air condition YAMAHA YZF-R1SC 2004 Owner's Manual

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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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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7-32
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.
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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.
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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.
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7-46
AIR INDUCTION SYSTEMFI
EAS00507
AIR INDUCTION SYSTEM
AIR INJECTION
The air induction system burns unburned ex-
haust gases by injecting fresh air (secondary
air) into the exhaust port, reducing the emission
of hydrocarbons.
When there is negative pressure at the exhaust
port, the reed valve opens, allowing secondary
air to flow into the exhaust port. The required
temperature for burning the unburned exhaust
gases is approximately 600 to 700C (1112 to
1292F).
EAS0097
AIR CUT-OFF VALVE
The air cut-off valve is controlled by the signals
from the ECU in accordance with the combus-
tion conditions. Ordinarily, the air cut-off valve
opens to allow the air to flow during idle and
closes to cut-off the flow when the motorcycle is
being driven. However, if the coolant tempera-
ture is below the specified value, the air cut-off
valve remains open and allows the air to flow
into the exhaust pipe until the temperature be-
comes higher than the specified value.
AFrom the air cleaner
BTo the cylinder head
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8-5
CHECKING THE BULBS AND BULB SOCKETSELEC
WARNING
EAS00732
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continu-
ity between the terminals.
Damage / wear
Repair or replace the bulb,
bulb socket or both.
Improperly connected
Properly connect.
No continuity
Repair or replace the bulb, bulb
socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown in
the illustration on the left.

Bulbs
A and B are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The ma-
jority of these types of bulbs can be removed
from their respective socket by turning them
counterclockwise.

Bulbs
C are used for turn signal and
tail / brake lights and can be removed from
the socket by pushing and turning the bulb
counterclockwise.
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:

bulb

Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.

When changing the tail / brake light bulb,
confirm that the frame has cooled accord-
ing to the warning label and change the
tail / brake light bulb.
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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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8-30

Does the Headlight relay (dimmer) have
continuity between red / yellow and
black / green ?
NOYES
Replace the dimmer
relay. Positive tester probe
red / yellow
Negative tester probe
black / green
1
2
3
4
5. Headlight relay (on / off)

Disconnect the headlight relay (on / off) from
the coupler.

Connect the pocket tester (Ω
1) and bat-
tery (12 V) to the headlight relay (on / off) as
shown.
Positive battery lead
red / yellow
Negative battery lead
yellow / black
EAS00787
YESNO 7. Wiring

Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.

Is the lighting system’s wiring properly con-
nected and without defects?
Properly connect or
repair the lighting
system’s wiring.
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECK-
ING THE LIGHTING
SYSTEM”.

Does the headlight relay (dimmer) have
continuity between black / green and
black / yellow ?
Positive tester probe
black / green
Negative tester probe
black / yellow
1
2
3
4
6. Headlight relay (dimmer)

Disconnect the headlight relay (dimmer)
from the coupler.

Connect the pocket tester (Ω
1) and bat-
tery (12 V) to the headlight relay (dimmer) as
shown.
Positive battery lead
black
Negative battery lead
yellow
3
4
3
4
YESNO
Replace the head-
light relay (dimmer).
LIGHTING SYSTEMELEC
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8-36
YESNO

Clean the battery
terminals.

Recharge or re-
place the battery.
EAS00749
3. Main switch

Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the main switch OK?
YESNO
Replace the main
switch.
YESNO 1. Horn switch

Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the horn switch OK?
Replace the left han-
dlebar switch.
EAS00796
CHECKING THE SIGNALING SYSTEM
1. The horn fails to sound.
EAS00795
4. Wiring

Check the entire signaling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.

Is the signaling system’s wiring properly
connected and without defects?
YESNO
Properly connect or
repair the signaling
system’s wiring.
Check the condition
of each of the signal-
ing system’s circuits.
Refer to “CHECK-
ING THE LIGHTING
SYSTEM”.
SIGNALING SYSTEMELEC
NOTE:
YESNO
1. Backup, main, ignition, signal and park
fuses

Check the backup, main, ignition, signal and
park fuses for continuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3.

Are the backup, main, ignition, signal and
park fuses OK?
Replace the fuse(s).
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?
EAS00739EAS00794
TROUBLESHOOTING

Any of the following fail to light: turn sig-
nal light, brake light or an indicator light.

The horn fails to sound.
Check:
1. backup, main, ignition, signal, and park
fuses
2. battery
3. main switch
4. wiring connections
(of the entire signaling system)

Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. side cowlings

Troubleshoot with the following special tool(s).
Pocket tester
90890-03112, YU-3112
EAS00738
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