YAMAHA YZF-R1SC 2004 Service Manual

7-47
AIR INDUCTION SYSTEMFI
A To cylinder #1 and #2
B To cylinder #3 and #41 Air cut-off valve
2 Plate
3 Reed valve assembly
4 Reed valve cap
5 To air filter case
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
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7-48
AIR INDUCTION SYSTEMFI
EAS00510
CHECKING THE AIR INDUCTION SYSTEM
1. Check:

hoses
Loose connection
Connect properly.
Cracks / damage
Replace.

pipes
Cracks / damage
Replace.
2. Check:

reed valve
1

reed valve stopper

reed valve seat
Cracks / damage
Replace the reed valve.
3. Measure:

reed valve bending limit
a
Out of specification
Replace the reed
valve.
Reed valve bending limit
0.4 mm (0.016 in)
1Surface plate
4. Check:

air cut-off valve
Cracks / damage
Replace.
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7-49
AIR INDUCTION SYSTEMFI
5. Check:

Air induction system solenoid
a. Remove the Air induction system solenoid
coupler from the wire harness.
b. Connect the pocket tester (Ω  1) to the Air
induction system solenoid terminal as
shown.
Tester positive probe
orange
1
Tester negative probe
green 2
c. Measure the Air induction system solenoid
resistance.
Air induction system solenoid
resistance
18
22 Ω at 20C (68F)
d. Out of specification
Replace.
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8-1
8
ELECTRICAL COMPONENTSELEC
9Oil level switch
10Radiator fan motor
11Horn
12Ignition coil
1Main switch
2Front brake light switch
3Starter relay
4Battery
5Fuse box
6Rear brake light switch
7Neutral switch
8Sidestand switch
EAS00729
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
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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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8-3
CHECKING SWITCH CONTINUITYELEC
CAUTION:
NOTE:
NOTE:
EAS00730
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect,
check the wiring connections and if necessary,
replace the switch.
Never insert the tester probes into the cou-
pler terminal slots. Always insert the probes
from the opposite end of the coupler
1 tak-
ing care not to loosen or damage the leads.
Pocket tester
90890-03112, YU-3112

Before checking for continuity, set the pocket
tester to “0” and to the “Ω
1” range.

When checking for continuity, switch back and
forth between the switch positions a few times.
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions
a are shown in the far left
column and the switch lead colors
b are shown
in the top row in the switch illustration.
“
” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows
that:
There is continuity between red and brown / red
when the switch is set to “P”.
There is continuity between red, brown / blue
and brown / red when the switch is set to “ON”.
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8-4
11Neutral switch
12Rear brake light switch
13Fuse box
1Main switch
2Horn switch
3Dimmer switch
4Turn signal switch
5Clutch switch
6Sidestand switch
7Engine stop switch
8Front brake light switch
9Start switch
10Oil level switch
CHECKING THE SWITCHESELEC
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage / wear
Repair or replace.
Improperly connected
Properly connect.
Incorrect continuity reading
Replace the switch.
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8-5
CHECKING THE BULBS AND BULB SOCKETSELEC
WARNING
EAS00732
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continu-
ity between the terminals.
Damage / wear
Repair or replace the bulb,
bulb socket or both.
Improperly connected
Properly connect.
No continuity
Repair or replace the bulb, bulb
socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown in
the illustration on the left.

Bulbs
A and B are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The ma-
jority of these types of bulbs can be removed
from their respective socket by turning them
counterclockwise.

Bulbs
C are used for turn signal and
tail / brake lights and can be removed from
the socket by pushing and turning the bulb
counterclockwise.
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:

bulb

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

When changing the tail / brake light bulb,
confirm that the frame has cooled accord-
ing to the warning label and change the
tail / brake light bulb.
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8-6
CHECKING THE BULBS AND BULB SOCKETSELEC
CAUTION:
NOTE:

Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
the coupler.

Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb, and the luminous flux will be adverse-
ly affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Check:

bulb (for continuity)
(with the pocket tester)
No continuity
Replace.
Pocket tester
90890-03112, YU-3112
Before checking for continuity, set the pocket
tester to “0” and to the “Ω
1” range.
a. Connect the positive tester probe to terminal
1 and the negative tester probe to terminal
2, and check the continuity.
b. Connect the positive tester probe to terminal
1 and the negative tester probe to terminal
3, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:

bulb socket (for continuity)
(with the pocket tester)
No continuity
Replace.
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8-7
CHECKING THE BULBS AND BULB SOCKETSELEC
NOTE:
NOTE:
WARNING
Pocket tester
90890-03112, YU-3112
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the re-
spective leads of the bulb socket.
c. Check the bulb socket for continuity. If any of
the readings indicate no continuity, replace
the bulb socket.
CHECKING THE LEDs
The following procedures applies to all of the
LEDs.
1. Check:

LED (for proper operation)
Improper operation
Replace.
a. Disconnect the meter assembly coupler (me-
ter assembly side).
b. Connect two jumper leads
1 from the bat-
tery terminals to the respective coupler ter-
minal.
As for connecting with which coupler terminal,
refer to “CABLE ROUTING” in chapter 2.

A wire that is used as a jumper lead must
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
burn.

This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.
c. When the jumper leads are connected to the
terminals the respective LED should illumi-
nate.
Does not light
Replace the meter assem-
bly.
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