Yamaha Fz 09 2014 Manual
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charging. TIP~~~~~~~~~~~~~~ Voltage sh ou ld be measu red 30 m inutes after the engine is s topped. b . Connec t a cha rger and ammeter to t he bat- tery and start charg i ng. TIP~~~~~~~~~~~~~~ Set the charg ing voltage to 16-17 V. If the set tin g is lower, charging w ill be insu fficient. If too h ig h, the battery will be over -charged. c. Make sure that the current is h igher than the standard chargi ng current wr itt e n on the bat tery . TIP~~~~~~~~~~~~~~~ If the cu rren t is lower t han the standard charging c u rren t wr itt en on the battery, set the charg ing vo ltage adj ust d ial at 20-24 V and monit or the ampe rage for 3-5 min utes to ch ec k th e battery. • Sta ndard charg in g cur ren t is reac hed Batte ry is good . • Sta ndard charging current is not reached Replace the batte ry. d. Adjust the voltage so that the c urr en t is at t he s ta nda rd cha rg ing level. e. Set the time acco rd in g to the ch arg ing time suitable f o r th e open -c ir cu it vo ltage . f. If charg ing requires more than 5 hou rs , it is adv isable t o c heck th e charg ing current after a l apse o f 5 hours. If the re is a ny cha nge in the ampe rage , read ju st t he vo ltage t o obtain the standard ch argi ng cu rrent. g. Meas ure the battery open-c ircu it vo ltage after leav ing the battery unuse d for more than 30 minutes . 1 2.8 V o r mo re ---C harging is comp lete. 1 2.7 V or less ---Recharging is required . Under 12 .0 V --- Replace th e battery . ••••••••••••••••••\ •••••••••••••• YYTTTYTTTYYTTTYTTTYYTTYYTTTYTTTY Charging method using a constant voltage charger a. Meas ure the open -circuit vo ltage prior to c harg in g. TIP~~~~~~~~~~~~~~ Vo ltage should be measured 30 minutes after th e engin e is stopped . b. Connect a charger and ammeter to t he bat tery and start charging. ELECTRICAL COMPONENTS c. Make s ure t hat the curren t is hig h er t han the standa rd c hargin g current written on the ba t tery. TIP~~~~~~~~~~~~~~ lf the current is lower than the standard charging current written on the battery, this ty pe of bat tery charger cannot charge the VALA (Valve Regu l ated Lead Acid) battery. A variab le voltage charger is rec omm ended . d. Cha rge the battery un til the batterys charg- ing voltage is 15 V. TIP~~~~~~~~~~~~~~ Set the ch arg ing ti me at 20 ho urs (max imum). e . Measu re the battery open-c i rcuit voltage after leav ing the battery unused for more than 30 min ut es . 12.8 V or more ---C ha rg in g is comple te. 12.7 V or less ---Recharg ing is req uir ed. Under 12.0 V ---Rep lace the battery. ••••••••••••••••••\ •••••••••••••• 6. Install: • Battery Refe r t o GENERA L CHASS IS on page 4-1. 7. Con nect: • Battery leads (t o th e battery termina ls) NOTICE ~~~~~~~~~~~~~ Fir st, connect the positive batte ry lead 1 , an d then th e negati ve battery lea d 2. 8. C heck : • Battery terminals Dirt 4 C lean wit h a wi re brus h. Loose connec ti on 4 Co nnect p ro pe rly . 9. Lubricate : • Battery termina ls R ecommended lubricant 1--al D ielectric gre ase 8-96
1 O.lnstall: • R ide r seat Refer to GENERAL CHASSIS on page 4-1. EA80 I I RS ., I! tJYIRW L0(BR Sb . ~ 1 . Posttive ba ttery term ina l 2. Negative battery termi nal 3. Posttive tester probe 4 . Ne gative teste r probe Result Continuity ViiL RL 8V SbW (between 3 and 4) Relay unit (fuel pump relay) 3 ~ 1 I I I -Ill ] R UV/ ~ r I RB / • uvl~, ~ele• Sb J 1. Positiv e batte ry te rm ina l 2. Negative battery terminal 3. Positiv e teste r prob e 4 . Negat ive teste r prob e Result Continuity 4 \Vil M. BN SbNI (between 3 and 4) -
