Yamaha Fz6 N Service Manual
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ELECTRICAL COMPONENTS 8-128 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 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. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1) to the fuel pump coupler as shown. b. Measure the fuel pump resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28370 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1. Check: Air induction system solenoid resistance Out of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1. Check: Intake air pressure sensor output voltage Out 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”. 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. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 100) to the intake air temperature sensor terminal as shown. b. Measure the intake air temperature sensor resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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