2004 YAMAHA YZF-R1SC relay

7-14
FUEL INJECTION SYSTEMFI
Diagnostic
codeItemDescription of actionData displayed on meter
(reference value)
52
Headlight relay 1After the engine stop switch has been turned from OFF to
ON, it actuates the headlight relay five times every
5 seconds and illuminates the engine trouble warning light.
(ON 2 seconds, OFF 3 seconds)
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check the headlight relay
operating sound 5 times with the
engine stop switch ON.
(At that time, the headlight turns
ON.)
53
EXUP servo motorAfter the engine stop switch has been turned from OFF to
ON, it actuates the servo motor turns to open side and to
close side.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Turn on the engine trouble
warning light while servo motor
is operated. (Operating angle is
displayed on the LCD meter)
56
Sub-throttle servo
motorAfter the engine stop switch has been turned from OFF to
ON, it actuates the servo motor turns to open side and to
close side.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back on.Turn on the engine trouble warn-
ing light while servo motor is op-
erated (Operating angle is dis-
played on the LCD meter).
60
EEPROM fault code
display
Transmits the abnormal portion of the data in the E2PROM
that has been detected as a self-diagnostic fault code 44.

If multiple malfunctions have been detected, different
codes are displayed at 2-second intervals, and this
process is repeated.(01
04) Displays the cylinder
number.
(00) Displays when there is no
malfunction.
61
Malfunction history
code display
Displays the codes of the history of the self-diagnosis
malfunctions (i.e., a code of a malfunction that occurred
once and which has been corrected).

If multiple malfunctions have been detected, different
codes are displayed at 2-second intervals, and this
process is repeated.11
50
(00) Displays when there is no
malfunction.
62
Malfunction history
code erasure
Displays the total number of codes that are being detected
through self diagnosis and the fault codes in the past
history.

Erases only the history codes when the engine stop switch
is turned from OFF to ON. If the engine stop switch is ON,
turn it OFF once, and then turn it back ON.00
25
(00) Displays when there is no
malfunction.
70Control number
Displays the program control number.00
255
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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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8-1
8
ELECTRICAL COMPONENTSELEC
9Oil level switch
10Radiator fan motor
11Horn
12Ignition coil
1Main switch
2Front brake light switch
3Starter relay
4Battery
5Fuse box
6Rear brake light switch
7Neutral switch
8Sidestand switch
EAS00729
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
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8-2
9Radiator fan motor relay
10Turn signal relay
11Rectifier / regulator
12Throttle position sensor
13Sub-throttle position sensor
1Coolant temperature sensor
2Intake air temperature sensor
3Intake air pressure sensor
4Fuel pump
5ECU
6Lean angle cut-off switch
7Starting circuit cut-off relay
8Headlight relay (dimmer)
ELECTRICAL COMPONENTSELEC
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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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8-13
IGNITION SYSTEMELEC
12. Starting circuit cut-off relay (diode)

Disconnect the starting circuit cut-off relay
coupler from the wire harness.

Connect the pocket tester (Ω
1) to the
starting circuit cut-off relay coupler as
shown.

Check the starting circuit cut-off relay for
continuity.
Positive tester probe

blue / yellow
Negative tester probe

sky blue
1
2
EAS00753
Positive tester probe

blue / yellow
Negative tester probe

blue / black Continuity
1
3
Positive tester probe

sky blue
Negative tester probe

blue / yellow
2
1
Positive tester probe

blue / black
Negative tester probe

blue / yellow No
continuity
3
1
YESNO
Replace the starting
circuit cut-off relay. When you switch the positive and negative
tester probes, the readings in the above chart
will be reversed.

Are the tester readings correct?
NOTE:
13. Lean angle cut-off switch

Check the lean angle cut-off switch.
Refer to “FUEL INJECTION SYSTEM” in
chapter 7.

Is the lean angle cut-off switch OK?
YESNO
Replace the lean
angle cut-off switch.
EAS00754
14. Wiring

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

Is the ignition system’s wiring properly con-
nected and without defects?
YESNO
Properly connect or
repair the ignition
system’s wiring.
Replace the ECU.
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