELECT” and “RESET” buttons for 2 se-
conds or more to execute the selection.
6. Select the diagnostic code number that ap-
plies to the item that was verified with the
fault code number by pressing the “SELECT”
and “RESET” buttons.

The diagnostic code number appears on the
LCD meter (01-70).

To decrease the selected diagnostic code
number, press the “RESET” button. Press the
“RESET” button for 1 second or longer to auto-
matically decrease the diagnostic code num-
bers.

To increase the selected diagnostic code num-
ber, press the “SELECT” button. Press the
“SELECT” button for 1 second or longer to au-
tomatically increase the diagnostic code num-
bers.
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7-40
THROTTLE BODIESFI
NOTE: CHECKING THE PRESSURE REGULATOR
1. Check:

pressure regulator
Damage
Replace.
CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION
1. Check:

pressure regulator operation
a. Remove the fuel tank.
Refer to “FUEL TANK” in chapter 3.
b. Disconnect the negative pressure hose
1
from the pressure regulator at the joint.
c. Connect the vacuum / pressure pump gauge
set
2 onto the negative pressure hose from
the pressure regulator.
d. Connect the pressure gauge
3 and adapter
4 onto the fuel injection pipe.
Vacuum / pressure pump gauge set
90890-06756, YB-35956
Pressure gauge
90890-03153, YU-03153
Adapter
90890-03176, YM-03176
e. Install the fuel tank.
Refer to “FUEL TANK” in chapter 3.
f. Start the engine.
g. Measure the fuel pressure.
Fuel pressure
294 kPa (2.94 kg / cm
2, 42.6 psi)
h. Use the vacuum pressure pump gauge set to
adjust the fuel pressure in relation to the vac-
uum pressure as described below.
The vacuum pressure should not exceed 100
kPa (760 mmHg, 29.9 inHg).
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8-2
9Radiator fan motor relay
10Turn signal relay
11Rectifier / regulator
12Throttle position sensor
13Sub-throttle position sensor
1Coolant temperature sensor
2Intake air temperature sensor
3Intake air pressure sensor
4Fuel pump
5ECU
6Lean angle cut-off switch
7Starting circuit cut-off relay
8Headlight relay (dimmer)
ELECTRICAL COMPONENTSELEC
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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)
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8-41
SIGNALING SYSTEMELEC
3. Voltage

Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
Positive tester probe
black / red
Negative tester probe
black / white
1
2

Turn the main switch to “ON”.

Measure the voltage (DC 12V) of black /
red and black / white at the meter as-
sembly coupler.

Is the voltage within specification?
12
YESNO
The wiring circuit
from the main switch
to the meter assem-
bly is faulty and must
be repaired.
This circuit is OK.
EAS00803
6. The fuel level warning light fails to come on.
1. Fuel sender

Drain the fuel from the fuel tank and remove
the fuel pump from the fuel tank.

Disconnect the fuel sender coupler from the
wire harness.

Connect the pocket tester (Ω
10) to the
fuel sender terminals as shown.
Positive tester probe
green / white
Negative tester probe
black
1
2
Fuel sender resistance
Full position of the float
20  26 Ω at 20C (68F)
Empty position of the float
134  140 Ω at 20C (68F)

Is the fuel sender OK? Measure the resistances when the float arm
is in contact with the full position and empty
position of the stopper.
NOTE:
Measure the fuel sender resistances.
YESNO
Replace the fuel
pump.
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8-48
1Main switch
4Fuse (main)
6Battery
7Fuse (fuel injection)
10Starting circuit cut-off relay
13Fuel pump
14E.C.U.
53Engine stop switch
FUEL PUMP SYSTEMELEC
EAS00814
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM
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8-49
FUEL PUMP SYSTEMELEC
1Battery
2Fuse (main)
3Main switch
4Fuse (ignition)
5Engine stop switch
6ECU
7Fuse (fuel injection)
8Starting circuit cut-off relay (fuel injection
system relay)
9Fuel pump
EAS00815
FUEL PUMP SYSTEM
The ECU includes the control unit for the
fuel pump.
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