engine YAMAHA YZF-R1SC 2004 Service Manual

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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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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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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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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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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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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8-14
1Main switch
4Fuse (main)
6Battery
8Starter relay
9Starter motor
10Starting circuit cut-off relay
11Neutral switch
12Sidestand switch
53Engine stop switch
54Start switch
73Fuse (ignition)
ELECTRIC STARTING SYSTEMELEC
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
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