Fuel Injection System. Yamaha XF50W

FUEL INJECTION SYSTEM

EAS00894



1 ECU

2 Engine trouble warning light

3 Lean angle cut-off switch

4 Fuel hose

5 Ignition coil

6 Fuel injector

7 Intake air pressure sensor

8 ISC(idle speed control) valve

9 Intake air temperature sensor

0 Battery q Air filter case w Catalytic converter e Crankshaft position sensor r Coolant temperature sensor t Spark plug y Fuel tank u Fuel pump i Throttle position sensor

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7-1

WIRING DIAGRAM


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Y L

< P/W

Br/W x

B/L

Br/W B/L

< P/W x

Y

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5:

G/Y

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L / G

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W

W

7-2

1 AC magneto

3 Main fuse

4 Battery

8 Engine stop switch

9 ECU

0 Main switch q Intake air pressure sensor w Intake air temperature sensor e Throttle position sensor r Lean angle cut-off switch t Coolant temperature sensor y Ignition coil u Spark plug i Fuel injector o Fuel pump p ISC (idle speed control) valve s Dimmer switch f Headlight c High beam indicator light b Engine trouble warning light n Coolant temperature indicator light m Speed sensor

.

FI diagnostic tool (optional)

/ Sidestand switch (optional)


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7-3


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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.

1 Engine trouble warning light

8 To inform the rider that the fuel injection system is not functioning correctly, the engine trouble warning light flashes when the start switch is being pushed to start the engine.

8 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 the engine trouble warning light.

8 After the engine has been stopped, the lowest fault code number appears on the engine trouble warning light (or displayed on the Fl diagnostic tool). It remains stored in the memory of the ECU until it is deleted.

Engine trouble warning light fault code indication

Digit of 10: Cycles of 1 see. ON and 1.5 sec. OFF.

Digit of 1 : Cycles of 0.5 sec, ON and 0.5 sec. OFF.

<Example> 42

Light ON

Light OFF

1 1.5 1 1.5 1 1.5 1 0.5 0.5 0.5 3

EAS00900

Engine trouble warning light indication and Fl system operating condition

Engine condition

Stop

Warning light indication

Flashing

Remains ON

Flashing

(indicate the fault code)

Fl operation Vehicle operation

Operation stopped

Operated with substitute characteristics in accordance with the description of the malfunction

Unable

Able

_ _

7-4


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EAS00901

CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT BULB

The engine trouble warning light comes on for 2 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.

Engine trouble warning light

Main switch Main switch

OFF ON

Light

OFF

Light ON for

2 seconds

Intialize

Light

OFF

EAS00902

SELF-DIAGNOSTIC FANCTION TABLE

If the ECU detects an abnormal signal from a sensorwhile 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.

Self-diagnostic fanction table

Fault code No.

Item Symptom

12 Crankshaft position sensor No normal signals are received from the crankshaft position sensor.

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.

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.

19 Broken or disconnected blue/ yellow lead of the ECU

Open circuit in the input line (blue/yellow lead) of the ECU is detected.

21 Coolant temperature sensor Coolant temperature sensor-open or short circuit is detected.

22 Intake temperature sensor Intake temperature sensor-open or short circuit is detected.

33 Faulty ignition Open circuit detected in the primary lead of the ignition coil.

37 ISC (idle speed control) valve

(stuck fully open)

Engine speed is high when the engine is idling.

Engine startability

Vehicle driveability

Unable

Able

Able

Unable

Able

Able

Unable

Able

Unable

Able

Able

Unable

Able

Able

Unable

Able

7-5


Fault code No.

Item Symptom

39

30

41

Fuel injector

Lean angle cut-off switch

(latch up detected) (open or short circuit)

The vehicle has overturned.

Lean angle cut-off switch-open or short circuit is detected.

42 Speed sensor

Fuel injector open or short circuit is detected.

No normal signals are received from the speed sensor.

43 Fuel system voltage (monitoring voltage)

44

Error in reading from or writing on E2PROM

46 Vehicle system power supply (monitoring voltage)

Power supply to the fuel injector, fuel pump and ignition coil are not normal.

An error is delected while reading from or writing on E2PROM (CO adjustment value).

Power supply to Fl system is not normal.

(red lead)

50

61

ECU internal malfunction

(memory check error)

ISC (idle speed control) valve unit (open or short circuit)

Faulty ECU memory. When this malfunction is detected, the code number might not appear on the engine trouble warning light or displayed on Fl diagnostic tool.

ISC (idle speed control) valve unit-open or short circuit detected.

_

Start unable warning

Engine trouble warning light flashes when the start switch is turned ON.

Relay is not activated even if the crank signal is input while the start switch is pushed.

Engine startability

Vehicle driveability

Unable

Unable

Able

Able

Able

Able

Unable

Able

Unable

Unable

Unable

Able

Able

Able

Able

Unable

Able

Unable

7-6

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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.

I

The engine trouble warning light comes on.

I

The engine trouble warning light does not come on.

T

Check the fault code number displayed on the Fl diagnostic tool.

I

Identify the system with the malfunction. Refer to

“FAIL-SAFE ACTIONS TABLE”.

T

Identify the probable cause of malfunction. Refer to “Fault code table”.

T

Check and repair the probable cause of malfunction.

Faultcode No.YES Faultcode No. NO

Check and repair.

Refer to “TROUBLE

SHOOTING DE-

TAILS”.

Monitor the operation of the sensors and actuators in the diagnostic mode. Refer to

“Diagnostic mode table”.

Check and repair.

Refer to “FAIL-SAFE

ACTIONS TABLE”.

I

Check the operation of following sensors and actuators in the diagnostic mode. Refer to “Diagnostic mode table”.

33: Ignition coil

39: Fuel injector

Parform ECU reinstatement action. Refer to “Reinstatement method” in ‘TROUBLESHOOTING DE-

TAILS”.

Fault code number displayed

Turn the main switch to “OFF”, turn the main switch back to “ON”, and then check if the fault code number is still displayed.

X 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 diagnostic mode. Referto “Diagnostic mode table (Diagnostic code No.62)”.

* Operated when the engine trouble warning light is on.

7-7

O POWER OWARNING

Fl Diagnostic Tool ©YAMAHA

2100 rpm 60 ° o o

(

D

OPOWER OWARNING

Fl Diagnostic Tool « YAM AHA'

Orpm 60 °C

S/D: 12


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EAS00905

DIAGNOSTIC MODE

It is possible to monitor the sensor output data or check the activation of actuators with connecting the Fl diagnostic tool to the normal mode or the diagnostic monitoring mode.

<P Fl diagnostic tool

90890-03182

YU-03182

Setting the normal mode

NOTE:

The engine speed, engine temperature, and fault code, if detected, can be displayed on the LCD of the Fl diagnostic tool when the tool is connected to the vhicle and is set to the normal mode.

1. Turn the main switch to “OFF” and the engine stop switch to “RUN”.

2. Disconnect the self diag signal connector

1 , and then connect the Fl diagnostic tool

2 as shown.

3. Turn the main switch to “ON” and start the engine.

NOTE:

8 Engine temperature and engine revolution appears on the LCD of the Fl diagnostic tool.

8 ”POWER” LED (Green) comes on.

8 If a malfunction is detected in the system,

“WARNING” LED (Orange) comes on. How ever the fault code is not appears on the

LCD of Fl diagnostic tool.

4. Stop the engine.

NOTE:

If a malfunction is detected in the system, the fault code appears on the LCD of the Fl diagnostic tool. And also, “WARNING” LED(Orange) comes on.

5. Turn the main switch to “OFF” to cancel the normal mode.

6. Disconnect the Fl diagnostic tool and connect the self diag signal connector.

7-8

OPOWER OWARNING

Fl Diagnostic Tool ©YAMAHA

D03: 101

JP MODE DOWN o o o


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Setting the diagnostic mode

1. Turn the main switch to “OFF” and the engine stop switch to “RUN”..

2. Disconnect the self diag signal connector

1 , and then connect the Fl diagnostic-tool

2 as shown.

3. While press the “MODE” button, turn the main switch to “ON”.

NOTE:

8 ”DIAG” appears on the LCD of the Fl diagnostic tool.

8 ”POWER” LED (Green) comes on.

