Crypton-115 Fi (178-192)

1FDF8197E1.
book Page 8 Thursday, September 10, 2015 3:45 PM
FUEL INJECTION SYSTEM FI

DIAGNOSTIC CODE TABLE
Fault code
Diagnostic
(Meter Symptom Probable cause of malfunction
code No.
display)
12 No normal signals are received from • Faulty coupler. –
the crankshaft position sensor. • Open or short circuit in wire harness.
• Defective crankshaft position sensor.
• Malfunction in generator rotor.
• Malfunction in ECU (engine control unit).
• Improperly installed sensor.
13 No normal signals are received from • Faulty coupler D03
intake air pressure sensor. • Open or short circuit in wire harness.
• Defective intake air pressure sensor.
14 Faulty throttle body • Sensor module is detached. D03
(Clogged sensor hole or detached • Improperly installed throttle body.
sensor) • Intake air pressure sensor hole is clogged.
Faulty intake air system
(Stable pressure is not supplied to the
sensor)
15 No normal signals are received from • Faulty coupler. D01
the throttle position sensor. • Open or short circuit in wire harness.
• Defective throttle position sensor.
• Improperly installed sensor module.
16 Stuck throttle position sensor • Improperly installed sensor module. D01
detected. • Defective throttle position sensor.
• Mechanical connection is not correct between from
throttle position sensor to throttle body.
22 No normal signals are received from • Faulty coupler D05
the intake temperature sensor. • Open or short circuit in wire harness.
• Defective intake temperature sensor.
• Improperly installed sensor module.
24 No normal signals are received from • Faulty coupler. –
the O2 sensor. • Open or short circuit in wire harness.
• Defective O2 sensor.
• Improperly fuel pressure.
• Improperly installed O2 sensor.
the engine temperature sensor. • Open or short circuit in wire harness.
• Defective engine temperature sensor.
• Improperly installed engine temperature sensor.
5-8
1FDF8197E1.book Page 9 Thursday, September 10, 2015 3:45 PM

Fault code
Diagnostic
(Meter Symptom Probable cause of malfunction
code No.
display)
the fuel injector. • Open or short circuit in wire harness.
• Defective fuel injector.
• Malfunction in ECU.
• Improperly installed fuel injector.
44 Error is detected while reading or • Malfunction in ECU (engine control unit). D60
writing on EEPROM (CO adjustment • Throttle valve fully closed notification valve is not
value). properly written.
46 The regulator is not functioning • Battery overcharging (faulty rectifier/regulator) –
properly. • Battery overcharging (broke or disconnected lead
The battery cannot be charged in rectifier/regulator wire harness)
properly. • Battery over-discharging (broken or disconnected
lead in charging system)
• Battery over-discharging (faulty rectifier/regulator)
50 The program and data are not • Malfunction in ECU (engine control unit). –
properly written on or read from the
internal memory.
96 The battery voltage drops • Battery over-discharging –
immediately after the main switch is • Faulty battery
set to “ON”. • Battery deterioration
• Faulty charging system
Waiting for No signals are transmitted to the • Improperly connected.
connection service tool. • Faulty coupler.
• Open or short circuit in wire harness.
• Malfunction in Service tool.
• Malfunction in ECU
Er-4 No signals are received from the • Faulty coupler.
service tool. • Open or short circuit in wire harness.
• Malfunction in service tool.
5-9