Headlight relay ,........,....._,,,.3 Bri\V 2 1. Posit ive battery term ina l 2 . Negat ive batte ry term ina l 3 . Posit ive tes ter probe 4 . Negat ive tes t er probe Result Continuity (between 3 and 4 ) Radiator fan motor relay -=- 2 1. P os it ive batt ery term ina l 2 . Negat ive batte ry term ina l 3 . Posit ive tes ter probe 4 . Negat ive tes t er probe Result Continuity :>.. ~ . f (between 3 and 4 ) EAS1RCl801 4 1 , 3 4 1 CHECKING THE TURN SIGNAUHAZARD RELAY 1. Check: • Tum sig naVhazard relay inp ut vol tage O ut of speci ficat ion --t T he wiri ng c ircuit from the ma in switch to the turn signaVhazard re l ay cou p ler is fau lty and must be repaired. Turn signaVhazard relay input voltage DC 12V ELECTRICAL COMPONENTS TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a. Con nect the pocket tester (DC 20 V) to the tum signa l/hazard r elay termina l as sh own. Pocket tester 90890-03112 Analog pocket tester VU -03112 -C • Positive tester probe blue/ red 1 • N ega tive tester probe G rou nd UR 1 b. Turn the main swi tc h to ON. c. Measure the tum signa l/haza rd relay inpu t volta ge . ••••••••••••••••••\ •••••••••••••• 2. Check: •Tu m signa l/haza rd relay o utput vo ltage O ut of spec ification --t Rep lace. Turn signal/hazard relay output voltage DC 12V TTYTTTYYTTTYTTTYYTTTYTTTYTTTYYTT a. Con nect the pocket tester (DC 20 V) to the tu rn s igna l/haza rd r elay terminal as sh own. Pocket tester 90890-03112 Analog pocket tester VU-03112-C • Po sitive tes te r probe b row n /white 1 8-98 • Nega tive tester probe G rou nd
b. Tur n th e main sw itch to O N. c. M eas ure t he turn sig nal/h aza rd re lay ou tp ut vo lt age . ··-CHECKING THE RELAY UNIT (DIODE) 1. Check: • Re lay u nit (d iode ) Out of sp eci fica tion -> R ep lace. Pocket tester 90890 -03112 Analog pocket tester YU-03112-C TIP-------------- T h e pocket te st er or th e an alog po cket teste r r ea din gs are shown in th e follow in g tab le. ELECTRICAL COMPONENTS Continuity Positive tester probe sky blue 1 Negative tester probe black/yellow 2 No continuity Positive tester probe black/yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe black/red 3 No continuity Positive tester probe black/red 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe sky blue/white 4 No continuity Positive tester probe sky blue/white 4 Nega tive tester probe sky blue 1 Continuity Positive tester probe blue/black 5 Negative te ster probe black/red 3 No continuity A Positive tester probe black/red 3 Negative tester probe blue/black 5 ~ ~ 1 ~ 1 n I I I Il UV/ I I RB IWL Rl ...,.. UV 1, .. ~el RR Sb BIY SblW , - ••••••••••••••••••\ •••••••••••••• a . Disco nnect the re la y unit cou p ler fr om the w i re ha rness . b . C on nect th e pocket tester (!1 x 1) to the rela y 8-99
unit term ina l as sh own. c . Ch eck the re lay un it (d iode) for continu ity. d. Ch eck the re lay un it (d iode) for no con ti n u ity. E A S2$ 100 CHECKING THE IGNITION COILS The following proced ure applies to all of the igni tion coils. 1. C heck: • Primary coil r es is ta nce O ut of speci fica tion -> Replace. Primary coil resistanc e 1.1s-1.61 n YYTTTYTTTYYTTTYTTTYYTTYYTTTYTTTY a. Remove the ignit io n coil from the spark plug. b. Connec t the pocket teste r (0 x 1) to the igni t io n coil as sh own. Pocket tester 90890-0 3112 A nalog pocket tester YU-03 112-C • Pos iti ve tes te r probe -> red/b lack 1 • Negat ive tester probe -> Cylinder-#1 ign iti on coil orange 2 Cy lin der-#2 ig nit io n coil g ray /red 2 Cylinder-# 3 ignit ion coi l ora nge/gree n 2 c. Measure the prim ary coil resistance. ••••••••••••••••••\ •••••••••••••• 2. Chec k: • Secondary coil res istance Out of specificat ion -> Replace. ELECTRICAL COMPONENTS Secondary coil res is ta n ce 9.35-12 .6 5 kn TTYTTTYTTTTTTTTYTTTTTTTTYTTTYTTT a. Con nec t the pocket teste r (n x 1 k) to the ig nit io n coil as shown. P oc ket tester 90 890-03 112 Analog pocket t ester YU-0 3 11 2-C • Negative tester probe -> red/black 1 • Pos itive teste r probe -> spark plug termina l 2 D -§+ b. Measu re t he secondary coil res is ta nce . ....,..,. CHECKING THE IGN ITION SPARK GAP 1. C heck: • Ign ition spark gap Out of spec ificat i on -> Perform the igniti on sys tem tr oub les hoot ing , start ing with step 5. Refe r t o T RO UBLESHOOT ING on page 8-4 . Min imum ignition spa rk gap 6. 0 m m (0.24 in ) TIP~~~~~~~~~~~~~~ lf the ignit ion spark gap is wit h in spec ification, the ign it ion system circ uit is operating normally. TTTTTTTYTTTYTTTTYTTTYTTTTTTTTYTT a. Remove the ignitio n coil from the spa rk p lug . b. Con n ect the ign itio n checker 1 as shown . Ignition checker 9 0890-0 6754 Oppama pet-4 000 spark checker YM-34487 8-100
