relay YAMAHA YZF-R1SC 2004 Owner's Guide

8-30

Does the Headlight relay (dimmer) have
continuity between red / yellow and
black / green ?
NOYES
Replace the dimmer
relay. Positive tester probe
red / yellow
Negative tester probe
black / green
1
2
3
4
5. Headlight relay (on / off)

Disconnect the headlight relay (on / off) from
the coupler.

Connect the pocket tester (Ω
1) and bat-
tery (12 V) to the headlight relay (on / off) as
shown.
Positive battery lead
red / yellow
Negative battery lead
yellow / black
EAS00787
YESNO 7. Wiring

Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.

Is the lighting system’s wiring properly con-
nected and without defects?
Properly connect or
repair the lighting
system’s wiring.
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECK-
ING THE LIGHTING
SYSTEM”.

Does the headlight relay (dimmer) have
continuity between black / green and
black / yellow ?
Positive tester probe
black / green
Negative tester probe
black / yellow
1
2
3
4
6. Headlight relay (dimmer)

Disconnect the headlight relay (dimmer)
from the coupler.

Connect the pocket tester (Ω
1) and bat-
tery (12 V) to the headlight relay (dimmer) as
shown.
Positive battery lead
black
Negative battery lead
yellow
3
4
3
4
YESNO
Replace the head-
light relay (dimmer).
LIGHTING SYSTEMELEC
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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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8-38
SIGNALING SYSTEMELEC
NO
YESNO
The wiring circuit
from the main switch
to the tail / brake light
coupler is faulty and
must be repaired.
This circuit is OK.
YES 1. Turn signal indicator light (LEDs)

Check the turn signal indicator light for conti-
nuity.
Refer to “CHECKING THE LEDs”.

Are the turn signal indicator light OK?
Replace the meter
assembly.
EAS00799
3. The turn signal / position light, turn signal in-
dicator light or both fail to blink.
YES
2. Turn signal switch

Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the turn signal switch OK?
Replace the left han-
dlebar switch.
3. Voltage

Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
Positive tester probe
brown
Negative tester probe
ground
1

Turn the main switch to “ON”.

Measure the voltage (DC 12 V) on brown
at the turn signal relay coupler (wire harness
side).

Is the voltage within specification?
1
YESNO
The wiring circuit
from the main switch
to the turn signal
relay coupler is faulty
and must be re-
paired.
YESNO 4. Voltage

Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
The turn signal relay
is faulty and must be
replaced. Positive tester probe
brown / white
Negative tester probe
ground
1

Turn the main switch to “ON”.

Measure the voltage (DC 12 V) on
brown / white at the turn signal relay cou-
pler (wire harness side).

Is the voltage within specification?
1
NO
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8-39
SIGNALING SYSTEMELEC
C
YESNO
The wiring circuit
from the turn signal
switch to the turn sig-
nal light connector is
faulty and must be
repaired. Left turn signal / position light
Positive tester probe
chocolate
Negative tester probe
ground
Right turn signal / position light
Positive tester probe
dark green
Negative tester probe
ground
1
2

Turn the main switch to “ON”.

Set the turn signal switch to “ ” or “ ”.

Measure the voltage (DC 12 V) of the choco-
late or dark green at the turn signal light
connector (wire harness side).

Is the voltage within specification?
12
This circuit is OK.
AB
1. Neutral indicator light (LEDs)

Check the neutral indicator light for continu-
ity.
Refer to “CHECKING THE LEDs”.

Are the neutral indicator light OK?
EAS00801
4. The neutral indicator light fails to come on.
YESNO
Replace the meter
assembly.
YESNO 2. Neutral switch

Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the neutral switch OK?
Replace the neutral
switch.
3. Starting circuit cut-off relay (diode)

Disconnect the starting circuit cut-off relay
coupler from the wire harness.

Connect the pocket tester (Ω
1) to the
starting circuit cut-off relay coupler as
shown.