EAS00907
SENSOR AND ACTUATOR OPERATION TABLE

TIP
● Inspect air temperature at each closed air intake and the engine temperature, which may be the
same as that of the intake air temperature sensor and the engine temperature sensor.
● If the intake air temperature cannot be confirmed, use the nearby air temperature as a reference.
Diagnostic
Item Checking method Meter display or Actuation
code
D01 Throttle angle Throttle angle. 0 ~ 125
Fully closed position Fully closed position: 7–18
D03 Intake pressure Displays intake air pressure. 0 ~ 126[kPa]
Check intake manifold pressure Stop engine: Display atmospheric pressure
Push starter switch, and check 0 m (0 ft) above sea level: Approx. 101 kPa
pressure difference (757.6 mmHg, 29.8 inHg)
3000 m (9800 ft) above sea level: Approx.
70 kPa (525.0 mmHg, 20.7 inHg)
Cranking engine: Display data is changing
D05 Intake temperature Display intake temperature. -30 ~ 120 degree
Check temperature inside of intake Cold engine: Display close open air
manifold or air cleaner. temperature
Warm up engine: Open air temperature +
about 20 degree
D09 Battery voltage Display fuel system voltage 0 ~ 18.7[V]
Standard data: about 12[V]
D11 Engine temperature Display engine temperature -30 ~ 150 degree
Check engine temperature Cold engine: Display open air temperature
(Minimum display: -30 degree)
Warm up engine: Display engine
temperature (Example: 60-100 degree)
D30 Ignition coil Check continuity ignition coil Actuates the ignition coil five times at one-
Check spark second intervals.
Illuminates the warning light on the FI
diagnostic tool
D36 Injector Check continuity injector (NOTICE) Before operating this step,
Check the operating sound or visually remove fuel pump coupler.
of fuel injector Actuates the fuel injector five times at one-
second intervals.
Illuminates the warning light on the FI
diagnostic tool
D60 EEPROM fault code Display EEPROM fault code 00: No history
No. When it is detected fault code No. 44. 01: CO adjustment value is detected.
If more than one code number is
detected, the display alternates every
two seconds to show all the detected
code number.
D61 Malfunction history Display malfunction history code 00: No history
code display If more than one code number is Fault code No.: History exists
detected, the display alternates every
two seconds to show all the detected
code numbers.
D62 Malfunction history Erase malfunction history code 00: No history
code erasure Displays total number of malfunctions
D70 Control number Check control number 0 ~ 254
5-10

Communication error with the FI diagnostic tool
LCD displays Symptom Posible reason for error
Waiting for connection. No signals are transmitted to • Improperly connected.
the service tool. • Faulty coupler.
• Open or short circuit in wire harness.
• Malfunction in Service tool.
• Malfunction in ECU
Er-4 No signals are received from • Faulty coupler.
the service tool. • Open or short circuit in wire harness.
• Malfunction in service tool.
EAS00908
TROUBLESHOOTING DETAILS
This section explains how to handle problems when the Yamaha diagnostic tool shows error codes.
Follow the sequence to check and repair the reasons and factors that cause faults.
After checking and repairing the faulty items, follow the adjustment method to make the message
displayed on the Yamaha diagnostic tool “Recover initial status”.
Fault code No.:

Error code No. will be displayed on the Yamaha diagnostic tool when the engine is operating
abnormally.
Refer to “DIAGNOSTIC CODE TABLE”.
Diagnostic code No.:

The diagnostic code No. is the diagnostic code displayed in the diagnostic mode. Refer to
“SENSOR AND ACTUATOR OPERATION TABLE”.
Crankshaft position sensor: no normal signals

Fault code 12 Symptom
are received from the crankshaft position sensor.
Diagnostic code No.:---
Probable cause of malfunction Confirmation of service
Item Maintenance job
and check completion
1 • Connection of crankshaft Improperly connected → Connect the • Crank the engine.
position sensor coupler. coupler securely or replace the wire • Fault code number is not
• Check the locking condition of harness. displayed → Service is
the coupler. finished.
• Disconnect the coupler and • Fault code number is
check the pins (bent or bro-ken displayed → Go to item 2.
terminals and locking condition
of the pins).
2 • Connection of wire harness Improperly connected → Connect the • Crank the engine.
ECU coupler. coupler securely or replace the wire • Fault code number is not
of the pins).
3 Continuity of wire harness • Open or short circuit → Replace the wire • Crank the engine.
harness. • Fault code number is not
• Between the crankshaft position sensor displayed → Service is
coupler and ECU coupler. finished.
(Red-Red) • Fault code number is
(Black/Blue-Black/Blue) displayed → Go to item 4.
5-11

