fuel YAMAHA YZF-R1S 2004 Repair Manual

7-14
FUEL INJECTION SYSTEMFI
Diagnostic
codeItemDescription of actionData displayed on meter
(reference value)
52
Headlight relay 1After the engine stop switch has been turned from OFF to
ON, it actuates the headlight relay five times every
5 seconds and illuminates the engine trouble warning light.
(ON 2 seconds, OFF 3 seconds)
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check the headlight relay
operating sound 5 times with the
engine stop switch ON.
(At that time, the headlight turns
ON.)
53
EXUP servo motorAfter the engine stop switch has been turned from OFF to
ON, it actuates the servo motor turns to open side and to
close side.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Turn on the engine trouble
warning light while servo motor
is operated. (Operating angle is
displayed on the LCD meter)
56
Sub-throttle servo
motorAfter the engine stop switch has been turned from OFF to
ON, it actuates the servo motor turns to open side and to
close side.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back on.Turn on the engine trouble warn-
ing light while servo motor is op-
erated (Operating angle is dis-
played on the LCD meter).
60
EEPROM fault code
display
Transmits the abnormal portion of the data in the E2PROM
that has been detected as a self-diagnostic fault code 44.

If multiple malfunctions have been detected, different
codes are displayed at 2-second intervals, and this
process is repeated.(01
04) Displays the cylinder
number.
(00) Displays when there is no
malfunction.
61
Malfunction history
code display
Displays the codes of the history of the self-diagnosis
malfunctions (i.e., a code of a malfunction that occurred
once and which has been corrected).

If multiple malfunctions have been detected, different
codes are displayed at 2-second intervals, and this
process is repeated.11
50
(00) Displays when there is no
malfunction.
62
Malfunction history
code erasure
Displays the total number of codes that are being detected
through self diagnosis and the fault codes in the past
history.

Erases only the history codes when the engine stop switch
is turned from OFF to ON. If the engine stop switch is ON,
turn it OFF once, and then turn it back ON.00
25
(00) Displays when there is no
malfunction.
70Control number
Displays the program control number.00
255
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7-15
FUEL INJECTION SYSTEMFI
Cylinder identification sensor
output voltage
When sensor is on
4.8 V or more
When sensor is off
0.8 V or less Tester positive probe
white / black
Tester negative probe
black / blue
1
2
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the meter. Carry out check
and maintenance on items or components that could be a cause of malfunction in accordance with the
order.
When the check and maintenance of malfunctioned part is completed, restore the meter display ac-
cording to the “Restore method”.
Fault code No.:
Fault code number displayed on the meter when the engine failed to work normally. (Refer to “Diag-
nostic fault code table”.)
Diagnostic code No.:
Code number to be used when the diagnostic monitoring mode is operated. (Refer to “DIAGNOS-
TIC MODE”.)
Fault code No.11SymptomNo normal signals are received from the cylinder identification sensor.
Used diagnostic code No. – –
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Installed condition of sensorCheck the installed area for looseness or
pinching.Reinstated by
starting the
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.
Cylinder identification sensor coupler
Main wiring harness ECU coupler
Sub-wire harness couplerengine and
operating it at
idle.
3Open 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
Blue – Blue
White / Black – White / Black
Black / Blue – Black / Blue
4Defective cylinder identification sensor.Replace if defective.
1. Connect the pocket tester (DC 20 V) to the
cylinder identification sensor coupler terminal
as shown.
2. Set the main switch to “ON”.
3. Measure the cylinder identification sensor out-
put voltage.
4. Is the cylinder identification sensor OK?
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7-16
Crankshaft position sensor
resistance
336
504 Ω at 20C (68F)
(between gray and black) Tester positive probe
gray
Tester negative probe
black
1
2
12
FUEL INJECTION SYSTEMFI
Fault code No.12SymptomNo normal signals are received from the crankshaft position sensor.
