Yamaha Fz6n Manual
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8-13 IGNITION SYSTEMELEC EAS00754 15. Wiring Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the ignition system’s wiring properly con- nected and without defects? YESNO Properly connect or repair the ignition system’s wiring. Replace the ECU.
8-14 1Main switch 6Fuse (main) 7Starter relay 8Starter motor 9Battery 10Starting circuit cut-off relay 11Sidestand switch 12Neutral switch 40Engine stop switch 41Start switch 47Fuse (ignition) 54Clutch switch ELECTRIC STARTING SYSTEMELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM
8-15 ELECTRIC STARTING SYSTEMELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so cur- rent cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the starter switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1Battery 2Main fuse 3Main switch 4Ignition fuse 5Engine stop switch 6Starting circuit cut-off relay 7Diode 8Clutch switch 9Sidestand switch 10Neutral switch 11Start switch 12Starter relay 13Starter motor
8-16 YESNO 3. Starter motor Connect the positive battery terminal and starter motor lead with a jumper lead . Repair or replace the starter motor. A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, other- wise the jumper lead may burn. This check is likely to produce sparks, therefore make sure nothing flammable is in the vicinity. Does the starter motor turn? WARNING 1 23 EAS00758 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 ELECTRIC STARTING 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). EAS00757 TROUBLESHOOTING The starter motor fails to turn. Check: 1. main and ignition fuses 2. battery 3. starter motor 4. starting circuit cut-off relay 5. starter relay 6. main switch 7. engine stop switch 8. neutral switch 9. sidestand switch 10. clutch switch 11. start switch 12. wiring connections (of the entire starting system) Before troubleshooting, remove the following part(s): 1. seat 2. front cowling inner panel (left and right) 3. fuel tank 4. left side cover Troubleshoot with the following special tool(s). Pocket tester 90890-03112, YU-3112 EAS00738
8-17 4. Starting circuit cut-off relay Disconnect the starting circuit cut-off relay coupler from the wire harness. Connect the pocket tester (Ω 1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown. YESNO Replace the starting circuit cut-off relay. Positive tester probe white / blue Negative tester probe blue / white Does the starting circuit cut-off relay have continuity between white / blue and blue / white? 1 2 3 4 EAS00759 Positive battery terminal red / black Negative battery terminal black / yellow EAS00761 5. Starter relay Disconnect the starter relay coupler from the coupler. Connect the pocket tester (Ω 1) and battery (12 V) to the starter relay coupler as shown. YESNO Replace the starter relay. Positive battery terminal red / white Negative battery terminal blue / white Positive tester probe red Negative tester probe black 1 2 3 4 Does the starter relay have continuity be- tween red and black? EAS00749 6. Main switch Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the main switch OK? YESNO Replace the main switch. EAS00750 7. 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 8. Neutral switch Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the neutral switch OK? YESNO Replace the neutral switch. ELECTRIC STARTING SYSTEMELEC
8-18 Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the starting system’s wiring properly con- nected and without defects? EAS00766 12. Wiring YESNO Properly connect or repair the starting system’s wiring. The starting system circuit is OK. 11. Start switch Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the start switch OK? YESNO Replace the right handlebar switch. EAS00764 10. Clutch switch Check the clutch switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the clutch switch OK? YESNO Replace the clutch switch. EAS00763EAS00752 9. Sidestand switch Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the sidestand switch OK? YESNO Replace the side- stand switch. ELECTRIC STARTING SYSTEMELEC
8-19 STARTER MOTORELEC Order Job / Part Q’ty Remarks 1 2Removing the starter motor Seat Front cowling inner panel (left and right) Fuel tank Throttle bodies Starter motor lead Starter motor1 1Remove the parts in the order listed. Refer to “SEAT” in chapter 3. Refer to “COWLINGS” in chapter 3. Refer to “FUEL TANK” in chapter 3. Refer to “THROTTLE BODIES” in chapter 7. For installation, reverse the removal procedure. 10 Nm (1.0 mkg, 7.2 ftlb) 5 Nm (0.5 mkg, 3.6 ftlb) EAS00767 STARTER MOTOR
8-20 STARTER MOTORELEC Order Job / Part Q’ty Remarks Disassembling the starter motor O-ring Front cover Lock washer Oil seal Bearing Washer set Rear cover Washer set O-ring Brush holder Armature assembly Starter motor yoke O-ring1 1 1 1 1 1 1 1 2 1 1 1 2Disassembly the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 6 7 8 9 10 11 12 3.4 Nm (0.34 mkg, 2.5 ftlb) 7.8 Nm (0.78 mkg, 5.6 ftlb) 13 EAS00768
8-21 STARTER MOTORELEC NOTE: EAS00770 CHECKING THE STARTER MOTOR 1. Check: commutator Dirt Clean with 600 grit sandpaper. 2. Measure: commutator diameter a Out of specification Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3. Measure: mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commuta- tor. Mica undercut 0.7 mm (0.03 in) The mica of the commutator must be undercut to ensure proper operation of the commutator. 4. Measure: armature assembly resistances (commuta- tor and insulation) Out of specification Replace the starter motor. a. Measure the armature assembly resistances with the pocket tester. Pocket tester 90890-03112, YU-3112 Armature coil Commutator resistance 1 0.0012 0.0022 Ω at 20C (68F) Insulation resistance 2 Above 1 MΩ at 20C (68F) b. If any resistance is out of specification, re- place the starter motor.
8-22 STARTER MOTORELEC NOTE: 5. Measure: brush length a. Out of specification Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: brush spring force Out of specification Replace the brush springs as a set. Brush spring force 7.16 9.52 N (730 971 gf, 25.77 34.27 oz) 7. Check: gear teeth Damage / wear Replace the gear. 8. Check: bearing oil seal Damage / wear Replace the defective part(s). EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: brush seat 1 2. Install: armature 2 O-ring 3 New Align the tab a on the brush seat with the slot b in the starter motor rear cover.