Crankshaft position sensor: no normal signals
are received from the crankshaft position sensor.
Diagnostic code No.:---
4 • Installed condition of crankshaft Improperly installed sensor → Reinstall or • Crank the engine.
position sensor. replace the sensor. • Fault code number is not
• Check for looseness or displayed → Service is
pinching. finished.
• Check clearance (0.85mm) • Fault code number is
between sensor and rotor displayed → Go to item 5.
5 Defective crankshaft position • Check the crankshaft position sensor. • Crank the engine.
sensor. Refer to “CHECKING THE • Fault code number is not
CRANKSHAFT POSITION SENSOR” in displayed → Service is
chapter 7. finished.
• Fault code number is
displayed → Go to item 6.
6 Malfunction in ECU. • Replace the ECU.
Fault code 13 Symptom Intake air pressure sensor: open or short circuit detected.
Diagnostic code No.: D03 (Intake air pressure)

TIP
Do not remove the throttle body sensor assembly.
If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first.

1 • Connection of throttle body Improperly connected → Connect the • Set the main switch to “ON”.
sensor assembly coupler. coupler securely or replace the wire • Fault code number is not
of the pins).
2 • Connection of wire harness Improperly connected → Connect the • Set the main switch to “ON”.
ECU coupler. coupler securely or replace the wire • Fault code number is not
of the pins).
3 Wire harness continuity. • Open or short circuit → Replace the wire • Set the main switch to “ON”.
• Between intake air pressure sensor displayed → Service is
(Black / blue-Black / blue) • Fault code number is
(Pink / white-Pink / white) displayed → Go to item 4.
(Blue-Blue)
4 Installed condition of sensor. Improperly installed sensor → Reinstall or • Set the main switch to “ON”.
replace the sensor. • Fault code number is not
displayed → Service is
finished.
5-12
Fault code 13 Symptom Intake air pressure sensor: open or short circuit detected.
Diagnostic code No.: D03 (Intake air pressure)

5 Defective intake air pressure • Execute the diagnostic mode. (Code No. • Set the main switch to “ON”.
sensor. D03) • Fault code number is not
• When engine is stopped: Atmospheric displayed → Service is
pressure at the current altitude and finished.
weather conditions is indicated. • Fault code number is
• At sea level: Approx. 101 kPa displayed → Go to item 6.
1000 m above sea level: Approx. 90 kPa
• When engine is cranking: Make sure that
the indication value changes.
• The value does not change when engine
is cranking. → Replace the throttle body.
6 Malfunction in ECU Replace the ECU.
Fault code 14 Symptom Intake air pressure sensor malfunction (clogged hole or loose).
Diagnostic code No.: d03 (Intake air pressure)

TIP
If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first.

1 The throttle body sensor Check the mounting section for loose or • Start the engine and let it idle
assembly is loosen. pinched mounting. for approximately 5 seconds.
• Fault code number is not
finished.
displayed → Proceed to the
next item.
2 Defective intake air pressure • Execute the diagnostic mode.
sensor. (Code No. d03)
• When engine is stopped: Atmospheric
pressure at the current altitude and
weather conditions is indicated.
At sea level:
Approx. 101 kPa
1000 m above sea level:
Approx. 90 kPa
Approx. 80 kPa
Approx. 70 kPa
• When engine is cranking: Make sure that
the indication value changes.
• The value does not change when engine
is cranking. → Replace the throttle body.
5-13
Fault code 15 Symptom Throttle position sensor: open or short circuit detected.
Diagnostic code No.: d01 (Throttle position sensor)

TIP

sensor assembly. coupler securely or replace the wire • Fault code number is not
of the pins).
2 • Connection of ECU wire Improperly connected → Connect the • Set the main switch to “ON”.
harness coupler. coupler securely or replace the wire • Fault code number is not
of the pins).
• Between throttle position sensor coupler displayed → Service is
and ECU coupler. finished.
Black / blue-Black / blue • Fault code number is
Yellow-Yellow displayed → Go to item 4.
Blue-Blue
4 Installed condition of sensor. • Improperly installed sensor → Reinstall • Set the main switch to “ON”.
or replace the throttle body. • Fault code number is not
finished.
5 Defective throttle position sensor. • Execute the diagnostic mode. • Set the main switch to “ON”.
(Code No. d01). • Fault code number is not
• When throttle is fully closed: displayed → Service is
A value of 7-18 is indicated. finished.
• When throttle is fully open: • Fault code number is
A value of 103-119 is indicated. displayed → Go to item 6.
• If the indication is outside of range →
Replace the throttle body.
6 Malfunction in ECU. Replace the ECU.
5-14

Throttle position sensor: stuck throttle position sensor detected.
(signal from throttle position sensor will not change.)
Diagnostic code No.: d01 (Throttle position sensor)
TIP

1 Installed condition of throttle body • Check for loose mounting, pinched • Set the main switch to “ON”.
sensor assembly. mounting, or hard mounting. • Fault code number is not
• Make sure that the mounting position is displayed → Service is
correct. finished.
2 Defective throttle position sensor. • Execute the diagnostic mode. • Set the main switch to “ON”.
(Code No. d01). • Fault code number is not
• When throttle is fully closed: displayed → Service is
A value of 7-18 is indicated. finished.
• When throttle is fully open: • Fault code number is
A value of 103-119 is indicated. displayed → Go to item 3.
• If the indication is outside of range →
Replace the throttle body.
3 Malfunction in ECU • Replace the ECU.
5-15

Intake air temperature sensor: open or short circuit detected.
(no normal signals are received from the intake air temperature sensor.)
Diagnostic code No.: d05 (Intake air temperature)
TIP
Make sure that the engine is completely cool before checking the following items.

sensor assembly coupler coupler securely or replace the wire • Fault code number is not
of the pins).
ECU coupler coupler securely or replace the wire • Fault code number is not
of the pins).
• Between intake air temperature sensor displayed → Service is
(Brown / white-Brown / white) displayed → Go to item 4.
4 • Installed condition of throttle Improperly installed sensor → Reinstall or • Set the main switch to “ON”.
body sensor assembly. replace the sensor. • Fault code number is not
pinching. finished.
5 Defective intake air temperature • Execute the diagnostic mode. • Set the main switch to “ON”.
sensor. (Code No. d05) • Fault code number is not
• During cold starting: A temperature close displayed → Service is
to the ambient temperature is indicated. finished.
• Indication is incorrect. → Replace the • Fault code number is
throttle body. displayed → Go to item 6.
5-16
Fault code 24 Symptom O2 sensor: Not activated.
Diagnostic code No. ---

1 Installed condition of O2 sensor. Improperly installed sensor → Reinstall or • Start the engine, warm it up,
replace the sensor. and then race it.
finished.
2 • Connection of O2 sensor Improperly connected → Connect the • Start the engine, warm it up,
coupler. coupler securely replace the wire harness. and then race it.
• Check the locking condition of • Fault code number is not
the coupler. displayed → Service is
• Disconnect the coupler and finished.
check the pins (bent or bro-ken • Fault code number is
terminals and locking condition displayed → Go to item 3.
of the pins).
3 • Connection of wire harness Improperly connected → Connect the • Start the engine, warm it up,
ECU coupler coupler securely or replace the wire and then race it.
• Check the locking condition of harness. • Fault code number is not
check the pins (bent or bro-ken • Fault code number is
of the pins).
4 Wire harness continuity. • Open or short circuit → Replace the wire • Start the engine, warm it up,
harness. and then race it.
• Between O2 sensor coupler and ECU • Fault code number is not
coupler. displayed → Service is
• Gray / red-Gray / red finished.
5 Check fuel pressure. Refer to “CHECKING THE FUEL PUMP • Start the engine, warm it up,
OPERATION” on page 5-26. and then race it.
finished.
6 O2 sensor malfunction • Check the O2 sensor for an abnormality. • Start the engine, warm it up,
• O2 sensor malfunction → Replace the and then race it.
O2 sensor. • Fault code number is not
Refer to “REMOVING THE ENGINE” on displayed → Service is
page 4-1. finished.
5-17
Fault code 28 Symptom Engine temperature sensor: open or short circuit detected.
Diagnostic code No.: d11 (Engine temperature)

TIP
Make sure that the engine is completely cool before checking the following items.

1 • Connection of engine Improperly connected → Connect the • Set the main switch to “ON”.
temperature sensor coupler coupler securely or replace the wire • Fault code number is not
check the pins (bent or broken displayed → Go to item 2.
of the pins).
ECU coupler coupler securely or replace the wire • Fault code number is not
check the pins (bent or broken displayed → Go to item 3.
of the pins).
• Between intake air temperature sensor displayed → Service is
(Green / red-Green / red) displayed → Go to item 4.
4 • Installed condition of engine Improperly installed sensor → Reinstall or • Set the main switch to “ON”.
temperature sensor. replace the sensor. • Fault code number is not
pinching. finished.
5 Defective intake air temperature • Execute the diagnostic mode. • Set the main switch to “ON”.
sensor. (Code No. d11) • Fault code number is not
• During cold starting: A temperature close displayed → Service is
to the ambient temperature is indicated. finished.
• Indication is incorrect. → Replace the • Fault code number is
engine temperature sensor. displayed → Go to item 6.
5-18
Fault code 39 Symptom Fuel injector-open or short circuit detected.
Diagnostic code No.: d36 (Fuel injector)

1 • Connection of fuel injector Improperly connected → Connect the • Execute the diagnostic
coupler. coupler securely or replace the wire mode. (Code No. d36)
• Check the locking condition of harness. • Fuel injector operation sound
the coupler. is heard. → Go to item 6.
• Disconnect the coupler and • Fuel injector operation sound
check the pins (bent or bro-ken is not heard. → Go to item 2.
of the pins).
2 Defective injector • Measure the injector resistance. • Execute the diagnostic
If the resistance is not 12 Ω , replace the mode. (Code No. d36)
injector. • Fuel injector operation sound
is heard. → Go to item 6.
• Fuel injector operation sound
is not heard. → Go to item 3.
3 • Connection of wire harness Improperly connected → Connect the • Execute the diagnostic
ECU coupler. coupler securely or replace the wire mode. (Code No. d36)
• Check the locking condition of harness. • Fuel injector operation sound
the coupler. is heard. → Go to item 6.
• Disconnect the coupler and • Fuel injector operation sound
check the pins (bent or bro-ken is not heard. → Go to item 4.
of the pins).
4 Continuity of wire harness • Open or short circuit → Replace the wire • Execute the diagnostic
harness. mode. (Code No. d36)
• Between fuel injection coupler and ECU • Fuel sound is heard. → Go to
coupler item 6.
(Orange / black-Orange / black) • Fuel injector operation sound
• Between fuel injection coupler and main is not heard. → Go to item 5.
switch coupler
(Red/white-Red/white)
5 Malfunction in ECU • Replace the ECU. ---
6 • Delete the fault codes. --- ---
• Start the engine and let it idle for
approximately 5 seconds.
• After completing the above
operation, check the fault code
display.
5-19
Fault code 44 Symptom Error is detected while reading or writing on EEPROM.
Diagnostic code No.: d60 (EEPROM fault code display)

1 Locate the malfunction. • Check in the diagnostic mode ----
(Code No. D60)
00: Perform the procedure in item 3.
01: Perform the procedure in item 2.
2 • “01” is indicated in Diagnostic • Change the CO concentration, and Set the main switch to “ON”.
mode (Code No. D60) rewrite in EEPROM. Fault code number is not
• EEPROM data error for Refer to “CHECKING THE EXHAUST displayed → Service is
adjustment of CO concentration GAS VOLUME” on page 3-9. finished.
• After this adjustment is made, the main Fault code number is
switch is turned OFF. displayed → Repeat the
procedure in item 1.
If the same number is
indicated, perform the
Fault code 46 Symptom Incorrect voltage is supplied to the injector.
Diagnostic code No.: -----

1 Malfunction in charging system. • Check the charging system. • Start the engine and let it idle
Refer to “CHARGING SYSTEM” on page for approximately 5 seconds.
7-21. • Fault code number is not
• Check the rectifier / regulator, AC displayed → Service is
magneto and wire harness. → Replace if finished.
defective. • Fault code number is
displayed → Repeat the
Fault code 50 Symptom Faulty ECU memory.

1 Malfunction in ECU • Replace the ECU. • Set the main switch to “ON”.
• Check that the fault code
number is not displayed.
5-20
Fault code 96 Symptom Incorrect voltage is supplied to the injector.

1 Battery voltage. • Check the battery voltage betweenthe • Less than 12.4V → Go to
battery positive terminal and negative item 2.
terminal. • More than 12.4V → Go to
item 4.
2 Battery over dis-charging. • Charging the battery. • Battery charging is complete
→ Go to item 4.
• Battery charging can not
coplete → Go to item 3.
3 Faulty battery. • Replace the battery. • Go to item 4.
4 Malfunction in charging system. • Check the charging system. • Set the main swtich to “ON”.
• Refer to “CHARGING SYSTEM” on page • Fault code number is not
7-21. displayed → Service is
finished.
harness. Between AC magneto coupler • Faut code number is not
and rectifier/regulator coupler. displayed → Service is
White-White. finished.
Black-Black • Fault code number is
• Between AC magneto coupler and Body displayed → Go to item 6.
ground. Black-Body ground.
6 Malfunction in ECU. • Replace the ECU.
5-21
Fault code Er-4 Symptom No signals are received from the service tool.
Diagnostic code No.: ------

1 • Connection of Yamaha Improperly connected → Connect the • Set the Yamaha diagnostic
diagnostic tool connector. coupler securely or replace the wire tool to “ON”.
the connector. displayed → Service is
• Disconnect the connector and finished.
check the connector (bent or • Fault code number is
broken terminals and locking displayed → Go to item 2.
condition of the connector).
2 • Connection of wire harness Improperly connected → Connect the • Set the Yamaha diagnostic
ECU coupler. coupler securely or replace the wire tool to “ON”.
check the pins (bent or broken • Fault code number is
of the pins).
3 Wire harness continuity. • Open or short circuit → Replace the wire • Set the Yamaha diagnostic
harness. tool to “ON”.
Between FI diagnostic tool coupler and • Fault code number is not
ECU coupler. displayed → Service is
(Light green-Light green) finished.
4 Defective FI diagnostic tool. • Replace FI diagnostic tool. • Set the Yamaha diagnostic
tool to “ON”.
finished.
SV. PORTAL VER.
5-22

Crypton-115 Fi (178-192)

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1FDF8197E1.

book Page 8 Thursday, September 10, 2015 3:45 PM

FUEL INJECTION SYSTEM FI

FUEL INJECTION SYSTEM FI

FUEL INJECTION SYSTEM FI

SENSOR AND ACTUATOR OPERATION TABLE

FUEL INJECTION SYSTEM FI

Fault code No.:

Diagnostic code No.:

Crankshaft position sensor: no normal signals

FUEL INJECTION SYSTEM FI

Diagnostic code No.: D03 (Intake air pressure)

Probable cause of malfunction Confirmation of service

FUEL INJECTION SYSTEM FI

Diagnostic code No.: D03 (Intake air pressure)

Diagnostic code No.: d03 (Intake air pressure)

Probable cause of malfunction Confirmation of service

FUEL INJECTION SYSTEM FI

Diagnostic code No.: d01 (Throttle position sensor)

Probable cause of malfunction Confirmation of service

FUEL INJECTION SYSTEM FI

Probable cause of malfunction Confirmation of service

FUEL INJECTION SYSTEM FI

Probable cause of malfunction Confirmation of service

FUEL INJECTION SYSTEM FI

Fault code 24 Symptom O2 sensor: Not activated.

Diagnostic code No. ---

FUEL INJECTION SYSTEM FI

Diagnostic code No.: d11 (Engine temperature)

Probable cause of malfunction Confirmation of service

FUEL INJECTION SYSTEM FI

Fault code 39 Symptom Fuel injector-open or short circuit detected.

Diagnostic code No.: d36 (Fuel injector)

FUEL INJECTION SYSTEM FI

Fault code 44 Symptom Error is detected while reading or writing on EEPROM.

Diagnostic code No.: d60 (EEPROM fault code display)

Fault code 46 Symptom Incorrect voltage is supplied to the injector.

Diagnostic code No.: -----

Fault code 50 Symptom Faulty ECU memory.

Diagnostic code No.: -----

FUEL INJECTION SYSTEM FI

Fault code 96 Symptom Incorrect voltage is supplied to the injector.

Diagnostic code No.: -----

FUEL INJECTION SYSTEM FI

Diagnostic code No.: ------

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