ECU YAMAHA YZF-R1SC 2004 Owner's Manual

5-34
VALVES AND VALVE SPRINGSENG
CAUTION:
NOTE: 5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
Hitting the valve tip with excessive force
could damage the valve.
6. Install:

valve pad
1

valve lifter 2

Lubricate the valve lifter and valve pad with
molybdenum disulfide oil.

The valve lifter must move smoothly when ro-
tated with a finger.

Each valve lifter and valve pad must be rein-
stalled in its original position.
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7-1
FUEL INJECTION SYSTEMFI
19Atmospheric pressure
sensor
20Fuel injection system
relay
21Engine trouble warning
light
22Lean angle cut-off
switch
23Air cut-off valve
13Coolant temperature
sensor
14Spark plug
15Cylinder identification
sensor
16Pressure regulator
17Battery
18ECU
1Ignition coil
2Air filter case
3Intake temperature
sensor
4Fuel delivery hose
5Fuel tank
6Fuel pump
7Fuel return hose
8Intake air presure sen-
sor
9Throttle position sen-
sor
10Fuel injector
11Catalytic converter
12Crankshaft position
sensor
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
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7-4
30: Lean angle cut-off switch
(latch up detected)
41: Lean angle cut-off switch
(open or short circuit)
50: ECU internal malfunction
(memory check error)
FUEL INJECTION SYSTEMFI
EAS00899
ECU’S SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is
stored in the memory of the ECU.

To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes when the start switch is being pushed to start the engine.

If a malfunction is detected in the system by the self-diagnostic function, this mode provides an ap-
propriate substitute characteristic operation, and alerts the rider of the detected malfunction by illumi-
nating an engine trouble warning light.

