Yamaha FZS6W 07 User Manual
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FUEL INJECTION SYSTEM 8-31 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM
FUEL INJECTION SYSTEM 8-32 1. Main switch 5. Fuel injection system fuse 6. Main fuse 9. Battery 10.Starting circuit cut-off relay 11.Sidestand switch 12.Neutral switch 13.Fuel pump 14.Throttle position sensor 15.Intake air pressure sensor 16.O 2 sensor 17.Lean angle sensor 18.Crankshaft position sensor 19.Intake air temperature sensor 20.Coolant temperature sensor 21.ECU (engine control unit) 22.Injector #1 23.Injector #2 24.Injector #3 25.Injector #4 27.Speed sensor 28.Cylinder-#1/#4 ignition coil 29.Cylinder-#2/#3 ignition coil 30.Spark plug 34.Neutral indicator light 36.Multi-function meter 37.Engine trouble warning light 46.Engine stop switch 53.Ignition fuse
FUEL INJECTION SYSTEM 8-33 EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malf unction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the syst em. 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, the ECU provides an appropriate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminating the engine trouble warning light. After the engine has been stopped, the lowest fault code number appears on the clock LCD. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is deleted. Engine trouble warning light indication and FI system operation * The warning light flashes when any one of the co nditions listed below is present and the start switch is pushed: 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 to “ON” and when the start switch is being pushed. If the warning light does not come on under these conditions, the warning light bulb may be defective. Warning light indica- tion ECU operation FI operation Vehicle operation Flashing* Warning provided when unable to start engineOperation stopped Cannot be operated Remains on Malfunction detected Operated with substi- tute characteristics in accordance with the description of the mal- functionCan or cannot be oper- ated depending on the fault code 12: Crankshaft position sensor 41: Lean angle sensor (open or short-circuit) 19: Sidestand switch (open circuit in the wire to the ECU) 50:ECU internal malfunction (faulty ECU memory) 30: Lean angle sensor (latch up detected) a. Main switch “OFF” b. Main switch “ON” c. Engine trouble warning light off d. Engine trouble warning light on for 1.4 sec- onds
FUEL INJECTION SYSTEM 8-34 EAS27362 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provi des the engine with alternate operating instruc- tions 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. Self-Diagnostic Function Fault code No. Item Symptom Able / unable to start Able / unable to drive 12 Crankshaft position sensor No normal signals are received from the crankshaft position sen- sor. Unable Unable 13 Intake air pressure sensor (open or short circuit) Intake air pressure sensor-open or short circuit detected. Able Able 14 Intake air pressure sensor (pipe system) Intake air pressure sensor-pipe system malfunction (clogged or detached hose). Able Able 15 Throttle position sen- sor (open or short circuit) Throttle position sensor-open or short circuit detected. Able Able 16 Throttle position sen- sor (stuck) The throttle position sensor is stuck. Able Able 19 Sidestand switch (open circuit wire har- ness to ECU) Open circuit is detected in the input line from the sidestand switch to the ECU. Unable Unable 21 Coolant temperature sensor Coolant temperature sensor-open or short circuit detected. Able Able 22 Intake air temperature sensor Intake air temperature sensor- open or short circuit detected. Able Able 24 O 2 sensor No normal signal is received from the O2 sensor. Able Able 30 Lean angle sensor Latch up detected. No normal signal is received from the lean angle sensor. Unable Unable 33 Ignition coil (#1, #4) (faulty ignition) Malfunction detected in the pri- mary wire of the ignition coil (#1, #4). Able (depending on the num- ber of faulty cylinders) Able (depending on the num- ber of faulty cylinders)
FUEL INJECTION SYSTEM 8-35 Communication error with the meter34 Ignition coil (#2, #3) (faulty ignition) Malfunction detected in the pri- mary wire of the ignition coil (#2, #3). Able (depending on the num- ber of faulty cylinders) Able (depending on the num- ber of faulty cylinders) 41 Lean angle sensor (open or short circuit) Lean angle sensor-open or short circuit detected. Unable Unable 42 Speed sensor Neutral switch No normal signals are received from the speed sensor. Open or short circuit is detected in the neutral switch. Able Able 43 Fuel system voltage (monitor voltage) The ECU is unable to monitor the battery voltage (an open circuit in the line to the ECU). Able Able 44 Error in writing the amount of CO adjust- ment on EEPROM Error is detected while reading or writing on EEPROM (CO adjust- ment value). Able Able 46 Vehicle system power supply (Monitoring voltage) Power supply to the fuel injection system is not normal. Able Able 50 ECU internal malfunc- tion (memory check error) Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number might not appear on the meter.) Unable Unable — Start unable warning Engine trouble warning light flashes when the start switch is turned ON. Relay 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.12, 19, 30, 41, 43 or 50. Unable Unable Fault code No. Item Symptom Able / unable to start Able / unable to drive Er-1 ECU internal malfunc- tion (output signal error) No signals are received from the ECU. Unable Unable Er-2 ECU internal malfunc- tion (output signal error) No signals are received from the ECU within the specified duration. Unable Unable Fault code No. Item Symptom Able / unable to start Able / unable to drive
