Yamaha Fz6n Manual
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8-53 SELF-DIAGNOSISELEC Repair or replace the wire harness. NO 1. Wire harness Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. Is the wire harness OK? YES NO 2. Fuel pump thermistor Check the fuel pump thermistor for continuity. Refer to “The fuel level indicator light fails to come on”. Is the fuel pump thermistor OK? YES Replace the fuel pump.Replace the multi- function meter. NOTE: 13Fuel pump 34Multi-function meter TROUBLESHOOTING The warning light starts to indicate the self-diagnosis sequence. Check: 1. fuel pump thermistor 2. oil level switch Before troubleshooting, remove the following part(-s): 1. seat 2. front cowling inner panel (left and right) 3. fuel tank Troubleshoot with the following special tool(-s). Pocket tester 90890-03112, YU-3112 1. Fuel pump thermistor CIRCUIT DIAGRAM
8-54 SELF-DIAGNOSISELEC Replace the oil level switch. NO 2. Oil level switch Check the oil level switch for continuity. Refer to “The oil level warning light fails to come on”. Is the oil level switch OK? YES Repair or replace the wire harness. NO 1. Wire harness Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. Is the wire harness OK? YES Replace the multi- function meter. 34Multi-function meter 37Oil level switch 2. Oil level switch CIRCUIT DIAGRAM
9-1 9 STARTING FAILURES TRBL SHTG NOTE: Air filter Improperly installed air filter Clogged air filter element Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft FUEL SYSTEM Fuel tank Empty fuel tank Clogged fuel filter Clogged fuel tank drain hose Deteriorated or contaminated fuel Fuel pump Faulty fuel pump Faulty fuel pump relay Throttle body(-ies) Deteriorated or contaminated fuel Sucked-in air Ignition coil(s) Cracked or broken ignition coil body Broken or shorted primary or secondary coils Faulty spark plug lead Ignition system Faulty ECU Faulty crankshaft position sensor EAS00844 TROUBLESHOOTING 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 procedure in this manual for checks, adjustments, and replacement of parts. STARTING FAILURES ENGINE Cylinder(s) and cylinder head(s) Loose spark plug Loose cylinder head or cylinder Damaged cylinder head 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 Piston(s) and piston ring(s) Improperly installed piston ring Damaged, worn or fatigued piston ring Seized piston ring Seized or damaged piston ELECTRICAL SYSTEMS Battery Discharged battery Faulty battery Fuse(s) Blown, damaged or incorrect fuse Improperly installed fuse 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
9-2 STARTING FAILURE / INCORRECT ENGINE IDLING SPEED / POOR MEDIUM-AND-HIGH-SPEED PERFORMANCETRBL SHTG Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut-off relay Faulty starter clutch ELECTRICAL SYSTEMS Battery Discharged battery Faulty battery 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 Ignition coil(s) Broken or shorted primary or secondary coils Faulty spark plug lead Cracked or broken ignition coil Ignition system Faulty ECU Faulty crankshaft position sensor 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 EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder(s) and cylinder head(s) Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Throttle body(-ies) Damaged or loose throttle body joint Improperly synchronized throttle bodies Improperly adjusted engine idling speed (throttle stop screw) Improper throttle cable free play Flooded throttle body Faulty air induction system EAS00849 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES”. ENGINE Air filter Clogged air filter element FUEL SYSTEM Fuel pump Faulty fuel pump
9-3 FAULTY GEAR SHIFTING / FAULTY CLUTCH TRBL SHTG 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 CLUTCH DRAGS 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 Engine oil Incorrect oil level Incorrect oil viscosity (high) Deteriorated oil EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to “CLUTCH DRAGS”. 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 EAS00852 FAULTY CLUTCH CLUTCH SLIPS Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate Damaged clutch release cylinder Engine oil Incorrect oil level Incorrect oil viscosity (low) Deteriorated oil
9-4 OVERHEATING / OVERCOOLING / POOR BRAKING PERFORMANCETRBL SHTG FUEL SYSTEM Throttle body(-ies) Damaged or loose carburetor joint Air filter Clogged air filter element CHASSIS Brake(s) Dragging brake ELECTRICAL SYSTEMS Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat range Ignition system Faulty ECU Cooling system Faulty radiator fan motor relay Faulty coolant temperature sensor Faulty ECU EAS00855 OVERHEATING ENGINE Clogged coolant passages Cylinder head(s) and piston(s) Heavy carbon buildup Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality COOLING SYSTEM Coolant Low coolant level Radiator Damaged or leaking radiator Faulty radiator cap Bent or damaged radiator fin 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 EAS00856 OVERCOOLING COOLING SYSTEM Thermostat Thermostat stays open EAS00857 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
9-5 FAULTY FRONT FORK LEGS / UNSTABLE HANDLING TRBL SHTG Rear shock absorber assembly(-ies) Faulty rear shock absorber spring Leaking oil or gas Tire(s) Uneven tire pressures (front and rear) Incorrect tire pressure Uneven tire wear Wheel(s) Incorrect wheel balance Deformed cast wheel Damaged wheel bearing Bent or loose wheel axle Excessive wheel runout Frame Bent frame Damaged steering head pipe Improperly installed bearing race EAS00861 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 EAS00862 UNSTABLE HANDLING Handlebar Bent or improperly installed handlebar Steering head components Improperly installed upper bracket Improperly installed lower bracket (improperly tightened ring nut) Bent steering stem Damaged ball bearing or bearing race 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 Swingarm Worn bearing or bushing Bent or damaged swingarm
9-6 FAULTY LIGHTING OR SIGNALING SYSTEM TRBL SHTG 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 EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM 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
56Hazard switch 57Turn signal switch 58Horn switch 59Horn 60Dimmer relay 61Headlight (high beam) 62Headlight (low beam) 63Rear turn signal light (right) 64Rear turn signal light (left) 65Front turn signal / position light (right) 66Front turn signal / position light (left) 1Main switch 2A.C. magneto 3Rectifier / regulator 4Fuse (backup) 5Fuse (fuel injection) 6Fuse (main) 7Starter relay 8Starter motor 9Battery 10Starting circuit cut-off relay 11Sidestand switch 12Neutral switch 13Fuel pump 14Throttle position sensor 15Intake air presser sensor 16Lean angle cut-off switch 17Crankshaft position sensor 18Intake air temperature sensor 19Coolant temperature sensor 20ECU 21Cylinder #1-injector 22Cylinder #2-injector 23Cylinder #3-injector 24Cylinder #4-injector 25Air cut-off valve 26Speed sensor 27Ignition coil #1 and #4 28Ignition coil #2 and #3 29Spark plug 30Meter assembly 31Oil level warning light 32Engine trouble warning light 33Neutral indicator light 34Multi-function meter 35High beam indicator light 36Turn signal indicator light 37Oil level switch 38Right handlebar switch 39Front brake light switch 40Engine stop switch 41Start switch 42Fuse (radiator fan motor) 43Radiator fan motor relay 44Radiator fan motor 45Fuse (signal) 46Fuse (headlight) 47Fuse (ignition) 48Fuse (tail) 49Turn signal relay 50Rear brake light switch 51License plate light 52Tail / brake light 53Left handlebar switch 54Clutch switch 55Dimmer switch FZ6-SS/FZ6-SSC WIRING DIAGRAM