FZ6-SS(C) Service Manual

FZ6-SS(C) Service Manual
FI
FUEL INJECTION SYSTEM
EAS00899
ECU’S SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is
operating normally. If this function detects a malfunction 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 system. Once a malfunction has been detected, a fault code is
stored in the memory of the ECU.
S 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.
S If a malfunction is detected in the system by the self-diagnostic function, this mode provides an appropriate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminating an engine trouble warning light.
S After the engine has been stopped, the lowest fault code number appears on the LCD meter. Once a
fault code has been displayed, it remains stored in the memory of the ECU until it is deleted.
EAS00900
Engine trouble warning light indication and FI system operating condition
Warning light
indication
ECU’s operation
FI operation
Vehicle operation
Flashing*
Warning provided
when unable to start
engine
Operation stopped
Unable
Remains ON
Malfunction detected
Operated with
substitute
characteristics
in accordance with the
description of the
malfunction
Able/Unable depending on the self-diagnostic fault code
* The warning light flashes when any one of the conditions listed below is present and the start switch is
pushed.
12:
Crankshaft position sensor
41:
19:
Sidestand switch
(open circuit in wire to ECU)
Lean angle cut-off switch
(latch up detected)
50:
30:
Lean angle cut-off switch
(open or short circuit)
ECU internal malfunction
(memory check error)
EAS00901
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 “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.
7-3
FUEL INJECTION SYSTEM
FI
EAS00902
ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION)
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illuminates 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.
Item
Symptom
Fail-safe action
Crankshaft position
sensor
No normal signals are received from
the crankshaft position sensor.
S Stops the engine (by stopping the
injection and ignition).
13
14
Intake air pressure
sensor (open or short
circuit) (pipe system)
Intake air pressure sensor-open or
short circuit detected.
Faulty intake air pressure sensor pipe
system.
S Fixes the intake air pressure to
101.3 kpa.
15
16
Throttle position sensor
(open or short circuit)
(stuck)
Throttle position sensor-open or short
circuit detected.
A stuck throttle position sensor is
detected.
S Fixes the throttle position sensor to
fully open.
Sidestand switch (open
circuit in wire to ECU)
Open circuit in the input line of ECU
No.4 terminal is detected when the start
switch is pressed.
-- (No start)
19
21
Coolant temperature
sensor
Coolant temperature sensor-open or
short circuit detected.
S Fixes the coolant temperature to
60_C.
22
Intake temperature
sensor
Intake temperature sensor-open or
short circuit detected.
S Fixes the intake temperature to 20_C.
Faulty ignition
33
Open circuit detected in the primary
lead of the ignition coil. (#1, #4)
34
Open circuit detected in the primary
lead of the ignition coil. (#2, #3)
S Cut the injection of other cylinder in
the same group with the cylinder that
the error is detected. (Example: when
the #1 cylinder is defective cut the injection of #1 and #4 cylinders)
S Turn on the power to the air induction
solenoid to always cut-off the air.
12
Lean angle cut-off
switch (latch up
detected) (open or short
circuit)
The motorcycle has over turned.
Lean angle cut-off switch-open or short
circuit detected.
S Turns OFF the fuel injection system
relay of the fuel system.
Speed sensor, neutral
switch
No normal signals are received from the
speed sensor; or, an open or short
circuit is detected in the neutral switch.
S Fixes the gear to the top gear.
Fuel system voltage
(monitor voltage)
Supply power to the injector and fuel
pump is not normal.
S Fixes the battery voltage to 12 V.
Error in writing the
amount of CO
adjustment on
EEPROM
An error is detected while reading or
writing on EEPROM (CO adjustment
value).
--
44
46
Vehicle system power
supply (Monitor voltage)
Power supply to the FI system not
normal
--
50
ECU internal
malfunction (memory
check error)
Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the meter.
S Shut down all functions except the
communication with the meter.
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.12, 19, 30, 41,
43 or 50.
Engine trouble warning light flashes
when the start switch is turned ON.
30
41
42
43
—
7-4
Engine
startability
Vehicle
drivability
Unable
Unable
Able
Able
Able
Able
Unable
Unable
Able
Able
Able
Able
Able
(depending
on the num
number of faulty
cylinders)
Able
(depending
on the num
number of faulty
cylinders)
Unable
Unable
Able
Able
Depending
on the malfunction
case.
