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Yamaha Fz6 N Service Manual

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    Page
    of 538
    							
    ELECTRICAL COMPONENTS
    8-128
    e. Check the coolant temperature sensor for continuity at the temperatures indicated in 
    the table.
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    EAS28300
    CHECKING THE THROTTLE POSITION 
    SENSOR
    1. Remove:
     Throttle position sensor (from the throttle body)
    2. Check:  Throttle position sensor
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    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 turning the throttle position 
    sensor shaft, check t hat the throttle posi-
    tion sensor resistance is within the speci-
    fied range.
    The resistance does not change or it 
    changes abruptly  → Replace the throttle 
    position sensor.
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    3. Install:
     Throttle position sensor
    NOTE:
    When installing the throttle position sensor, 
    adjust its angle properly. Refer to ADJUST-
    ING THE THROTTLE POSITION SENSOR 
    on page 7-6.
    EAS28350
    CHECKING THE FUEL PUMP
    WARNING
    EWA13850
    Gasoline is extremely flammable and under 
    certain circumstances there can be a dan-
    ger of an explosion or fire. Be extremely 
    careful and note the following points:
     Stop the engine before refueling.
     Do not smoke, and keep away from open flames, sparks, or any other source of 
    fire.
     If you do accidentally spill gasoline, wipe  it up immediately with dry rags.
     If gasoline touches the engine when it is  hot, a fire may occur. Therefore, make 
    sure the engine is completely cool before 
    performing the following test.
    1. Disconnect:  Fuel pump coupler
    (from the wire harness)
    2. Check:  Fuel pump 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”
    Resistance 4.0–6.0 k Ω
     Tester positive lead  →
    Ye l l o w  “ 3 ”
     Tester negative lead  →
    Black/Blue “2”
    Throttle position sensor resis-
    tance
    0 to 3.5–6.5 k Ω at 20 °C (68 °F) 
    						
    							
    ELECTRICAL COMPONENTS
    8-129
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    a. Connect the pocket tester (Ω ×  1) to the 
    fuel pump coupler as shown.
    b. Measure the fuel pump resistance.
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    EAS28370
    CHECKING THE AIR INDUCTION SYSTEM 
    SOLENOID
    1. Check:  Air induction system solenoid resistance Out of specification  → Replace.
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    a. Remove the air induc tion system solenoid 
    coupler from the wire harness.
    b. Connect the pocket tester ( Ω ×  1) to the air 
    induction system so lenoid terminal as 
    shown. c. Measure the air induc
    tion system solenoid 
    resistance.
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    EAS28410
    CHECKING THE INTAKE AIR PRESSURE 
    SENSOR
    1. Check:  Intake air pressure sensor output voltage Out of specification  → Replace.
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    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”.
    Fuel pump resistance 0.2–3.0  Ω at 20 °C (68 °F)
    Pocket tester
    90890-03112
    Analog pocket tester YU-03112-C
     Positive tester probe Red/blue “1”
     Negative tester probe Black “2”
    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/Red “1”
     Negative tester probe
    Red/White “2”
    Intake air pressure sensor out-
    put voltage 3.75–4.25 V
    Pocket tester90890-03112
    Analog pocket tester
    YU-03112-C
     Positive tester probe Pink/White “1”
     Negative tester probe Black/Blue “2” 
    						
    							
    ELECTRICAL COMPONENTS
    8-130
    c. Measure the intake air pressure sensor 
    output voltage.
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    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 resistance Out of specification  → Replace.
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    a. Connect the pocket tester ( Ω ×  100) to the 
    intake air temperature sensor terminal as 
    shown.
    b. Measure the intake air temperature sensor  resistance.
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    Intake air pressure sensor
    resistance
    2.2–2.7 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” 
    						
    							
    9
    TROUBLESHOOTING
    TROUBLESHOOTING.................................................................................. 9-1
    GENERAL INFORMATION ..................................................................... 9-1
    STARTING FAILURES ............................................................................ 9-1
    INCORRECT ENGINE IDLING  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 SIGNALING SYSTEM ...................................... 9-4
    TROUBLESHOOTING AT THE ABS WARNING LIGHT......................... 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 tank drain 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
     Faulty spark plug cap
    4. Ignition coil(s)  Cracked or broken ignition coil body
     Broken or shorted primary or secondary  coils
     Faulty spark plug lead
    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 carburetors
     Improperly adjusted engine idling speed  (throttle stop 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
     Faulty spark plug cap
    3. Ignition coil(s)  Broken or shorted primary or secondary 
    coils
     Faulty spark plug lead
     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
     Damaged 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 
    						