4. Press the “UP” button to select the CO adjustment mode “CO” or the diagnostic mode

“DIAG”.

5. After selecting “DIAG”, press the “MODE” button.

6. Select the diagnostic code number that applies to the item that was verified with the fault code number by pressing the “UP” and

“DOWN” buttons.

NOTE:

8 The diagnostic code number appears on the

LCD (D01-D70).

8 To decrease the selected diagnostic code number, press the “DOWN” button. Press the “DOWN” button for 1 second or longer to automatically decrease the diagnostic code numbers.

8 To increase the selected diagnostic code number, press the “UP” button. Press the

“UP” button for 1 second or longer to automatically increase the diagnostic code numbers.

7. Verify the operation of the sensor or actuator.

8Sensor operation

The data representing the operating conditions of the sensor appears on the LCD.

8Actuator operation

Press the “MODE” button to.operate the actuator.

8. Turn the main switch to “OFF” to cancel the diagnostic mode.

9. Disconnect the Fl diagnostic tool and connect the self diag signal connector.

7-9


Fault code table

Fault codeNo.

12

13

14

15

16

19

21

22

30

33

37

39

41

42

43

44

46

50

61

Symptom Probable cause of malfunction

No normal signals are received from the crankshaft position sensor.

Intake air pressure sensor-open or short circuit detected.

Faulty intake air pressure sensor pipe system

Throttle position sensor-open or short circuit detected.

A stuck throttle position sensor is detected.

Open circuit in the input line (blue/ yellow lead) of ECU is detected when the start switch is pressed.

Coolant temperature sensor-open or short circuit detected.

• Open or short circuit in wiring harness.

• Defective crankshaft position sensor.

• Malfunction in pickup rotor.

• Improperly installed sensor lead connector in the coupler.

• Open or short circuit in wiring sub lead.

• Open orshort circuit in wiring harness.

• Defective intake air pressure sensor.

• Improperly installed sendor lead connector in the coupler.

• Intake air pressure sensor is disconnected or clogged.

• Open or short circuit in wiring sub lead.


• Defective throttle position sensor.

• Improperly installed throttle’position sensor lead connector in the coupler.

• Stuck throttle position sensor.

• Defective throttle position sensor.

• Open circuit in wiring harness (ECU coupler).

Intake air temperature sensor-open or short circuit detected.

The vehicle has overturned.

Open circuit is detected in the primary lead of the ignition coil.

The ISC (idle speed control) valve is stuck fully open.

Fuel injector open or short circuit is detected.

Lean angle cut-off switch-open or short circuit detected.

No normal signals are received from the speed sensor.


• Defective coolant temperature sensor.

• Improperly installead sensor lead connector in the coupler.

• Open or short circuit in wire sub lead.


• Defective intake temperature sensor.

• Improperly installed sensor lead connector in the coupler.

• Overturned condition.

• Open circuit in wiring harness.

• Malfunction in ignition coil.

• Improperly installed primary lead connector in the coupler.

• Malfunction in throttle body.

• Malfunction in throttle cables.

• ISC (idle speed control) valve is stuck fully open.


• Defective fuel injector.

• Improperly installed lead connector in the coupler.


• Defective lean angle cut-off switch.

• Improperly installed lead connector in the coupler.


• Defective speed sensor.

• Improperly installead lead connector in the coupler.

• Open or short circuit in wiring harness. Power supply to the fuel injector, fuel pump and ignition coil are not normal.

An error is detected while reading or writing on E2PROM.

• Malfunction in ECU. (The CO adjustment value, code reregistering key code, and throttle valve fully closed notification value are not properly written on or read from the internal memory.)

• Malfunction in charging system. Power supply to Fl system is not normal.(red lead)

Faulty ECU memory. When this malfunction is detected, the code number might not appear on the meter.

ISC (idle speed control) valve open or short circuit is detected. •

•

• Malfunction in ECU. (The program and data are not properly written on or read from the internal memory.)

Open or short circuit in wiring harness.

Improperly installed lead connector in the coupler.