Depending
on the malfunction
case.
Able
Able
Able
Able
Unable
Unable
Unable
Unable
FUEL INJECTION SYSTEM
FI
Communication error with the meter
Er-1
ECU internal malfunction
(output signal error)
No signals are received from
the ECU.
–
Unable
Unable
Er-2
ECU internal malfunction
(output signal error)
No signals are received from
the ECU within the specified
duration.
–
Unable
Unable
Er-3
ECU internal malfunction
(output signal error)
Data from the ECU cannot be
received correctly.
–
Unable
Unable
Er-4
ECU internal malfunction
(input signal error)
Non-registered data has been
received from the meter.
–
Unable
Unable
7-5
FI
FUEL INJECTION SYSTEM
EAS00904
TROUBLESHOOTING CHART
Engine operation is not normal or the engine trouble warning light is on.
* Engine trouble warning light may not come on even if the engine operation is not normal.
The engine trouble warning light does not come
on.
The engine trouble warning light comes on.
Check the fault code number displayed on the meter.
Check the operation of following sensors and actuators in the diagnostic mode (Refer to “Diagnostic mode table” in chapter 7.)
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: Al system solenoid
Identify the system with the malfunction. (Refer to
the “FAIL-SAFE ACTIONS TABLE”.)
Identify the probable cause of malfunction. (Refer
to the “Fault code table”.)
Check and repair the probable case of malfunction.
Fault code No. YES
Fault code No. NO
Check and repair.
(Refer to “TROUBLESHOOTING DETAILS”.)
Monitor the operation
of the sensors and
actuators in the diagnostic mode. (Refer
to “Diagnostic mode
table” in chapter 7)
Check and repair.
(Refer to “TROUBLESHOOTING DETAILS”.)
OK
Turn the main switch to “OFF”, turn the main switch
back to “ON”, and then check if the fault code number is still displayed.
Malfunction of engine
Defective sensor
or actuator
Check and repair
the inner parts of
engine. (Refer to
Chapter 5)
Check and repair
the corresponding
sensor or actuator.
OK
Perform ECU reinstatement action. (Refer to “Reinstatement method” in “TROUBLESHOOTING
DETAILS”.)
NG
NG
OK
Check the engine condition.
Fault code
number displayed
OK
Fault code number not displayed
Repairs completed
Erasing the malfunction history:*
The malfunction history is stored even if the main
switch is turned OFF.
The malfunction history must be erased in the * Operated when the engine trouble warning light is on.
diagnostic mode. (Refer to the “Diagnostic mode
table (Diagnostic code No.62)”)
7-6
FUEL INJECTION SYSTEM
FI
EAS00905
DIAGNOSTIC MODE
It is possible to monitor the sensor output data
or check the activation of actuators without connecting 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 engine stop switch to “OFF”.
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:
S All displays on the meter disappear except the
clock and tripmeter displays.
S “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 seconds or more to execute the selection.
6. 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:
S The diagnostic code number appears on the
LCD meter (01-70).
S To decrease the selected diagnostic code
number, press the “RESET” button. Press the
“RESET” button for 1 second or longer to automatically decrease the diagnostic code numbers.
S To increase the selected diagnostic code number, press the “SELECT” button. Press the
“SELECT” button for 1 second or longer to automatically increase the diagnostic code numbers.
7-7
FUEL INJECTION SYSTEM
FI
7. Verify the operation of the sensor or actuator.
S Sensor operation
The data representing the operating conditions of the sensor appears on the trip LCD.
S Actuator operation
Set the engine stop switch to “ON” to operate
the actuator.
* If the engine stop switch is set to “ON”, set it
to “OFF”, and then set it to “ON” again.
8. Turn the main switch to “OFF” to cancel the
the diagnostic mode.
NOTE:
To perform a reliable diagnosis, make sure to
turn “OFF” the power supply before every check
and then start right from the beginning.
7-8
FUEL INJECTION SYSTEM
FI
Fault code table
Fault
code No.
Symptom
Open or short circuit in wiring harness.
Defective crankshaft position sensor.
Malfunction in pickup rotor.
Malfunction in ECU.
Improperly installed sensor.
—
Intake air pressure sensor-open or
short circuit detected.
S
S
S
S
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective intake air pressure sensor.
Malfunction in ECU.