    							
    TROUBLESHOOTING
    9-3
    2. Engine oil Incorrect oil level
     Incorrect oil viscosity
     Inferior oil quality
    Cooling system
    1. Coolant  Low coolant level
    2. Radiator  Damaged or leaking radiator
     Faulty radiator cap
     Bent or damaged radiator fin
    3. Water pump  Damaged or faulty water pump
     Thermostat
     Thermostat stays closed
    Oil cooler
     Clogged or damaged oil cooler
     Hose(s) and pipe(s)
     Damaged hose
     Improperly connected hose
     Damaged pipe
     Improperly connected pipe
    Fuel system
    1. Throttle body(-ies)  Damaged or loose throttle body joint
    2. Air filter  Clogged air filter element
    Chassis
    1. Brake(s)  Dragging brake
    Electrical system
    1. Spark plug(s)  Incorrect spark plug gap
     Incorrect spark plug heat range
    2. Ignition system
     Faulty ECU
    3. Cooling system  Faulty radiator fan motor relay
     Faulty coolant temperature sensor
     Faulty ECU
    EAS28610
    OVERCOOLING
    Cooling system
    1. Thermostat
     Thermostat stays open
    EAS28620
    POOR BRAKING PERFORMANCE
     Worn brake pad  Worn brake disc
     Air in hydraulic brake system
     Leaking brake fluid
     Faulty brake caliper kit
     Faulty brake caliper seal
     Loose union bolt
     Damaged brake hose
     Oil or grease on the brake disc
     Oil or grease on the brake pad
     Incorrect brake fluid level
    EAS28660
    FAULTY FRONT FORK LEGS
    Leaking oil
     Bent, damaged or rusty inner tube
     Cracked or damaged outer tube
     Improperly installed oil seal
     Damaged oil seal lip
     Incorrect oil level (high)
     Loose damper rod assembly bolt
     Damaged damper rod assembly bolt copper 
    washer
     Cracked or damaged cap bolt O-ring
    Malfunction
     Bent or damaged inner tube
     Bent or damaged outer tube
     Damaged fork spring
     Worn or damaged outer tube bushing
     Bent or damaged damper rod
     Incorrect oil viscosity
     Incorrect oil level
    EAS28670
    UNSTABLE HANDLING
    1. Handlebar  Bent or improperly installed handlebar
    2. Steering head components  Improperly installed upper bracket
     Improperly installed lower bracket
    (improperly tightened ring nut)
     Bent steering stem
     Damaged ball bearing or bearing race
    3. Front fork leg(s)  Uneven oil levels (both front fork legs)
     Unevenly tensioned fork spring (both front 
    fork legs)
     Broken fork spring
     Bent or damaged inner tube
     Bent or damaged outer tube
    4. Swingarm
     Worn bearing or bushing
     Bent or damaged swingarm
    5. Rear shock absorber assembly(-ies) 
    						
    							
    TROUBLESHOOTING
    9-4
     Faulty rear shock absorber spring
     Leaking oil or gas
    6. Tire(s)  Uneven tire pressures (front and rear)
     Incorrect tire pressure
     Uneven tire wear
    7. Wheel(s)  Incorrect wheel balance
     Deformed cast wheel
     Damaged wheel bearing
     Bent or loose wheel axle
     Excessive wheel runout
    8. Frame  Bent frame
     Damaged steering head pipe
     Improperly installed bearing race
    EAS28710
    FAULTY LIGHTING OR SIGNALING SYS-
    TEM
    Headlight does not come on
     Wrong headlight bulb
     Too many electrical accessories
     Hard charging
     Incorrect connection
     Improperly grounded circuit
     Poor contacts (main or light switch)
     Burnt-out headlight bulb
    Headlight bulb burnt out
     Wrong headlight bulb
     Faulty battery
     Faulty rectifier/regulator
     Improperly grounded circuit
     Faulty main switch
     Faulty light switch
     Headlight bulb life expired
    Tail/brake light does not come on
     Wrong tail/brake light bulb
     Too many electrical accessories
     Incorrect connection
     Burnt-out tail/brake light bulb
    Tail/brake light bulb burnt out
     Wrong tail/brake light bulb
     Faulty battery
     Incorrectly adjusted rear brake light switch
     Tail/brake light bulb life expired
    Turn signal does not come on
     Faulty turn signal switch
     Faulty turn signal relay
     Burnt-out turn signal bulb  Incorrect connection
     Damaged or faulty wire harness
     Improperly grounded circuit
     Faulty battery
     Blown, damaged or incorrect fuse
    Turn signal blinks slowly
     Faulty turn signal relay
     Faulty main switch
     Faulty turn signal switch
     Incorrect turn signal bulb
    Turn signal remains lit
     Faulty turn signal relay
     Burnt-out turn signal bulb
    Turn signal blinks quickly
     Incorrect turn signal bulb
     Faulty turn signal relay
     Burnt-out turn signal bulb
    Horn does not sound
     Improperly adjusted horn
     Damaged or faulty horn
     Faulty main switch
     Faulty horn switch
     Faulty battery
     Blown, damaged or incorrect fuse
     Faulty wire harness
    EAS4S81006
    TROUBLESHOOTING AT THE ABS WARN-
    ING LIGHT
    When the main switch is turned “ON”. (Engine 
    does not start.)
    Only the ABS warning light does not come
    on
     Defective connection of the ABS wire har-
    ness and the wire harness
     Defective connection of the ABS wire har-
    ness and the ABS ECU
     ABS warning light bulb is burnt out or the  bulb contact is defective
     ABS ECU defective
    All indicators do not come on
     Battery defective
     Blown, damaged, or incorrect fuse (main  fuse)
     Defective connection of the main fuse cou- pler
     Defective connection of the wire harness
     Defective connection of the main switch cou-
    pler 
    						
    							
    TROUBLESHOOTING
    9-5
     Defective connection of the meter coupler
    ABS warning light continues to flashes
     Brake light switch (front or rear) is defective
     Brake light switch front or rear coupler has come off
     Defective starter motor monitor
     Other defective
    ABS warning light flashes every 0.5 sec-
    onds
     Voltage drop (Less than 10 V)  Battery
     Rectifier/regulator
     AC magneto
     Strong radio waves or static electricity
     Test coupler adapter is connected to test  coupler
    ABS Warning light continues to come on
     Defective connection of the wheel sensor  (front or rear) circuit
     Wheel sensor lead (front or rear) coupler has 
    come off
     Wheel sensor lead (front or rear) or the IC  internal circuit is disconnected
     Sensor circuit of the ABS harness is discon- nected
     ABS ECU coupler terminal has come off 
    						
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