Yamaha Wr250r 2008 Manual
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FUEL INJECTION SYSTEM 8-30 1. AC magneto 3. Main switch 4. Battery 5. Main fuse 6. Starter relay 8. Right handlebar switch 9. Engine stop switch 10. Start switch 11. Relay unit 12. Sidestand switch 13. Neutral switch 14. Clutch switch 15. Fuel pump 16. ECU 17. Ignition coil 18. Spark plug 19. ITS solenoid 20. Fuel injector 21. AI solenoid 22. Intake air temperature sensor 23. Coolant temperature sensor 24. Speed sensor 25. Throttle position sensor 26. Intake air pressure sensor 27. Lean angle sensor 28. EXUP servo motor 32. Engine trouble warning light 42. Headlight relay 52. Radiator fan motor relay 54. Headlight fuse 55. Signaling system fuse 56. Ignition fuse 58. EFI fuse 59. Backup fuse
FUEL INJECTION SYSTEM 8-31 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 en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. 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 appro- priate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminat- ing 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 conditions 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 con- ditions, the warning light bulb may be defective. Warning light indicationECU operation FI operation Vehicle operation Flashing*Warning provided when unable to start engineOperation stopped Cannot be operated Remains on Malfunction detectedOperated with substitute characteristics in accor- dance with the descrip- tion of the malfunctionCan 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) 33:Ignition coil (Malfunction detected in the primary wire of the ignition coil) ab c cd a. Main switch OFF b. Main switch ON c. Light OFF d. Light ON for 1.4 seconds
FUEL INJECTION SYSTEM 8-32 EAS27393 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 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. Self-Diagnostic Function Fault code No.Item SymptomAble / unable to startAble / unable to drive 12Crankshaft position sen- sorNo normal signals are received from the crankshaft position sensor.Unable Unable 13Intake air pressure sen- sor (open or short circuit)Intake air pressure sensor-open or short circuit detected.Able Able 14Intake air pressure sen- sor (pipe system)Intake air pressure sensor-pipe sys- tem malfunction (clogged or detached hose).Able Able 15Throttle position sensor (open or short circuit)Throttle position sensor-open or short circuit detected.Able Able 16Throttle position sensor (stuck)The throttle position sensor is stuck. Able Able 17EXUP servo motor cir- cuit (open or short-circuit)EXUP servo motor circuit open or short circuit.Able Able 18EXUP servomotor (stuck)EXUP servo motor is stuck. Able Able 19Sidestand 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 21Coolant temperature sensorCoolant temperature sensor-open or short circuit detected.Able Able 22Intake air temperature sensorIntake air temperature sensor-open or short circuit detected.Able Able 30 Lean angle sensorLatch up detected. No normal signal is received from the lean angle sensor.Unable Unable 33Ignition coil (faulty ignition)Malfunction detected in the primary wire of the ignition coil.Unable Unable 41Lean angle sensor (open or short circuit)Lean angle sensor-open or short cir- cuit detected.Unable Unable 42Speed sensorNo normal signals are received from the speed sensor.Able Able Neutral switchOpen or short circuit is detected in the neutral switch.Able Able 43Fuel system voltage (monitor voltage)Supply power to the fuel injector and fuel pump is not normal.Able Able
FUEL INJECTION SYSTEM 8-33 Communication error with the multifunction meter * If multiple malfunctions have been detected for the ECU, you may not be able to start or drive the vehicle. 44Error in writing the amount of CO adjust- ment on EEPROMError is detected while reading or writ- ing on EEPROM (code re-registering key code and throttle valve fully closed notification value).Able Able 46Vehicle system power supply (Monitor voltage)Power supply to the ECU system relay is not normal.Able Able 50ECU internal malfunc- tion (memory check error)Faulty ECU memory. (When this mal- function is detected in the ECU, the fault code number might not appear on the meter.)Unable Unable 70 Left idle controlAfter 20 minutes left idling, the ECU automatically stops the engine.Able Able —Start unable warningEngine 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 or 50.Unable Unable Fault code No.Item SymptomAble / unable to startAble / unable to drive Er-1ECU internal malfunc- tion (output signal error)No signals are received from the ECU.Able* Able* Er-2ECU internal malfunc- tion (output signal error)No signals are received from the ECU within the specified duration.Able* Able* Er-3ECU internal malfunc- tion (output signal error)Data from the ECU cannot be received correctly.Able* Able* Er-4ECU internal malfunc- tion (input signal error)Non-registered data has been received from the meter.Able* Able* Fault code No.Item SymptomAble / unable to startAble / unable to drive
