Yamaha Yzf R1 2007 Manual
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THROTTLE BODIES 7-5 Removing the injectors Order Job/Parts to remove Q’ty Remarks 1 Intake air pressure sensor coupler 1 Disconnect. 2 Cylinder #1-injector coupler 1 Disconnect. 3 Cylinder #2-injector coupler 1 Disconnect. 4 Cylinder #3-injector coupler 1 Disconnect. 5 Cylinder #4-injector coupler 1 Disconnect. 6 Sub-wire harness 1 7 Negative pressure hose 1 Disconnect. 8 Intake air pressure sensor 1 9Fuel distributor 1 10 Injector 4 11 Throttle position sensor (for throttle valves) 1 12 Throttle position sensor (for throttle cable pulley) 1 13 Throttle body assembly 1 For installation, reverse the removal proce- dure.
THROTTLE BODIES 7-6 EAS26980 CHECKING THE INJECTORS 1. Check: Injectors Damage → Replace. EAS26990 CHECKING THE THROTTLE BODIES 1. Check: Throttle bodies Cracks/damage → Replace the throttle bodies as a set. 2. Check: Fuel passages Obstructions → Clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash the throttle bodies in a petroleum- based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages with com- pressed air. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4S81001 CHECKING THE FUEL PRESSURE 1. Check: Fuel pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the rider and passenger seat. Refer to GENERAL CHASSIS on page 4- 1. b. Disconnect the fuel hose (fuel tank to pri- mary injector fuel rail) “1” from the primary injector fuel rail. WARNING EWA4C81001 Cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when removing the hoses.c. Connect the pressure gauge “2” and adapter “3” to the fuel hose (fuel tank to pri- mary injector fuel rail). d. Start the engine. e. Measure the fuel pressure. Faulty → Replace fuel pump. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR (FOR THROTTLE VALVES) 1. Check: Throttle position sensor (for throttle valves) Refer to CHECKING THE THROTTLE POSITION SENSOR (FOR THROTTLE VALVES) on page 8-97. 2. Adjust: Throttle position sensor angle Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter 90890-03176 YM-03176 Fuel pressure 324 kPa (46.1 psi) (3.24 kg/ cm 2)
THROTTLE BODIES 7-7 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Temporary tighten the throttle position sen- sor (for throttle valves). b. Check that the throttle valves are fully closed. c. Connect the throttle position sensor (for throttle valves), throttle position sensor (for throttle cable pulley) and throttle servo motor to the wire harness. d. Turn the main switch to “OFF” and set the engine stop switch to “ON”. e. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to ON, and continue to press the buttons for 8 seconds more. NOTE: “dIAG” appears on the odometer, tripmeter and fuel reserve trip LCD. f. Diagnostic code 01 is selected. g. Adjust the position of the throttle position sensor angle so that 16 can appear in the meter. h. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws “1”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4C81023 ADJUSTING THE THROTTLE POSITION SENSOR (FOR THROTTLE CABLE PUL- LEY) 1. Check: Throttle position sensor (for throttle cable pulley) Refer to ADJUSTING THE THROTTLE POSITION SENSOR (FOR THROTTLE CABLE PULLEY) on page 7-7. 2. Adjust: Throttle position sensor (for throttle cable pulley) angle ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Temporary tighten the throttle position sen- sor (for throttle cable pulley). b. Check that the throttle valves are fully closed. c. Connect the throttle position sensor (for throttle valves), throttle position sensor (for throttle cable pulley) and throttle servo motor to the wire harness. d. Turn the main switch to “OFF” and set the engine stop switch to “ON”. e. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to ON, and continue to press the buttons for 8 seconds more. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to ON, and continue to press the buttons for 8 seconds more. NOTE: “dIAG” appears on the odometer, tripmeter and fuel reserve trip LCD. f. Diagnostic code 14 is selected. g. Adjust the position of the throttle position sensor angle so that 17 can appear in the meter. h. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws “1”.
THROTTLE BODIES 7-8 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
AIR INDUCTION SYSTEM 7-9 EAS27040 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses Order Job/Parts to remove Q’ty Remarks 1 Air cut-off valve coupler 1 Disconnect. 2 Air cut-off valve hose 1 1 Disconnect. 3 Air cut-off valve hose 2 1 Disconnect. 4 Air cut-off valve hose 3 1 Disconnect. 5 Air cut-off valve 1 6 Reed valve cap 2 7 Reed valve assembly 2 8Plate 4 For installation, reverse the removal proce- dure.
