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The one thing I've been putting off for as long as possible is trying to get teh engine started. Not because I didn't want to hear it run but because the thought of faffing about with electrics is not my idea of fun. One thing I did have problems with was not being able to find a "This is what you need to do" to wire up the Fuel Injected engine. I did vow that I'd make sure that I put everything together to make it easier for others wiring up a Fuel Injected R1.
I couldn't put it off any longer as it's one of the jobs that's preventing other things from happening.
Here's how I approached the first start. First I disconnected the fuel pipe to the fuel rail and plumbed it to the return pipe so I could check if fuel was getting back to the fuel tank when I had some fuel in the tank.
Secondly, I removed a spark plug and disconnected the other coils.
Third I started with the wiring, these are the connectors that I had to modify with the Yamaha number from the wiring diagram. Main Switch (Red 2 pin connector) [1 on Yamaha wiring diagram] Join Blue/Black --> Blue / Yellow Main switch (White 2 pin connector) Join Brown / Blue --> Red (connected via the ignition switch) Right Handlebar switch (Blue 6 pin connector) [59 on Yamaha wiring diagram] Join Red /Black --> Red White (Engine kill) Side stand (2 pin Blue connector) [11 on Yamaha wiring diagram] Join Black --> Blue / black Left handlebar (10 pin white connector) [41 on Yamaha wiring diagram] Join Blue / Yellow -> Black yellow (Clutch) Fuel Pump (Green connector) [52 on Yamaha wiring diagram] Use Red / blue as Fuel pump positive, this is fed by a relay in the start circuit cut-off switch. As a temporary measure I have a switch in the connection so that I can stop the pump from firing.
Once I made these connections I connected the red and black main wires to the battery, turning the key resulted in a click and nothing else. I checked everything over again and I couldn't see anything wrong so I placed a quick call to Mal at Yorkshire Engines for a sanity check. I was out by one connector.
Right Handlebar switch (Blue 6 pin connector) [60 on Yamaha wiring diagram] Join Blue/White -> Black with a push to make switch as a starter button As soon as this was done the engine turned over and with the sparkplug touching the rocker bolt I got a nice healthy spark.
Next step is to put some petrol in the tank and try and get it to start. I poured a small amount of petrol in the tank and filled the drip tray underneath the fuel tank. Checking the jubilee clips I hadn't tightened the main line from the tank to the fuel filter. Ooops!
Powering up the pump I was soon listening to fuel being returned to the tank so it seemed there were no more reasons to not try! I reconnected the fuel lines and put the pump into the wiring loom. Joining the wires that will go to the ignition switch I heard the click of the cut-off circuit and the fuel pump power up, once the pump had stopped I crossed fingers and joined the start wires. The starter turned I could hear the engine trying to fire, a couple of coughs and splutters later and I was completely deafend by the roar of my engine!
Movie and mp3 footage will be uploaded when I'm allowed to play with it.
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