03
Faulty intake air pressure sensor pipe
system
S detected hose
S clogged hose
S Intake air pressure sensor hose is detached, clogged,
kinked, or pinched.
S Malfunction in ECU.
Throttle position sensor-open or
short circuit detected.
S
S
S
S
S
12
14
Diagnostic
code
S
S
S
S
S
No normal signals are received from
the crankshaft position sensor.
13
Probable cause of malfunction
15
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective throttle position sensor.
Malfunction in ECU.
Improperly installed throttle position sensor.
03
01
16
A stuck throttle position sensor is
detected.
S Stuck throttle position sensor.
S Malfunction in ECU.
19
Open circuit in the input line of ECU
No4 terminal is detected when the
start switch is pressed.
S Open circuit in wiring harness (ECU coupler).
S Malfunction in ECU.
Coolant temperature sensor-open or
short circuit detected.
S
S
S
S
Open or short circuit in wiring harness.
Defective coolant temperature sensor.
Malfunction in ECU.
Improperly installed sensor.
06
Intake air temperature sensor-open or
short circuit detected.
S
S
S
S
Open or short circuit in wiring harness.
Defective intake temperature sensor.
Malfunction in ECU.
Improperly installed sensor.
05
The motorcycle has overturned.
S Overturned.
S Malfunction in ECU.
08
Open circuit is detected in the primary
lead of the ignition coil (#1, #4).
S
S
S
S
Open circuit in wiring harness.
Malfunction in ignition coil.
Malfunction in ECU.
Malfunction in a component of ignition cut-off circuit system.
30
Open circuit is detected in the primary
lead of the ignition coil (#2, #3).
S
S
S
S
Open circuit in wiring harness.
Malfunction in ignition coil.
Malfunction in ECU.
Malfunction in a component of ignition cut-off circuit system.
31
Lean angle cut-off switch-open or
short circuit detected.
S Open or short circuit in wiring harness.
S Defective lean angle cut-off switch.
S Malfunction in ECU.
08
No normal signals are received from
the speed sensor; or, an open or
short circuit is detected in the neutral
switch.
S
S
S
S
S
S
07
21
Supply power to the injector and fuel
pump is not normal
S Open circuit in wiring harness. (red / blue line or blue / yellow
line)
S Malfunction in ECU.
09
44
An error is detected while reading or
writing on EEPROM.
S Malfunction in ECU. (The CO adjustment value is not
properly written on or read from the internal memory).
60
46
Power supply to the FI system is not
normal.
S Malfunction in “CHARGING SYSTEM”.
21
22
30
33
34
41
42
43
Open or short circuit in wiring 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.
7-9
01
20
—
FUEL INJECTION SYSTEM
Fault
code No.
50
Symptom
Probable cause of malfunction
FI
Diagnostic
code
Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the
meter.
S Malfunction in ECU. (The program and data are not
properly written on or read from the internal memory.)
No signals are received from the ECU.
S Open or short circuit in wiring sub lead.
S Malfunction in meter.
S Malfunction in ECU.
—
Er-1
—
Er-2
No signals are received from the ECU
within the specified duration.
S Improper connection in wiring sub lead.
S Malfunction in meter.
S Malfunction in ECU.
—
Er-3
Data from the ECU cannot be
received correctly.
S Improper connection in wiring sub lead.
S Malfunction in meter.
S Malfunction in ECU.
—
Er-4
Non-registered data has been
received from the meter.
S Improper connection in wiring sub lead.
S Malfunction in meter.
S Malfunction in ECU.
—
7-10
FUEL INJECTION SYSTEM
FI
EAS00907
Diagnostic mode table
Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to
“DIAGNOSTIC MODE”.
NOTE:
S Check the intake air temperature and coolant temperature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively.
S If it is not possible to check the intake air temperature, use the ambient temperature as reference.
Diagnostic
code
Item
Description of action
Data displayed on meter
(reference value)
Throttle angle
Displays the throttle angle.
S Check with throttle fully closed.
S Check with throttle fully open.
0 X 125 degrees
S Fully closed position (15 X 17)
S Fully open position (97 X 100)
Intake air pressure
Displays the intake air pressure.
Engine stop switch is on.
* Generate the pressure difference by cranking the engine
with the starter, without actually starting the engine.
