sensor YAMAHA YZF-R1SC 2004 Workshop Manual

8-9
IGNITION SYSTEMELEC
1Main switch
4Fuse (main)
6Battery
10Starting circuit cut-off relay
11Neutral switch
12Sidestand switch
14E.C.U.
15Ignition coil #1
16Ignition coil #2
17Ignition coil #3
18Ignition coil #4
19Spark plug
31Crankshaft position sensor
35Cylinder identification sensor
36Lean angle cut-off switch
53Engine stop switch
59Clutch switch
73Fuse (ignition)
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8-10
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
YESNO
EAS00741
3. Spark plugs
The following procedure applies to all of the
spark plugs.

Check the condition of the spark plug.

Check the spark plug type.

Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUGS”
in chapter 3.
Standard spark plug
CR9EK (NGK)
Spark plug gap
0.6  0.7 mm (0.0236  0.0276 in)

Is the spark plug in good condition, is it of the
correct type, and is its gap within specifica-
tion?
Re-gap or replace
the spark plug.
IGNITION SYSTEMELEC
NOTE:
YESNO
1. Main and ignition fuses

Check the main and ignition fuses for conti-
nuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3.

Are the main and ignition fuses OK?
Replace the fuse(s).
EAS00737
TROUBLESHOOTING
The ignition system fails to operate (no
spark or intermittent spark).
Check:
1. main and ignition fuses
2. battery
3. spark plugs
4. ignition spark gap
5. ignition coil resistance
6. crankshaft position sensor
7. main switch
8. engine stop switch
9. neutral switch
10. sidestand switch
11. clutch switch
12. starting circuit cut-off relay (diode)
13. lean angle cut-off switch
14. wiring connections
(of the entire ignition system)

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

Troubleshoot with the following special tool(s).
Ignition checker
90890-06754
Dynamic spark tester
YM-34487
Pocket tester
90890-03112, YU-3112
EAS00738
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8-12
IGNITION SYSTEMELEC
6. Crankshaft position sensor resistance

Disconnect the crankshaft position sensor
coupler from the wire harness.

Connect the pocket tester (Ω
100) to the
crankshaft position sensor coupler as shown.
Positive tester probe
gray
Negative tester probe
black
1
2

Measure the crankshaft position sensor
resistance.
Crankshaft position sensor
resistance
336  504 Ω at 20C
(between gray and black)

Is the crankshaft position sensor OK?
YESNO
Replace the
crankshaft position
sensor.
EAS00749
7. Main switch

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

Is the main switch OK?
YESNO
Replace the main
switch.
EAS00748EAS00750
8. Engine stop switch

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

Is the engine stop switch OK?
YESNO
Replace the right
handlebar switch.
EAS00751
9. Neutral switch

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

Is the neutral switch OK?
YESNO
Replace the neutral
switch.
EAS00752
10. Sidestand switch

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

Is the sidestand switch OK?
YESNO
Replace the side-
stand switch.
EAS00763
11. Clutch switch

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

Is the clutch switch OK?
YESNO
Replace the clutch
switch.
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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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8-42
SIGNALING SYSTEMELEC
YESNO 2. 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
green / white
Negative tester probe
black / white
1
2

Turn the main switch to “ON”.

Measure the voltage (DC 12 V) of
green / white and black / white at the
meter assembly coupler.

Is the voltage within specification?
This circuit is OK.
12
Replace the multi-
function meter.
NO
1. Multi-function meter bulb socket

Check the multi-function meter bulb socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.

Is the multi-function meter bulb socket OK?
YES
EAS008067. The speedometer fails to come on.
2. Speed sensor

Connect the pocket tester (DC 20 V) to the
speed sensor coupler (wire harness side)
as shown.
Replace the speed
sensor.
NOYES
Positive tester probe
white / yellow
Negative tester probe
black / blue1
2

Set the main switch to “ON”.

Elevate the rear wheel and slowly rotate it.

Measure the voltage (DC 5 V) of white / yel-
low and blue. With each full rotation of the
rear wheel, the voltage reading should cycle
from 0.6 V to 4.8 V to 0.6 V to 4.8 V.

Does the voltage reading cycle correctly?
This circuit is OK.
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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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8-47
COOLING SYSTEMELEC

Remove the coolant temperature sensor.

Connect the pocket tester (Ω
1k) to the
coolant temperature sensor as shown.

Immerse the coolant temperature sensor in
a container filled with coolant .
Make sure the coolant temperature sensor
terminals do not get wet.

Place a thermometer in the coolant.

Slowly heat the coolant, and then let it cool to
the specified temperature indicated in the
table.

Check the coolant temperature sensor for
continuity at the temperatures indicated in
the table.
EAS00812
1
Coolant temperature sensor
resistance
0C (32F): 5.21  6.37 kΩ
80C (176F): 0.29  0.35 kΩ
WARNING

Handle the coolant temperature sensor
with special care.

Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace
it.
6. Coolant temperature sensor
Replace the coolant
temperature sensor.
NOYES
Coolant temperature sensor
20 Nm (2.0 m
kg, 14 ft
lb)
Three bond sealock
10

Does the coolant temperature sensor oper-
ate properly?
7. Wiring

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

Is the cooling system’s wiring properly con-
nected and without defects?
Properly connect or
repair the cooling
system’s wiring.
NOYES
This circuit is OK.
EAS00813
2
NOTE:
3
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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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