YAMAHA YZF-R1SC 2004 Service Manual
Manufacturer: YAMAHA, Model Year: 2004, Model line: YZF-R1SC, Model: YAMAHA YZF-R1SC 2004Pages: 457, PDF Size: 7.58 MB
Page 441 of 457
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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8-50
FUEL PUMP SYSTEMELEC
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”.
YESNO
Replace the main
switch. Is the main switch OK?
EAS00750
4. Engine stop switch
Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
YESNO
Replace the right
handlebar switch. Is the engine stop switch OK?
NOTE:
YESNO
1. Main, ignition and fuel injection system
fuses
Check the main, ignition and fuel system
fuses for continuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3.
Replace the fuse(s).
Are the main, ignition and fuel injection sys-
tem fuses OK?
EAS00816
TROUBLESHOOTING
If the fuel pump fails to operate.
Check:
1. main, ignition and fuel injection fuses
2. battery
3. main switch
4. engine stop switch
5. starting circuit cut-off relay
(the fuel injection system relay)
6. fuel pump
7. wiring connections
(the entire fuel 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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8-51
FUEL PUMP SYSTEMELEC
YESNO 5. Starting circuit cut-off relay (fuel injection
system relay)
Disconnect the starting circuit cut-off relay
coupler from the wire harness.
Connect the pocket tester (Ω 1) and bat-
tery (12 V) to the starting circuit cut-off relay
coupler as shown.
Replace the starting
circuit cut-off relay.
Positive battery lead red / black
Negative battery lead blue / yellow 1
2
Positive tester probe red
Negative tester probe red / blue3
4
Does the starting circuit cut-off relay have
continuity between red and red / blue?
YESNO 6. Fuel pump resistance
Disconnect the fuel pump coupler from the
wire harness.
Connect the pocket tester (Ω 1) to the fuel
pump coupler as shown.
Properly connect or
repair the fuel sys-
tem’s wiring.
1
2
Positive tester probe red / blue
Negative tester probe black
EAS00817
YESNO Fuel pump resistance
0.2 3.0 Ω at 20C (68F)
Is the fuel pump OK?
Replace the fuel
pump.
Measure the fuel pump resistance.
7. Wiring
Check the entire fuel pump system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the fuel system’s wiring properly con-
nected and without defects?
EAS00818
Replace the ECU.
EAS00759
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8-52
FUEL PUMP SYSTEMELEC
WARNING
EAS00819
CHECKING THE FUEL PUMP
Gasoline is extremely flammable and under
certain circumstances there can be a danger
of an explosion or fire. Be extremely careful
and note the following points:
Stop the engine before refueling.
Do not smoke, and keep away from open
flames, sparks, or any other source of fire.
If you do accidentally spill gasoline, wipe it
up immediately with dry rags.
If gasoline touches the engine when it is
hot, a fire may occur. Therefore, make sure
the engine is completely cool before per-
forming the following test.
1. Check:
Fuel pump operation
a. Insert the plug
1 to fuel return hose end.
b. Fill the fuel tank.
c. Put the end of the fuel hose into an open con-
tainer.
d. Connect the battery (DC 12 V) to the fuel
pump coupler as shown.
Positive battery lead red / blue
2
Negative battery lead black 3
e. If fuel flows out of the fuel hose, the fuel pump
is OK. If fuel does not flow, replace the fuel
pump.
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8-53
SELF-DIAGNOSISELEC
SELF-DIAGNOSIS
The YZF-R1(S) features a self-diagnosing system for the following circuit(-s):
Fuel pump thermistor
Oil level switch
If any of these circuits are defective, their respective condition codes will be displayed on the warning
light when the main switch is turned “ON” (irrespective of whether the engine is running or not).
Circuit
Defect(-s)System responseCondition code
Fuel pump
thermistorOpen-circuit
Short-circuitThe fuel level warning light indi-
cate the condition code.Refer to *1
Oil level switchOpen-circuit
Short-circuitThe oil level warning light indicate
the condition code.Refer to *2
*1Condition code
Fuel level warning light
*
2Condition code
Oil level warning light
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SELF-DIAGNOSISELEC
L/B B
Lg
B
BG/W
B R/L
Y/LY/BR/G
Sb/W
W
G/W
G/W
R/L
B
R/W
LgLgB
Sb/WSb/WA
Br BrA
R/G R/GBB/R B/RBY/B Y/BBY/L Y/LBG/W G/WA
GY
14
3839
40
41
42
43
44
45
Repair or replace the
wire harness.
NO
1. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
NO
2. Fuel pump thermistor
Check the fuel pump thermistor for continuity.
Refer to “The fuel level warning light fails to
come on”.