S Not cranking-atmospheric
pressure
S Cranking-intake air pressure It
changes at the value whitch is
smaller than in the atomospheric pressure.
Intake air
temperature
Displays the intake air temperature.
* Check the temperature in the air cleaner case.
Compare it to the value
displayed on the meter.
Coolant temperature
Displays the coolant temperature.
* Check the temperature of the coolant.
Compare it to the value
displayed on the meter.
Vehicle speed pulse
Displays the accumulation of the vehicle pulses that are
generated when the tire is spun.
(0 X 999; resets to 0 after 999)
OK if the numbers appear on
the meter.
08
Lean angle cut-off
switch
Displays the lean angle cut-off switch values.
Upright: 0.4 X 1.4 V
Overturned: 3.7 X 4.4 V
09
Fuel system voltage
(battery voltage)
Displays the fuel system voltage (battery voltage).
Engine stop switch is on.
0 X 18.7 V
Normally, approximately 12.0 V
Sidestand switch
Displays that the switch is ON or OFF. (When the gear is in a
position other than neutral.)
Stand retracted: ON
Stand extended: OFF
Neutral switch
Displays that the switch is ON or OFF.
Neutral: ON
In gear: OFF
Ignition coil #1, #4
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates ignition
coil #1 and #4 for five times every second and illuminates
the engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Check that spark is generated,
5 times with the engine stop
switch ON.
Ignition coils #2, #3
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates ignition
coil #2 and #3 for five times every second and illuminates
the engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Check that spark is generated,
5 times with the engine stop
switch ON.
Injector #1, #4
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the
injector #1 and #4 five times every second and illuminates
the engine trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Check the operating sound of
the injector five times with
engine stop switch ON.
Injector #2, #3
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the
injector #2 and #3 five times every second and illuminates
the engine trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Check the operating sound of
the injector five times with
engine stop switch ON.
01
03
05
06
07
20
21
30
31
36
37
7-11
FI
FUEL INJECTION SYSTEM
Diagnostic
code
Item
Data displayed on meter
(reference value)
AI system solenoid
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the AI
system solenoid five times every second and illuminates the
engine trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Check the operating sound of
the AI system solenoid 5 times
with the engine stop
switch ON.
Fuel injection system
relay
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the fuel
injection system relay five times every second and
illuminates the engine trouble warning light (the light is OFF
when the relay is ON, and the light is ON when the relay is
OFF).
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Check the fuel injection system
relay operating sound 5 times
with the engine stop
switch ON.
Radiator fan motor
relay
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the
radiator fan motor 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 radiator fan motor
relay operating sound 5 times
with the engine stop
switch ON.
(At that time, the fan motor
rotates.)
Headlight relay 1
After 1 second has elapsed from the time 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.)
EEPROM fault code
display
S Transmits the abnormal portion of the data in the EEPROM
that has been detected as a fault code 44.
S If multiple malfunctions have been detected, different
codes are displayed at 2-second intervals, and this
process is repeated.
(01 X 02) Displays the cylinder
number.
01: #1 and #4 02: #2 and #3
(00) Displays when there is no
malfunction.
Malfunction history
code display
S 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).
S If multiple malfunctions have been detected, different
codes are displayed at 2-second intervals, and this
process is repeated.
12 X 50
(00) Displays when there is no
malfunction.
Malfunction history
code erasure
S Displays the total number of codes that are being detected
through self diagnosis and the fault codes in the past
history.
S 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 X 17
(00) Displays when there is no
malfunction.
Control number
S Displays the program control number.
00 X 255
48
50
51
52
60
61
62
70
Description of action
7-12
FUEL INJECTION SYSTEM
FI
EAS00908
TROUBLESHOOTING DETAILS
This section describes the countermeasures per fault code number displayed on the meter. Check and
service the items or components that are the probable cause of the malfunction following the order.
After the check and service of the malfunctioned part has been completed, reset the meter display according to the “Reinstatement method”.
Fault code No.:
Fault code number displayed on the meter when the engine failed to work normally. (Refer to the
“Fault code table”.)
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. (Refer to “DIAGNOSTIC
MODE”.)
Fault code No.
12
Symptom
No normal signals are received from the crankshaft position sensor.
Used diagnostic code No. – –
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
cranking the
engine.
1
Installed condition of sensor.
Check the installed area for looseness or
pinching.