FI

Diagnostic code

_

D03

D03

D01

D01

D20

D06

D06

D08

D30

D54

D36

D08

D07

D09

D60

_

_

D54

7-10


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EAS00907

Diagnostic mode table

NOTE:

8 Check the intake air temperature and coolant temprature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively.

8 If it is not possible to check the intake air temperature, use the ambient temperature as reference.

Diagnostic code

D01

D03

D05

D06

D07

D08

D09

D20

D30

D36

D52

D54

D60

D61

D62

D70

Item Description of action

Data displayed on FI diagnostic tool

(reference value)

Throttle angle

Intake air pressure

Displays the throttle angle.

• Check with throttle fully closed.

• Check with throttle fully open.

Displays the intake air pressure.

• Check the pressure in the intake manifold.

Intake air temperature Displays the intake air temperature.

• Check the temperature in the intake manifold.

Coolant temperature

Vehicle speed pulse

Displays the coolant temperature.

• Check the temperature of the coolant.

Displays the accumulation of the vehicle pulses that are generated when the tire is spun.

Lean angle cut-off switch

Fuel system voltage

(battery voltage)

Sidestand switch (Option)

Ignition coil

Displays the lean angle cut-off switch values.

Displays the fuel system voltage (battery voltage).

Displays that the switch is ON or OFF.

Fuel injector

Headlight

ISC (idle speed control) valve

E2PROM fault code display.

When the “MODE” button is pressed, the ignition coil is actuated five times per second and the

“WARNING” LED (orange) comes on.

• Connect an ignition checker.

When the “MODE”-button is pressed, the fuel injector is actuated five times per second and the

“WARNING” LED (orange) comes on.

When the “MODE” button is pressed, the headlight is actuated five times every 5 seconds and the engine trouble warning light comes on. (ON 2 seconds, OFF 3 seconds)

When the the “MODE” button is pressed, the ISC

(idle speed control) valve fully closes, and then it opens until it is at the standby opening position when the engine is started. This operation takes approximately 3 seconds until it is completed.

• Transmits the abnormal portion of the data in the E2PROM that has been detected as a fault code 44.

• If multiple malfunctions have been detected, different codes are displayed at 2-second intervals, and this process is repeated.

Malfunction history code display

• Displays the codes of the history of the selfdiagnosis malfunctions (i.e., a code of a malfunction that occurred once and which has been corrected).

• If multiple malfunctions have been detected, different codes are displayed at 2-second intervals, and this process is repeated.

Malfunction history code erasure

• Displays the total number of codes that are being detected through self diagnosis and the fault codes in the past history.

Control number

• Erases only the history codes when the

“MODE” button is pressed.

Displays the program control number.

0-125 degrees

• Fully closed position (14-20)

• Fully open position (97-107)

Compare it to the value displayed on the

Fl diagnostic tool.


Fl diagnostic tool.


FI diagnostic tool.

(0-999; resets to 0 after 999)

OK if the numbers appear on the FI diagnostic tool.

Upright: 0.4-1.4 V

Overturned: 3.7-4.4V

0-18.7 V

Normally, approximately 12.0 V

Stand retracted: ON

Stand extended: OFF

Check that spark is generated, 5 times with the “MODE” button press.

Check the operating sound of the fuel injector five times with “MODE” button press.

Check the headlight operating 5 times with the “MODE” button is pressed.

The ISC (idle speed control) valve unit vibrates when the ISC (idle speed control) valve operates.

01 CO adjustment value is detected.

(00) Displays when there is no malfunction.

12-61

(00) Displays when there is no malfunction.

00-18

(00) Dispiays when there is no malfunction.

00-254

7-11


Communication error with the FI diagnostic tool

LCD Display Sympton Probable cause of malfunction

Waiting for connection...

ERROR 4

No signals are received from the

ECU.

Commands from the Fl diagnostic tool are not accepted by the ECU.

• Improper installed lead connector in the coupler.

• The main switch is OFF position.

• Malfunction in Fl diagnostic tool.

• Malfunction in ECU.

• Turn the main switch to “OFF” once, and then turn it back to CO adjustment mode or diagnostic mode.

• Vehicle battery is insufficiently charged.

• Malfunction in Fl diagnostic tool.

• Malfunction in ECU.

EAS00908

TROUBLESHOOTING DETAILS

This section describes the countermeasures per fault code number displayed on the Fl diagnostic tool. Check and service the items or components that are the probable cause of the malfunction following the order given.

After the check and service of the malfunctioned part has been completed, reset the Fl diagnostic tool display according to the “Reinstatement method”.

Fault code No.:

Fault code number displayed on the Fl diagnostic tool when the engine failed to work normally.

Refer to “Fault code table”.

Diagnostic code No.:

Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAG-

NOSTIC MODE”.

7-12


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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

Installed condition of sensor. Check the installed area for looseness or pinching.

Connected condition of connector.

Inspect the coupler for any pins that may have pulled out.

Check that the coupler is connected securely.

NOTE:

Set the main switch to OFF before connecting or disconnecting the connector.

If there is a malfunction, repair it and connect it securely.

Crankshaft position sensor coupler

Main wiring harness ECU coupler

Reinstatement method


4 Defective crankshaft position sensor.

Repair or replace if there is an open or short circuit between the main wiring harnesses.

Between sensor coupler and ECU coupler. white/red black/blue

Replace if defective.

Refer to “IGNITION SYSTEM” in chapter 8.

7-13


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Fault code No. 13 Symptom Intake air pressure sensor-open or short circuit detected.

Used diagnostic code No. D03 (intake air pressure sensor)

Order

1




Connected condition of connector


Check the locking condition of the coupler.

NOTE:

Set the main switch to OFF before connecting or disconnecting the connector.

If there is a malfunction, reper it and connect it securely.

Intake air pressure sensor coupler


Sub-wire harness coupler

Reinstated by turning the main switch

ON.

2

3

Open or short circuit in wiring harnes and /or sub lead.

Defective intake air pressure sensor.

Repair or replace if there is an open or short circuit.

Between sensor coupler and ECU coupler black/blue - black/blue pink/white - pink/whte blue- blue

Execute the diagnostic mode (code No. D03)

Replace the throttle body.

NOTE:

Do not remove the sensor assembly (MAQS).

1. Connect the digital circuit tester to the intake air pressure sensor coupler as shown.

Positive tester probe -» pink/white 0

Negative tester prove -» black/blue (2)

^T^S,

Br/W P/W B/L Y L

YZZZ^

^

© ©

n n

^ n • • • •

2. Set the main switch to “ON”.

3. Measure the intake air pressure sensor output voltage. n. Intake air pressure sensor output voltage

3.9~4.1V

4. Is the intake air pressure sensor OK?

7-14


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Intake air pressure sensor-hose system malfunction

Fault code No. 14 Symptom

(clogged or detached hose). tached hose).

Used diagnostic code No. D03 (intake air pressure sensor)

Order




Connected state of connector

Intake air pressure sensor coupler

Main wirring harness ECU coupler


2 Defective intake air pressure sensor.

Check the coupler for any pins that may have pulled out.

Check that the coupler is connected securely.




NOTE:


Refer to “Fault code No. 13”.

Fault code No. 15 Symptom Throttle position sensor-open or short circuit detected.

Used diagnostic code No. D01 (throttle position sensor)

Order



4

Installed condition of throttle position sensor.




Open or short circuit in wiring harness and/or sub lead.

Check the installed area for looseness or pinching.

Check that it is installed in the specified position.

Refer to “THROTTLE BODY AND FUEL IN-

JECTOR”.


Throttle position sensor coupler



Defective throttle position sensor.


Between sensor coupler and ECU coupler black/blue - black/blue yellow - yellow blue -blue



NOTE:




JECTOR ”.

7-15


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Fault code No. 16 Symptom Stuck throttle position sensor detected.

Used diagnostic code No. D01 (throttle position sensor)

Order



Installed condition of throttle position sensor.

Defective throttle position sensor


Check that it is installed in the specified position.


JECTOR ”.

Execute the diagnostic mode (code No. 01)


NOTE:



3 When fault code No.15 has been detected


JECTOR ”.

Refer to “Fault code No.15”. Refer to “Fault code

No. 15”.

Fault code No. 19 Symptom Open circuit in the input line of ECU (blue/yellow lead) detected.

Used diagnostic code No. D20 (sidestand switch :option)

Order



Connected state of connector


(blue/yellow connector)

2 Open or short circuit in wiring harness and/or sub lead.


Check the coupler for any pins that may have pulled out.



