Yamaha R1 2004 ServiceManual
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7-27 FUEL INJECTION SYSTEMFIFUEL INJECTION SYSTEMFI Fault code No.33SymptomMalfunction detected in the primary lead of the ignition coil (#1). Used diagnostic code No. 30 (ignition coil #1) 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. Ignition coil primary side coupler – Orange Main wiring harness ECU couplerReinstated by starting the en- gine and oper- ating it at idle. 2Open or short circuit in lead.Repair or replace if there is an open or short circuit. Between ignition coil coupler (#1) and ECU coupler / main harness Orange – Orange Red / Black – Red / Black 3Detective ignition coil (test the primary and secondary coils for continuity).Execute the diagnostic mode (Code No.30). Replace if defective. Refer to “IGNITION SYSTEM” in chapter 8. Fault code No.34SymptomMalfunction detected in the primary lead of the ignition coil (#2). Used diagnostic code No. 31 (ignition coil #2) 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. Ignition coil primary side coupler – Gray / Red Main wiring harness ECU couplerReinstated by starting the en- gine and oper- ating it at idle. 2Open or short circuit in lead wire.Repair or replace if there is an open or short circuit. Between ignition coil coupler (#2) and ECU coupler / main harness Gray / Red – Gray / Red Red / Black – Red / Black 3Defective ignition coil (test the primary and secondary coils for continuity).Execute the diagnostic mode (Code No.31). Replace if defective. Refer to “IGNITION SYSTEM” in chapter 8. Fault code No.35SymptomMalfunction detected in the primary lead of the ignition coil (#3). Used diagnostic code No. 32 (ignition coil #3) 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. Ignition coil primary side coupler – Orange / Green Main wiring harness ECU couplerReinstated by starting the en- gine and oper- ating it at idle. 2Open or short circuit in lead wire.Repair or replace if there is an open or short circuit. Between ignition coil coupler (#3) and ECU coupler / main harness Orange / Green – Orange / Green Red / Black – Red / Black 3Defective ignition coil (test the primary and secondary coils for continuity).Execute the diagnostic mode (Code No.32). Replace if defective. Refer to “IGNITION SYSTEM” in chapter 8.
7-28 FUEL INJECTION SYSTEMFI Fault code No.36SymptomMalfunction detected in the primary lead of the ignition coil (#4). Used diagnostic code No. 33 (ignition coil #4) OrderInspection operation item and probable causeOperation item and countermeasureReinstatement method 1Connected state 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. Ignition coil primary side coupler – Gray / Green Main wiring harness ECU couplerReinstated by starting the en- gine and oper- ating it at idle. 2Open or short circuit in lead wire.Repair or replace if there is an open or short circuit. Between ignition coil coupler (#4) and ECU coupler / main harness Gray / Green – Gray / Green Red / Black – Red / Black 3Defective ignition coil (test the primary and secondary coils for continuity).Execute the diagnostic mode (Code No.33). Replace if defective. Refer to “IGNITION SYSTEM” in chapter 8. Fault code No.41SymptomOpen or short circuit detected in the lean angle cut-off switch. Used diagnostic code No. 08 (lean angle cut-off switch) 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. Lean angle cut-off switch coupler Main wiring harness ECU couplerReinstated by turning the main switch ON. 2Open or short circuit in wiring harness.Repair or replace if there is an open or short circuit. Between switch coupler and ECU coupler Black / Blue – Black / Blue Yellow / Green – Yellow / Green Blue – Blue 3Defective lean angle cut-off switchExecute the diagnostic mode (Code No.08). Replace if defective. Refer to Fault code No. 30.
7-29 FUEL INJECTION SYSTEMFI Speed sensor output voltage When sensor is on DC 4.8 V or more When sensor is off DC 0.6 V or less Tester positive probe white Tester negative probe black / blue 1 2 Fault code No.42Symptom1 No normal signals are received from the speed sensor. 2 Open or short circuit is detected in the neutral switch. Used diagnostic code No. 07 (speed sensor) A1 A4 No. 21 (neutral switch) B1 B4 OrderInspection operation item and probable causeOperation item and countermeasureReinstatement method A1Connected condition of speed sensor 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. Speed sensor coupler Main wiring harness ECU couplerReinstated by starting the engine, and inputting the vehicle speed signals by ti thA2Open or short circuit in speed sensor lead.Repair or replace if there is an open or short circuit. Between sensor coupler and ECU coupler. Blue – Blue White / Yellow – White / Yellow Black / Blue – Black / Blueoperating the motorcycle at a low speed of 20 to 30 km / h. A3Defective speed sensorExecute the diagnostic mode (Code No.07). Replace if defective. 1. Measure the speed sensor output voltage. 2. Connect the pocket tester (DC 20 V) to the speed sensor coupler terminal as shown. 3. Measure the speed sensor output voltage. 4. Is the speed sensor OK? A4Gear for detecting vehicle speed has broken.Replace if defective. Refer to “TRANSMISSION” in chapter 5. OrderInspection operation item and probable causeOperation item and countermeasureReinstatement method. B1Connected 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. Neutral switch connector Main wiring harness ECU couplerReinstated by starting the engine, and inputting the vehicle speed ilbB2Open or short circuit in neutral switch lead.Repair or replace if there is an open or short circuit. Between switch connector and ECU coupler Sky blue – Black / Yellowsignals by operating the motorcycle at a low speed ofB3Defective neutral switchExecute the diagnostic mode (Code No.21). Replace if defective. Refer to “CHECKING THE SWITCHES” in chapter 8.low s eed of20 to 30 km / h. B4Faulty shift drum (neutral detection area)Replace if defective. Refer to “TRANSMISSION” in chapter 5.
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?
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
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.
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.
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.
7-35 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8Removing the throttle bodies Seat Fuel tank Air filter case Sub-wire harness coupler Coolant temperature sensor coupler Thermo wax inlet hose Thermo wax outlet hose Idle adjust screw wire Throttle body joint clamp Throttle bodies Throttle cables2 1 1 1 1 4 1 2Remove the parts in the order listed. Refer to “SEAT” in chapter 3. Refer to “FUEL TANK” in chapter 3. Refer to “AIR FILTER CASE” in chapter 3. Disconnect. Disconnect. Loosen. If it loosens too much, the nut will sepa- rate. Disconnect. NOTE: THROTTLE BODIESFI THROTTLE BODIES
7-36 Order Job / Part Q’ty Remarks 9 10 11Throttle body joint Heat protector Fuel hose4 1 1To install the throttle body joint, make sure to install it to the cylinder with the same figures corresponding to the fig- ures stated on the throttle body joint. For installation, reverse the removal procedure. NOTE: THROTTLE BODIESFI