2004 YAMAHA YZF-R1S wiring

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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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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9-2
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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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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