Repair or replace if there is an open circuit.

Between main switch coupler and ECU coupler. blue/yellow - blue/yellow

Sidestand switch signal input line of main switch coupler. blue/green - blue/green


7-16


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Fault code No. 21 Symptom Coolant temperature sensor open or short circuit is detected.

Used diagnostic code No. D06 (coolant temperature sensor)

Order



Installed condition of sensor Check the installed area for looseness or pinching.

4






Coolant temperature sensor coupler


Defective coolant temperature sensor.


Between sensor coupler and ECU coupler black/blue-black/blue green/red - green/red

Execute the diagnostic mode (code No.D06)


Refer to “COOLING SYSTEM” in chapter 8.


7-17


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Fault code No. 22 Symptom Intake temperature sensor open or short circuit is detected.

Used diagnostic code No. D05 (intake air temperature sensor)

Order

1

2

3

4




Installed condition of sensor Check the installed area for looseness or pinching.




Open or short circuit in wireing harness and/or sub lead.


Intake air temperature sensor coupler



Defective intake air temperature sensor.


Between sensor coupler and ECU coupler black/blue - black/blue brown/white - brown/white



NOTE:



ON.

1 . Connect the digital circuit tester to the intake air temperature sensor terminal as shown.

Positive tester probe -» brown/white 1

Negative tester probe -» black/blue 2

2. Measure the intake air temperature sensor resistance. n„

Intake air temperature sensor resistance

2.4~2.9k at 20°C (68°F)

w

8 Handle the intake air temperature sensor with special care.

8 Never subject the intake air temperature sensor to strong shocks. If the intake air temperature sensor is dropped, replace it.

3. Is the intake air temperature sensor OK?

7-18


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Fault code No. 30 Symptom The vehicle has overturned.

Used diagnostic code No. D08 (lean angle cut-off switch)

Order

1

2

3

4




The vehicle has overturned. Raise the vehicle upright.

Installed condition of the lean angle cut-off switch




Defective lean angle cut-off switch



Lean angle cut-off switch coupler




1 . Remove the lean angle cut-off switch from the vehicle.

2. Connect the lean angle cut-off switch coupler to the wire harness.

3. Connect the digital circuit tester to the lean angle cut-off switch terminals as shown.


ON (however, the engine cannot be restarted unless the main switch is first turned OFF).

4. When turning the lean angle cut-off switch approximately 65°, the voltage reading change from 0.4 V to 4.4 V.

5. Is the lean angle cut-off switch OK?

7-19


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Fault codeNo. 33 Symptom Open circuit detected in the primary lead of the ignition coil.

Used diagnostic code No. D30

Order







Ignition coil primary side coupler - orange


Open or short circuit in lead. Repair or replace if there is an open or short circuit.

Between ignition coil coupler and ECU coupler/main harness orange - orange

3 Defective ignition coil (test the primary and secondary coils for continuity).



Refer to “IGNITION SYSTEM” in chapter 8.


Reinstated by starting the engine and operating it at idle.

Fault code No. 37 Symptom Engine speed is high when the engine is idling.

Used diagnostic code No. D54 (ISC (idle speed control) valve)

Order



Incorrect speed sensor signal Check the speed sensor.

Check the speed sensor leads.

Check the speed sensor coupler.

Throttle valve does not fully close

Check the throttle body.

Refer to “THROTTLE BODY ASSEMBLY AND

FUEL INJECTOR ASSEMBLY” .

Check the throttle cables.

Refer to “ADJUSTING THE THROTTLE

CABLE FREE PLAY” in chapter 3.

ISC (idle speed control) valve stuck fully open

The ISC (idle speed control) valve is stuck fully open if it does not operate when the main switch is set to OFF.

(Touch the ISC (idle speed control) valve unit with your hand and check if it is vibrating to confirm if the ISC (idle speed control) valve is operating.)

NOTE:

Do not remove the ISC (idle speed control) valve unit.


ISC (idle speed control) valve not moving correctly


After the ISC (idle speed control) valve is fully closed, it opens until it is at the standby opening position when the engine is started. This operation takes approximately 3 seconds until it is completed. Start the engine. If the error recurs, replace the throttle body assembly.

