2004 YAMAHA YZF-R1S check engine

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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8-12
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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8-16
YESNO
3. Starter motor

Connect the positive battery terminal and
starter motor lead with a jumper lead .
Repair or replace the
starter motor.
A wire that is used as a jumper lead
must have at least the same capacity or
more as that of the battery lead, other-
wise the jumper lead may burn.

This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.

Does the starter motor turn?
WARNING
1
23
EAS00758
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
ELECTRIC STARTING 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).
EAS00757
TROUBLESHOOTING
The starter motor fails to turn.
Check:
1. main and ignition fuses
2. battery
3. starter motor
4. starting circuit cut-off relay
5. starter relay
6. main switch
7. engine stop switch
8. neutral switch
9. sidestand switch
10. clutch switch
11. start switch
12. wiring connections
(of the entire starting system)

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

Troubleshoot with the following special tool(s).
Pocket tester
90890-03112, YU-3112
EAS00738
ProCarManuals.com

8-17
4. Starting circuit cut-off 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.
YESNO
Replace the starting
circuit cut-off relay.
Positive tester probe
blue / white
Negative tester probe
blue / white

Does the starting circuit cut-off relay have
continuity between blue / white and
blue / white ?
1
2
3
4
EAS00759
Positive battery terminal
red / black
Negative battery terminal

black / yellow
EAS00761
5. Starter relay

Disconnect the starter relay coupler from the
coupler.

Connect the pocket tester (Ω
1) and battery
(12 V) to the starter relay coupler as shown.
YESNO
Replace the starter
relay.
Positive battery terminal
blue / white
Negative battery terminal
red / white
Positive tester probe
red
Negative tester probe
black
1
2
3
4

Does the starter relay have continuity be-
tween red and black?
EAS00749
6. Main switch

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

Is the main switch OK?
YESNO
Replace the main
switch.
EAS00750
7. 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
8. Neutral switch

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

Is the neutral switch OK?
YESNO
Replace the neutral
switch.
3
4
ELECTRIC STARTING SYSTEMELEC
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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
ProCarManuals.com

8-31
High beam indicator light (LEDs)
Positive tester probe
black / yellow
Negative tester probe

black / white
YESNO 1. Headlight bulb and socket

Check the headlight bulb and socket for con-
tinuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.

Are the headlight bulb and socket OK?
Replace the head-
light bulb, socket or
both.
YESNO 2. Voltage

Connect the pocket tester (DC 20 V) to the
headlight and meter assembly couplers as
shown.
The wiring circuit
from the main switch
to the headlight cou-
pler is faulty and
must be repaired.
When the dimmer switch is set to “ ”
When the dimmer switch is set to “ ”
Headlight coupler (wire harness side)
Low beam
Headlight
Positive tester probe
black
Negative tester probe
black / green
1
2
Meter assembly coupler (wire harness side)

Turn the main switch to “ON”.

Start the engine.

Set the dimmer switch to “ ” or “ ”.

Measure the voltage (DC 12 V) of
black / green or black / yellow on the
headlight coupler (wire harness side).

Is the voltage within specification?
2
This circuit is OK.
A
B
Headlight
Positive tester probe
black
Negative tester probe
black / yellow
A
Headlight coupler (wire harness side)
High beam
B
6
5
3
4
4
LIGHTING SYSTEMELEC
EAS00788
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator
light fail to come on.
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8-40
SIGNALING SYSTEMELEC
YESNO
Replace the starting
circuit cut-off relay.
YESNO 4. 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
brown
Negative tester probe
ground
1

Turn the main switch to “ON”.

Measure the voltage (DC 12 V) of brown
at the meter assembly coupler (wire harness
side).

Is the voltage within specification?
This circuit is OK.

Are the tester readings correct?
YESNO 1. Oil level warning light (LEDs)

Check the oil level warning light for continu-
ity.
When the main switch is turn to “ON”, the oil
level warning light is come on.

Are the oil level warning light OK?
Replace the meter
assembly.
EAS00802
5. The oil level warning light fails to come on.
YESNO 2. Oil level switch

Drain the engine oil and remove the oil level
switch from the oil pan.

Connect the pocket tester (Ω
100) to the
oil level switch as shown.
Replace the oil level
switch. Positive tester probe

Connector (white)
Negative tester probe
Body ground
1
12

Measure the oil level switch resistance.
Oil level switch resistance
114  126 Ω at 20C (68F)
484  536 Ω at 20C (68F)
1
2

Is the oil level switch OK?
2
When you switch the positive and negative
tester probes, the readings in the above
chart will be reversed.
NOTE:
1
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