Yamaha Fz6n Manual
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8-3 CHECKING SWITCH CONTINUITYELEC CAUTION: NOTE: NOTE: EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Never insert the tester probes into the cou- pler terminal slots. Always insert the probes from the opposite end of the coupler 1 tak- ing care not to loosen or damage the leads. Pocket tester 90890-03112, YU-3112 Before checking for continuity, set the pocket tester to “0” and to the “Ω 1” range. When checking for continuity, switch back and forth between the switch positions a few times. The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustration similar to the one on the left. The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration. “ ” indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the respective switch position). The example illustration on the left shows that: There is continuity between red and brown / red when the switch is set to “P”. There is continuity between red, brown / blue and brown / red when the switch is set to “ON”.
8-4 11Oil level switch 12Neutral switch 13Rear brake light switch 14Fuse box 1Main switch 2Horn switch 3Dimmer switch 4Turn signal switch 5Clutch switch 6Hazard switch 7Sidestand switch 8Engine stop switch 9Front brake light switch 10Start switch CHECKING THE SWITCHESELEC EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage / wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch.
8-5 CHECKING THE BULBS AND BULB SOCKETSELEC WARNING EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage / wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect. No continuity Repair or replace the bulb, bulb socket or both. TYPES OF BULBS The bulbs used on this motorcycle are shown in the illustration on the left. Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb. The ma- jority of these types of bulbs can be removed from their respective socket by turning them counterclockwise. Bulbs C are used for turn signal and tail / brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise. CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: bulb Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. When changing the tail / brake light bulb, comfirm that the frame has cooled accord- ing to the warning label and change the tail / brake light bulb.
8-6 CHECKING THE BULBS AND BULB SOCKETSELEC CAUTION: NOTE: Be sure to hold the socket firmly when re- moving the bulb. Never pull the lead, other- wise it may be pulled out of the terminal in the coupler. Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adverse- ly affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 2. Check: bulb (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03112, YU-3112 Before checking for continuity, set the pocket tester to “0” and to the “Ω 1” range. a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2, and check the continuity. b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3, and check the continuity. c. If either of the readings indicate no continuity, replace the bulb. CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: bulb socket (for continuity) (with the pocket tester) No continuity Replace.
8-7 CHECKING THE BULBS AND BULB SOCKETSELEC NOTE: NOTE: WARNING Pocket tester 90890-03112, YU-3112 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 re- spective leads of the bulb socket. c. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket. CHECKING THE LEDs The following procedures applies to all of the LEDs. 1. Check: LED (for proper operation) Improper operation Replace. a. Disconnect the meter assembly coupler (me- ter assembly side). b. Connect two jumper leads 1 from the bat- tery terminals to the respective coupler ter- minal. As for connecting with which coupler terminal, refer to “CABLE ROUTING” in chapter 2. A wire that is used as a jumper lead must have at least the same capacity of the bat- tery lead, 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. c. When the jumper leads are connected to the terminals the respective LED should illumi- nate. Does not light Replace the meter assem- bly.
