Yamaha R1 2004 ServiceManual
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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
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
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
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
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