Used diagnostic code No. – –
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Installed condition of sensorCheck the installed area for looseness or
pinching.Reinstated by
cranking the
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.
Crankshaft position sensor coupler
Main wiring harness ECU couplerengine.
3Open or short circuit in wiring harness.Repair or replace if there is an open or short
circuit between the main wiring harnesses.
Between sensor coupler and ECU coupler
Gray – Gray
Black / Blue – Black / Blue
4Defective crankshaft position sensor.Replace if defective.
1. Disconnect the crankshaft position sensor cou-
pler from the wire harness.
2. Connect the pocket tester (Ω  100) to the
crankshaft position sensor coupler as shown.
3. Measure the crankshaft position sensor resis-
tance.
4. Is the crankshaft position sensor OK?
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7-17
Intake air pressure sensor output
voltage
3.75
4.25 V Tester positive probe
pink / white
Tester negative probe
black / blue
1
2
FUEL INJECTION SYSTEMFI
Fault code No.13SymptomIntake air pressure sensor – open or short circuit detected.
Used diagnostic code No. 03 (intake air pressure sensor)
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.
Intake air pressure 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
Black / Blue – Black / Blue
Pink / White – Pink / White
Blue – Blue
3Defective intake air pressure sensorExecute the diagnostic monitoring mode (Code
No.03).
Replace if defective.
1. Connect the pocket tester (DC 20 V) to the
intake air pressure sensor coupler terminal as
shown.
2. Set the main switch to “ON”.
3. Measure the intake air pressure sensor output
voltage.
4. Is the intake air pressure sensor OK?
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7-18
FUEL INJECTION SYSTEMFI
Fault code No.14SymptomIntake air pressure sensor – hose system malfunction (clogged or detached
hose).
Used diagnostic code No. 03 (intake air pressure sensor)
OrderInspection operation item and probable
causeOperation item and countermeasuerReinstatement
method
1Intake air pressure sensor hose detached,
clogged, kinked, or pinched.
Intake air pressure sensor malfunction at
intermediate electrical potential.Repair or replace the sensor hose.
Inspect and repair the connection.Reinstated by
starting the
engine and
operating it at
2Connected condition of connector
Intake air pressure sensor coupler
Main wiring harness ECU couplerCheck the coupler for any pins that may have
pulled out.
Check the looking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.idle.
3Defective intake air pressure sensor.Execute the diagnostic mode (Code No.03).
Replace if defective.
Refer to “Fault code No. 13”.
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7-19
FUEL INJECTION SYSTEMFI
Fault code No.15SymptomThrottle position sensor – open or shrt circuit detected.
Used diagnostic code No. 01 (throttle position sensor)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Installed condition of throttle position
sensor.Check the installed area for looseness or
pinching.
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
circuit.
Between sensor coupler and ECU coupler
Black / Blue – Black / Blue
Yellow – Yellow
Blue – Blue
4Throttle position sensor lead wire open
circuit output voltage check.Check for open circuit and replace the throttle
position sensor.
Black / Blue – Yellow
Open circuit item Output voltage
Ground wire open 5 V
circuit
Output wire open 0V
circuit
Power supply wire 0V
open circuit
5Defective throttle position sensor.Execute the diagnostic mode (Code No.01).
Replace if defective.
Refer to “THROTTLE BODIES” section.
Fault code No.16SymptomStuck throttle position sensor detected.
Used diagnostic code No.01 (throttle position sensor)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1When detecting fault code No.15.Refer to “Fault code No.15”.Reinstated by
2Installed condition of throttle position
sensor.Check the installed area for looseness or pinching.
Check that it is installed in the specified position.
Refer to “THROTTLE BODIES” section.starting the
engine,
operating it at
idle and then3Defective throttle position sensorExecute the diagnostic mode (Code No.01).
Replace if defective.
Refer to “THROTTLE BODIES” section.idle, and then
racing it.