8-8 1Main switch 6Fuse (main) 9Battery 10Starting circuit cut-off relay 11Sidestand switch 12Neutral switch 16Lean angle cut-off switch 17Crankshaft position sensor 20ECU 27Ignition coil #1 and #4 28ignition coil #2 and #3 29Spark plug 40Engine stop switch 47Fuse (ignition) 54Clutch switch IGNITION SYSTEMELEC EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM
8-9 YESNO 2. Battery Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20C (68F) Is the battery OK? Clean the battery terminals. Recharge or re- place the battery. EAS00739 YESNO EAS00741 3. Spark plugs The following procedure applies to all of the spark plugs. Check the condition of the spark plug. Check the spark plug type. Measure the spark plug gap. Refer to “CHECKING THE SPARK PLUGS” in chapter 3. Standard spark plug CR9EK (NGK) Spark plug gap 0.6 0.7 mm (0.0236 0.0276 in) Is the spark plug in good condition, is it of the correct type, and is its gap within specifica- tion? Re-gap or replace the spark plug. IGNITION SYSTEMELEC NOTE: YESNO 1. Main and ignition fuses Check the main and ignition fuses for conti- nuity. Refer to “CHECKING THE FUSES” in chap- ter 3. Are the main and ignition fuses OK? Replace the fuse(s). EAS00737 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Check: 1. main and ignition fuses 2. battery 3. spark plugs 4. ignition spark gap 5. spark plug cap resistance 6. ignition coil resistance 7. crankshaft position sensor 8. main switch 9. engine stop switch 10. neutral switch 11. sidestand switch 12. clutch switch 13. starting circuit cut-off relay (diode) 14. lean angle cut-off switch 15. wiring connections (of the entire ignition system) Before troubleshooting, remove the following part(s): 1. seat 2. fuel tank 3. side cowlings Troubleshoot with the following special tool(s). Dynamic spark tester YM-34487 Ignition checker 90890-06754 Pocket tester 90890-03112, YU-3112 EAS00738
8-10 IGNITION SYSTEMELEC NOYES 1 a 2 4. Ignition spark gap The following procedure applies to all of the spark plugs. Disconnect the spark plug cap from the spark plug. Connect the ignition checker and spark plug cap as shown. Set the main switch to “ON”. Measure the ignition spark gap . Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs. Minimum ignition spark gap 6 mm (0.24 in) Is there a spark and is the spark gap within specification? The ignition system is OK. EAS00745 5. Spark plug cap resistance The following procedure applies to all of the spark plug caps. Remove the spark plug cap from the spark plug lead. Connect the pocket tester (Ω 1k) to the spark plug cap as shown. Measure the spark plug cap resistance. YESNO Spark plug cap resistance 10 kΩ at 20C (68F) Is the spark plug cap OK? Replace the spark plug cap. EAS00747 6. Ignition coil resistance The following procedure applies to all of the ignition coils. Disconnect the ignition coil leads from the wire harness. Connect the pocket tester (Ω 1) to the ignition coil as shown. Positive tester probe red / black Negative tester probe orange / black (gray / black) Connect the pocket tester (Ω 1k) to the ignition coil as shown. Measure the primary coil resistance. Primary coil resistance 1.53 2.07 Ω at 20C (68F) EAS00743
8-11 IGNITION SYSTEMELEC Negative tester probe spark plug lead Positive tester probe spark lug lead 1 2 Measure the secondary coil resistance. Secondary coil resistance 12 18 kΩ at 20C (68F) Is the ignition coil OK? YESNO Replace the ignition coil. 7. Crankshaft position sensor resistance Disconnect the crankshaft position sensor coupler from the wire harness. Connect the pocket tester (Ω 100) to the crankshaft position sensor coupler as shown. Positive tester probe gray Negative tester probe black 1 2 Measure the crankshaft position sensor re- sistance. EAS00748 Crankshaft position sensor resis- tance 248 372 Ω at 20C (68F) (between gray and black) Is the crankshaft position sensor OK? YESNO Replace the crank- shaft position sen- sor. EAS00749 8. Main switch Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the main switch OK? YESNO Replace the main switch. EAS00750 9. Engine stop switch Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the engine stop switch OK? YESNO Replace the right handlebar switch. EAS00751 10. Neutral switch Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the neutral switch OK? YESNO Replace the neutral switch.
8-12 IGNITION SYSTEMELEC EAS00752 11. Sidestand switch Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the sidestand switch OK? YESNO Replace the side- stand switch. EAS00763 12. Clutch switch Check the clutch switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the clutch switch OK? YESNO Replace the clutch switch. 13. Starting circuit cut-off relay (diode) Disconnect the starting circuit cut-off relay coupler from the wire harness. Connect the pocket tester (Ω 1) to the starting circuit cut-off relay coupler as shown. Check the starting circuit cut-off relay for continuity. Positive tester probe black / red Negative tester probe sky blue 1 2 EAS00753 Positive tester probe black / red Negative tester probe blue / green Continuity 1 3 Positive tester probe sky blue Negative tester probe black / red 2 1 Positive tester probe blue / green Negative tester probe black / red No continuity 3 1 YESNO Replace the starting circuit cut-off relay. When you switch the positive and negative tester probes, the readings in the above chart will be reversed. Are the tester readings correct? NOTE: 14. Lean angle cut-off switch Check the lean angle cut-off switch. Refer to “FUEL INJECTION SYSTEM” in chapter 7. Is the lean angle cut-off switch OK? YESNO Replace the lean angle cut-off switch.