Yamaha Fz1n Service Manual
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FUEL INJECTION SYSTEM 8-37 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 malfunction in the system, it immediately operates the engine under substitute characteristics and illuminat es 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 odometer/tripme- ter/fuel reserve tripmeter 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 c onditions listed below is present and the start switch is pushed: Checking the engine trouble warning light The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned to “ON” and it comes on while the start switch is being pushed. If the warning light does not come on under these conditions, the warning light (LED) 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 11: Cylinder identification sensor 30: Lean angle sensor (latch up detected) 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)
FUEL INJECTION SYSTEM 8-38 ET2D1027 SELF-DIAGNOSTIC FUNCTION TABLE 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 provides 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. Self-Diagnostic Function table 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 Fault code No. Item Symptom Able/ unable to start Able/ unable to drive 11 Cylinder identifica- tion sensor No normal signals are received from the cylinder identificati on sensor when the engine is started or while the vehicle is being driven. Unable Able 12 Crankshaft position sensor No normal signals are received from the crankshaft position sensor. 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 hose line (piping system) Intake air pressure sensor: faulty intake air pressure sensor system. 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) Throttle position sensor is stuck. Able Able 17 EXUP servo motor potention circuit (open or short circuit) EXUP servo motor potension circuit: open or short circuit detected. Able Able 18 EXUP servo motor (stuck) EXUP servo motor is stuck. Able Able 19 Sidestand switch (open circuit in the wire to the ECU) Open circuit in the input line of ECU No.24 terminal is detected when start switch is pressed from the sidestand switch to the ECU. Unable Unable 20 Intake air pressure sensor or atmo- spheric pressure sen- sor When the main switch is turned to “ON”, the atmospheric pressure sensor voltage and intake air pressure sensor voltage dif- fer greatly. Able Able
FUEL INJECTION SYSTEM 8-39 21Coolant temperature sensor (open or short circuit) Coolant temperature sensor: open or short circuit detected. Able Able 22 Intake air temperature sensor (open or short circuit) Intake air temperature sensor: open or short circuit detected. Able Able 23 Atmospheric pressure sensor (open or short circuit) Atmospheric pressure 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 Cylinder-#1 ignition coil (open circuit) Primary lead of the cylinder-#1 ignition coil: open circuit detected. Able (depend- ing on the num- ber of faulty cylin- ders) Able (depend- ing on the num- ber of faulty cylin- ders) 34 Cylinder-#2 ignition coil (open circuit) Primary lead of the cylinder-#2 ignition coil: open circuit detected. Able (depend- ing on the num- ber of faulty cylin- ders) Able (depend- ing on the num- ber of faulty cylin- ders) 35 Cylinder-#3 ignition coil (open circuit) Primary lead of the cylinder-#3 ignition coil: open circuit detected. Able (depend- ing on the num- ber of faulty cylin- ders) Able (depend- ing on the num- ber of faulty cylin- ders) 36 Cylinder-#4 ignition coil (open circuit) Primary lead of the cylinder-#4 ignition coil: open circuit detected. Able (depend- ing on the num- ber of faulty cylin- ders) Able (depend- ing on the num- ber of faulty cylin- ders) Fault code No. Item Symptom Able/ unable to start Able/ unable to drive
FUEL INJECTION SYSTEM 8-40 Communication error with the meter39 Injector (open circuit) Injector: open circuit detected. Able (depend- ing on the num- ber of faulty cylin- ders) Able (depend- ing on the num- ber of faulty cylin- ders) 41 Lean angle sensor (open or short-circuit) Lean angle sensor: open or short circuit detected. Unable Unable 42 Speed sensor No normal signals are received from the speed sensor. Able Able Neutral switch Neutral switch: open or short circuit detected. 43 Fuel system voltage (monitoring voltage) Power supply to the injectors and the fuel pump is not normal. Able Able 44 Error in writing the amount of CO adjust- ment on EEPROM An error is detected while reading or writ- ing on EEPROM (CO adjustment value). Able Able 46 Vehicle system power supply (monitoring voltage) Power supply to the fuel injection system is not normal. Able Able 47 Sub-throttle servo motor potention (open or short circuit) sub-throttle servo motor potention:open or short circuit detected. Able Able 48 Sub-throttle servo motor (lock) A lock of the sub-throttle servo motor is detected. Able Able 50 ECU internal malfunc- tion (memory check error) ECU memory is faulty. (When this mal- function is detected in the ECU, the fault code number might not appear on the meter.) Unable Unable – Start unable warning 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.11, 12, 19, 30, 41 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 Fault code No. Item Symptom Able/ unable to start Able/ unable to drive
FUEL INJECTION SYSTEM 8-41 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 faulty system with the fault code. Refer to “Self-Diagnostic Function table”. c. Identify the probable cause of malfunction. Refer to “Diagnostic code table”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Checking and repair the probable cause 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 that no fault code number is displayed. NOTE: If fault codes are displayed, repeat steps (1) to (4) until no fault code number is displayed. 5. Erase the malfunction history in the diag- nostic mode. Refer to “Sensor operation table (Diagnostic code No.62)”. NOTE: Turning the main switch to “OFF” will not erase the malfunction history. 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” and “Actuator operation table”. Er-2 ECU internal malfunc- tion (output signal error) No signals are received from the ECU within the specified duration. Unable Unable 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. Fault code No. Check and repair. Refer to TROUBLE- SHOOTING DETAILS on page 8- 50. Monitor the operation of the sensors and actuators in the diag- nostic mode. Refer to “Sensor operation table” and “Actuator operation table”. Check and repair. Refer to Self-Diag- nostic Function table. 01: Throttle position sensor (throttle angle) 02: Atmospheric pressure sensor 05: Intake air pressure sensor 06: Coolant temperature sensor 07: Vehicle speed pulse 09: Fuel system voltage (battery bolt) 21: Neutral switch 30: Ignition coil #1 31: Ignition coil #2 32: Ignition coil #3 33: Ignition coil #4 36: Injector #1 37: Injector #2 38: Injector #3 39: Injector #4 48: AI system solenoid 53: EXUP servo motor 56: Sub-throttle servo motor
FUEL INJECTION SYSTEM 8-42 If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.If no malfunction is detected in the sensors and actuators, check and repair inner parts of the engine. EAS27420 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. 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 odometer/tripmeter/fuel reserve tripmeter display. “dI” appears on the odometer/tripmeter/fuel reserve tripmeter LCD. 4. Press the “SELECT” button to select the diagnostic mode “dI”. 5. After selecting “dI”, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or more to activate the diagnostic mode. The diagnostic code number “d01” appears on the clock LCD. 6. Set the engine stop switch to “ ”. 7. Select the diagnostic code number corresponding to the fault code number by pressing the “SELECT” and “RESET” buttons. NOTE: The diagnostic code number appears on the LCD meter (d01–70). To decrease the selected diagnostic code number , press the “RESET” button. Press the “RESET” button for 1 second or longer to automati cally decrease the diagnostic code numbers. To increase the selected diagnostic code number, press the “SELECT” button. Press the “SELECT” button for 1 second or longer to au tomatically increase the diagnostic code numbers. 8. Verify the operation of the sensor or actuator. Sensor operation
FUEL INJECTION SYSTEM 8-43 The data representing the operating conditions of the sensor appears on the odometer/tripme- ter/fuel reserve tripmeter LCD. Actuator operation Set the engine stop switch to “ ” to operate the actuator. 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. Fault code table Fault code No. Symptom Probable cause of malfunction Diagnostic code No. 11 No normal signals are received from the cylin- der identification sensor when the engine is started or while the vehi- cle is being driven. Open or short circuit in sub wire harness. Open or short circuit in wire harness. Defective cylinder id entification sensor. Improperly installed sensor. Malfunction in ECU. — 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. Improperly installed sensor. Malfunction in ECU. — 13 Intake air pressure sensor: open or short circuit detected. Open or short circuit in wire harness. Open or short circuit in sub wire harness. Defective intake air pressure sensor. Malfunction in ECU. 03 14 Intake air pressure sensor: faulty intake air pressure sensor system. 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 harness. Open or short circuit in sub wire harness. Defective throttle position sensor. Improperly installed throttle position sensor. Malfunction in ECU. 01 16 Throttle position sensor: stuck Stuck throttle position sensor. Malfunction in ECU. 01 17 EXUP servo motor poten- tion circuit: open or short circuit detected. Open or short circuit in sub wire harness. Detective EXUP servo motor (potention cir- cuit). 53 18 EXUP servo motor is stuck. Open or short circuit in sub wire harness. Stuck EXUP servo motor (mechanism). Stuck EXUP servo motor (motor). 53 19 Open circuit is detected in the input line of ECU No.24 terminal is detected when the start switch is pressed. Open circuit in wire harness (ECU Coupler). Malfunction in ECU. 20