FUEL INJECTION SYSTEM 8-34 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. Re- fer 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 (Di- agnostic 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 actuators, check and repair the engine inner parts. EAS27441 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the en- gine stop switch to “ON”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT1” “1”and “RESET” “2” 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 “SELECT1” 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 seconds or more to execute the selection. 6. Set the engine stop switch to “OFF”. 7. Select the diagnostic code number that ap- plies to the item that was verified with the fault code number by pressing the “SELECT1” and “RESET” buttons. NOTE: The diagnostic code number appears on the clock LCD (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- Fault code No. YES Fault code No. NO Check and repair. Refer to “TROUBLESHOOT- ING DETAILS” on page 8-41. Monitor the operation of the sensors and actua- tors in the diagnostic mode. Refer to “Sensor operation table”.Check and repair. Refer to “TROUBLESHOOT- ING DETAILS” on page 8-41. 01: Throttle position sensor (throttle angle) 30: Ignition coil #1 36: Injector #1 48: AI solenoid 21
FUEL INJECTION SYSTEM 8-35 bers. 8. Verify the operation of the sensor or actuator. Sensor operation The data representing the operating condi- tions of the sensor appears on the trip LCD. Actuator operation Set the engine stop switch to “ON” to operate the actuator. NOTE: If the engine stop switch is set to “ON”, set it to “OFF”, and then set it to “ON” again. 9. Turn the main switch to “OFF” to cancel the diagnostic mode.
FUEL INJECTION SYSTEM 8-36 Diagnostic code table Fault code No.Symptom Probable cause of malfunctionDiagnostic code No. 12No normal signals are received from the crankshaft position sensor. Open or short circuit in wire harness. Defective crankshaft position sensor. Malfunction in pickup rotor. Malfunction in ECU. Improperly installed sensor. — 13Intake air pressure sen- sor-open or short circuit detected. Open or short circuit in wire harness. Defective intake air pressure sensor. Malfunction in ECU. 03 14Intake air pressure sen- sor-pipe system malfunction (clogged hose). Intake air pressure sensor hose is clogged. Malfunction in ECU. 03 15Throttle position sensor-open or short circuit detected. Open or short circuit in wire harness. Defective throttle position sensor. Malfunction in ECU. 01 16Stuck throttle position sensor detected. Stuck throttle position sensor. Malfunction in ECU. 01 17EXUP servo motor circuit open or short circuit. Open circuit in wire harness. Defective EXUP servo motor. ECU is defective. 53 18 EXUP servo motor is stuck. Open circuit in wire harness. EXUP servo motor lockup (valve or motor) 53 19Open circuit is detected in the input line from the sidestand switch to the ECU. Open or short circuit in wire harness. Malfunction in ECU. 20 21Coolant temperature sen- sor-open or short circuit detected. Open or short circuit in wire harness. Defective coolant temperature sensor. Malfunction in ECU. 06 22Intake 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 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 33Malfunction detected in the primary wire of the ignition coil. 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 41Lean angle sensor-open or short circuit detected. Open or short circuit in wire harness. Defective lean angle sensor. Malfunction in ECU. 08