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7-20
FUEL INJECTION SYSTEMFI
EXUP servomotor resistance
(when the pulley is turned once)
5.25
9.75 kΩ at 20C (68F) Positive tester terminal
blue
Negative tester probe
white / red
1
2
Fault code No.17SymptomEXUP servo motor potention circuit – open or short circuit detected.
Used diagnostic code 53
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.
EXUP servo motor coupler
Main wireharness ECU couplerReinstated by
turning the
main switch
ON.
2Open or short circuit in wire harness.Repair or replace if there is an open or short
circuit.
Between motor coupler and ECU coupler
Blue – Blue
White / Red – White / Red
Black / Blue – Black / Blue
3Defective EXUP servo motor potention
circuit.Execute the diagnostic mode (Code No.53).
Replace if defective.
1. Disconnect the EXUP servomotor coupler from
the wire harness.
2. Connect the pocket tester (Ω  1k) to the
EXUP servomotor coupler.
3. While slowly turning the EXUP servomotor
pulley, measure the EXUP servomotor resis-
tance.
4. Is the EXUP servomotor OK?
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7-21
FUEL INJECTION SYSTEMFI
To prevent damaging the EXUP servomo-
tor, perform this test within a few seconds
of connecting the battery. Positive battery terminal
black / green
Negative battery lead
black / red
1
2
CAUTION:
Fault code No.18SymptomEXUP servo motor is stuck.
Used diagnostic code 53
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.
EXUP 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.
Black / Green – Black / Green
Black / Red – Black / Redseconds at the
maximum
before the
original state
returns.
3Defective EXUP servo motor.Execute the diagnostic mode (Code No.53).
Replace if defective.
1. Disconnect the EXUP cables from the EXUP
servomotor pulley.
2. Disconnect the EXUP servomotor coupler from
the wire harness.
3. Connect the battery leads to the EXUP servo-
motor coupler as shown.
4. Check that the EXUP servomotor pulley ro-
tates several times.
5. Does the EXUP servomotor pulley turn?
4Defective EXUP valve, pulley, cable.Replace if defective
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7-22
FUEL INJECTION SYSTEMFI
Fault code No.19SymptomOpen circuit in the input line of ECU No.15 terminal is detected.
Used diagnostic code No. 20 (sidestand switch)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected condition of connector
Main wiring harness ECU coupler
(No.15 pin)
Execute the diagnostic mode (Code No.20).
Check 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 connected it
securely.If the
transmission is
in gear, it is
reinstated by
retracting the
sidestand.
If the
2Open or short circuit in wiring harness
and / or sub lead.Repair or replace if there is an open or short
circuit.
Between sidestand switch coupler and ECU
coupler
Blue / Black – Blacktransmission is
in neutral, it is
reinstated by
reconnecting
the wiring.
3The malfunction of the sidestand switch.Replace if defective.
Refer to “CHECKING THE SWITCHES” in
chapter 8.
Fault code No.20SymptomDefective values are detected due to the internal malfunction of the intake air
pressure sensor or the atmospheric pressure sensor.
Used diagnostic code No. 02 (atmospheric pressure sensor)
1
03 (intake air pressure sensor)
2
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Defective atmospheric pressure sensorExecute the diagnostic mode (Code No.02).
Replace if defective.
Refer to “Fault code No.23”.Reinstated by
turning the
main switch
2Defective intake air pressure sensorExecute the diagnostic mode (Code No.03).
Replace if defective.
Refer to “Fault code No.13”.ON.
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7-23
FUEL INJECTION SYSTEMFI
Fault code No.21SymptomOpen or short circuit is detected from the coolant temperature sensor.
Used diagnostic code No. 06 (coolant temperature sensor)
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.
Coolant temperature 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
Black / Blue – Black / Blue
Green / White – Green / White
3Defective coolant temperature sensor.Execute the diagnostic mode (Code No.06).
Replace if defective.
Refer to “COOLING SYSTEM” in chapter 8.
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