2004 YAMAHA YZF-R1S Service Manual

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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9-3
FAULTY GEAR SHIFTING / FAULTY CLUTCH
TRBL
SHTG
JUMPS OUT OF GEAR
Shift shaft

Incorrect shift pedal position

Improperly returned stopper lever
Shift forks

Worn shift fork
Shift drum

Incorrect axial play

Worn shift drum groove
Transmission

Worn gear dog
CLUTCH DRAGS
Clutch

Unevenly tensioned clutch springs

Warped pressure plate

Bent clutch plate

Swollen friction plate

Bent clutch pull rod

Broken clutch boss

Burnt primary driven gear bushing

Match marks not aligned
Engine oil

Incorrect oil level

Incorrect oil viscosity (high)

Deteriorated oil
EAS00850
FAULTY GEAR SHIFTING
SHIFTING IS DIFFICULT
Refer to “CLUTCH DRAGS”.
SHIFT PEDAL DOES NOT MOVE
Shift shaft

Improperly adjusted shift rod

Bent shift shaft.
Shift drum and shift forks

Foreign object in a shift drum groove

Seized shift fork

Bent shift fork guide bar
Transmission

Seized transmission gear

Foreign object between transmission gears

Improperly assembled transmission
EAS00851
FAULTY CLUTCH
CLUTCH SLIPS
Clutch

Improperly assembled clutch

Improperly adjusted clutch cable

Loose or fatigued clutch spring

Worn friction plate

Worn clutch plate
Engine oil

Incorrect oil level

Incorrect oil viscosity (low)

Deteriorated oil
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9-4
OVERHEATING / OVERCOOLING /
POOR BRAKING PERFORMANCETRBL
SHTG
FUEL SYSTEM
Throttle body (-ies)

Damaged or loose throttle body joint
Air filter

Clogged air filter element
CHASSIS
Brake(s)

Dragging brake
ELECTRICAL SYSTEMS
Spark plug(s)

Incorrect spark plug gap

Incorrect spark plug heat range
Ignition system

Faulty E.C.U.

Loose union bolt

Damaged brake hose

Oil or grease on the brake disc

Oil or grease on the brake pad

Incorrect brake fluid level
EAS00855
OVERHEATING
ENGINE
Clogged coolant passages

Cylinder head(s) and piston(s)

Heavy carbon buildup
Engine oil

Incorrect oil level

Incorrect oil viscosity

Inferior oil quality
COOLING SYSTEM
Coolant

Low coolant level
Radiator

Damaged or leaking radiator

Faulty radiator cap

Bent or damaged radiator fin
Water pump

Damaged or faulty water pump

Thermostat

Thermostat stays closed

Oil cooler

Clogged or damaged oil cooler

Hose(s) and pipe(s)

Damaged hose

Improperly connected hose

Damaged pipe

Improperly connected pipe
EAS00856
OVERCOOLING
COOLING SYSTEM
Thermostat

Thermostat stays open
EAS00857
POOR BRAKING PERFORMANCE

Worn brake pad

Worn brake disc

Air in hydraulic brake system

Leaking brake fluid

Faulty brake caliper kit

Faulty brake caliper seal
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9-5
FAULTY FRONT FORK LEGS / UNSTABLE HANDLING
TRBL
SHTG
MALFUNCTION

Bent or damaged inner tube

Bent or damaged outer tube

Damaged fork spring

Worn or damaged outer tube bushing

Bent or damaged damper rod

Incorrect oil viscosity

Incorrect oil level
Rear shock absorber assembly(-ies)

Faulty rear shock absorber spring

Leaking oil or gas
Tire(s)

Uneven tire pressures (front and rear)

Incorrect tire pressure

Uneven tire wear
Wheel(s)

Incorrect wheel balance

Deformed cast wheel

Damaged wheel bearing

Bent or loose wheel axle

Excessive wheel runout
Frame

Bent frame

Damaged steering head pipe

Improperly installed bearing race
EAS00861
FAULTY FRONT FORK LEGS
LEAKING OIL

Bent, damaged or rusty inner tube

Cracked or damaged outer tube

Improperly installed oil seal

Damaged oil seal lip

Incorrect oil level (high)

Loose damper rod assembly bolt

Damaged damper rod assembly bolt
copper washer

Cracked or damaged cap bolt O-ring
EAS00863
UNSTABLE HANDLING
Handlebars

Bent or improperly installed right handlebar

Bent or improperly installed left handlebar
Steering head components

Improperly installed upper bracket

Improperly installed under bracket
(improperly tightened ring nut)

Bent steering stem

Damaged ball bearing or bearing race
Front fork leg(s)

Uneven oil levels (both front fork legs)

Unevenly tensioned fork spring (both front
fork legs)

Broken fork spring

Bent or damaged inner tube

Bent or damaged outer tube
Swingarm

Worn bearing or bushing

Bent or damaged swingarm
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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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