FUEL INJECTION SYSTEM 8-37 Sensor operation table 42No normal signals are received from the speed sen- sor. Open or short circuit in wiring harness. Defective speed sensor. Malfunction in vehicle speed sensor detected unit. Malfunction in ECU. 07 Open or short circuit in neutral switch. Open circuit in wire harness. Defective neutral switch. ECU is defective. 21 43Supply power to the fuel injec- tor and fuel pump is not nor- mal. Open circuit in wire harness. Malfunction in ECU. Defective relay unit (fuel pump). 09 44Error is detected while read- ing or writing on EEPROM. Malfunction in ECU. (CO concentration adjustment valve cannot be correctly writ- ten to or read from internal memory) 60 46Power supply to the FI system relay is not normal. Malfunction in charging system. — 50Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code num- ber might not appear on the meter.) Malfunction in ECU. (The program and data are not properly written on or read from the internal memory.) — 70 Left idle control After 20 minutes left idling, the ECU auto- matically stops the engine. — Er-1No signals are received from the ECU. Open or short circuit in communication line. Malfunction in meter unit. Malfunction in ECU. — Er-2No signals are received from the ECU within the specified duration. Open or short circuit in communication line. Malfunction in meter unit. Malfunction in ECU. — Er-3Data from the ECU cannot be received correctly. Open or short circuit in communication line. Malfunction in meter unit. Malfunction in ECU. — Er-4Non-registered data has been received from the meter. Open or short circuit in communication line. Malfunction in meter unit. Malfunction in ECU. — Fault code No.Symptom Probable cause of malfunctionDiagnostic code No. Diagnos tic monitori ng code No.Item Meter display Checking method 01 Throttle angle Fully closed position 15 – 19 Check with throttle fully closed. Fully opened position 95 – 100 Check with throttle fully open.
FUEL INJECTION SYSTEM 8-38 03 Pressure difference (atmospheric pressure-intake air pressure)Displays the intake air pressure. Set “” the engine stop switch, and then push the start switch. (If the display value changes, the perfor- mance is OK.) 05 Intake air temperature Displays the intake air tempera- ture.Compare the actually mea- sured intake air temperature with the meter display value. (*1) 06 Coolant temperature Displays the coolant tempera- ture.Compare the actually mea- sured coolant temperature with the meter display value. 07 Vehicle speed pulse 0 – 999 Check that the number changes (integrating) when the rear wheels are rotated. 08 Lean angle sensor Remove the lean angle sen- sor and incline it more than 65 degrees. Upright 0.4 – 1.4 V Overturned 3.7 – 4.4 V 09 Fuel system voltage (battery voltage) Approximately 12.0 VCompare with the actually measured battery voltage. (If the battery voltage is lower, perform recharging.) 20 Sidestand switch Set ON/OFF the sidestand switch. (with the transmission in gear) Stand retracted ON Stand extended OFF 21 Neutral switch Shift the transmission. Neutral ON In gear OFF 60 EEPROM fault code display— No fault 00 History exists 04 (Throttle valve fully open notification value is detected.) Diagnos tic monitori ng code No.Item Meter display Checking method
FUEL INJECTION SYSTEM 8-39 *1 If it is not possible to check the intake temperature, use the ambient temperature as reference (use the compared values for reference). Actuator operation table 61 Malfunction history code dis- play— No history 00 History exists 12 – 70 (Fault detection code) (If code numbers more than one are detected, the display alternates every two seconds to show all the detected code numbers. When all code numbers are shown, the display repeats the same process.) 62 Malfunction history code era- sure No history 00— History exists 00 – 20 (Memory numbers of the fault detection)To erase the history, turn ON the engine stop switch. 63 Repeated display of trouble code No malfunction code 0— Malfunction code exists Trouble code 24 70 Control number 00 – 255— Diagnos tic monitori ng code No.Item Meter display Checking method Diagnos tic monitori ng code No.Item Actuation Checking method 30 Ignition coilActuates the ignition coil for five times every second. Illuminates the engine trouble warning light.Check the spark five times. Connect an ignition checker. 36 InjectorActuates the injector for five times every second. Illuminates the engine trouble warning light.Check the operating sound of the injector five times. 48 Air induction system solenoidActuates the air inducton sys- tem solenoid for five times every second. Illuminates the engine trouble warning light. (Light OFF: Air induction system solenoid “ON”, Light OFF: Air induction system solenoid “OFF”)Check the operating sound of the solenoid five times.