7-20


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Fault code No. 39 Symptom Fuel injector open or short circuit is detected.

Used diagnostic code No. D36 (fuel injector)

Order



3





Fuel injector coupler - orange/black


Open or short circuit in lead wire.

Defective fuel injector


Between fuel injector coupler and ECU coupler/main harness orange/black - orange/black




Reinstated by starting the engine.

Fault code No. 41 Symptom Lean angle cut-off switch open or short circuit is detected.

Used diagnostic code No. D08 (lean angle cut-off switch)

Order








Lean angle cut-off switch coupler



Between switch coupler and ECU coupler black/blue - black/blue yellow/green - yellow/green blue- blue

3 Defective lean angle cut-off switch



Refer to Fault code No. 30.



ON.

7-21


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Fault code No. 42 Symptom No normal signals are received from the speed sensor.

Used diagnostic code No. D07 (speed sensor)

Order

1

2

3




Connected condition of speedometer connector




Speedometer coupler


Open or short circuit in speedometer lead.

Breakage speedometer cable or speedometer gear unit.


Between speedometer coupler and ECU coupler white - white black/blue - black/blue

Execute the diagnostic mode (code No.D07)

Checking the speedometer cable breakage and loose connection.

Checking the movement of the speedometer gear unit 1 .

Checking the breakage of the speedometer clutch projections a and speedometer gear unit slots b .

Reinstated by inputting the vehicle speed signals by turning the front wheel.

4 Defective speed sensor. Execute the diagnostic mode (code No. D07)

Replace the meter assembly.

7-22


FI ifl


Power supply to the fuel injector, fuel pump and ignistion coil are not normal.

Used diagnostic code No. D09 (fuel system voltage)

Order




3




Faulty battery


ECU coupler


Replace or charge the battery.

Refer to “CHECKING AND CHARGING THE

BATTERY” in chapter 3.


NOTE:

When the leads are disconnected, the voltage check by the code No. D09 is impossable.

Reinstated by starting the engine and operating it at idle.


8 Between battery and main switch red-red

8 Between main switch and handlebar switch

(engine stop switch) brown-brown

8 Between handlebar switch (engine stop switch) and ECU red/white-red/black

Error is detected while reading from or writing on EEROM (code re-

Fault code No. 44 Symptom registering key code and throttle valve fully closed notification valve).

Used diagnostic code No. D60 (EEPROM improper cylinder indication)

Order




1 Malfunction in ECU Execute the diagnostic mode (code No. D60)

8 01 is displayed on meter.

Readjust the CO of the displayed cylinder.

Refer to “ADJUSTING THE EXHAUST

GAS VOLUME” in chapter 3.

Replace ECU if defective.


ON.

7-23


FI ifl

Fault code No. 46 Symptom Power supply to FI system is not normal. (red lead)


Order



4





ECU coupler

Faulty battery

Malfunction in rectifier/ regulator


Replace or charge the battery.

Refer to “CHECKING AND CHARGING THE

BATTERY” in chapter 3.


Refer to “CHARGING SYSTEM” in chapter 8.


Between battery and ECU red-red



Faulty ECU memory. (when this malfunction is detected in the ECU, the fault code number might not appear on the meter.)


Order


1 Malfunction in ECU


Replace the ECU.



ON.

7-24


FI ifl

Fault code No. 61 Symptom ISC (idle speed control) valve open or short circuit is detected.


Order







ISC (idle speed control) valve coupler


Open or short circuit in lead. Repair or replace if there is an open or short circuit.

Between ISC (idle speed control) valve and

ECU coupler/main harness pink- pink green/yellow-green/yellow gray - gray sky blue-sky blue

3 Detective ISC (idle speed control) valve

Execute diagnostic mode (code No.D54)


NOTE:

Do not remove the ISC (idle speed control) valve.


Reinstated by setting the main switch to ON, The ISC (idle speed control) valve fully closes, and then it opens until it is at the standby opening position when the engine is started.


JECTOR ”.

7-25

Fuel Injection System. Yamaha XF50W

T

T

YZZZ^

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Fuel Injection System. Yamaha XF50W

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