relay YAMAHA YZF-R1SC 2004 Workshop Manual

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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9-1
STARTING FAILURES
TRBL
SHTG
NOTE:
FUEL SYSTEM
Fuel tank
Empty 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 system
Faulty 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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9-6
FAULTY LIGHTING OR SIGNALING SYSTEM
TRBL
SHTG
TURN SIGNAL DOES NOT COME ON

Faulty turn signal switch

Faulty turn signal relay

Burnt-out turn signal bulb

Incorrect connection

Damaged or faulty wire harness

Improperly grounded circuit

Faulty battery

Blown, damaged or incorrect fuse
TURN SIGNAL BLINKS SLOWLY

Faulty turn signal relay

Faulty main switch

Faulty turn signal switch

Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT

Faulty turn signal relay

Burnt-out turn signal bulb
TURN SIGNAL BLINKS QUICKLY

Incorrect turn signal bulb

Faulty turn signal relay

Burnt-out turn signal bulb
HORN DOES NOT SOUND

Improperly adjusted horn

Damaged or faulty horn

Faulty main switch

Faulty horn switch

Faulty battery

Blown, damaged or incorrect fuse

Faulty wire harness
EAS00866
FAULTY LIGHTING OR SIGNALING SYSTEM
HEADLIGHT DOES NOT COME ON

Wrong headlight bulb

Too many electrical accessories

Hard charging

Incorrect connection

Improperly grounded circuit

Poor contacts (main or light switch)

Burnt-out headlight bulb
HEADLIGHT BULB BURNT OUT

Wrong headlight bulb

Faulty battery

Faulty rectifier / regulator

Improperly grounded circuit

Faulty main switch

Faulty light switch

Headlight bulb life expired
TAIL / BRAKE LIGHT DOES NOT COME ON

Too many electrical accessories

Incorrect connection
TAIL / BRAKE LIGHT BULB BURNT OUT

Faulty battery

Incorrectly adjusted rear brake light switch
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59Clutch 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)
66Headlight
67Auxiliary light
68License plate light
69Rear brake light switch
70Tail / brake light
71Headlight relay (on / off)
72Headlight relay (dimmer)
73Fuse (ignition)
74Fuse (signal)
75Fuse (headlight)
76Radiator fan motor relay
77Fuse (radiator fan motor left)
78Fuse (radiator fan motor light)
79Radiator fan motor 2
80Radiator fan motor 1
81Ground
COLOR CODE
B Black. . . . .
Br Brown. . . .
Ch Chocolate. . .
Dg Dark green. . .
G Green. . . .
Gy Gray. . .
L Blue. . . . .
Lg Light green. . . .
O Orange. . . .
P Pink. . . . .
R Red. . . . .
Sb Sky blue. . . .
W White. . . .
Y Yellow. . . . .
B / G Black / Green. .
B / L Black / Blue. . .
B / R Black / Red. .
B / W Black / White. .
B / Y Black / Yellow. .
Br / G Brown / Green.
Br / L Brown / Blue. .
Br / R Brown / Red. .
Br / W Brown / White.
G / B Green / Black. .
G / R Green / Red. .
G / W Green / White. . G / Y Green / Yellow. .
Gy / B Gray / Black.
Gy / G Gray / Green.
Gy / R Gray / Red.
L / B Blue / Black. . .
L / R Blue / Red. .
L / W Blue / White. .
L / Y Blue / Yellow. . .
O / B Orange / Black. .
O / G Orange / Green. .
P / W Pink / White. .
R / B Red / Black. .
R / G Red / Green. .
R / L Red / Blue. .
R / W Red / White. .
R / Y Red / Yellow. .
Sb / W Sky blue / White.
W / B White / Black. .
W / R White / Red. .
W / Y White / Yellow. .
Y / B Yellow / Black. .
Y / G Yellow / Green. .
Y / L Yellow / Blue. . .
Y / R Yellow / Red. .
Y / W Yellow / White. .
YZF-R1S / YZF-R1SC WIRING DIAGRAM
1Main switch
2A.C. magneto
3Rectifier / regulator
4Fuse (main)
5Fuse (backup)
6Battery
7Fuse (fuel injection)
8Starter relay
9Starter motor
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
24Air induction system solenoid
25Sub-throttle position sensor
26EXUP servo motor
27Speed sensor
28Coolant temperature sensor
29Intake air temperature sensor
30Option switch
31Crankshaft position sensor
32Throttle position sensor
33Intake air pressure sensor
34Atmospheric pressure sensor
35Cylinder identification sensor
36Lean angle cut-off switch
37Meter assembly
38Fuel level warning light
39Oil level warning light
40Neutral indicator light
41Tacho meter
42Shift timing indicator light
43Multi function meter
44Engine trouble warning light
45Coolant temperature indicator light
46Hi beam indicator light
47Turn signal indicator light (left)
48Turn signal indicator light (light)
49Meter light
50Oil level switch
51Right handlebar switch
52Front brake light switch
53Engine stop switch
54Start switch
55Turn signal relay
56Left handlebar switch
57Dimmer switch
58Horn switch
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