YAMAHA YZF-R1S 2004 Service 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.
ProCarManuals.com

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.
ProCarManuals.com

7-29
FUEL INJECTION SYSTEMFI
Speed sensor output voltage
When sensor is on
DC 4.8 V or more
When sensor is off
DC 0.6 V or less Tester positive probe
white
Tester negative probe
black / blue
1
2
Fault code No.42Symptom1 No normal signals are received from the speed sensor.
2 Open or short circuit is detected in the neutral switch.
Used diagnostic code No. 07 (speed sensor)
A1
A4
No. 21 (neutral switch)
B1
B4
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
A1Connected condition of speed sensor
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.
Speed sensor coupler
Main wiring harness ECU couplerReinstated by
starting the
engine, and
inputting the
vehicle speed
signals by
ti thA2Open or short circuit in speed sensor
lead.Repair or replace if there is an open or short circuit.
Between sensor coupler and ECU coupler.
Blue – Blue
White / Yellow – White / Yellow
Black / Blue – Black / Blueoperating the
motorcycle at a
low speed of
20 to 30 km / h.
A3Defective speed sensorExecute the diagnostic mode (Code No.07).
Replace if defective.
1. Measure the speed sensor output voltage.
2. Connect the pocket tester (DC 20 V) to the
speed sensor coupler terminal as shown.
3. Measure the speed sensor output voltage.
4. Is the speed sensor OK?
A4Gear for detecting vehicle speed has
broken.Replace if defective.
Refer to “TRANSMISSION” in chapter 5.
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method.
B1Connected 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.
Neutral switch connector
Main wiring harness ECU couplerReinstated by
starting the
engine, and
inputting the
vehicle speed
ilbB2Open or short circuit in neutral switch
lead.Repair or replace if there is an open or short circuit.
Between switch connector and ECU coupler
Sky blue – Black / Yellowsignals by
operating the
motorcycle at a
low speed ofB3Defective neutral switchExecute the diagnostic mode (Code No.21).
Replace if defective.
Refer to “CHECKING THE SWITCHES” in
chapter 8.low s eed of20 to 30 km / h.
B4Faulty shift drum
(neutral detection area)Replace if defective.
Refer to “TRANSMISSION” in chapter 5.
ProCarManuals.com

7-30
FUEL INJECTION SYSTEMFI
Battery positive terminal
red / black
Battery positive terminal
blue/ yellow1
2
Tester positive probe
red
Tester negative probe
red / blue
3
4 When the leads are disconnected, the voltage
check by the code No.09 is impossible.
NOTE:
Fault code No.43SymptomThe ECU is unable to monitor the battery voltage.
Used diagnostic code No. 09 (fuel system voltage)
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.
Starting circuit cut-off relay coupler
(fuel injection system relay)
ECU couplerReinstated by
starting the
engine and
operating it at
idle.
2Malfunction in ECUFuel injection system relay is on.
3Open or short circuit in the wiring harness.Repair or replace if there is an open or short
circuit.
Between battery terminal and ECU coupler
Red / white – Red / white
Red – Blue / Yellow (Main switch and engine
stop switch are on.)
Red – Red / Blue (Fuel injection system
relay is on.)
4Malfunction or open circuit in fuel injection
system relayExecute the diagnostic mode (Code No.09).
Replace if defective.
1. Disconnect the starting circuit cut-off relay
from the wire harness.
2. Connect the pocket tester (Ω  1) and battery
(12 V) to the starting circuit cut-off relay termi-
nals as shown.
3. Does the starting circuit cut-off relay have con-
tinuity between blue / white and black?
ProCarManuals.com