After the engine has been stopped, the fault code number appears from the lowest value in order of
precedence on the LCD meter. Once a fault code has been displayed, it remains stored in the memory
of the ECU until it is deleted.
EAS00900
Engine trouble warning light indication and FI system operating condition
Warning light
indication
ECU’s operationFI operationVehicle operation
Flashing*Warning provided
when unable to start
engineOperation stoppedUnable
Remains ONMalfunction detectedOperated with
substitute
characteristics
in accordance with the
description of the
malfunctionAble / Unable depend-
ing on the self-diag-
nostic fault code
* The warning light flashes when any one of the conditions listed below is present and the start switch is
pushed.
11: Cylinder identification sensor
12: Crankshaft position sensor
19: Sidestand switch
(open circuit in wire to ECU)
EAS00901
Checking for a defective engine trouble warning light bulb
The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned “ON”
and when the start switch is being pushed. If the warning light does not come on under these condi-
tions, the warning light bulb may be defective.
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7-5
FUEL INJECTION SYSTEMFI
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION)
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions
that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue to operate or stop operating, depending on the conditions.
The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value,
and the other in which the ECU directly operates an actuator. Details on the fail-safe actions are given
in the table below.
FAIL-SAFE ACTIONS TABLE
Fault
Code No.ItemSymptomFail-safe actionAble / unable
to startAble / unable
to drive
11
Cylinder identification
sensorNo normal signals are received from
the cylinder identification sensor.Continues to operate the engine based
on the results of the cylinder
identification that existed up to that
point.
UnableAble
12Crankshaft position
sensorNo normal signals are received from
the crankshaft position sensor.
Stops the engine (by stopping the
injection and ignition).UnableUnable
13
14Intake air pressure
sensor (open or short
circuit) (pipe system)Intake air pressure sensor-open or
short circuit detected.
Faulty intake air pressure sensor
system.
Fixes the intake air pressure to
101.3 kpa.
AbleAble
15
16Throttle position sensor
(open or short circuit)
(stuck)Throttle position sensor-open or short
circuit detected.
Fixes the throttle position sensor to
fully open.AbleAble
17EXUP servo motor
potention
(open or short circuit)EXUP servo motor potention-open or
short circuit detected.
Turn the EXUP servo motor toward
the open side for 3 seconds and then
stop it.AbleAble
18
EXUP servo motor (lock)A lock of the EXUP servo motor is
detected.
Perform the preventive control
against motor locking.
Perform the lock release operation
twice every 100 seconds.
AbleAble
19Sidestand switch (open
circuit in wire to ECU)Open circuit in the input line of ECU
No.15 terminal is detected when the
start switch is pressed.-- (No start)UnableUnable
20Intake air pressure
Atmospheric pressureDefective values are detected due to
the internal malfunction
Fixes the intake air pressure and
atmospheric pressure to 101.3 kpa.AbleAble
21Coolant temperature
sensorCoolant temperature sensor-open or
short circuit detected.
Fixes the coolant temperature to
60C.AbleAble
22Intake temperature
sensorIntake temperature sensor-open or
short circuit detected.
Fixes the intake temperature to 20C.AbleAble
23Atmospheric pressure
sensorAtmospheric pressure sensor-open or
short circuit detected.
Fixes the atmospheric pressure to
101.3 kpa.AbleAble
33
34
35
36
Faulty ignitionOpen circuit detected in the primary
lead of the ignition coil.
Cut the injection of other cylinder in
the same group with the cylinder that
the error is detected.
(Example: when the #1 cylinder is
detective, cut the injection of #1 and
#4 cylinders, when the #2 cylinder is
detective, cut the injection of #2 and
#3 cylinders).
Turn on the power to the air induction
solenoid to always cut-off the air.
Able
(depending
on the num-
ber of faulty
cylinders)Able
(depending
on the num-
ber of faulty
cylinders)
30
41Lean angle cut-off
switch (latch up
detected) (open or short
circuit)Lean angle cut-off switch-open or short
circuit detected.
Turns OFF the fuel injection system
relay of the fuel system.
UnableUnable
42Speed sensor, neutral
switchNo normal signals are received from the
speed sensor; or, an open or short
circuit is detected in the neutral switch.
Fixes the gear to the top gear.AbleAble
43Fuel system voltage
(monitor voltage)The ECU is unable to monitor the
battery voltage (an open circuit in the
line to the ECU).
Fixes the battery voltage to 12 V.AbleAble
44
Error in writing the
amount of CO
adjustment on
EEPROMAn error is detected while reading or
writing on EEPROM (CO adjustment
value).--
AbleAble
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7-6
FUEL INJECTION SYSTEMFI
Fault
Code No.ItemSymptomFail-safe actionAble / unable
to startAble / unable
to drive
46Vehicle system power
supply (Monitor voltage)Power supply to the FI system is not
normal.--AbleAble
47Sub-throttle servo motor
potention (open or short
circuit)sub-throttle servo motor potention-
open or short circuit detected.
Turn the sub-throttle servo motor
toward the close side for 4 seconds
and then stop it.AbleAble
48
Sub-throttle servo motor
(lock)A lock of the sub-throttle servo motor is
detected.
Perform the preventative control
against motor locking.
(Perform the lock release operation
twice every 100 seconds.)
AbleAble
50ECU internal
malfunction (memory
check error)Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the meter.--UnableUnable
—
Start unable warningRelay is not turned ON even if the crank
signal is input while the start switch is
turned ON.
When the start switch is turned ON
while an error is detected with the fault
code of No.11, 12, 19, 30, 41 or 50.Engine trouble warning light flashes
when the start switch is turned ON.
UnableUnable
Communication error with the meter
Fault
Code No.ItemSymptomFail-safe actionAble / unable
to startAble / unable
to drive
Er-1ECU internal malfunction
(output signal error)No signals are received from the ECU.–UnableUnable
Er-2ECU internal malfunction
(output signal error)No signals are received from the ECU
within the specified duration.–UnableUnable
Er-3ECU internal malfunction
(output signal error)Data from the ECU cannot be received
correctly.–UnableUnable
Er-4ECU internal malfunction
(input signal error)Non-registered data has been received
from the meter.–UnableUnable
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7-7
Engine operation is not normal or the engine trouble warning light is on.
* Engine trouble warning light may not come on even if the engine operation is not normal.
The engine trouble warning light comes on.
Check the fault code number displayed on the me-
ter.
Identify the probable cause of malfunction. (Refer
to the “Diagnostic fault code table”.)
Check and repair the probable case of malfunc-
tion.
Fault code No.
appearFault code No.
disappear
Check and repair.
(Refer to “TROU-
BLESHOOTING DE-
TAILS”.)
Monitor the operation
of the sensors and
actuators in the diag-
nostic mode. (Refer
to “Diagnostic mode
table” in chapter 7)Check and repair.
(Refer to “FAIL-SAFE
ACTIONS TABLE”.)
Perform ECU reinstatement action. (Refer to “Re-
instatement method” in “TROUBLESHOOTING
DETAILS”.)
Turn the main switch to “OFF”, turn the main switch
back to “ON”, and then check if the fault code num-
ber is still displayed.
Erasing the malfunction history:*
The malfunction history is stored even if the main
switch is turned OFF.
The malfunction history must be erased in the
diagnostic mode. (Refer to the “Diagnostic mode
table (Diagnostic code No.62)”)Repairs completed
The engine trouble warning light does not come
on.
Check the operation of following sensors and ac-
tuators in the diagnostic mode (Refer to “Diagnos-
tic mode table” in chapter 7.)
Malfunction of en-
gineDefective sensor
or actuator
Check and repair
the inner parts of
engine. (Refer to
Chapter 5)Check and repair
the corresponding
sensor or actua-
tor.
* Operated when the engine trouble warning light is on.
Fault code
number displayed
Fault code number not displayed
OKNG
OK
OK
Check the engine condition.
OK NG
01: Throttle position
sensor (throttle
angle)
03: Intake air pressure
07: Vehicle speed pulse
09: Fuel system volt-
age (battery bolt)
21: Neutral switch
30: Ignition coil #1
31: Ignition coil #232: Ignition coil #3
33: Ignition coil #4
36: Injector #1
37: Injector #2
38: Injector #3
39: Injector #4
48: Al system solenoid
53: EXUP servo motor
56: Sub-throttle servo
motor
FUEL INJECTION SYSTEMFI
EAS00904
TROUBLESHOOTING CHART
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7-8
FUEL INJECTION SYSTEMFI
NOTE:
NOTE:
EAS00905
DIAGNOSTIC MODE
It is possible to monitor the sensor output data
or check the activation of actuators without con-
necting the measurement equipment by simply
switching the meter indication from the normal
mode to the diagnostic monitoring mode.
Setting the diagnostic mode
1. Turn the main switch to “OFF” and set the en-
gine stop switch to “OFF”.
2. Disconnect the wire harness coupler from
the fuel pump.
3. Simultaneously press and hold the “SE-
LECT” and “RESET” buttons, turn the main
switch to “ON”, and continue to press the but-
tons for 8 seconds or more.

