Yamaha FZS6W 07 User Manual

							
COOLING SYSTEM
8-30 
						

							
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.