2
Connected 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 coupler
NOTE:
When installing or removing the connector, main switch turn to “OFF”.
3
Open 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
4
Defective crankshaft position sensor.
Replace if defective.
1. Disconnect the crankshaft position sensor coupler from the wire harness.
2. Connect the pocket tester (Ω
100) to the
crankshaft position sensor coupler as shown.
Tester positive probe ! gray 1
Tester negative probe ! black 2
3. Measure the crankshaft position sensor resistance.
Crankshaft position sensor
resistance
248 X 372 Ω at 20_C (68_F)
(between gray and black)
4. Is the crankshaft position sensor OK?
7-13
FUEL INJECTION SYSTEM
Fault code No.
13
Symptom
FI
Intake air pressure sensor - open or short circuit detected.
Used diagnostic code No. 03 (intake air pressure sensor)
Order Inspection operation item and probable
cause
1
Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.
Operation item and countermeasure
Reinstatement
method
If there is a malfunction, repair it and connect it
securely.
Intake air pressure sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
Reinstated by
turning the
main switch
ON.
NOTE:
When installing or removing the connector, main switch turn to “OFF”.
2
Open 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
3
Defective intake air pressure sensor
Execute the diagnostic 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.
Tester positive probe ! pink / white 1
Tester negative probe ! black / blue 2
2
1
2. Set the main switch to “ON”.
3. Measure the intake air pressure sensor output
voltage.
Intake air pressure sensor output
voltage
3.75 X 4.25 V
4. Is the intake air pressure sensor OK?
7-14
FUEL INJECTION SYSTEM
Fault code No.
14
Symptom
FI
Intake air pressure sensor - hose system malfunction (clogged or detached
hose).
Used diagnostic code No. 03 (intake air pressure sensor)
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
starting the engine and operating it at idle.
1
Intake air pressure sensor hose detached, clogged, kinked, or pinched.
Intake air pressure sensor malfunction
at intermediate electrical potential.
Repair or replace the sensor hose.
Inspect and repair the connection.
2
Connected state of connector
Intake air pressure sensor coupler
Main wiring harness ECU coupler
Check the coupler for any pins that may have
pulled out.
Check the looking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
3
Defective intake air pressure sensor.
Fault code No.
15
Symptom
Execute the diagnostic mode (code No. 03)
Replace if defective.
Refer to “Fault code No. 13”.
Throttle position sensor - open or short circuit detected.
Used diagnostic code No. 01 (throttle position sensor)
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
turning the
main switch
ON.
1
Installed condition of throttle position
sensor.
Check the installed area for looseness or
pinching.
Check that it is installed in the specified
position.
Refer to “THROTTLE BODIES” section.
2
Connected 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.
Throttle position sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
3
Open 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
yellow - yellow
blue - blue
4
Throttle position sensor lead wire open
circuit output voltage check.
Check for open circuit and replace the throttle
position sensor.
Black / Blue - Yellow
5
Defective throttle position sensor.
Open circuit item
Output voltage
Ground wire open
circuit
5V
Output wire open
circuit
0V
Power supply wire
open circuit
0V
Execute the diagnostic mode (code No. 01)
Replace if defective.
Refer to “THROTTLE BODIES” section.
7-15
FUEL INJECTION SYSTEM
Fault code No.
16
Symptom
FI
Stuck throttle position sensor detected.
Used diagnostic code No. 01 (throttle position sensor)
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
starting the
engine,
ti it
operating
at idle, and
then racing it.
1
Installed condition of throttle position
sensor.
Check the installed area for looseness or pinching.
Check that it is installed in the specified position.
Refer to “THROTTLE BODIES” section.
2
Defective throttle position sensor
Execute the diagnostic mode (code No. 01)
Replace if defective.
Refer to “THROTTLE BODIES” section.
3
When detecting fault code No. 15
Refer to “Fault code No. 15”.
Fault code No.
19
Symptom
Refer to “Fault
code No. 15”.
Open circuit in the input line of ECU No. 4 terminal is detected.
Used diagnostic code No. 20 (sidestand switch)
Order Inspection operation item and probable
cause
1
Connected state of connector
Main wiring harness ECU coupler
(No. 4 pin)
Operation item and countermeasure
Reinstatement
method
Execute the diagnostic mode (code No. 20)
Check the coupler for any pins that may have
pulled out.
Check the locking condition of the coupler.
If the transmission is in gear,
it is reinstated
by retracting
the sidestand.
If the transmission is in neutral it is reintral,
stated by reconnecting the
wiring.
If there is a malfunction, repair it and connect it
securely.
2
Open or short circuit in wiring harness
and / or sub lead.
Fault code No.
21
Symptom
Repair or replace if there is an open circuit.
Sidestand switch signal input line of ECU coupler
black / red
Open or short circuit is detected from the coolant temperature sensor.
Used diagnostic code No. 06 (coolant temperature sensor)
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
turning the
main switch
ON.
1
Installed condition of sensor
Check the installed area for looseness or
pinching.
2
Connected 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.
Coolant temperature sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
3
Open 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
green / white - green / white
4
Defective coolant temperature sensor.
Execute the diagnostic mode (code No. 06)
Replace if defective.
Refer to “COOLING SYSTEM” in chapter 8.
7-16
FUEL INJECTION SYSTEM
FI
Fault code No.
22
Symptom Open or short circuit detected from the intake air temperature sensor.
Used diagnostic code No. 05 (intake air temperature sensor)
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
turning the
mainswitch
ON.
1
Installed condition of sensor
Check the installed area for looseness or
pinching.
2
Connected 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 temperature sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
3
Open 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
brown / white - brown / white
4
Defective intake air temperature sensor.
Execute the diagnostic mode (code No. 05)
Replace if defective.
1. Remove the intake air temperature sensor
from the air filter case.
2. Connect the pocket tester (Ω
100) to the
intake air temperature sensor terminal as
shown.
Tester positive probe ! brown / white 1
Tester negative probe ! black / blue 2
3. Measure the intake air temperature sensor
resistance.
Intake air temperature sensor
resistance
2.2 X 2.7 kΩ at 20_C (68_F)
WARNING
S Handle the intake air temperature sensor
with special care.
S Never subject the intake air temperature sensor to strong shocks. If the intake air temperature sensor is dropped, replace it.
4. Is the intake air temperature sensor OK?
7-17
FUEL INJECTION SYSTEM
Fault code No.
30
Symptom
FI
The motorcycle has overturned.
Used diagnostic code No. 08 (lean angle cut-off switch)
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
turning the
main switch
ON (however
(however,
the engine cannot be restarted unless
the main switch
is first turned
OFF).
1
The motorcycle has overturned.
Raise the motorcycle upright.
2
Installed condition of the lean angle cutoff switch
Check the installed area for looseness or
pinching.
3
Connected 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.
Lean angle cut-off switch coupler
Main wiring harness ECU coupler
4
Defective lean angle cut-off switch
Execute the diagnostic mode (code No. 08)
Replace if defective.
1. Remove the lean angle cut-off switch from the
motorcycle.
2. Connect the lean angle cut-off switch coupler
to the wireharness.
3. Connect the pocket tester (DC 20 V) to the
lean angle cut-off switch coupler as shown.
Tester positive prove ! blue 1
Tester negative prove ! yellow / green 2
4. When turning the lean angle cut-off switch
approx. 65_, the voltage reading change from
1.0 V to 4.0 V.
5. Is the emergency stop switch OK?
7-18
FUEL INJECTION SYSTEM
Fault code No.
33
Symptom
FI
Malfunction detected in the primary lead of the ignition coil (#1, #4).
Used diagnostic code No. 30 (ignition coil #1, #4)
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
starting the engine and operating it at idle.
In case of multi l cylinder
tiple
li d
open or short
circuit in lead,
make sure to
turn ON and
OFF the main
switch after
each time of
cranking.
1
Connected 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.
Ignition coil primary side coupler - orange/black
Main wiring harness ECU coupler
Sub-wire harness coupler
2
Open or short circuit in lead.
Repair or replace if there is an open or short
circuit.
Between ignition coil coupler (#1 and #4) and
ECU coupler / main harness
orange / black – orange / black
red / black – red / black
3
Defective ignition coil (test the primary
and secondary coils for continuity).
Execute the diagnostic mode (code No. 30)
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
Fault code No.
34
Symptom
Malfunction detected in the primary lead of the ignition coil (#2, #3).
Used diagnostic code No. 31 (ignition coil #2, #3)
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
starting the engine and operating it at idle.
In case of multi l cylinder
tiple
li d
open or short
circuit in lead,
make sure to
turn ON and
OFF the main
switch after
each time of
cranking.
1
Connected 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.
Ignition coil primary side coupler - gray / black
Main wiring harness ECU coupler
Sub-wire harness coupler
2
Open or short circuit in lead wire.
Repair or replace if there is an open or short
circuit.
Between ignition coil coupler (#2 and #3) and
ECU
coupler / main harness
gray / black – gray / black
red / black – red / black
3
Defective ignition coil (test the primary
and secondary coils for continuity).
Execute the diagnostic mode (code No. 31)
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
Fault code No.
41
Symptom
Open or short circuit detected in the lean angle cut-off switch.
Used diagnostic code No. 08 (lean angle cut-off switch)
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
turning the
mains witch
ON.
1
Connected 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.
Lean angle cut-off switch coupler
Main wiring harness ECU coupler
2
Open or short circuit in wiring harness.
Repair or replace if there is an open or short
circuit.
Between switch coupler and ECU coupler
black / blue - black / blue
yellow / green - yellow / green
blue - blue
3
Defective lean angle cut-off switch
Execute the diagnostic mode (code No. 08)
Replace if defective.
Refer to Fault code No. 30.
7-19
FUEL INJECTION SYSTEM
Fault code No.
42
1 No normal signals are received from the speed sensor.
2 Open or short circuit is detected in the neutral switch.
Used diagnostic code No. 07 (speed sensor) ! A1 X A4
No. 21 (neutral switch) ! B1 X B4
Order Inspection operation item and probable Operation item and countermeasure
cause
A1
Connected condition of speed sensor
If there is a malfunction, repair it and connect it
connector
securely.
Inspect the coupler for any pins that
Speed sensor coupler
may have pulled out.
Main wiring harness ECU coupler
Check the locking condition of the coupler.
Symptom
A2
Open or short circuit in speed sensor
lead.
A3
Gear for detecting vehicle speed has
broken.
Defective speed sensor
A4
FI
Repair or replace if there is an open or short
circuit.
Between sensor coupler and ECU coupler.
blue - blue
white / yellow - white / yellow
black / blue - black / blue
Replace if defective.
Refer to “TRANSMISSION” in chapter 5.
Execute the diagnostic mode (code No. 07)
Replace if defective.
1. Measure the speed sensor output voltage.
2. Connect the pocket tester (DC 20 V) to the
speed sensor coupler terminal as shown.
Reinstatement
method
Reinstated by
starting the
engine, and
inputting the
vehicle speed
signals by
ti th
operating
the
motorcycle at a
low speed of
20 to 30 km / h.
Tester positive probe ! white 1
Tester negative probe ! black / blue 2
3. Measure the speed sensor output voltage.
Speed sensor output voltage
When sensor is on
DC 4.8 V or more
When sensor is off
DC 0.6 V or less
Order Inspection operation item and probable
cause
B1
Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the coupler.
B2
Open or short circuit in neutral switch
lead.
B3
Faulty shift drum
(neutral detection area)
Defective neutral switch
B4
4. Is the speed sensor OK?
Operation item and countermeasure
If there is a malfunction, repair it and connect it
securely.
Neutral switch connector
Main wiring harness ECU coupler
Repair or replace if there is an open or short
circuit.
Between switch connector and ECU coupler
sky blue - black / yellow
Replace if defective.
Refer to “TRANSMISSION” in chapter 5.
Execute the diagnostic mode (code No. 21)
Replace if defective.
Refer to “CHECKING THE SWITCHES” in
chapter 8.
7-20
Reinstatement
method
Reinstated by
starting the
engine, and
inputting the
vehicle speed
i
l by
b
signals
operating the
motorcycle at a
low speed of
20 to 30 km / h.
h
FUEL INJECTION SYSTEM
Fault code No.
43
Symptom
FI
The ECU is unable to monitor the battery voltage.
Used diagnostic code No. 09 (fuel system voltage)
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
starting the
engine and
operating it at
idle.
1
Connected 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)
Fuel pump coupler
Injector coupler
ECU coupler
2
Malfunction in ECU
Fuel injection system relay is on.
3
Open or short circuit in the wiring harness.
Repair or replace if there is an open or short
circuit.