Is the fuel pump thermistor OK?
YES
Replace the fuel
pump.Replace the multi-
function meter.
NOTE:
14Fuel pump
45Multi-function meter
TROUBLESHOOTING
The warning light starts to indicate the
self-diagnosis sequence.
Check:
1. fuel pump thermistor
2. oil level switch
Before troubleshooting, remove the following
part(-s):
1. seat
2. fuel tank
Troubleshoot with the following special
tool(-s).
Pocket tester
90890-03112, YU-3112
1. Fuel pump thermistor
CIRCUIT DIAGRAM
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8-55
SELF-DIAGNOSISELEC
Replace the oil level
switch.
NO
2. Oil level switch
Check the oil level switch for continuity.
Refer to “The oil level warning light fails to
come on”.
Is the oil level switch OK?
YES
Repair or replace the
wire harness.
NO
1. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
Replace the multi-
function meter.
B/WWW
Y/LY/BR/G
Sb/W
W
WG/W
R/WSb/WSb/WA
Br BrA
R/G R/GBB/R B/RBY/B Y/BBY/L Y/L
Dg
Ch
BG/W G/WA
B/W B/W
GY
B
40
41
42
43
44
45
46
47
48
49
50
51
52
45Multi-function meter
52Oil level switch
2. Oil level switch
CIRCUIT DIAGRAM
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9-1
STARTING FAILURES
TRBL
SHTG
NOTE:
FUEL SYSTEM
Fuel tankEmpty fuel tank
Clogged fuel filter
Clogged fuel strainer
Clogged fuel tank drain hose
Deteriorated or contaminated fuel
Fuel pump Faulty fuel pump
Faulty fuel pump relay
Throttle body (-ies)
Deteriorated or contaminated fuel
Sucked-in air
Ignition coil(s) Cracked or broken ignition coil body
Broken or shorted primary or secondary
coils
Ignition system Faulty ECU
Faulty crankshaft position sensor
EAS00844
TROUBLESHOOTING
The following guide for troubleshooting does not cover all the possible \
causes of trouble. It should be
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure i\
n this manual for
checks, adjustments, and replacement of parts.
STARTING FAILURES
ENGINE
Cylinder(s) and cylinder head(s)
Loose spark plug
Loose cylinder head or cylinder
Damaged cylinder head gasket
Damaged cylinder gasket
Worn or damaged cylinder
Incorrect valve clearance
Improperly sealed valve
Incorrect valve-to-valve-seat contact
Incorrect valve timing
Faulty valve spring
Seized valve
Piston(s) and piston ring(s) Improperly installed piston ring
Damaged, worn or fatigued piston ring
Seized piston ring
Seized or damaged piston
Air filter Improperly installed air filter
Clogged air filter element
Crankcase and crankshaft Improperly assembled crankcase
Seized crankshaft
ELECTRICAL SYSTEMS
Battery Discharged battery
Faulty battery
Fuse(s) Blown, damaged or incorrect fuse
Improperly installed fuse
Spark plug(s)
Incorrect spark plug gap
Incorrect spark plug heat range
Fouled spark plug
Worn or damaged electrode
Worn or damaged insulator
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9-2
9
Starting systemFaulty starter motor
Faulty starter relay
Faulty starting circuit cut-off relay
Faulty starter clutch
STARTING FAILURES / INCORRECT ENGINE IDLING SPEED /
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCETRBL
SHTG
ELECTRICAL SYSTEMS
Battery
Discharged battery
Faulty battery
Spark plug(s) Incorrect spark plug gap
Incorrect spark plug heat range
Fouled spark plug
Worn or damaged electrode
Worn or damaged insulator
Ignition coil(s)
Broken or shorted primary or secondary
coils
Cracked or broken ignition coil
Ignition system Faulty ECU
Faulty crankshaft position sensor
Switches and wiring
Faulty main switch
Faulty engine stop switch
Broken or shorted wiring
Faulty neutral switch
Faulty start switch
Faulty sidestand switch
Faulty clutch switch
Improperly grounded circuit
Loose connections
EAS00846
INCORRECT ENGINE IDLING SPEED
ENGINE
Cylinder(s) and cylinder head(s)
Incorrect valve clearance
Damaged valve train components
Air filter Clogged air filter element
FUEL SYSTEM
Throttle body (-ies) Damaged or loose throttle body joint
Improperly synchronized throttle bodies
Improperly adjusted engine idling speed (idle
adjusting screw)
Improper throttle cable free play
Flooded throttle body
Faulty air induction system
EAS00848
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURES”.
ENGINE
Air filter
Clogged air filter element
FUEL SYSTEM
Fuel pump Faulty fuel pump
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