Yamaha Fz1n Service Manual
Have a look at the manual Yamaha Fz1n Service Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 255 Yamaha manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
ELECTRICAL COMPONENTS 8-107 c. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: Horn soundFaulty sound → Adjust or replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a battery (12 V) to the horn. b. Turn the adjusting screw in direction “a” or “b” until the specified horn sound is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28230 CHECKING THE FUEL SENDER 1. Remove: Fuel tank 2. Disconnect: Fuel pump coupler Fuel sender coupler(from the wire harness) 3. Remove: Fuel pump (from the fuel tank) 4. Check: Fuel sender resistance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 10) to the fuel sender terminal as shown. b. Measure the fuel sender resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28240 CHECKING THE SPEED SENSOR 1. Check: Speed sensor output voltageOut of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness side) as shown. Pocket tester90890-03112 Analog pocket tester YU-03112-C Positive tester probe Horn terminal “1” Negative tester probe Horn terminal “2” Fuel sender resistance Full position of the float 19–21 Ω at 20 °C (68 °F) Empty position of the float 139–141 Ω at 20 °C (68 °F) Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Green/white “1” Negative tester probe Black “2” Output voltage reading cycle 0.6 V to 4.8 V to 0.6 V to 4.8 V Pocket tester90890-03112 Analog pocket tester YU-03112-C
ELECTRICAL COMPONENTS 8-108 b. Set the main switch to “ON”. c. Elevate the rear wheel and slowly rotate it. d. Measure the voltage (DC 5 V) of White/Yel-low and Blue. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28250 CHECKING THE RADIATOR FAN MOTOR 1. Check: Radiator fan motorFaulty/rough movement → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the radiator fan motor coupler from the wire harness. b. Connect the battery (DC 12 V) as shown. c. Measure the radiator fan motor movement. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28260 CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: Coolant temperature sensor WARNING EWA14130 Handle the coolant temperature sensor with special care. Never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor is dropped, replace it. 2. Check: Coolant temperature sensor resistanceOut of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 1k) to the coolant temperature sensor “1” as shown. b. Immerse the coolant temperature sensor in a container filled with coolant “2”. NOTE: Make sure the coolant temperature sensor ter- minals do not get wet. c. Place a thermometer “3” in the coolant. Positive tester probe White/Yellow “1” Negative tester probe Black/Blue “2” Positive tester probe Blue “1” Negative tester probe Black “2” Coolant temperature sensor resistance 0°C (32 °F) : 5.21–6.37 k Ω 80 °C (176 °F) : 0.29–0.35 k Ω Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Coolant temperature sensor terminal Negative tester probe Coolant temperature sensor terminal
ELECTRICAL COMPONENTS 8-109 d. Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table. e. Check the coolant temperature sensor for continuity at the temperatures indicated in the table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28300 CHECKING THE THROTTLE POSITION SENSOR 1. Remove: Throttle position sensor(from the throttle body) 2. Check: Throttle position sensor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 1k) to the throttle position sensor as shown. b. Check the throttle position sensor maxi- mum resistance. Out of specification → Replace the throttle position sensor. c. Connect the pocket tester ( Ω × 1k) to the throttle position sensor as shown. d. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range. The resistance does not change or it changes abruptly → Replace the throttle position sensor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: Throttle position sensor Pocket tester90890-03112 Analog pocket tester YU-03112-C Tester positive lead → Blue “1” Tester negative lead → Black/Blue “2” Maximum throttle position sen- sor resistance 4–6 k Ω at 20 °C (68 °F) Tester positive lead → Ye l l o w “ 3 ” Tester negative lead → Black/Blue “2” Throttle position sensor resis- tance 0–6 k Ω at 20 °C (68 °F)