AIR INDUCTION SYSTEM 7-10 EAS27060 CHECKING THE AIR INDUCTION SYSTEM Air injection The air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons. When there is neg- ative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approximately 600 to 700°C. Air cut-off valve The air cut-off valve is controlled by the signals from the ECU in accordance with the combus- tion conditions. Ordinarily, the air cut-off valve opens to allow the air to flow during idle and closes to cut-off the flow when the vehicle is being driven. However, if the coolant tempera- ture is below the specified value, the air cut-off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value.1. Check: Hoses Loose connections → Connect properly. Cracks/damage → Replace. Pipes Cracks/damage → Replace. 2. Check: Reed valve “1” Reed valve stopper Reed valve seat Cracks/damage → Replace the reed valve. 3. Measure: Reed valve bending limit “a” Out of specification → Replace the reed valve. 4. Check: Air cut-off valve Cracks/damage → Replace. 5. Check Air induction system solenoid Refer to CHECKING THE AIR INDUC- TION SYSTEM SOLENOID on page 8-98.A. From the air cleaner B. To the cylinder head Reed valve bending limit 0.4 mm (0.016 in)
ELECTRICAL SYSTEM IGNITION SYSTEM....................................................................................... 8-1 CIRCUIT DIAGRAM............. ................................................................... 8-1 TROUBLESHOOTING ............................................................................ 8-3 ELECTRIC STARTING SYSTEM .................................................................. 8-5 CIRCUIT DIAGRAM............. ................................................................... 8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......................... 8-7 TROUBLESHOOTING ............................................................................ 8-9 CHARGING SYSTEM ................................................................................. 8-11 CIRCUIT DIAGRAM............. ................................................................. 8-11 TROUBLESHOOTING .......................................................................... 8-13 LIGHTING SYSTEM ................................................................................... 8-15 CIRCUIT DIAGRAM............. ................................................................. 8-15 TROUBLESHOOTING .......................................................................... 8-17 SIGNALING SYSTEM ................................................................................. 8-19 CIRCUIT DIAGRAM............. ................................................................. 8-19 TROUBLESHOOTING .......................................................................... 8-21 COOLING SYSTEM .................................................................................... 8-25 CIRCUIT DIAGRAM............. ................................................................. 8-25 TROUBLESHOOTING .......................................................................... 8-26 FUEL INJECTION SYSTEM ....................................................................... 8-29 CIRCUIT DIAGRAM............. ................................................................. 8-29 ECU SELF-DIAGNOSTIC FUNCTION ................................................. 8-31 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) .......... 8-32 TROUBLESHOOTING METHOD ......................................................... 8-35 DIAGNOSTIC MODE ............................................................................ 8-36 TROUBLESHOOTING DETAILS .......................................................... 8-44 FUEL PUMP SYSTEM ................................................................................ 8-65 CIRCUIT DIAGRAM............. ................................................................. 8-65 TROUBLESHOOTING .......................................................................... 8-67 IMMOBILIZER SYSTEM ............................................................................. 8-69 CIRCUIT DIAGRAM............. ................................................................. 8-69 GENERAL INFORMATION ................................................................... 8-71 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS ................................................................................. 8-71 TROUBLESHOOTING .......................................................................... 8-74 SELF-DIAGNOSIS FAULT CODE INDICATION.................................... 8-75
ELECTRICAL COMPONENTS................................................................... 8-77 CHECKING THE SWITCHES............................................................... 8-81 CHECKING THE BULBS AND BULB SOCKETS ................................. 8-84 CHECKING THE FUSES...................................................................... 8-85 CHECKING AND CHARGING THE BATTERY ..................................... 8-85 CHECKING THE RELAYS .................................................................... 8-88 CHECKING THE TURN SIGNAL RELAY ............................................. 8-89 CHECKING THE RELAY UNIT (DIODE) .............................................. 8-90 CHECKING THE IGNITION COILS ...................................................... 8-91 CHECKING THE CRANKSHAFT POSITION SENSOR ....................... 8-92 CHECKING THE LEAN ANGLE SENSOR ........................................... 8-92 CHECKING THE STARTER MOTOR OPERATION.............................. 8-93 CHECKING THE STATOR COIL ........................................................... 8-93 CHECKING THE RECTIFIER/REGULATOR ........................................ 8-93 CHECKING THE HORN ....................................................................... 8-94 CHECKING THE OIL LEVEL SWITCH ................................................ 8-94 CHECKING THE FUEL SENDER ........................................................ 8-95 CHECKING THE SPEED SENSOR ..................................................... 8-95 CHECKING THE RADIATOR FAN MOTORS ....................................... 8-96 CHECKING THE COOLANT TEMPERATURE SENSOR .................... 8-96 CHECKING THE THROTTLE POSITION SENSOR (FOR THROTTLE CABLE PULLEY)..................................................... 8-97 CHECKING THE THROTTLE POSITION SENSOR (FOR THROTTLE VALVES).................................................................. 8-97 CHECKING THE AIR INDUCTION SYSTEM SOLENOID ................... 8-98 CHECKING THE ATMOSPHERIC PRESSURE SENSOR ................... 8-98 CHECKING THE CYLINDER IDENTIFICATION SENSOR .................. 8-99 CHECKING THE INTAKE AIR PRESSURE SENSOR ......................... 8-99 CHECKING THE INTAKE AIR TEMPERATURE SENSOR .................. 8-99
IGNITION SYSTEM 8-1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM