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Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 20

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FUEL INJECTION SYSTEM

EBS30278

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

comes on or 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 multi-function meter

display. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is

deleted.

1

1. Engine trouble warning light

Engine trouble warning light indication and fuel injection system operation

Warning light indication

ECU operation

FI operation

Vehicle operation

Warning provided when

Flashing*

Operation stopped

Cannot be operated

unable to start engine

Operated with substitute

Can or cannot be operat-

characteristics in accor-

Remains on

Malfunction detected

ed depending on the fault

dance with the descrip-

code

tion of the malfunction

* The warning light flashes when any one of the conditions listed below is present and the start switch

“

” is pushed:

Fuel injector

12:

Crankshaft position sensor

39:

(open or short-circuit)

Lean angle sensor

Lean angle sensor

30:

41:

(latch up detected)

(open or short-circuit)

ECU internal malfunction

33:

Faulty ignition

50:

(faulty ECU memory)

Checking for a defective engine trouble warning light bulb

The engine trouble warning light comes on for around 2 seconds after the main switch has been turned

to “

” (on). If the warning light does not come on under these conditions, the warning light (LED) may

be defective.

ECU detects an abnormal signal from a sensor

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.

9-31

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FUEL INJECTION SYSTEM

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.

EBS30279

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 or Yamaha diagnostic tool.

b. Identify the faulty system with the fault code.

c. Identify the probable cause of the malfunction.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Check and repair the probable cause of malfunction.

Fault code No.

No fault code No.

Check and repair. Refer to “TROUBLESHOOTING

Check and repair.

DETAILS (FUEL INJECTION SYSTEM)” on page

9-35.

Monitor the operation of the sensors and actuators in

the diagnostic mode. Refer to “TROUBLESHOOT-

ING DETAILS (FUEL INJECTION SYSTEM)” on

page 9-35 and “SELF-DIAGNOSTIC FUNCTION

AND DIAGNOSTIC CODE TABLE” on page 10-7.

3. Perform the reinstatement action for the fuel injection system.

Refer to “Confirmation of service completion” of table in “TROUBLESHOOTING DETAILS (FUEL

INJECTION SYSTEM)” on page 9-35.

4. Turn the main switch to “

” (off) and back to “

” (on), then check that no fault code number is dis-

played.

TIP

If another fault code are displayed, repeat steps (1) to (4) until no fault code number is displayed.

5. Erase the malfunction history in the diagnostic mode (code No. 62). Refer to “SELF-DIAGNOSTIC

FUNCTION AND DIAGNOSTIC CODE TABLE” on page 10-7.

TIP

Turning the main switch to “

” (off) will not erase the malfunction history.

The engine operation is not normal, but the engine trouble warning light does not come on.

1. Check the operation of the following sensors and actuators in the diagnostic mode.

Refer to “TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)” on page 9-35 and “SELF-

DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 10-7.

01: Throttle position sensor signal (throttle angle)

30: Ignition coil

36: Fuel injector

48: Air induction system solenoid

If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.

If no malfunction is detected in the sensors and actuators, check and repair inner parts of the engine.

EBS30280

YAMAHA DIAGNOSTIC TOOL

This model uses the Yamaha diagnostic tool to identify malfunctions.

9-32

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FUEL INJECTION SYSTEM

For information about using the Yamaha diagnostic tool, refer to the operation manual that is included

with the tool.

Yamaha diagnostic tool

90890-03231

Features of the Yamaha diagnostic tool

You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth-

ods.

By connecting the adapter interface, which is connected to the USB port of a computer, to a vehicle’s

ECU using the communication cable, you can display information that is necessary for identifying mal-

functions and for maintenance to display on the computer. The displayed information includes the sen-

sor output data and information recorded in the ECU.

Functions of the Yamaha diagnostic tool

Fault diagnosis mode:

Fault codes recorded on the ECU are read, and the contents are dis-

played.

Function diagnostic mode:

Check the operation of the output value of each sensor and actuator.

Inspection mode:

Determine whether each sensor or actuator is functioning properly.

Monitoring mode:

Displays a graph of sensor output values for actual operating condi-

tions.

Logging mode:

Records and saves the sensor output value in actual driving conditions.

View log:

Displays the logging data.

ECU rewrite:

If necessary, the ECU is rewritten using ECU rewrite data provided by

Yamaha.

Ignition timing adjustment, etc. cannot be changed from the vehicle’s

original state.

However, the diagnostic tool cannot be used to freely change the basic vehicle functions, such as ad-

justing the ignition timing.

Connecting the Yamaha diagnostic tool

Remove the protective cap, and then connect the Yamaha diagnostic tool to the coupler “1”.

1

TIP

When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter

and indicators will be different from the normal operation.

9-33

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FUEL INJECTION SYSTEM

Operation of the Yamaha diagnostic tool (Malfunction mode)

Malfunction results are displayed in the top part of the window area.

3

4

5

6

7

8

9

10

11

12

2

1

1. Recovered

The item list of the malfunction detected in the past (already recovered) are displayed.

2. Detected

The item list of the malfunction currently occurred are displayed.

3. Code

The following icons and the fault code numbers for the detected malfunctions are displayed.

A

B

A. Detected malfunction

B. Recovered malfunction

4. ECU

The types of the control units are displayed.

9-34

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FUEL INJECTION SYSTEM

5. Item

The item names of the detected malfunction are displayed.

6. Condition

The current conditions are displayed. (Detected/Recovered)

7. Symptom

The symptoms of the detected malfunction are displayed.

8. Diagnosis code

The diagnosis codes related to the detected malfunction are displayed.

9. FFD (only for models that can display freeze frame data)

The mark “

” is displayed when the freeze frame data is available.

10.ECU conduction time (hour: minute: second)

The total ECU conduction time (total hours the vehicle’s main switch was ON) when the malfunction

was detected is displayed.

11.Number of main switch operation after detection

The number of times the main switch was turned on between the malfunction detection and code

reading is displayed.

12.Number of occurrences

The number of malfunction occurrences between the malfunction detection and code reading is dis-

played.

EBS30281

TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)

This section describes the measures per fault code number displayed on the Yamaha diagnostic tool

or multi-function meter display. 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 malfunctioning part has been completed, reset the Yamaha diagnos-

tic tool or multi-function meter display according to the “Confirmation of service completion”.

Fault code No.:

Fault code number displayed on the Yamaha diagnostic tool or multi-function meter when the engine

failed to work normally.

Diagnostic code No.:

Diagnostic code number to be used when the diagnostic mode is operated.

Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 10-7.

Fault code No. 12

Fault code No.

12

Crankshaft position sensor: no normal signals are received from the

Item

crankshaft position sensor.

Unable to start engine

Fail-safe system

Unable to drive vehicle

Diagnostic code No.

—

Indicated

—

Procedure

—

Probable cause of malfunc-

Confirmation of service com-

Item

Maintenance job

tion and check

pletion

9-35

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FUEL INJECTION SYSTEM

Fault code No.

12

Crankshaft position sensor: no normal signals are received from the

Item

crankshaft position sensor.

1

Connection of crankshaft posi-

Improperly connected → Con-

Crank the engine.

tion sensor coupler.

nect the coupler securely or re-

Fault code number is not dis-

Check the locking condition of

place the wire harness.

played → Service is finished.

the coupler.

Fault code number is displayed

Disconnect the coupler and

→ Go to item 2.

check the pins (bent or broken

terminals and locking condition

of the pins).

2

Connection of ECU coupler.

Improperly connected → Con-

Crank the engine.

Check the locking condition of

nect the coupler securely or re-

Fault code number is not dis-

the coupler.

place the wire harness.

played → Service is finished.

Disconnect the coupler and

Fault code number is displayed

check the pins (bent or broken

→ Go to item 3.

terminals and locking condition

of the pins).

3

Wire harness continuity.

Open or short circuit → Replace

Crank the engine.

the wire harness.

Fault code number is not dis-

Between crankshaft position

played → Service is finished.

sensor coupler and ECU cou-

Fault code number is displayed

pler.

→ Go to item 4.

gray-gray

Between crankshaft position

sensor coupler and joint cou-

pler.

black/blue-black/blue

Between joint coupler and ECU

coupler.

black/blue-black/blue

4

Installed condition of crank-

Improperly installed sensor →

Crank the engine.

shaft position sensor.

Reinstall or replace the sensor.

Fault code number is not dis-

Check for looseness or pinch-

played → Service is finished.

ing.

Fault code number is displayed

→ Go to item 5.

5

Defective crankshaft position

Check the crankshaft position

Crank the engine.

sensor.

sensor.

Fault code number is not dis-

Refer to “CHECKING THE

played → Service is finished.

CRANKSHAFT POSITION

Fault code number is displayed

SENSOR” on page 9-91.

→ Go to item 6.

Replace if defective.

6

Malfunction in ECU.

Replace the ECU.

Fault code No. 13

TIP

If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number

“13” first.

Fault code No.

13

Item

Intake air pressure sensor: open or short circuit detected.

Able to start engine

Fail-safe system

Able to drive vehicle

Diagnostic code No.

03

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FUEL INJECTION SYSTEM

Fault code No.

13

Item

Intake air pressure sensor: open or short circuit detected.

Indicated

Displays the intake air pressure.

Set the engine stop switch to “

”, and then operate the throttle while

Procedure

pushing the start switch “

”. (If the display value changes, the perfor-

mance is OK.)

Probable cause of malfunc-

Confirmation of service com-

Item

Maintenance job

tion and check

pletion

1

Connection of intake air pres-

Improperly connected → Con-

Turn the main switch to “

”

sure sensor coupler.

nect the coupler securely or re-

(on).

