2004 YAMAHA YZF-R1S oil

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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8-6
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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8-9
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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8-11
IGNITION SYSTEMELEC
NOYES
1
a
2
4. Ignition spark gap
The following procedure applies to all of the
spark plugs.

Disconnect the spark plug cap from the
spark plug.

Connect the ignition checker and spark
plug cap as shown.

Set the main switch to “ON”.

Measure the ignition spark gap .

Crank the engine by pushing the starter
switch and gradually increase the spark gap
until a misfire occurs.
Minimum ignition spark gap
6 mm (0.24 in)

Is there a spark and is the spark gap within
specification?
The ignition system
is OK.
5. Ignition coil resistance
The following procedure applies to all of the
ignition coils.

Disconnect the ignition coil leads from the
wire harness.

Connect the pocket tester (Ω
1) to the
ignition coil as shown.
EAS00747
Positive tester probe

ignition coil terminal
Negative tester probe

ignition coil terminal

Connect the pocket tester (Ω
1k) to the
ignition coil as shown.
Measure the primary coil resistance.
Primary coil resistance
1.19  1.61 Ω at 20C
Negative tester probe

ignition coil terminal
Positive tester probe

spark plug terminal
1
2

Measure the secondary coil resistance.
Secondary coil resistance
8.5  11.5 kΩ at 20C

Is the ignition coil OK?
YESNO
Replace the ignition
coil.
EAS00743
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8-21
STARTER MOTORELEC
NOTE:
EAS00770
CHECKING THE STARTER MOTOR
1. Check:

commutator
Dirt
Clean with 600 grit sandpaper.
2. Measure:

commutator diameter
a
Out of specification
Replace the starter
motor.
Commutator wear limit
24.5 mm (0.96 in)
3. Measure:

mica undercut
a
Out of specification
Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commuta-
tor.
Mica undercut
1.5 mm (0.06 in)
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
4. Measure:

armature assembly resistances (commuta-
tor and insulation)
Out of specification
Replace the starter
motor.
a. Measure the armature assembly resistances
with the pocket tester.
Pocket tester
90890-03112, YU-3112
Armature coil
Commutator resistance
1
0.0090  0.0110 Ω
at 20C (68F)
Insulation resistance
2
Above 1 MΩ at 20C (68F)
b. If any resistance is out of specification, re-
place the starter motor.
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8-25
NOYES
3. Charging voltage

Set the engine tachometer to the ignition coil
of cylinder #1.

Connect the pocket tester (DC 20 V) to the
battery as shown.
The charging circuit
is OK. Positive tester probe

positive battery terminal
Negative tester probe

negative battery terminal

Start the engine and let it run at approxi-
mately 5,000 r / min.

Measure the charging voltage.
Charging voltage
14 V at 5,000 r / min

Is the charging voltage within specification?
EAS00775
YESNO

Clean the battery
terminals.

Recharge or re-
place the battery.
Make sure the battery is fully charged.
NOTE:
Minimum open-circuit voltage
12.8 V or more at 20C (68F)

Is the battery OK?
CHARGING SYSTEMELEC
NOTE:
YESNO
1. Main fuse

Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3.

Is the main fuse OK?
Replace the fuse.
2. Battery

Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
EAS00739 EAS00774
TROUBLESHOOTING
The battery is not being charged.
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil lead
5. stator coil resistance
6. wiring connections
(of the entire charging system)

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
EAS00738
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8-26
CHARGING SYSTEMELEC
YESNO 5. Stator coil resistance

Remove the generator cover.

Connect the pocket tester (Ω
1) to the sta-
tor coils as shown.
Replace the stator
coil assembly.
EAS00776
Positive tester probe
white
Negative tester probe
white
Positive tester probe
white
Negative tester probe
white1
1
2
3

Measure the stator coil resistances.
Stator coil resistance
0.14  0.18 Ω at 20C (68F)

Is the stator coil OK?
YESNO 6. Wiring

Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.

Is the charging system’s wiring properly con-
nected and without defects?
Properly connect or
repair the charging
system’s wiring.
EAS00779
Replace the rectifi-
er / regulator.
4. Stator coil lead

Disconnect stator coil lead coupler.

Connect the pocket tester (Ω
1) to the sta-
tor coil lead coupler as shown.
Positive tester probe

white
Negative tester probe

ground
3
Positive tester probe

white
Negative tester probe

ground
1
Positive tester probe

white
Negative tester probe

groundNo
continuity
2
YESNO
Replace the stator
coil lead.
Are the tester readings correct?
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