All displays on the meter disappear except the
clock and tripmeter displays.

“dIAG” appears on the LCD meter.
4. Press the “SELECT” button to select the CO
adjustment mode “Co” or the diagnostic
mode “dIAG”.
5. After selecting “dIAG”, simultaneously press
the “SELECT” and “RESET” buttons for 2 se-
conds or more to execute the selection.
6. Select the diagnostic code number that ap-
plies to the item that was verified with the
fault code number by pressing the “SELECT”
and “RESET” buttons.

The diagnostic code number appears on the
LCD meter (01-70).

To decrease the selected diagnostic code
number, press the “RESET” button. Press the
“RESET” button for 1 second or longer to auto-
matically decrease the diagnostic code num-
bers.

To increase the selected diagnostic code num-
ber, press the “SELECT” button. Press the
“SELECT” button for 1 second or longer to au-
tomatically increase the diagnostic code num-
bers.
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7-10
FUEL INJECTION SYSTEMFI
Diagnostic fault code table
Fault
code No.SymptomProbable cause of malfunctionDiagnostic
code
11
No normal signals are received from
the cylinder identification sensor.
Open or short circuit in wiring sub lead.

Open or short circuit in wiring harness.

Defective cylinder identification sensor.

Malfunction in ECU.

Improperly installed sensor.
—
12
No normal signals are received from
the crankshaft position sensor.
Open or short circuit in wiring harness.

Defective crankshaft position sensor.

Malfunction in pickup rotor.

Malfunction in ECU.

Improperly installed sensor.
—
13
Intake air pressure sensor-open or
short circuit detected.
Open or short circuit in wiring sub lead.

Open or short circuit in wiring harness.

Defective intake air pressure sensor.

Malfunction in ECU.
03
14
Faulty intake air pressure sensor hose
system; a hose is detached, causing
constant application of the
atmospheric pressure to the sensor;
or, the hose is clogged.
Intake air pressure sensor hose is detached, clogged,
kinked, or pinched.

Malfunction in ECU.
03
15
Throttle position sensor-open or
short circuit detected.
Open or short circuit in wiring sub lead.

Open or short circuit in wiring harness.

Defective throttle position sensor.

Malfunction in ECU.

Improperly installed throttle position sensor.
01
16A stuck throttle position sensor is
detected.
Stuck throttle position sensor.

Malfunction in ECU.01
17EXUP servo motor potention
circuit-open or short circuit detected.
Open or short circuit in wiring sub lead.