Check the starting circuit cut-off relay for
continuity.
Positive tester probe

blue / yellow
Negative tester probe

sky blue Continuity
Positive tester probe

sky blue
Negative tester probe

blue / yellow No
continuity
1
2
2
1
EAS00753
5. Voltage

Connect the pocket tester (DC 20 V) to the
turn signal light connector or meter assem-
bly coupler (wire harness side) as shown.
Left turn signal light
Right turn signal light
Turn signal indicator light
A
B
C
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8-40
SIGNALING SYSTEMELEC
YESNO
Replace the starting
circuit cut-off relay.
YESNO 4. Voltage

Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
The wiring circuit
from the main switch
to the meter assem-
bly coupler is faulty
and must be re-
paired. Positive tester probe
brown
Negative tester probe
ground
1

Turn the main switch to “ON”.

Measure the voltage (DC 12 V) of brown
at the meter assembly coupler (wire harness
side).

Is the voltage within specification?
This circuit is OK.

Are the tester readings correct?
YESNO 1. Oil level warning light (LEDs)

Check the oil level warning light for continu-
ity.
When the main switch is turn to “ON”, the oil
level warning light is come on.

Are the oil level warning light OK?
Replace the meter
assembly.
EAS00802
5. The oil level warning light fails to come on.
YESNO 2. Oil level switch

Drain the engine oil and remove the oil level
switch from the oil pan.

Connect the pocket tester (Ω
100) to the
oil level switch as shown.
Replace the oil level
switch. Positive tester probe

Connector (white)
Negative tester probe
Body ground
1
12

Measure the oil level switch resistance.
Oil level switch resistance
114  126 Ω at 20C (68F)
484  536 Ω at 20C (68F)
1
2

Is the oil level switch OK?
2
When you switch the positive and negative
tester probes, the readings in the above
chart will be reversed.
NOTE:
1
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8-44
1Main switch
4Fuse (main)
6Battery
14E.C.U.
28Coolant temperature sensor
73Fuse (ignition)
76Radiator fan motor relay
77Fuse (radiator fan motor left)
78Fuse (radiator fan motor right)
79Radiator fan motor 2
80Radiator fan motor 1
COOLING SYSTEMELEC
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8-45
YESNO 2. Battery

Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20C (68F)

Is the battery OK?

Clean the battery
terminals.

Recharge or re-
place the battery.
EAS00739
EAS00749
3. Main switch

Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the main switch OK?
YESNO
Replace the main
switch.
COOLING SYSTEMELEC
NOTE:
YESNO
1. Main, ignition and radiator fan motor fuses

Check the main, ignition and radiator fan
motor fuses for continuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3.

Are the main, ignition and radiator fan motor
fuses OK?
Replace the fuse(s).
EAS00808
TROUBLESHOOTING

The radiator fan motor fails to turn.

The coolant temperature indicator light
fails to light when the engine is warm.
Check:
1. main, ignition, and radiator fan motor fuses
2. battery
3. main switch
4. radiator fan motor
5. radiator fan motor relay
6. coolant temperature sensor
7. wiring connections
(the entire cooling system)

Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. side cowlings

Troubleshoot with the following special tool(s).
Pocket tester
90890-03112, YU-3112
EAS00738
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8-46
YESNO
4. Radiator fan motor

Disconnect the radiator fan motor coupler
from the wire harness.

Connect the battery (DC 12 V) as shown.
The radiator fan mo-
tor is faulty and must
be replaced.
Positive battery lead
blue
Negative battery lead
black1
2

Does the radiator fan motor turn?
5. Radiator fan motor relay

Disconnect the radiator fan motor relay
form the wire harness.

Connect the pocket tester (Ω
1) and bat-
tery (12 V) to the radiator fan motor terminal
as shown.

Check the radiator fan motor for continuity.
Replace the radiator
fan motor relay.
NOYES
Battery positive terminal
red / white
Battery negative terminal

green / yellow 1
2

Does the radiator fan motor relay have conti-
nuity between red and brown / green?
Tester positive probe
red
Tester negative probe
brown / green3
4
COOLING SYSTEMELEC
EAS00809
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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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