FUEL INJECTION SYSTEM 8-36 EAS27400 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on. 1. Check: Fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the fault code number displayed on the meter. b. Identify the system with the malfunction. Refer to “Self-Diagnostic Function table”. c. Identify the probable cause of malfunction. Refer to “Diagnostic monitoring code table”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Checking and repair the probable case of malfunction. 3. Perform ECU reinstatement action. Refer to “Reinstatement method” of table in “TROUBLESHOOTING DETAILS”. 4. Turn the main switch to “OFF” and back to “ON”, then check the fault code number is not displayed. NOTE: If other fault code displayed, repeat steps (1) to (4) until all fault code number is not displayed. 5. 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 “Sensor operation table (Diagnostic code No.62)”. The engine operation is not normal but the engine trouble warning light does not come on. 1. Check the operation of following sensors and actuators in the Diagnostic mode. Refer to “Sensor operation table”. If malfunction the sensors or actuators, repair or replace it. If not malfunction the sensors and actua- tors, check and repair the engine inner parts. Er-3 ECU internal malfunc- tion (output signal error) Data from the ECU cannot be received correctly. Unable Unable Er-4 ECU internal malfunc- tion (input signal error) Non-registered data has been received from the meter. Unable Unable Fault code No. Item Symptom Able / unable to start Able / unable to drive Fault code No. YES Fault code No. NO Check and repair. Refer to TROUBLE- SHOOTING DETAILS on page 8- 43. Monitor the operation of the sensors and actuators in the diag- nostic mode. Refer to “Sensor operation table”. Check and repair. Refer to Self Diagnos- tic Function. 01: Throttle position sensor (throttle angle) 30: Ignition coil #1, #4 31: Ignition coil #2, #3 36: Injector #1, #4 37: Injector #2, #3 48: AI system solenoid
FUEL INJECTION SYSTEM 8-37 EAS27411 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more. NOTE: All displays on the meter disappear except the clock and tripmeter displays. “dIAG” appears on the clock LCD. 4. Press the “SELECT” button to select the diagnostic monitoring mode “dIAG”. 5. After selecting “dIAG”, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or more to execute the selection. 6. Set the engine stop switch to “OFF”. 7. Select the diagnostic code number that applies to the item that was verified with the fault code number by pressing the “SELECT” and “RESET” buttons. NOTE: The diagnostic code number appears on the clock LCD (01–70). To decrease the selected diagnos tic code number, press the “RESET” button. Press the “RESET” button for 1 second or longer to automatically decrease the diagnostic code numbers. To increase the selected diagnostic code num ber, press the “SELECT” button. Press the “SELECT” button for 1 second or longer to automatically increase the diagnostic code numbers. 8. Verify the operation of the sensor or actuator. Sensor operationThe data representing the oper ating conditions of the sensor appears on the trip LCD. Actuator operation Set the engine stop switch to “ ” to operate the actuator.
FUEL INJECTION SYSTEM 8-38 NOTE: If the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ ” again. 9. Turn the main switch to “OFF” to cancel the diagnostic mode. Diagnostic code tableFault code No. Symptom Probable cause of malfunction Diagnostic code No. 12 No normal signals are received from the crank- shaft position sensor. Open or short circuit in wire 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 wire sub lead. Open or short circuit in wire harness. Defective intake air pressure sensor. Malfunction in ECU. 03 14 Intake air pressure sensor- pipe system malfunction (clogged or detached hose). Detected hose Clogged hose 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 wire sub lead. Open or short circuit in wire harness. Defective throttle position sensor. Malfunction in ECU. Improperly installed throttle position sensor. 01 16 Stuck throttle position sen- sor detected. Defective sensor (stuck throttle position sensor). Malfunction in ECU. 01 19 Open circuit is detected in the input line from the start switch to the ECU. Open or short circuit in wire harness. Malfunction in ECU. 20 21 Coolant temperature sen- sor-open or short circuit detected. Open or short circuit in wire harness. Defective coolant temperature sensor. Malfunction in ECU. Improperly installed coolant temperature sensor. 06 22 Intake air temperature sen- sor-open or short circuit detected. Open or short circuit in wire harness. Defective intake temperature sensor. Malfunction in ECU. Improperly installed intake air temperature sensor. 05 24 No normal signal is received from the O 2 sen- sor. Open or short circuit in wire harness. Defective O2 sensor. Malfunction in ECU. Improperly installed O 2 sensor. —
FUEL INJECTION SYSTEM 8-39 30Latch up detected. No normal signal is received from the lean angle sensor. The vehicle has overturned. Defective lean angle sensor. Malfunction in ECU. Improperly installed lean angle sensor. 08 33 Malfunction detected in the primary wire of the ignition coil (#1and #4). Open or short circuit in wire harness. Malfunction in ignition coil. Malfunction in ECU. Malfunction in a component of ignition cut- off circuit system. 30 34 Malfunction detected in the primary wire of the ignition coil (#2 and #3). Open or short circuit in wire harness. Malfunction in ignition coil. Malfunction in ECU. Malfunction in a component of ignition cut- off circuit system. 31 41 Lean angle sensor-open or short circuit detected. Open or short circuit in wire harness. Defective lean angle sensor. Malfunction in ECU. 08 42 No normal signals are received from the speed sensor. Open or short circuit is detected in the neutral switch. Open or short circuit in wire 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 43 The ECU is unable to moni- tor the battery voltage (an open circuit in the line to the ECU). Open circuit in wire harness. Malfunction in ECU. 09 44 Error is detected while reading or writing on EEPROM (CO adjustment value). Malfunction in ECU. (The CO adjustment value is not properly written on or read from the internal memory). 60 46 Power supply to the fuel injection system is not nor- mal. Malfunction in the charging system. Refer to CHARGING SYSTEM on page 8-11. — 50 Faulty ECU memory. (When this malfunction is detected in the ECU, the fault 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 signals are received from the ECU. Open or short circuit in communication line. Malfunction in meter unit. Malfunction in ECU. — Er-2 No signals are received from the ECU within the specified duration. Open or short circuit in communication line. Malfunction in meter unit. Malfunction in ECU. — Fault code No. Symptom Probable cause of malfunction Diagnostic code No.