ignition YAMAHA YZF-R1S 2004 Owner's Manual

7-27
FUEL INJECTION SYSTEMFIFUEL INJECTION SYSTEMFI
Fault code No.33SymptomMalfunction detected in the primary lead of the ignition coil (#1).
Used diagnostic code No. 30 (ignition coil #1)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
Ignition coil primary side coupler – Orange
Main wiring harness ECU couplerReinstated by
starting the en-
gine and oper-
ating it at idle.
2Open or short circuit in lead.Repair or replace if there is an open or short
circuit.
Between ignition coil coupler (#1) and ECU
coupler / main harness
Orange – Orange
Red / Black – Red / Black
3Detective ignition coil (test the primary
and secondary coils for continuity).Execute the diagnostic mode (Code No.30).
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
Fault code No.34SymptomMalfunction detected in the primary lead of the ignition coil (#2).
Used diagnostic code No. 31 (ignition coil #2)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
Ignition coil primary side coupler – Gray / Red
Main wiring harness ECU couplerReinstated by
starting the en-
gine and oper-
ating it at idle.
2Open or short circuit in lead wire.Repair or replace if there is an open or short
circuit.
Between ignition coil coupler (#2) and ECU
coupler / main harness
Gray / Red – Gray / Red
Red / Black – Red / Black
3Defective ignition coil (test the primary
and secondary coils for continuity).Execute the diagnostic mode (Code No.31).
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
Fault code No.35SymptomMalfunction detected in the primary lead of the ignition coil (#3).
Used diagnostic code No. 32 (ignition coil #3)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
Ignition coil primary side coupler – Orange /
Green
Main wiring harness ECU couplerReinstated by
starting the en-
gine and oper-
ating it at idle.
2Open or short circuit in lead wire.Repair or replace if there is an open or short
circuit.
Between ignition coil coupler (#3) and ECU
coupler / main harness
Orange / Green – Orange / Green
Red / Black – Red / Black
3Defective ignition coil (test the primary
and secondary coils for continuity).Execute the diagnostic mode (Code No.32).
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
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7-28
FUEL INJECTION SYSTEMFI
Fault code No.36SymptomMalfunction detected in the primary lead of the ignition coil (#4).
Used diagnostic code No. 33 (ignition coil #4)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected state of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
Ignition coil primary side coupler – Gray / Green
Main wiring harness ECU couplerReinstated by
starting the en-
gine and oper-
ating it at idle.
2Open or short circuit in lead wire.Repair or replace if there is an open or short
circuit.
Between ignition coil coupler (#4) and ECU
coupler / main harness
Gray / Green – Gray / Green
Red / Black – Red / Black
3Defective ignition coil (test the primary
and secondary coils for continuity).Execute the diagnostic mode (Code No.33).
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
Fault code No.41SymptomOpen or short circuit detected in the lean angle cut-off switch.
Used diagnostic code No. 08 (lean angle cut-off switch)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
Lean angle cut-off switch coupler
Main wiring harness ECU couplerReinstated by
turning the
main switch
ON.
2Open or short circuit in wiring harness.Repair or replace if there is an open or short
circuit.
Between switch coupler and ECU coupler
Black / Blue – Black / Blue
Yellow / Green – Yellow / Green
Blue – Blue
3Defective lean angle cut-off switchExecute the diagnostic mode (Code No.08).
Replace if defective.
Refer to Fault code No. 30.
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7-31
FUEL INJECTION SYSTEMFI
Fault code No.44SymptomError is detected while reading or writing on EEP-ROM
(CO adjustment value).
Used diagnostic No. 60 (EEP-ROM improper cylinder indication)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Malfunction in ECUExecute diagnostic code 60
1. Check the faulty cylinder. (If there are multiple
cylinders, the number of the faulty cylinders
appear alternately at 2-second intervals.)
2. Readjust the CO of the displayed cylinder.
Refer to “ADJUSTING THE EXHAUST GAS
VALUME” in chapter 3.
Replace ECU if defective.Reinstated by
turning the
main switch
ON.
Fault code No.46SymptomPower supply to the FI system relay is not normal.
Used diagnostic code No. – –
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
ECU coupler.Reinstated by
starting the
engine and
operating it at
idle.
2Faulty batteryReplace or change the battery
Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
3The malfunction of the rectifier / regula-
tor.Replace if defective.
Refer to “CHARGING SYSTEM” in chapter 8.
4Open or short circuit in wiring harness.Repair or replace if there is an open or short
circuit.

Between battery and main switch
red – red

Between main switch and fuse (ignition)
brown/blue – brown/blue

Between fuse (ignition) and ECU
red/white – red/white
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8-1
8
ELECTRICAL COMPONENTSELEC
9Oil level switch
10Radiator fan motor
11Horn
12Ignition coil
1Main switch
2Front brake light switch
3Starter relay
4Battery
5Fuse box
6Rear brake light switch
7Neutral switch
8Sidestand switch
EAS00729
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
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8-8
IGNITION SYSTEMELEC
EAS00735
IGNITION SYSTEM
CIRCUIT DIAGRAM
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8-9
IGNITION SYSTEMELEC
1Main switch
4Fuse (main)
6Battery
10Starting circuit cut-off relay
11Neutral switch
12Sidestand switch
14E.C.U.
15Ignition coil #1
16Ignition coil #2
17Ignition coil #3
18Ignition coil #4
19Spark plug
31Crankshaft position sensor
35Cylinder identification sensor
36Lean angle cut-off switch
53Engine stop switch
59Clutch switch
73Fuse (ignition)
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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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8-13
IGNITION SYSTEMELEC
12. Starting circuit cut-off relay (diode)

Disconnect the starting circuit cut-off relay
coupler from the wire harness.

Connect the pocket tester (Ω
1) to the
starting circuit cut-off relay coupler as
shown.

Check the starting circuit cut-off relay for
continuity.
Positive tester probe

blue / yellow
Negative tester probe

sky blue
1
2
EAS00753
Positive tester probe

blue / yellow
Negative tester probe

blue / black Continuity
1
3
Positive tester probe

sky blue
Negative tester probe

blue / yellow
2
1
Positive tester probe

blue / black
Negative tester probe

blue / yellow No
continuity
3
1
YESNO
Replace the starting
circuit cut-off relay. When you switch the positive and negative
tester probes, the readings in the above chart
will be reversed.

Are the tester readings correct?
NOTE:
13. Lean angle cut-off switch

Check the lean angle cut-off switch.
Refer to “FUEL INJECTION SYSTEM” in
chapter 7.

Is the lean angle cut-off switch OK?
YESNO
Replace the lean
angle cut-off switch.
EAS00754
14. Wiring

Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.

Is the ignition system’s wiring properly con-
nected and without defects?
YESNO
Properly connect or
repair the ignition
system’s wiring.
Replace the ECU.
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