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
ProCarManuals.com

7-32
FUEL INJECTION SYSTEMFI
Fault code No.47SymptomSub-throttle position sensor – open or short circuit detected.
Used diagnostic code 56
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Installed condition of sub-throttle position
sensor.Check the installed area for looseness or pinch-
ing.
Check that it is installed in the specified position.
Refer to “THROTTLE BODIES” section.Reinstated by
turning the
main switch
ON.
2Connected 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.
Throttle position sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
3Open or short circuit in wiring harness
and / or sub lead.Repair or replace if there is an open or short cir-
cuit.
Between sensor coupler and ECU coupler
Black / Blue – Black / Blue
Green / yellow – Green / yellow
Blue – Blue
4Defective sub-throttle position sensor.Replace if defective.
Refer to “THROTTLE BODIES” section.
ProCarManuals.com

7-33
FUEL INJECTION SYSTEMFI
To prevent damaging the sub-throttle ser-
vomotor, perform this test within a few se-
conds of connecting the battery. Positive battery terminal
yellow / red
Negative battery terminal
yellow / white
1
2
CAUTION:
Fault code No.48SymptomSub-throttle servo motor is stuck.
Used diagnostic code 56
OrderInspection operation item and probable
couseOperation 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
couplerIf there is a malfunction repair it and
connect it securely.
Sub-throttle servo motor coupler
Main wire harness ECU coupler.Reinstated by
turning the
main switch
ON.
It takes 120
2Open or short circuit in wire harness.Repair or replace if there is an open
or short circuit.
Between motor coupler and ECU coupler.
Yellow / Red – Yellow / Red
Yellow / White – Yellow / Whiteseconds at the
maximum
before the
original state
returns.
3Defective sub-throttle servo motor.Execute the diagnostic mode (Code No.56).
Replace if defective.
1. Disconnect the sub-throttle cables from the
Sub-throttle servomotor pulley.
2. Disconnect the sub-throttle servomotor coupler
from the wire harness.
3. Connect the battery leads to the sub-throttle
servomotor coupler as shown.
4. Check that the sub-throttle servomotor pulley
rotates several times.
5. Does the sub-throttle servomotor pulley turn?
Fault code No.50SymptomFaulty ECU memory. (When this malfunction is detected in the ECU, the fault
code number might not appear on the meter.)
Used diagnostic code No. – –
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Malfunction in ECUReplace the ECU.Reinstated by
turning the
main switch
ON.
ProCarManuals.com

7-34
FUEL INJECTION SYSTEMFI
Fault code No.Er-1SymptomNo signal are received from the ECU.
Er-2SymptomNo signal are received from the ECU within the specified duration.
Er-3SymptomData from the ECU cannot be received correctly.
Er-4SymptomNon-registered data has been received from the meter.
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.
Cylinder identification sensor coupler
Main wiring harness ECU coupler
Sub-wire harness couplerReinstated by
turning the
main switch
ON.
2Open or short circuit in wiring harness
and / or sub lead.Repair or replace if there is an open or short
circuit.
Between sensor coupler and ECU coupler
Yellow / Blue – Yellow / Blue
Black / White – Black / White
3Malfunction in meterReplace the meter.
4Malfunction in ECUReplace the ECU.
ProCarManuals.com

7-35
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the throttle bodies
Seat
Fuel tank
Air filter case
Sub-wire harness coupler
Coolant temperature sensor coupler
Thermo wax inlet hose
Thermo wax outlet hose
Idle adjust screw wire
Throttle body joint clamp
Throttle bodies
Throttle cables2
1
1
1
1
4
1
2Remove the parts in the order listed.
Refer to “SEAT” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Disconnect.
Disconnect.
Loosen.
If it loosens too much, the nut will sepa-
rate.
Disconnect.
NOTE:
THROTTLE BODIESFI
THROTTLE BODIES
ProCarManuals.com

7-36
Order Job / Part Q’ty Remarks
9
10
11Throttle body joint
Heat protector
Fuel hose4
1
1To install the throttle body joint, make
sure to install it to the cylinder with the
same figures corresponding to the fig-
ures stated on the throttle body joint.
For installation, reverse the removal
procedure.
NOTE:
THROTTLE BODIESFI
ProCarManuals.com