ELECTRICAL COMPONENTS 8-110 NOTE: When installing the throttle position sensor, adjust its angle properly. Refer to ADJUST- ING THE THROTTLE POSITION SENSOR on page 7-8. EAS2D1010 CHECKING THE SUB-THROTTLE POSITION SENSOR 1. Remove: Sub-throttle position sensor(from the throttle body) 2. Check: Sub-throttle position sensor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the sub-throttle motor coupler. b. Disconnect the sub-throttle position sensor coupler. c. Remove the sub-throttle position sensor from the sub-throttle servo motor. d. Connect the pocket tester ( Ω × 1k) to the sub-throttle position sensor as shown. e. Check the throttle position sensor maxi- mum resistance. Out of specification → Replace the throttle position sensor. f. Connect the pocket tester ( Ω × 1k) to the throttle position sensor as shown. g. While slowly opening the sub-throttle worm nut, check that the sub-throttle position sensor resistance is within the specified range. The resistance does not change or it changes abruptly → Replace the sub-throt- tle position sensor. NOTE: Check mainly that the resistance changes gradually when turning the sub-throttle worm nut, since the readings (from closed to wide- open sub-throttle) may diff er slightly from those specified. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: Sub-throttle position sensor NOTE: When installing the throttle position sensor, adjust its angle properly. Refer to CHECKING THE SUB-THROTTLE POSITION SENSOR on page 8-110. EA2D1012 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1. Check: Air induction system solenoid resistance Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Tester positive lead → Blue “1” Tester negative lead → Black/Blue “2” Maximum sub-throttle position sensor resistance 4–6 k Ω at 20 °C (68 °F) Tester positive lead → Green/Yellow “3” Tester negative lead → Black/Blue “2” Throttle position sensor resis- tance 0–6 k Ω at 20 °C (68 °F)
ELECTRICAL COMPONENTS 8-111 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the Air induction system solenoid coupler from the wire harness. b. Connect the pocket tester ( Ω × 1) to the Air induction system solenoid terminal as shown. c. Measure the Air induction system solenoid resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28380 CHECKING THE ATMOSPHERIC PRES- SURE SENSOR 1. Check: Atmospheric pressure sensor output volt-age Out of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the atmospheric pressure sensor coupler (wire harness side) as shown. b. Set the main switch to “ON”. c. Measure the atmospheric pressure sensor output voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28390 CHECKING THE CYLINDER IDENTIFICA- TION SENSOR 1. Check: Cylinder identification sensor output volt-age Out of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the cylinder identification sensor coupler (wire harness side) as shown. Air induction system solenoid resistance 18–22 Ω at 20 °C (68 °F) Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Brown “1” Negative tester probe Brown/Red “2” Atmospheric pressure sensor output voltage3.75–4.25 V Pocket tester90890-03112 Analog pocket tester YU-03112-C Positive tester probe Pink “1” Negative tester probe Black/Blue “2” Cylinder identification sensor output voltage When sensor is on 4.8 V or more When sensor is off 0.8 V or less Pocket tester90890-03112 Analog pocket tester YU-03112-C Positive tester probe White/Black “1” Negative tester probe Black/Blue “2”
ELECTRICAL COMPONENTS 8-112 b. Set the main switch to “ON”. c. Rotate the crankshaft. d. Measure the voltage (DC 20 V) of White/Black and Black/Blue. With each full rota- tion of the crankshaft, the voltage reading should cycle from 0.8 V to 4.8 V to 0.8 V to 4.8 V. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1. Check: Intake air pressure sensor output voltageOut of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the intake air pressure sensor coupler (wire harness side) as shown. b. Set the main switch to “ON”. c. Measure the intake air pressure sensor output voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28420 CHECKING THE INTAKE AIR TEMPERA- TURE SENSOR 1. Remove: Intake air temperature sensor(from the air filter case.) WARNING EWA14110 Handle the intake air temperature sensor with special care. Never subject the intake air temperature sensor to strong shocks. If the intake air temperature sensor is dropped, replace it. 2. Check: Intake air temperature sensor resistanceOut of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 100) to the intake air temperature sensor terminal as shown. b. Measure the intake air temperature sensor resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: Intake air temperature sensor Intake air pressure sensor out- put voltage3.75–4.25 V Pocket tester90890-03112 Analog pocket tester YU-03112-C Positive tester probe Pink/White “1” Negative tester probe Black/Blue “2” Intake air temperature sensor resistance2.21–2.69 k Ω at 20 °C (68 °F) Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Brown/White “1” Negative tester probe Black/Blue “2” Intake air temperature sensor bolt 1.2 Nm (0.12 m·kg, 0.87 ft·lb)
