2004 YAMAHA YZF-R1SC lock

5-99
Order Job / Part Q’ty Remarks
Disassembling the main axle
assembly
2nd pinion gear
Toothed lock washer
Toothed lock washer retainer
6th pinion gear
Collar
Washer
Circlip
3rd pinion gear
Circlip
Washer
5th pinion gear
Collar
Main axle1
1
1
1
1
1
1
1
1
1
1
1
1Disassemble the parts in the order listed.
1
2
3
4
5
6
7
8
9
10
11
12
13
TRANSMISSIONENG
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5-101
Order Job / Part Q’ty Remarks
Disassembling the drive axle
assembly
Washer
1st wheel gear
Collar
5th wheel gear
Circlip
Washer
3rd wheel gear
Collar
Toothed lock washer
Toothed lock washer retainer
4th wheel gear
Collar
Washer
Circlip1
1
1
1
1
1
1
1
1
1
1
1
1
1Disassemble the parts in the order listed.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
TRANSMISSIONENG
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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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7-8
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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7-15
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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7-16
Crankshaft position sensor
resistance
336
504 Ω at 20C (68F)
(between gray and black) Tester positive probe
gray
Tester negative probe
black
1
2
12
FUEL INJECTION SYSTEMFI
Fault code No.12SymptomNo normal signals are received from the crankshaft position 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
cranking 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.
Crankshaft position sensor coupler
Main wiring harness ECU couplerengine.
3Open or short circuit in wiring harness.Repair or replace if there is an open or short
circuit between the main wiring harnesses.
Between sensor coupler and ECU coupler
Gray – Gray
Black / Blue – Black / Blue
4Defective crankshaft position sensor.Replace if defective.
1. Disconnect the crankshaft position sensor cou-
pler from the wire harness.
2. Connect the pocket tester (Ω  100) to the
crankshaft position sensor coupler as shown.
3. Measure the crankshaft position sensor resis-
tance.
4. Is the crankshaft position sensor OK?
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7-17
Intake air pressure sensor output
voltage
3.75
4.25 V Tester positive probe
pink / white
Tester negative probe
black / blue
1
2
FUEL INJECTION SYSTEMFI
Fault code No.13SymptomIntake air pressure sensor – open or short circuit detected.
Used diagnostic code No. 03 (intake air pressure sensor)
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.
Intake air pressure 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
Black / Blue – Black / Blue
Pink / White – Pink / White
Blue – Blue
3Defective intake air pressure sensorExecute the diagnostic monitoring mode (Code
No.03).
Replace if defective.
1. Connect the pocket tester (DC 20 V) to the
intake air pressure sensor coupler terminal as
shown.
2. Set the main switch to “ON”.
3. Measure the intake air pressure sensor output
voltage.
4. Is the intake air pressure sensor OK?
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