Detective EXUP servo motor (potention circuit).53
18EXUP servo motor is stuck.
Open or short circuit in wiring sub lead.

Stuck EXUP servo motor (mechanism).

Stuck EXUP servo motor (motor).53
19Open circuit in the input line of ECU
No.15 terminal is detected when the
start switch is pressed.
Open circuit in wiring harness (ECU Coupler).

Malfunction in ECU.20
20
When the main switch is turned to ON,
the atmospheric sensor voltage and
intake air pressure sensor voltage
differ greatly.
Atmospheric pressure sensor hose is clogged.

Intake air pressure sensor hose is clogged, kinked, or pinched.

Malfunction of the atmospheric pressure sensor in the
intermediate electrical potential.

Malfunction of the intake air pressure sensor in the
intermediate electrical potential.

Malfunction in ECU.
03
02
21Coolant temperature sensor-open or
short circuit detected.
Open or short circuit in wiring harness.

Defective coolant temperature sensor.

Malfunction in ECU.06
22Intake temperature sensor-open or
short circuit detected.
Open or short circuit in wiring harness.

Defective intake temperature sensor.

Malfunction in ECU.05
23Atmospheric pressure sensor-open or
short circuit detected.
Open or short circuit in wiring sub lead.

Defective atmospheric pressure sensor.

Malfunction in ECU.02
30The motorcycle has overturned.
Overturned.

Malfunction in ECU.08
33
Open circuit is detected in the primary
lead of the ignition coil (#1).
Open or short circuit in wiring harness.

Malfunction in ignition coil.

Malfunction in ECU.

Malfunction in a component of ignition cut-off circuit system.
30
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7-11
FUEL INJECTION SYSTEMFI
Fault
code No.SymptomProbable cause of malfunctionDiagnostic
code
34
Open circuit is detected in the primary
lead of the ignition coil (#2).
Open or short circuit in wiring harness.

Malfunction in ignition coil.

Malfunction in ECU.

Malfunction in a component of ignition cut-off circuit system.
31
35
Open circuit is detected in the primary
lead of the ignition coil (#3).
Open or short circuit in wiring harness.

Malfunction in ignition coil.

Malfunction in ECU.

Malfunction in a component of ignition cut-off circuit system.
32
36
Open circuit is detected in the primary
lead of the ignition coil (#4).
Open or short circuit in wiring harness.

Malfunction in ignition coil.

Malfunction in ECU.

Malfunction in a component of ignition cut-off circuit system.
33
41Lean angle cut-off switch-open or
short circuit detected.
Open or short circuit in wiring harness.

Defective lean angle cut-off switch.

Malfunction in ECU.08
42
No normal signals are received from
the speed sensor; or, an open or
short circuit is detected in the neutral
switch.
Open or short circuit in wiring harness.

Defective speed sensor.

Malfunction in vehicle speed sensor detected unit.

Defective neutral switch.

Malfunction in the engine side of the neutral switch.

Malfunction in ECU.
07
21
43The ECU is unable to monitor the
battery voltage (an open circuit in the
monitor line to the ECU).
Open circuit in wiring harness.

Malfunction in ECU.09
44An error is detected while reading or
writing on EEPROM.
Malfunction in ECU. (The CO adjustment value is not
properly written on or read from the internal memory).60
46Power supply to the FI system is not
normal.
Malfunction in “CHARGING SYSTEM”.—
47Sub-throttle servo motor potention cir-
cuit-open or short circuit detected.
Open or short circuit in wiring harness.

Detective Sub-throttle servo motor (potention circuit).56
48Sub-throttle servo motor is stuck.
Open or short circuit in wiring harness.

Stuck Sub-throttle servo motor (mechanism).

Stuck Sub-throttle servo motor (motor).56
50
Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the
meter.
Malfunction in ECU. (The program and data are not
properly written on or read from the internal memory.)
—
Er-1
No signal are received from the ECU.
Open or short circuit in wiring harness.

Malfunction in meter.

Malfunction in ECU.

Defective wire connection of the ECU coupler.
—
Er-2No signal are received from the ECU
within the specified duration.
Improper connection in wiring harness.

Malfunction in meter.

Malfunction in ECU.—
Er-3Data from the ECU can not be
received correctly.
Improper connection in wiring harness.

Malfunction in meter.

Malfunction in ECU.—
Er-4Non-registered data has been
received from the meter.
Improper connection in wiring harness.

Malfunction in meter.

Malfunction in ECU.—
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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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