Yamaha R1 2004 ServiceManual
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8-18 Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the starting system’s wiring properly con- nected and without defects? EAS00766 12. Wiring YESNO Properly connect or repair the starting system’s wiring. The starting system circuit is OK. 11. Start switch Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the start switch OK? YESNO Replace the right handlebar switch. EAS00764 10. Clutch switch Check the clutch switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the clutch switch OK? YESNO Replace the clutch switch. EAS00763EAS00752 9. Sidestand switch Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the sidestand switch OK? YESNO Replace the side- stand switch. ELECTRIC STARTING SYSTEMELEC
8-19 STARTER MOTORELEC Order Job / Part Q’ty Remarks 1 2Removing the starter motor Seat Fuel tank Throttle body assembly Starter motor lead Starter motor1 1Remove the parts in the order listed. Refer to “SEAT” in chapter 3. Refer to “FUEL TANK” in chapter 3. Refer to “THROTTLE BODIES” in chapter 7. For installation, reverse the removal procedure. 10 Nm (1.0 mkg, 7.2 ftlb)5 Nm (0.5 mkg, 3.6 ftlb) 5 Nm (0.5 mkg, 3.6 ftlb) EAS00767 STARTER MOTOR
8-20 STARTER MOTORELEC Order Job / Part Q’ty Remarks Disassembling the starter motor O-ring Front cover Lock washer Washer Starter motor yoke Armature assembly O-ring Starter motor lead Brush holder Rear cover1 1 1 1 1 1 2 2 1 1Disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 6 7 8 9 10 5 Nm (0.5 mkg, 3.6 ftlb) 5 Nm (0.5 mkg, 3.6 ftlb) 5 Nm (0.5 mkg, 3.6 ftlb) EAS00768
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.
8-22 STARTER MOTORELEC NOTE: 5. Measure: brush length a. Out of specification Replace the brushes as a set. Brush length wear limit 3.6 mm (0.14 in) 6. Measure: brush spring force Out of specification Replace the brush springs as a set. Brush spring force 5.28 7.92 N (538 808 gf, 18.99 28.48 oz) 7. Check: gear teeth Damage / wear Replace the gear. EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: brush seat 1 Align the slot a on the brush seat with the tab b in the starter motor rear cover. 2. Install: armature 1
8-23 STARTER MOTORELEC 5 Nm (0.5 mkg, 3.6 ftlb) NOTE: 3. Install: starter motor yoke 1 O-rings 2 New starter motor rear cover 3 bolts Align the match marks a on the starter motor yoke with the match marks b on the front and rear covers.
8-24 2A.C. magneto 3Rectifier / regulator 4Fuse (main) 6Battery CHARGING SYSTEMELEC EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM
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
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?
8-27 LIGHTING SYSTEMELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM