Yamaha Fz1n Service Manual

							
ELECTRICAL COMPONENTS
8-97
The following procedure applies to all of the 
bulb sockets.
1. Check: Bulb socket (for continuity)(with the pocket tester)
No continuity  → Replace.
NOTE:
Check each bulb socket for continuity in the 
same manner as described in the bulb section; 
however, note the following.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the 
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any  of the readings indicate no continuity, 
replace the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28000
CHECKING THE FUSES
The following procedure applies to all of the 
fuses.
CAUTION:
ECA13680
To avoid a short circuit, always set the main 
switch to “OFF” when checking or replac-
ing a fuse.
1. Remove:
 Rider and passenger seat
2. Check:
Fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and  check the continuity.
NOTE:
Set the pocket tester selector to “ Ω ×  1”.
b. If the pocket tester indicates “ ∞”, replace 
the fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Replace:  Blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage 
rating.
c. Set on the switches to verify if the electrical  circuit is operational.
d. If the fuse immediately blows again, check  the electrical circuit.
WARNING
EWA13310
Never use a fuse with an amperage rating 
other than that specified. Improvising or 
using a fuse with the wrong amperage rat-
ing may cause extensive damage to the 
electrical system, cause the lighting and 
ignition systems to malfunction and could 
possibly cause a fire.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install: Rider and passenger seat
EAS28030
CHECKING AND CHARGING THE BATTERY
WARNING
EWA13290
Batteries generate explosive hydrogen gas 
and contain electrolyte which is made of 
poisonous and highly caustic sulfuric acid. 
Therefore, always follow these preventive 
measures:
 Wear protective eye gear when handling or working near batteries.
 Charge batteries in a well-ventilated area.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Pocket tester90890-03112
Analog pocket tester YU-03112-C
Fuses Amperage  ratingQ’ty
Main 50 A 1
Headlight (FZ1-N) 15 A 1 Headlight (FZ1-S) 25 A 1 Signaling system 10 A 1 Tail/brake light 10 A 1 Ignition 15 A 1
Buckup 10 A 1
Radiator fan motor 10 A 2 Reserve 10 A 1
Reserve (FZ1-N) 15 A 1 Reserve (FZ1-S) 25 A 1 
						

							
ELECTRICAL COMPONENTS
8-98
 Keep batteries away from fire, sparks or open flames (e.g., welding equipment, 
lighted cigarettes).
 DO NOT SMOKE when charging or han- dling batteries.
 KEEP BATTERIES AND ELECTROLYTE  OUT OF REACH OF CHILDREN.
 Avoid bodily contact with electrolyte as it 
can cause severe burns or permanent eye 
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
 Skin — Wash with water.
 Eyes — Flush with water for 15 minutes 
and get immediate medical attention.
INTERNAL
 Drink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg 
or vegetable oil. Get immediate medical 
attention.
CAUTION:
ECA13660
 This is a sealed battery. Never remove the sealing caps because the balance 
between cells will not be maintained and 
battery performance will deteriorate.
 Charging time, charging amperage and  charging voltage for an MF battery are dif-
ferent from those of conventional batter-
ies. The MF battery should be charged as 
explained in the charging method illustra-
tions. If the battery is overcharged, the 
electrolyte level will drop considerably. 
Therefore, take special care when charg-
ing the battery.
NOTE:
Since MF batteries are sealed, it is not possi-
ble to check the charge state of the battery by 
measuring the specific gravity of the electro-
lyte. Therefore, the charge of the battery has to 
be checked by measuring the voltage at the 
battery terminals.
1. Remove: Rider and passenger seat
2. Disconnect:
 Battery leads(from the battery terminals)
CAUTION:
ECA13640
First, disconnect the negative battery lead 
“1”, and then positive battery lead “2”. 3. Remove:
 Battery
4. Check:  Battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery ter- minals.
NOTE:
 The charge state of an MF battery can be 
checked by measuring its open-circuit volt-
age (i.e., the voltage when the positive bat-
tery terminal is disconnected).
 No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown  in the charts and the following example.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Charge: Battery(refer to the appropriate charging method 
illustration)
WARNING
EWA13300
Do not quick charge a battery.
CAUTION:
ECA13670
 Never remove the MF battery sealing 
caps.
 Do not use a high-rate battery charger  since it forces a high-amperage current 
 Positive tester probe 
→
positive battery terminal
 Negative tester probe  →
negative battery terminal
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20–30% 
						

							
ELECTRICAL COMPONENTS
8-99
into the battery quickly and can cause 
battery overheating and battery plate 
damage.
 If it is impossible to regulate the charging  current on the battery charger, be careful 
not to overcharge the battery.
 When charging a battery, be sure to  remove it from the vehicle. (If charging 
has to be done with the battery mounted 
on the vehicle, disconnect the negative 
battery lead from the battery terminal.)
 To reduce the chance of sparks, do not  plug in the battery charger until the bat-
tery charger leads are connected to the 
battery.
 Before removing the battery charger lead  clips from the battery terminals, be sure 
to turn off the battery charger.
 Make sure the battery charger lead clips  are in full contact with the battery termi-
nal and that they are not shorted. A cor-
roded battery charger lead clip may 
generate heat in the contact area and a 
weak clip spring may cause sparks.
 If the battery becomes hot to the touch at  any time during the charging process, 
disconnect the battery charger and let the 
battery cool before reconnecting it. Hot 
batteries can explode!
 As shown in the following illustration, the 
open-circuit voltage of an MF battery sta-
bilizes about 30 minutes after charging 
has been completed. Therefore, wait 30 
minutes after charging is completed 
before measuring the open-circuit volt-
age.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a variable-current
(voltage) charger
a. Measure the open-circuit voltage prior to  charging.
NOTE:
Voltage should be measured 30 minutes after 
the machine is stopped.
b. Connect a charged and AMP meter to the battery and start charging.
NOTE:
Set the charging voltage at 16–17 V.If the set-
ting is lower, charging will be insufficient. If too 
high, the battery will be over-charged. c. Make sure that the current is higher than 
the standard charging current written on 
the battery.
NOTE:
If the current is lower than the standard charg-
ing current written on the battery, set the 
charging voltage adjust dial at 20–24 V and 
monitor the amperage for 3–5 minutes to 
check the battery.
d. Adjust the voltage so that the current is at the standard charging level.
e. Set the time according to the charging time  suitable for the open-circuit voltage.
Refer to “Battery condition checking steps”.
f. If charging requires more than 5 hours, it is  advisable to check the charging current 
after a lapse of 5 hours. If there is any 
change in the amperage, readjust the volt-
age to obtain the standard charging cur-
rent.
g. Measure the battery open-circuit voltage  after leaving the battery unused for more 
than 30 minutes.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant voltage
charger
a. Measure the open-circuit voltage prior to charging.
NOTE:
Voltage should be measured 30 minutes after 
the machine is stopped.
b. Connect a charger and AMP meter to the 
battery and start charging.
c. Make sure that the current is higher than  the standard charging current written on 
the battery.
 Reach the standard charging current
Battery is good.
 Does not reach the standard charging cur-
rent
Replace the battery.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery. 
						

							
ELECTRICAL COMPONENTS
8-100
NOTE:
If the current is lower than the standard charg-
ing current written on the battery, this type of 
battery charger cannot charge the MF battery. 
A variable voltage charger is recommended.
d. Charge the battery until the battery’s charg-ing voltage is 15 V.
NOTE:
Set the charging time  at 20 hours (maximum).
e. Measure the battery open-circuit voltage  after leaving the battery unused for more 
than 30 minutes.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install: Battery
7. Connect:
 Battery leads(to the battery terminals)
CAUTION:
ECA13630
First, connect the positive battery lead “1”, 
and then the negative battery lead “2”.
8. Check:  Battery terminals
Dirt  → Clean with a wire brush.
Loose connection  → Connect properly.
9. Lubricate:
 Battery terminals
10. Install:  Rider and passenger seat
EAS28040
CHECKING THE RELAYS
Check each switch for continuity with the 
pocket tester. If the continuity reading is incor-
rect, replace the relay.
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester ( Ω ×  1) and bat-
tery (12 V) to the relay terminal as shown.
Check the relay operation.
Out of specification  → Replace.
Relay unit (starting circuit cut-off relay)
FZ1-N
FZ1-S
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
Recommended lubricant
Dielectric grease
Pocket tester90890-03112
Analog pocket tester
YU-03112-C
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Relay operationContinuity/No continuity (between “3” to “4”)
1. Positive battery terminal 
						

							
ELECTRICAL COMPONENTS
8-101
Relay unit (fuel pump relay)
FZ1-N
FZ1-S
Headlight relay (on/off)
(FZ1-N)Headlight relay (on/off)
(FZ1-S)
Headlight relay (dimmer)
(FZ1-S)
Radiator fan motor relay
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity/No continuity
(between “3” to “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
ResultContinuity/No continuity
(between “3” to “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
ResultContinuity/No continuity
(between “3” to “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity/No continuity
(between “3” to “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
ResultContinuity/No continuity
(between “3” to “4”)
(between “3” to “5”) 
						

							
ELECTRICAL COMPONENTS
8-102
ET2D1030
CHECKING THE TURN SIGNAL/HAZARD 
RELAY
1. Check: Turn signal/hazard relay input voltageOut of specification  → The wiring circuit 
from the main switch to the turn signal/haz-
ard relay coupler is faulty and must be 
repaired.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the  turn signal/hazard relay terminal as shown. b. Turn the main switch to “ON”.
c. Measure the turn signal/hazard relay input 
voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check: Turn signal/hazard relay output voltageOut of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the 
turn signal/hazard relay terminal as shown.
b. Turn the main switch to “ON”.
c. Measure the turn signal/hazard relay out- put voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET2D1021
CHECKING THE RELAY UNIT (DIODE)
1. Check: Relay unit (diode)Out of specification  → Replace.
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity/No continuity
(between “3” to “4”)
Turn signal/hazard relay input 
voltageDC 12 V
Pocket tester90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe  →
Blue/Red “1”
 Negative tester probe  →
Ground
Turn signal/hazard relay output 
voltage DC 12 V
Pocket tester90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe  →
Brown/White “1”
 Negative tester probe  →
Ground 
						

							
ELECTRICAL COMPONENTS
8-103
NOTE:
The pocket tester and the analog pocket tester 
readings are shown in the following table.
FZ1-N
FZ1-S
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the relay unit coupler from the 
wire harness.
b. Connect the pocket tester ( Ω×1) to the 
relay unit terminal as shown.
c. Check the relay unit (diode) for continuity.
d. Check the relay unit (diode) for no continu- ity.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28100
CHECKING THE IGNITION COILS
The following procedure applies to all of the 
ignition coils.
1. Check: Primary coil resistanceOut of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil leads from the 
wire harness.
b. Connect the pocket tester ( Ω ×  1) to the 
ignition coil as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
ContinuityPositive tester probe  → Sky 
blue “1”
Negative tester probe  → Yel-
low/Black “2” (FZ1-N) Black/
Yellow “2” (FZ1-S)
No continuity Positive tester probe  → Yel-
low/Black “2” (FZ1-N) Black/
Yellow “2” (FZ1-S)
Negative tester probe  → Sky 
blue “1”
Continuity Positive tester probe  → Sky 
blue “1”
Negative tester probe  → Blue/
Yellow “3”
No continuity Positive tester probe  → Blue/
Yellow “3”
Negative tester probe  → Sky 
blue “1”
Continuity
Positive tester probe  → Sky 
blue “1”
Negative tester probe  → Sky 
blue/White “4”
No continuity Positive tester probe  → Sky 
blue/White “4”
Negative tester probe  → Sky 
blue “1”
Continuity Positive tester probe  → Blue/
Black “5”
Negative tester probe  → Blue/
Yellow “3”
No continuity
Positive tester probe  → Blue/
Yellow “3”
Negative tester probe  → Blue/
Black “5”
Primary coil resistance 1.19–1.61  Ω at 20 °C (68 °F)
Pocket tester
90890-03112
Analog pocket tester YU-03112-C 
						