Between starting circuit cut-off relay (fuel injection
system relay), fuel pump, injector (#1 X #4)
red / blue – red / blue
4
Malfunction or open circuit in fuel injection system relay
Execute the diagnostic mode (code No. 09)
NOTE:
When the leads are disconnected, the voltage
check by the code No. 09 is impossible.
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 terminals as shown.
Battery positive terminal ! red / black 1
Battery positive terminal ! blue / yellow 2
Tester positive probe ! red 3
Tester negative probe ! red / blue 4
3. Does the starting circuit cut-off relay have continuity between red and red / blue?
7-21
FUEL INJECTION SYSTEM
Fault code No.
44
Symptom
FI
Error is detected while reading or writing on EEP-ROM
(CO adjustment value).
Used diagnostic No. 60 (EEP-ROM improper cylinder indication)
Order Inspection operation item and probable
cause
1
Malfunction in ECU
Fault code No.
46
Symptom
Operation item and countermeasure
Reinstatement
method
Execute 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
VOLUME” in chapter 3.
Replace ECU if defective.
Reinstated by
turning the
main switch
ON.
Power supply to the FI system relay is not normal.
Used diagnostic code No. – –
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
starting the engine and operating it at idle.
1
Connected 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.
2
Faulty battery
Replace or change the battery
Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3.
3
Open or short circuit in wiring harness.
Repair or replace if there is an open or short circuit.
S Between battery and main switch
red – red
S Between main switch and fuse (ignition)
brown/blue – brown/blue
S Between fuse (ignition) and ECU
red/white – red/white
Fault code No.
50
Symptom
Faulty ECU memory. (When this malfunction is detected in the ECU, the fault
code number might not appear on the meter.)
Used diagnostic code No. – –
Order Inspection operation item and probable
cause
1
Malfunction in ECU
Operation item and countermeasure
Reinstatement
method
Replace the ECU.
Reinstated by
turning the
main switch
ON.
7-22
FUEL INJECTION SYSTEM
Fault code No.
Er-1
Symptom
FI
No signals are received from the ECU.
Used diagnostic code No. – –
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
turning the
main switch
ON and
receives a
normal signal.
1
Connected 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.
Main wiring harness ECU coupler
Sub-wire harness coupler
2
Open or short circuit in wiring harness
and / or sub lead.
Repair or replace if there is an open or short
circuit.
Between meter coupler and ECU coupler
yellow / blue - yellow / blue
black / white - black / white
3
Malfunction in meter
Replace the meter.
4
Malfunction in ECU
Replace the ECU.
Fault code No.
Er-2
Symptom
No signals are received from the ECU within the specified duration.
Used diagnostic code No. – –
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
turning the
main switch
ON and
receives a
normal signal.
1
Connected 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.
Main wiring harness ECU coupler
Sub-wire harness coupler
2
Open or short circuit in wiring harness
and / or sub lead.
Repair or replace if there is an open or short
circuit.
Between meter coupler and ECU coupler
yellow / blue - yellow / blue
black / white - black / white
3
Malfunction in meter
Replace the meter.
4
Malfunction in ECU
Replace the ECU.
Fault code No.
Er-3
Symptom
Data from the ECU cannot be received correctly.
Used diagnostic code No. – –
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
turning the
main switch
ON and
receives a
normal signal.
1
Connected 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.
Main wiring harness ECU coupler
Sub-wire harness coupler
2
Open or short circuit in wiring harness
and / or sub lead.
Repair or replace if there is an open or short
circuit.
Between meter coupler and ECU coupler
yellow / blue - yellow / blue
black / white - black / white
3
Malfunction in meter
Replace the meter.
4
Malfunction in ECU
Replace the ECU.
7-23
FUEL INJECTION SYSTEM
Fault code No.
Er-4
Symptom
FI
Non-registered data has been received from the meter.
Used diagnostic code No. – –
Order Inspection operation item and probable
cause
Operation item and countermeasure
Reinstatement
method
Reinstated by
turning the
main switch
ON and
receives a
normal signal.
1
Connected 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.
Main wiring harness ECU coupler
Sub-wire harness coupler
2
Open or short circuit in wiring harness
and / or sub lead.
Repair or replace if there is an open or short
circuit.
Between meter coupler and ECU coupler
yellow / blue - yellow / blue
black / white - black / white
3
Malfunction in meter
Replace the meter.
4
Malfunction in ECU
Replace the ECU.
7-24
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