9 TROUBLESHOOTING TROUBLESHOOTING.................................................................................. 9-1 GENERAL INFORMATION ..................................................................... 9-1 STARTING FAILURES ............................................................................ 9-1 INCORRECT ENGINE IDLI NG SPEED ................................................. 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........................ 9-2 FAULTY GEAR SHIFTING ...................................................................... 9-2 SHIFT PEDAL DOES NOT MOVE .......................................................... 9-2 JUMPS OUT OF GEAR .......................................................................... 9-2 FAULTY CLUTCH ................................................................................... 9-2 OVERHEATING ...................................................................................... 9-2 OVERCOOLING ..................................................................................... 9-3 POOR BRAKING PERFORMANCE ....................................................... 9-3 FAULTY FRONT FORK LEGS ................................................................ 9-3 UNSTABLE HANDLING.......................................................................... 9-3 FAULTY LIGHTING OR SIGN ALING SYSTEM ...................................... 9-4
TROUBLESHOOTING 9-1 EAS28450 TROUBLESHOOTING EAS28460 GENERAL INFORMATION NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative proce- dure in this manual for checks, adjustments, and replacement of parts. EAS28470 STARTING FAILURES Engine 1. Cylinder(s) and cylinder head(s) Loose spark plug Loose cylinder head or cylinder Damaged cylinder head gasket Damaged cylinder gasket Worn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timing Faulty valve spring Seized valve 2. Piston(s) and piston ring(s) Improperly installed piston ring Damaged, worn or fatigued piston ring Seized piston ring Seized or damaged piston 3. Air filter Improperly installed air filter Clogged air filter element 4. Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft Fuel system 1. Fuel tank Empty fuel tank Clogged fuel filter Clogged fuel strainer Clogged fuel tank drain hose Clogged rollover valve hose Deteriorated or contaminated fuel 2. Fuel pump Faulty fuel pump Faulty fuel pump relay 3. Throttle body (-ies) Deteriorated or contaminated fuel Sucked-in air Electrical system 1. Battery Discharged battery Faulty battery 2. Fuse(s) Blown, damaged or incorrect fuse Improperly installed fuse 3. Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4. Ignition coil(s) Cracked or broken ignition coil body Broken or shorted primary or secondary coils 5. Ignition system Faulty ECU Faulty crankshaft position sensor 6. Switches and wiring Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty start switch Faulty sidestand switch Faulty clutch switch Improperly grounded circuit Loose connections 7. Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut-off relay Faulty starter clutch EAS28490 INCORRECT ENGINE IDLING SPEED Engine 1. Cylinder(s) and cylinder head(s) Incorrect valve clearance Damaged valve train components 2. Air filter Clogged air filter element Fuel system 1. Throttle body (-ies) Damaged or loose throttle body joint Improperly synchronized throttle bodies Improperly adjusted engine idling speed (idle adjusting screw)
TROUBLESHOOTING 9-2 Improper throttle cable free play Flooded throttle body Faulty air induction system Electrical system 1. Battery Discharged battery Faulty battery 2. Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 3. Ignition coil(s) Broken or shorted primary or secondary coils Cracked or broken ignition coil 4. Ignition system Faulty ECU Faulty crankshaft position sensor EAS28510 POOR MEDIUM-AND-HIGH-SPEED PER- FORMANCE Refer to STARTING FAILURES on page 9-1. Engine 1. Air filter Clogged air filter element Fuel system 1. Fuel pump Faulty fuel pump EAS28530 FAULTY GEAR SHIFTING Shifting is difficult Refer to Clutch drags. EAS28540 SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28560 FAULTY CLUTCH Clutch slips 1. Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2. Engine oil Incorrect oil level Incorrect oil viscosity (low) Deteriorated oil Clutch drags 1. Clutch Unevenly tensioned clutch springs Warped pressure plate Bent clutch plate Swollen friction plate Bent clutch push rod Broken clutch boss Burnt primary driven gear bushing Match marks not aligned 2. Engine oil Incorrect oil level Incorrect oil viscosity (high) Deteriorated oil EAS28600 OVERHEATING Engine 1. Clogged coolant passages Cylinder head(s) and piston(s) Heavy carbon buildup