FUEL INJECTION SYSTEM 8-44 20When the main switch is turned to “ON”, the atmo- spheric pressure sensor voltage and intake air pres- sure sensor voltage differ greatly. Atmospheric pressure sensor hose is clogged. Intake air pressure sensor hose is clogged, kinked, or pinched. Malfunction of the atmospheric pressure sensor in the intermediate electrical poten- tial. Malfunction of the intake air pressure sen- sor in the intermediate electrical potential. Malfunction in ECU. 02 03 21 Coolant temperature sen- sor: open or short circuit detected. Open or short circuit in wire harness. Defective coolant temperature sensor. Improperly installed coolant temperature sensor. Malfunction in ECU. 06 22 Intake air temperature sen- sor: open or short circuit detected. Open or short circuit in wire harness. Defective intake air temperature sensor. Improperly installed intake air temperature sensor. Malfunction in ECU. 05 23 Atmospheric pressure sen- sor: open or short circuit detected. Open or short circuit in sub wire harness. Defective atmospheric pressure sensor. Improperly installed atmospheric pressure sensor. Malfunction in ECU. 02 24 No normal signal is received from the O 2 sen- sor. Open or short circuit in wire harness. Defective O2 sensor. Improperly installed O 2 sensor. Malfunction in ECU. — 30 No normal signal is received from the lean angle sensor. Vehicle has overturned. Defective lean angle sensor. Improperly installed lean angle sensor. Malfunction in ECU. 08 33 Open circuit detected in the primary lead of the cylinder- #1 ignition coil. Open circuit in wire harness. Malfunction in ignition coil. Malfunction in a component of ignition cut- off circuit system. Malfunction in ECU. 30 34 Open circuit detected in the primary lead of the cylinder- #2 ignition coil. Open circuit in wire harness. Malfunction in ignition coil. Malfunction in a component of ignition cut- off circuit system. Malfunction in ECU. 31 35 Open circuit detected in the primary lead of the cylinder- #3 ignition coil. Open or short circuit in wire harness. Malfunction in ignition coil. Malfunction in a component of ignition cut- off circuit system. Malfunction in ECU. 32 Fault code No. Symptom Probable cause of malfunction Diagnostic code No.
FUEL INJECTION SYSTEM 8-45 36Open circuit detected in the primary lead of the cylinder- #4 ignition coil. Open or short circuit in wire harness. Malfunction in ignition coil. Malfunction in a component of ignition cut- off circuit system. Malfunction in ECU. 33 39 Open circuit detected in a injector. Open or short circuit sub-wire- harness. Open or short circuit in wire harness. Improperly installed injector. Defective injector. 36 37 38 39 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 recieved from the speed sensor. Open or short circuit in wire harness. Malfunction in speed sensor. Malfunction in ECU. 07 Neutral switch: open or short circuit detected. Open or short circuit in wire haraness. Malfunction in neutral switch. Malfunction in ECU. 21 43 Power supply to the injec- tors and the fuel pump is not normal. Open circuit in wire harness. Malfunction in ECU. 09 44 An 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 relay is not normal. Malfunction in the charging system. Refer to CHARGING SYSTEM on page 8- 11. — 47 Sub-throttle servo motor potention circuit: open or short circuit detected. Open or short circuit in wire harness. Detective Sub-throttle servo motor (poten- tion circuit). 56 48 Sub-throttle servo motor is stuck. Open or short circuit in wire harness. Stuck Sub-throttle servo motor (mecha- nism). Stuck Sub-throttle servo motor (motor). 56 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 wire harness. Malfunction in meter. Defective wire connection of the ECU cou- pler. Malfunction in ECU. — Fault code No. Symptom Probable cause of malfunction Diagnostic code No.
FUEL INJECTION SYSTEM 8-46 Sensor operation tableEr-2 No signals are received from the ECU within the specified duration. Improper connection in wire harness. Malfunction in meter. Malfunction in ECU. — Er-3 Data from the ECU cannot be received correctly. Improper connection in wire harness. Malfunction in meter. Malfunction in ECU. — Er-4 Non-registered data has been received from the meter. Improper connection in wire harness. Malfunction in meter. Malfunction in ECU. — Diag- nostic code No. Item Meter display Checking method 01 Throttle position sensor sig- nal Fully closed position 15–18 Check with throttle valve fully closed. Fully opened position 95–100 Check with throttle valve fully opened. 02 Atmospheric pressure Displays the atmospheric pressure. Compare the actually mea- sured atmospheric pres- sure with the meter display value. 03 Intake air pressure Displays the cylinder-#1 intake air pressure. Set the engine stop switch to “ ” then operate the throttle while pushing the start switch “ ”. (If the dis- play value changes, the performance is OK.) 05 Intake air temperature Displays the intake air tem- perature. Compare the actually mea- sured air temperature with the meter display value. 06 Coolant temperature Displays the coolant tempera- ture. Compare the actually mea- sured coolant temperature with the meter diaplay value. 07 Vehicle speed pulse 0–999 Check that the number increases when the rear wheel is rotated. The num- ber is cumulative and does not reset each time the wheel is stopped. 08 Lean angle sensor Remove the lean angle sensor and incline it more than 65 degrees. Upright 0.4–1.4 Overturned 3.7–4.4 Fault code No. Symptom Probable cause of malfunction Diagnostic code No.