Check the locking condition of

place the wire harness.

Fault code number is not dis-

the coupler.

played → Service is finished.

Disconnect the coupler and

Fault code number is displayed

check the pins (bent or broken

→ Go to item 2.

terminals and locking condition

of the pins).

2

Connection of ECU coupler.

Improperly connected → Con-

Turn the main switch to “

”

Check the locking condition of

nect the coupler securely or re-

(on).

the coupler.

place the wire harness.

Fault code number is not dis-

Disconnect the coupler and

played → Service is finished.

check the pins (bent or broken

Fault code number is displayed

terminals and locking condition

→ Go to item 3.

of the pins).

3

Wire harness continuity.

Open or short circuit → Replace

Turn the main switch to “

”

the wire harness.

(on).

Between intake air pressure

Fault code number is not dis-

sensor coupler and ECU cou-

played → Service is finished.

pler.

Fault code number is displayed

pink-pink

→ Go to item 4.

Between intake air pressure

sensor coupler and joint cou-

pler.

blue-blue

black/blue-black/blue

Between joint coupler and ECU

coupler.

blue-blue

black/blue-black/blue

4

Installed condition of intake air

Improperly installed sensor →

Turn the main switch to “

”

pressure sensor.

Reinstall or replace the sensor.

(on).

Check for looseness or pinch-

Fault code number is not dis-

ing.

played → Service is finished.

Fault code number is displayed

→ Go to item 5.

9-37

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FUEL INJECTION SYSTEM

Fault code No.

13

Item

Intake air pressure sensor: open or short circuit detected.

5

Defective intake air pressure

Execute the diagnostic mode.

Turn the main switch to “

”

sensor.

(Code No. 03)

(on).

When engine is stopped:

Fault code number is not dis-

Atmospheric pressure at the

played → Service is finished.

current altitude and weather

Fault code number is displayed

conditions is indicated.

→ Go to item 6.

At sea level: Approx. 101 kPa

(757.6 mmHg, 29.8 inHg)

1000 m (3300 ft) above sea lev-

el: Approx. 90 kPa (675.1

mmHg, 26.6 inHg)

2000 m (6700 ft) above sea lev-

el: Approx. 80 kPa (600.0

mmHg, 23.6 inHg)

3000 m (9800 ft) above sea lev-

el: Approx. 70 kPa (525.0

mmHg, 20.7 inHg)

When engine is cranking: Make

sure that the indication value

changes.

The value does not change

when engine is cranking. →

Check the intake air pressure

sensor.

Replace if defective.

Refer to “CHECKING THE IN-

TAKE AIR PRESSURE SEN-

SOR” on page 9-97.

6

Malfunction in ECU.

Replace the ECU.

Fault code No. 14

TIP

If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number

“13” first.

Fault code No.

14

Intake air pressure sensor: hose system malfunction (clogged or de-

Item

tached hose).

Able to start engine

Fail-safe system

Able to drive vehicle

Diagnostic code No.

03

Indicated

Displays the intake air pressure.

Set the engine stop switch to “

”, and then operate the throttle while

Procedure

pushing the start switch “

”. (If the display value changes, the perfor-

mance is OK.)

Probable cause of malfunc-

Confirmation of service com-

Item

Maintenance job

tion and check

pletion

9-38

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FUEL INJECTION SYSTEM

Fault code No.

14

Intake air pressure sensor: hose system malfunction (clogged or de-

Item

tached hose).

1

Condition of intake air pressure

Clogged or detached hose →

Start the engine and let it idle

sensor hose.

Repair or replace the sensor

for approximately 5 seconds.

Check the intake air pressure

hose.

Fault code number is not dis-

sensor hose condition.

played → Service is finished.

Fault code number is displayed

→ Go to item 2.

2

Defective intake air pressure

Execute the diagnostic mode.

sensor.

(Code No. 03)

When engine is stopped:

Atmospheric pressure at the

current altitude and weather

conditions is indicated.

At sea level: Approx. 101 kPa

(757.6 mmHg, 29.8 inHg)

1000 m (3300 ft) above sea lev-

el: Approx. 90 kPa (675.1

mmHg, 26.6 inHg)

2000 m (6700 ft) above sea lev-

el: Approx. 80 kPa (600.0

mmHg, 23.6 inHg)

3000 m (9800 ft) above sea lev-

el: Approx. 70 kPa (525.0

mmHg, 20.7 inHg)

When engine is cranking: Make

sure that the indication value

changes.

The value does not change

when engine is cranking. →

Check the intake air pressure

sensor.

Replace if defective.

Refer to “CHECKING THE IN-

TAKE AIR PRESSURE SEN-

SOR” on page 9-97.

Fault code No. 15

TIP

If fault code numbers “15” and “16” are both indicated, take the actions specified for fault code number

“15” first.

Fault code No.

15

Item

Throttle position sensor: open or short circuit detected.

Able to start engine

Fail-safe system

Able to drive vehicle

Diagnostic code No.

01

Throttle position sensor signal

Indicated

• 14-20 (fully closed position)

Procedure

Check with throttle valve fully closed.

Probable cause of malfunc-

Confirmation of service com-

Item

Maintenance job

tion and check

pletion

9-39

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FUEL INJECTION SYSTEM

Fault code No.

15

Item

Throttle position sensor: open or short circuit detected.

1

Connection of throttle position

Improperly connected → Con-

Turn the main switch to “

”

sensor coupler.

nect the coupler securely or re-

(on).

Check the locking condition of

place the wire harness.

Fault code number is not dis-

the coupler.

played → Service is finished.

Disconnect the coupler and

Fault code number is displayed

check the pins (bent or broken

→ Go to item 2.

terminals and locking condition

of the pins).

2

Connection of ECU coupler.

Improperly connected → Con-

Turn the main switch to “

”

Check the locking condition of

nect the coupler securely or re-

(on).

the coupler.

place the wire harness.

Fault code number is not dis-

Disconnect the coupler and

played → Service is finished.

check the pins (bent or broken

Fault code number is displayed

terminals and locking condition

→ Go to item 3.

of the pins).

3

Wire harness continuity.

Open or short circuit → Replace

Turn the main switch to “

”

the wire harness.

(on).

Between throttle position sensor

Fault code number is not dis-

coupler and ECU coupler.

played → Service is finished.

yellow-yellow

Fault code number is displayed

Between throttle position sensor

→ Go to item 4.

coupler and joint coupler.

blue-blue

black/blue-black/blue

Between joint coupler and ECU

coupler.

blue-blue

black/blue-black/blue

4

Installed condition of throttle po-

Improperly installed sensor →

Turn the main switch to “

”

sition sensor.

Reinstall or adjust the sensor.

(on).

Check for looseness or pinch-

Refer to “ADJUSTING THE

Fault code number is not dis-

ing.

THROTTLE POSITION SEN-

played → Service is finished.

SOR” on page 7-7.

Fault code number is displayed

→ Go to item 5.

5

Throttle position sensor resis-

Measure the throttle position

Turn the main switch to “

”

tance.

sensor resistance.

(on).

Refer to “CHECKING THE

Fault code number is not dis-

THROTTLE POSITION SEN-

played → Service is finished.

SOR” on page 9-96.

Fault code number is displayed

→ Go to item 6.

6

Defective throttle position sen-

Check throttle position sensor

Turn the main switch to “

”

sor.

signal.

(on).

Execute the diagnostic mode.

Fault code number is not dis-

(Code No. 01)

played → Service is finished.

When the throttle valve is fully

Fault code number is displayed

closed:

→ Go to item 7.

A value of 14-20 is indicated.

An indicated value is out of the

specified range → Replace the

throttle position sensor.

7

Malfunction in ECU.

Replace the ECU.

9-40

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FUEL INJECTION SYSTEM

Fault code No. 16

TIP

• If fault code numbers “15” and “16” are both indicated, take the actions specified for fault code number

“15” first.

• If fault code numbers “16” and “37” are both indicated, take the actions specified for fault code number

“16” first.

Fault code No.

16

Item

Throttle position sensor: stuck throttle position sensor is detected.

Able to start engine

Fail-safe system

Able to drive vehicle

Diagnostic code No.

01

Throttle position sensor signal

Indicated

• 14-20 (fully closed position)

Procedure

Check with throttle valve fully closed.

Probable cause of malfunc-

Confirmation of service com-

Item

Maintenance job

tion and check

pletion

1

Installed condition of throttle po-

Improperly installed sensor →

Turn the main switch to “

”

sition sensor.

Reinstall or adjust the sensor.

(on), then push the throttle le-

Check for looseness or pinch-

Refer to “ADJUSTING THE

ver.

ing.

THROTTLE POSITION SEN-

Fault code number is not dis-

SOR” on page 7-7.

played → Service is finished.

Fault code number is displayed

→ Go to item 2.

2

Defective throttle position sen-

Check throttle position sensor

Turn the main switch to “

”

sor.

signal.

(on), then operate the throttle.

Execute the diagnostic mode.

Fault code number is not dis-

(Code No. 01)

played → Service is finished.

When the throttle valve is fully

Fault code number is displayed

closed:

→ Go to item 3.

A value of 14-20 is indicated.

An indicated value is out of the

specified range → Replace the

throttle position sensor.

3

Malfunction in ECU.

Replace the ECU.

Fault code No. 21

TIP

If fault code numbers “21” and “37” are both indicated, take the actions specified for fault code number

“21” first.

Fault code No.

21

Item

Coolant temperature sensor: open or short circuit detected.

Able to start engine

Fail-safe system

Able to drive vehicle

Diagnostic code No.

06

Indicated

Displays the coolant temperature.

Compare the actually measured coolant temperature with the indicated

Procedure

value.

Probable cause of malfunc-

Confirmation of service com-

Item

Maintenance job

tion and check

pletion

9-41

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FUEL INJECTION SYSTEM

Fault code No.

21

Item

Coolant temperature sensor: open or short circuit detected.

1

Connection of coolant tempera-

Improperly connected → Con-

Turn the main switch to “

”

ture sensor coupler.

nect the coupler securely or re-

(on).

Check the locking condition of

place the wire harness.

Fault code number is not dis-

the coupler.

played → Service is finished.

Disconnect the coupler and

Fault code number is displayed

check the pins (bent or broken

→ Go to item 2.

terminals and locking condition

of the pins).

2

Connection of ECU coupler.

Improperly connected → Con-

Turn the main switch to “

”

Check the locking condition of

nect the coupler securely or re-

(on).

the coupler.

place the wire harness.

Fault code number is not dis-

Disconnect the coupler and

played → Service is finished.

check the pins (bent or broken

Fault code number is displayed

terminals and locking condition

→ Go to item 3.

of the pins).

3

Wire harness continuity.

Open or short circuit → Replace

Turn the main switch to “

”

the wire harness.

(on).

Between coolant temperature

Fault code number is not dis-

sensor coupler and ECU cou-

played → Service is finished.

pler.

Fault code number is displayed

green/yellow-green/yellow

→ Go to item 4.

Between coolant temperature

sensor coupler and joint cou-

pler.

black/blue-black/blue

Between joint coupler and ECU

coupler.

black/blue-black/blue

4

Installed condition of coolant

Improperly installed sensor →

Turn the main switch to “

”

temperature sensor.

Reinstall or replace the sensor.

(on).

Check for looseness or pinch-

Fault code number is not dis-

ing.

played → Service is finished.

Fault code number is displayed

→ Go to item 5.

5

Defective coolant temperature

Execute the diagnostic mode.

Turn the main switch to “

”

sensor.

(Code No. 06)

(on).

When engine is cold:

Fault code number is not dis-

Displayed temperature is close

played → Service is finished.

to the ambient temperature.

Fault code number is displayed

The displayed temperature is

→ Go to item 6.

not close to the ambient tem-

perature → Check the coolant

temperature sensor.

Replace if defective.

Refer to “CHECKING THE

COOLANT TEMPERATURE

SENSOR” on page 9-95.

6

Malfunction in ECU.

Replace the ECU.

Fault code No. 22

TIP

If fault code numbers “22” and “37” are both indicated, take the actions specified for fault code number

“22” first.

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FUEL INJECTION SYSTEM

Fault code No.

22

Item

Intake air temperature sensor: open or short circuit detected.

Able to start engine

Fail-safe system

Able to drive vehicle

Diagnostic code No.

05

Indicated

Displays the intake air temperature.

Compare the actually measured intake air temperature with the indicated

Procedure

value.

Probable cause of malfunc-

Confirmation of service com-

Item

Maintenance job

tion and check

pletion

1

Connection of intake air tem-

Improperly connected → Con-

Turn the main switch to “

”

perature sensor coupler.

nect the coupler securely or re-

(on).

Check the locking condition of

place the wire harness.

Fault code number is not dis-

the coupler.

played → Service is finished.

Disconnect the coupler and

Fault code number is displayed

check the pins (bent or broken

→ Go to item 2.

terminals and locking condition

of the pins).

2

Connection of ECU coupler.

Improperly connected → Con-

Turn the main switch to “

”

Check the locking condition of

nect the coupler securely or re-

(on).

the coupler.

place the wire harness.

Fault code number is not dis-

Disconnect the coupler and

played → Service is finished.

check the pins (bent or broken

Fault code number is displayed

terminals and locking condition

→ Go to item 3.

of the pins).

3

Wire harness continuity.

Open or short circuit → Replace

Turn the main switch to “

”

the wire harness.

(on).

Between intake air temperature

Fault code number is not dis-

sensor coupler and ECU cou-

played → Service is finished.

pler.

Fault code number is displayed

brown/white-brown/white

→ Go to item 4.

Between intake air temperature

sensor coupler and joint cou-

pler.

black/blue-black/blue

Between joint coupler and ECU

coupler.

black/blue-black/blue

4

Installed condition of intake air

Improperly installed sensor →

Turn the main switch to “

”

temperature sensor.

Reinstall or replace the sensor.

(on).

Check for looseness or pinch-

Fault code number is not dis-

ing.

played → Service is finished.

Fault code number is displayed

→ Go to item 5.

9-43

-------------------------------------------------------------------------------------------------------------------------------------------------------------

FUEL INJECTION SYSTEM

Fault code No.

22

Item

Intake air temperature sensor: open or short circuit detected.

5

Defective intake air temperature

Execute the diagnostic mode.

Turn the main switch to “

”

sensor.

(Code No. 05)

(on).

When engine is cold:

Fault code number is not dis-

Displayed temperature is close

played → Service is finished.

to the ambient temperature.

Fault code number is displayed

The displayed temperature is

→ Go to item 6.

not close to the ambient tem-

perature. → Check the intake

air temperature sensor.

Replace if defective.

Refer to “CHECKING THE IN-

TAKE AIR TEMPERATURE

SENSOR” on page 9-97.

6

Malfunction in ECU.

Replace the ECU.

Fault code No. 30

Fault code No.

30

Item

Latch up detected.

Unable to start engine

Fail-safe system

Unable to drive vehicle

Diagnostic code No.

08

Lean angle sensor output voltage

Indicated

• 3.6-4.4 (upright)

• 0.7-1.3 (overturned)

Procedure

Remove the lean angle sensor and incline it more than 65 degrees.

Probable cause of malfunc-

Confirmation of service com-

Item

Maintenance job

tion and check

pletion

1

The vehicle has overturned.

Raise the vehicle upright.

Turn the main switch to “

”

(on), then to “

” (off), and then

back to “

” (on).

Fault code number is not dis-

played → Service is finished.

Fault code number is displayed

→ Go to item 2.

2

Installed condition of lean an-

Check the installed direction

Turn the main switch to “

”

gle sensor.

and condition of the sensor.

(on), then to “

” (off), and then

back to “

” (on).

Fault code number is not dis-

played → Service is finished.

Fault code number is displayed

→ Go to item 3.

3

Defective lean angle sensor.

Execute the diagnostic mode.

Turn the main switch to “

”

(Code No. 08)

(on) then to “

” (off), and then

An indicated value is out of the

back to “

” (on).

specified range → Check the

Fault code number is not dis-

lean angle sensor.

played → Service is finished.

Replace if defective.

Fault code number is displayed

Refer to “CHECKING THE

→ Go to item 4.

LEAN ANGLE SENSOR” on

page 9-92.

4

Malfunction in ECU.

Replace the ECU.

9-44

-------------------------------------------------------------------------------------------------------------------------------------------------------------

FUEL INJECTION SYSTEM

Fault code No. 33

Fault code No.

33

Ignition coil: open or short circuit detected in the primary lead of the

Item

ignition coil.

Unable to start engine

Fail-safe system

Unable to drive vehicle

Diagnostic code No.

30

Actuates the ignition coil five times at one-second intervals.

Actuation

The “CHECK” indicator and “

” on the Yamaha diagnostic tool screen

come on each time the ignition coil is actuated.

Check that a spark is generated five times.

Procedure

• Connect an ignition checker.

Probable cause of malfunc-

Confirmation of service com-

Item

Maintenance job

tion and check

pletion

1

Connection of ignition coil con-

Improperly connected → Con-

Start the engine and let it idle

nector.

nect the connector securely or

for approximately 5 seconds.

Check the locking condition of

replace the wire harness.

Fault code number is not dis-

the connector.

played → Service is finished.

Disconnect the connector and

Fault code number is displayed

check the pins (bent or broken

→ Go to item 2.

terminals and locking condition

of the pins).

2

Connection of ECU coupler.

Improperly connected → Con-

Start the engine and let it idle

Check the locking condition of

nect the coupler securely or re-

for approximately 5 seconds.

the coupler.

place the wire harness.

Fault code number is not dis-

Disconnect the coupler and

played → Service is finished.

check the pins (bent or broken

Fault code number is displayed

terminals and locking condition

→ Go to item 3.

of the pins).

3

Wire harness continuity.

Open or short circuit → Replace

Start the engine and let it idle

the wire harness.

for approximately 5 seconds.

Between ignition coil connector

Fault code number is not dis-

and ECU coupler.

played → Service is finished.

orange-orange

Fault code number is displayed

→ Go to item 4.

4

Installed condition of ignition

Improperly installed ignition coil

Start the engine and let it idle

coil.

→ Reinstall or replace the igni-

for approximately 5 seconds.

Check for looseness or pinch-

tion coil.

Fault code number is not dis-

ing.

played → Service is finished.

Fault code number is displayed

→ Go to item 5.

5

Defective ignition coil.

Measure the primary coil resis-

Start the engine and let it idle

tance of the ignition coil.

for approximately 5 seconds.

Replace if out of specification.

Fault code number is not dis-

Refer to “CHECKING THE IG-

played → Service is finished.

NITION COIL” on page 9-91.

Fault code number is displayed

→ Go to item 6.

6

Malfunction in ECU.

Execute the diagnostic mode.

(Code No. 30)

No spark → Replace the ECU.

9-45

-------------------------------------------------------------------------------------------------------------------------------------------------------------

FUEL INJECTION SYSTEM

Fault code No. 37

TIP

• If fault code numbers “16” and “37” are both indicated, take the actions specified for fault code number

“16” first.

• If fault code numbers “21” and “37” are both indicated, take the actions specified for fault code number

“21” first.

• If fault code numbers “22” and “37” are both indicated, take the actions specified for fault code number

“22” first.

• If fault code numbers “37” and “46” are both indicated, take the actions specified for fault code number

“46” first.

• If fault code numbers “37” and “42” are both indicated, take the actions specified for fault code number

“42” first.

Fault code No.

37

Component other than ISC (Idle Speed Control) unit is defective

A

(ISC operating sound is heard).

Item

Defective ISC (Idle Speed Control) unit (ISC operating sound is

B

not heard).

Able to start engine

Fail-safe system

Able to drive vehicle

Diagnostic code No.

54

Fully closes the ISC valve, and then opens the valve.

This operation takes approximately 3 seconds.

Actuation

The “CHECK” indicator and “

” on the Yamaha diagnostic tool screen

come on during the operation.

Procedure

The operating sound can be heard when ISC valve operates.

Probable cause of malfunc-

Confirmation of service com-

Item

Maintenance job

tion and check

pletion

A-1

Locate the malfunction.

Execute the diagnostic mode.

ISC operating sound is heard →

(Code No. 54)

Go to item A-2.

Fully closes the ISC (Idle Speed

ISC operating sound is not

Control) valve, and then fully

heard → Go to item B-2 for the

opens the valve.

defective ISC (Idle Speed Con-

trol) unit.

A-2

Incorrect speed sensor signal.

Check the speed sensor.

Start the engine and let it idle

Execute the diagnostic mode.

for approximately 10 seconds.

(Code No. 07)

Fault code number is not dis-

Rotate the rear wheel by hand

played → Service is finished.

and check that the indicated

Fault code number is displayed

value increases.

→ Go to item A-3.

Value does not increase → Go

to fault code No. 42.

A-3

Throttle valve does not fully

Check the throttle body.

Start the engine and let it idle

close.

Refer to “THROTTLE BODY” on

for approximately 10 seconds.

page 7-4.

Fault code number is not dis-

Check the throttle cable.

played → Service is finished.

Refer to “ADJUSTING THE

Fault code number is displayed

THROTTLE LEVER FREE

→ Go to item A-4.

PLAY” on page 3-33.

9-46

-------------------------------------------------------------------------------------------------------------------------------------------------------------

FUEL INJECTION SYSTEM

Fault code No.

37

Component other than ISC (Idle Speed Control) unit is defective

A

(ISC operating sound is heard).

Item

Defective ISC (Idle Speed Control) unit (ISC operating sound is

B

not heard).

A-4

ISC valve is not moving correct-

Replace the throttle body as-

Start the engine and let it idle

ly.

sembly.

for approximately 10 seconds.

Fault code number is not dis-

played → Service is finished.

Fault code number is displayed

→ Go to item A-5.

A-5

Malfunction in ECU.

Replace the ECU.

Fault code No.

37

Component other than ISC (Idle Speed Control) unit is defective

A

(ISC operating sound is heard).

Item

Defective ISC (Idle Speed Control) unit (ISC operating sound is

B

not heard).

Able to start engine

Fail-safe system

Able to drive vehicle

Diagnostic code No.

54

Fully closes the ISC valve, and then opens the valve.

This operation takes approximately 3 seconds.

Actuation

The “CHECK” indicator and “

” on the Yamaha diagnostic tool screen

come on during the operation.

Procedure

The operating sound can be heard when ISC valve operates.

Probable cause of malfunc-

Confirmation of service com-

Item

Maintenance job

tion and check

pletion

B-1

Locate the malfunction.

Execute the diagnostic mode.

ISC operating sound is heard →

(Code No. 54)

Go to item A-2 for the compo-

Fully closes the ISC (Idle Speed

nent other than ISC (Idle Speed

Control) valve, and then fully

Control) unit is defective.

opens the valve.

ISC operating sound is not

heard → Go to item B-2.

B-2

Connection of ISC (Idle Speed

Improperly connected → Con-

Execute the diagnostic mode.

Control) unit coupler.

nect the coupler securely or re-

(Code No. 54)

Check the locking condition of

place the wire harness.

ISC operating sound is heard →

the coupler.

Go to item B-8.

Disconnect the coupler and

ISC operating sound is not

check the pins (bent or broken

heard → Go to item B-3.

terminals and locking condition

of the pins).

B-3

Connection of ECU coupler.

Improperly connected → Con-

Execute the diagnostic mode.

Check the locking condition of

nect the coupler securely or re-

(Code No. 54)

the coupler.

place the wire harness.

ISC operating sound is heard →

Disconnect the coupler and

Go to item B-8.

check the pins (bent or broken

ISC operating sound is not

terminals and locking condition

heard → Go to item B-4.

of the pins).

9-47

-------------------------------------------------------------------------------------------------------------------------------------------------------------

FUEL INJECTION SYSTEM

Fault code No.

37

Component other than ISC (Idle Speed Control) unit is defective

A

(ISC operating sound is heard).

Item

Defective ISC (Idle Speed Control) unit (ISC operating sound is

B

not heard).

B-4

Wire harness continuity.

Open or short circuit → Replace

Execute the diagnostic mode.

the wire harness.

(Code No. 54)

Between ISC (Idle Speed Con-

ISC operating sound is heard →

trol) unit coupler and ECU cou-

Go to item B-8.

pler.

ISC operating sound is not

red/green-red/green

heard → Go to item B-5.

pink/blue-pink/blue

white/green-white/green

brown/blue-brown/blue

Between ISC (Idle Speed Con-

trol) unit coupler and joint cou-

pler.

red/white-red/white

red/white-red/white

B-5

Installed condition of ISC (Idle

Improperly installed ISC (Idle

Execute the diagnostic mode.

Speed Control) unit.

Speed Control) unit → Reinstall

(Code No. 54)

Check for looseness or pinch-

the ISC (Idle Speed Control)

ISC operating sound is heard →

ing.

unit.

Go to item B-8.

ISC operating sound is not

heard → Go to item B-6.

B-6

ISC valve is not moving correct-

Replace the throttle body as-

Execute the diagnostic mode.

ly.

sembly.

(Code No. 54)

ISC operating sound is heard →

Go to item B-8.

ISC operating sound is not

heard → Go to item B-7.

B-7

Malfunction in ECU.

Replace the ECU.

B-8

Delete the fault code.

Start the engine and let it idle

for approximately 10 seconds.

Check that the fault code num-

ber is not displayed.

Fault code No. 39

Fault code No.

39

Item

Fuel injector: open or short circuit detected.

Unable to start engine

Fail-safe system

Unable to drive vehicle

Diagnostic code No.

36

Actuates fuel injector five times at one-second intervals.

Actuation

The “CHECK” indicator and “

” on the Yamaha diagnostic tool screen

come on each time the fuel injector is actuated.

Disconnect the fuel pump coupler, and then check that fuel injector is ac-

Procedure

tuated five times by listening for the operating sound.

Probable cause of malfunc-

Confirmation of service com-

Item

Maintenance job

tion and check

pletion

9-48

-------------------------------------------------------------------------------------------------------------------------------------------------------------

FUEL INJECTION SYSTEM

Fault code No.

39

Item

Fuel injector: open or short circuit detected.

1

Connection of fuel injector cou-

Improperly connected → Con-

Execute the diagnostic mode.

pler.

nect the coupler securely or re-

(Code No. 36)

Check the locking condition of

place the wire harness.

Operating sound → Go to item

the coupler.

6.

Disconnect the coupler and

No operating sound → Go to

check the pins (bent or broken

item 2.

terminals and locking condition

of the pins).

2

Defective fuel injector.

Measure the fuel injector resis-

Execute the diagnostic mode.

tance.

(Code No. 36)

Replace if out of specification.

Operating sound → Go to item

Refer to “CHECKING THE

6.

FUEL INJECTOR” on page

No operating sound → Go to

9-96.

item 3.

3

Connection of ECU coupler.

Improperly connected → Con-

Execute the diagnostic mode.

Check the locking condition of

nect the coupler securely or re-

(Code No. 36)

the coupler.

place the wire harness.

Operating sound → Go to item

Disconnect the coupler and

6.

check the pins (bent or broken

No operating sound → Go to

terminals and locking condition

item 4.

of the pins).

4

Wire harness continuity.

Open or short circuit → Replace

Execute the diagnostic mode.

the wire harness.

(Code No. 36)

Between fuel injector coupler

Operating sound → Go to item

and ECU coupler.

6.

red/black-red/black

No operating sound → Go to

Between fuel injector coupler

item 5.

and joint coupler.

red/blue-red/blue

5

Malfunction in ECU.

Replace the ECU.

6

Delete the fault code.

Start the engine and let it idle

for approximately 5 seconds.

Check that the fault code num-

ber is not displayed.

Fault code No. 41

Fault code No.

41

Item

Lean angle sensor: open or short circuit detected.

Unable to start engine

Fail-safe system

Unable to drive vehicle

Diagnostic code No.

08

Lean angle sensor output voltage

Indicated

• 3.6-4.4 (upright)

• 0.7-1.3 (overturned)

Procedure

Remove the lean angle sensor and incline it more than 65 degrees.

Probable cause of malfunc-

Confirmation of service com-

Item

Maintenance job

tion and check

pletion

9-49

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