							
ELECTRICAL COMPONENTS
8-104
c. Measure the primary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check: Secondary coil resistanceOut of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil leads from the 
wire harness.
b. Connect the pocket tester ( Ω ×  1k) to the 
ignition coil as shown.
c. Measure the secondary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:  Ignition spark gap “a”
Out of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the 
spark plug.
b. Connect the ignition checker/dynamic  spark tester “2” as shown.
c. Set the main switch to “ON”.
d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the starter  switch and gradually increase the spark 
gap until a misfire occurs.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28120
CHECKING THE CRANKSHAFT POSITION 
SENSOR
1. Disconnect: Crankshaft position sensor coupler
(from the wire harness)
2. Check:  Crankshaft position sensor resistance
Out of specification  → Replace the crank-
shaft position sensor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
 Positive tester probe Ignition coil terminal
 Negative tester probe
Ignition coil terminal
Secondary coil resistance8.5–11.5 k Ω at 20 °C (68 °F)
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
 Negative tester probe Ignition coil terminal “1”
 Positive tester probe Spark plug terminal “2”
Minimum ignition spark gap6.0 mm (0.24 in)
Ignition checker90890-06754
Opama pet-4000 spark checker YM-34487
1. Spark plug cap
Crankshaft position sensor 
resistance336–504  Ω at 20 °C (68 °F) 
						

							
ELECTRICAL COMPONENTS
8-105
a. Connect the pocket tester (Ω ×  100) to the 
crankshaft position sensor coupler as 
shown.
b. Measure the crankshaft position sensor  resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28130
CHECKING THE LEAN ANGLE SENSOR
1. Remove:
 Lean angle sensor
2. Check:
 Lean angle sensor out put voltageOut of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the lean angle sensor coupler to 
the wire harness.
b. Connect the pocket tester (DC 20 V) to the  lean angle sensor coupler as shown. c. When turn the lean angle sensor to 65
°.
d. Measure the lean angle sensor output volt- age.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET2D1034
CHECKING THE STARTOR MOTOR OPERA-
TION
1. Check: Starter motor operation
Does not operate  → Perform the electric 
starting system troubleshooting, starting 
with step5.
Refer to TROUBLESHOOTING on page 
8-9.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive battery terminal “1”  and starter motor lead “2” with a jumper 
lead “3”.
WARNING
EWA13810
 A wire that is used as a jumper lead must have at least the same capacity of the bat-
tery, otherwise the jumper lead may burn.
 This check is likely to produce sparks,  therefore, make sure no flammable gas or 
fluid is in the vicinity.
b. Check the starter motor operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:  Startor coil resistance
Pocket tester90890-03112
Analog pocket tester
YU-03112-C
 Positive tester probe Gray “1”
 Negative tester probe Black “2”
Lean angle sensor output volt-
age
Less than 65 °: 0.4–1.4 V
More than 65 °: 3.7–4.4 V
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe Yellow/Green “1”
 Negative tester probe Black/Blue “2” 
						

							
ELECTRICAL COMPONENTS
8-106
Out of specification → Replace the startor 
coil.
EAS28150
CHECKING THE STATOR COIL
1. Disconnect:  Stator coil coupler
(from the wire harness)
2. Check:  Stator coil resistance
Out of specification  → Replace the startor 
coil.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester ( Ω ×  1) to the 
startor coil coupler as shown.
b. Measure the stator coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28170
CHECKING THE RECTIFIER/REGULATOR
1. Check:  Charging voltage
Out of specification  → Replace the rectifier/
regulator.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the engine tachometer to the ignition  coil of cylinder #1.
b. Connect the pocket tester (AC 20 V) to the  rectifier/regulator coupler as shown.
c. Start the engine and let it run at approxi- mately 5000 r/min.
d. Measure the charging voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28180
CHECKING THE HORN
1. Check:  Horn resistanceOut of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the horn leads from the horn 
terminals.
b. Connect the pocket tester ( Ω ×  1) to the 
horn terminals.
Stator coil resistance 0.14–0.18  Ω at 20 °C (68 °F)
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe White “1”
 Negative tester probe White “2”
 Positive tester probe White “1”
 Negative tester probe White “3”
 Positive tester probe White “2”
 Negative tester probe White “3”
Charging voltage14 V at 5000 r/min
Pocket tester90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe Red “1”
 Negative tester probe Black “2”
Horn resistance
1.15–1.25  Ω at 20 °C (68 °F)