check engine YAMAHA YZF-R1S 2004 Workshop Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: YZF-R1S, Model: YAMAHA YZF-R1S 2004Pages: 457, PDF Size: 7.58 MB
Page 374 of 457
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?
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Page 375 of 457
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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Page 384 of 457
7-40
THROTTLE BODIESFI
NOTE: CHECKING THE PRESSURE REGULATOR
1. Check:
pressure regulator
Damage Replace.
CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION
1. Check:
pressure regulator operation
a. Remove the fuel tank.
Refer to “FUEL TANK” in chapter 3.
b. Disconnect the negative pressure hose
1
from the pressure regulator at the joint.
c. Connect the vacuum / pressure pump gauge
set
2 onto the negative pressure hose from
the pressure regulator.
d. Connect the pressure gauge
3 and adapter
4 onto the fuel injection pipe.
Vacuum / pressure pump gauge set
90890-06756, YB-35956
Pressure gauge
90890-03153, YU-03153
Adapter
90890-03176, YM-03176
e. Install the fuel tank.
Refer to “FUEL TANK” in chapter 3.
f. Start the engine.
g. Measure the fuel pressure.
Fuel pressure
294 kPa (2.94 kg / cm
2, 42.6 psi)
h. Use the vacuum pressure pump gauge set to
adjust the fuel pressure in relation to the vac-
uum pressure as described below.
The vacuum pressure should not exceed 100
kPa (760 mmHg, 29.9 inHg).
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Page 385 of 457
7-41
THROTTLE BODIESFI
NOTE:
Increase the vacuum pressure
Fuel pressure is decreased
Decrease the vacuum pressure
Fuel pressure is increased
Faulty Replace the pressure regulator.
EAS00916
CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR
Before adjusting the throttle position sensor, the
engine idling speed should be properly ad-
justed.
1. Check:
throttle position sensor
a. Disconnect the throttle position sensor cou-
pler.
b. Remove the throttle position sensor from the
throttle body.
c. Connect the pocket tester (Ω 1k) to the
throttle position sensor.
Positive tester probe blue terminal
1
Negative tester probe
black / blue terminal
2
d. Measure the maximum throttle position sen-
sor resistance.
Out of specification Replace the throttle
position sensor.
Maximum throttle position
sensor resistance
4 6 kΩ at 20C (68F)
(blue – black / blue)
e. Connect the pocket tester (Ω 1k) to the
throttle position sensor.
Positive tester probe yellow terminal
3
Negative tester probe
black / blue terminal
2
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Page 396 of 457
8-3
CHECKING SWITCH CONTINUITYELEC
CAUTION:
NOTE:
NOTE:
EAS00730
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect,
check the wiring connections and if necessary,
replace the switch.
Never insert the tester probes into the cou-
pler terminal slots. Always insert the probes
from the opposite end of the coupler
1 tak-
ing care not to loosen or damage the leads.
Pocket tester
90890-03112, YU-3112
Before checking for continuity, set the pocket
tester to “0” and to the “Ω 1” range.
When checking for continuity, switch back and
forth between the switch positions a few times.
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions
a are shown in the far left
column and the switch lead colors
b are shown
in the top row in the switch illustration.
“
” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows
that:
There is continuity between red and brown / red
when the switch is set to “P”.
There is continuity between red, brown / blue
and brown / red when the switch is set to “ON”.
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Page 397 of 457
8-4
11Neutral switch
12Rear brake light switch
13Fuse box
1Main switch
2Horn switch
3Dimmer switch
4Turn signal switch
5Clutch switch
6Sidestand switch
7Engine stop switch
8Front brake light switch
9Start switch
10Oil level switch
CHECKING THE SWITCHESELEC
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage / wear Repair or replace.
Improperly connected Properly connect.
Incorrect continuity reading Replace the switch.
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Page 403 of 457
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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Page 404 of 457
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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Page 405 of 457
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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Page 409 of 457
8-16
YESNO
3. Starter motor
Connect the positive battery terminal and
starter motor lead with a jumper lead .
Repair or replace the
starter motor. A wire that is used as a jumper lead
must have at least the same capacity or
more as that of the battery lead, other-
wise the jumper lead may burn.
This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
Does the starter motor turn?
WARNING
1
23
EAS00758
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
ELECTRIC STARTING 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).
EAS00757
TROUBLESHOOTING
The starter motor fails to turn.
Check:
1. main and ignition fuses
2. battery
3. starter motor
4. starting circuit cut-off relay
5. starter relay
6. main switch
7. engine stop switch
8. neutral switch
9. sidestand switch
10. clutch switch
11. start switch
12. wiring connections
(of the entire starting system)
Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. side cowlings
4. throttle body assembly
Troubleshoot with the following special tool(s).
Pocket tester
90890-03112, YU-3112
EAS00738
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