2 1 2. Ignit ion coil c . Tum the ma in sw it ch to ON . d. Measu re the igni tion spark gap a. e. Crank th e eng ine by pushing th e(?) side of the sta rt/ eng ine stop switch and gra dually in· crease the spark gap un til a mis fir e occu rs. EAS2El120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 . Discon nect: • Crankshaft pos i tion sensor coupler (from the wire harness) 2. Check: • Cranks haft pos i ti on senso r resistance Ou t of spec ifica ti on -> Replace the crank · shaft pos i ti on senso r. Crankshaft position sensor resis· tance 228-342 Q (Gy·B) TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a. Connec t the poc ke t tester (n x 100) to the cra nkshaft pos i t ion sensor coup ler as shown. Pocket tester 90890-03112 Analog pocket tester YU -03 112-C • Posi tive tes ter probe gray 1 • Ne gative tester probe black 2 ELECTRICAL COMPONENTS 1 y B 2 b. Measure the cranks haft position se nsor re sistance. CHECKING THE LEAN ANGLE SENSOR 1. Remove : • Lea n ang le sensor (from the fue l tank bracket ) 2. Check: • Lean ang le s ensor ou tp ut vo lt ag e Out of sp ecifica tion -> Rep lace. Lean angle sensor output voltage Less than 65° 0.4-1.4 v More than 65° 3.7-4.4 v • ••••••••••••••••••\ ••••••••••••• a. Conn ect the test harness- lean angle senso r (6 P) 1 to the lea n ang le se nsor and wi re harne ss as shown . b. Conn ect the poc ket teste r (D C 20 V) to th e test harnes s-le an ang le s ens or (6P). Pocket tester 90890-03112 Analog pocket tester YU-03112..C Test harness· lean angle sensor (SP) 90890-03209 YU-03209 • Po sitive tester probe yellow/green (wi re harness color) • Negat ive tester probe black/ blue (wi re har ness color) 8-101
c. Set the main switch to ON. d. Tur n the lean angle sensor to 65 °. e. Me asure the lean angle sensor output volt age . EAS2e~ CHECKING THE STARTER MOTOR OPERATION 1. Check: • Sta rter mo tor operat ion Does not operat e --+ Perform the ele ctric s ta rting syste m troub l eshooting, startin g with s te p 4. Refe r to TROUBL ESHOOTING on page 8 -11. YYTTTYTTTYYTTTYTTTYYTTYYTTTYTTTY a. Con nect the pos iti ve battery terminal 1 and s ta rt er motor lead 2 w ith a jumper lea d 3. EWAl$810 AwARNING • 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. b. Check th e starter motor operat ion . ELECTRICAL COMPONENTS ......... CHECKING THE STATOR COIL 1. Disco nnect: • Stator co il coup ler (from the wire ha rnes s) 2. Check: • Sta tor coi l resist ance Out of spec ifica tion --+ Rep lace the stator coil. Stator coil resistance 0 .152--0 .228 n (W -W) • ••••••••••••••••••\ ••••••••••••• a. Connect the digit a l ci rcui t tester to t he stato r coi l coup l er as shown . Digital circuit tester 90890-03174 Model 88 Multimeter with tachom eter YU-A1927 • Positi ve teste r probe whit e 1 • Neg ative tester probe white 2 • Posi t ive teste r probe white 1 • Negat ive tester probe white 3 • Pos it ive tes te r p robe white 2 • Negat ive tester probe whit e 3 1 2 WWW b. Measure the stator coil res istance . .....,,,. 3 CHECKING THE RECTIFIER/REGULATOR 1. Check: • Rectifier/regu la to r inp ut vo lt age Out o f spec if icatio n --+ Correct the stato r co il cond itio n. Refer to CHECKING THE STATOR COIL on page 8-102. 8-102
Rectifier/regulator input voltage above 14 Vat 5000 r/min TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a. Set the engine tac hometer to the ignition coil of cylinde r #1. b. Connec t t he pocket tester (AC 20 V) to the rectifier/ regu lato r coup le r as shown. Pocket tester 90890-03112 Analog pocket tester YU -03112 -C • Posi tive tes ter probe w hit e 1 • N egative teste r prob e w hit e 2 • Posi tive tes ter probe w hit e 1 • N egative teste r p robe w hit e 3 • Posi ti ve tester probe w hit e 2 • N egative teste r p robe w hit e 3 1 2 3 1---1~ c. Start the engine and let it run at approx imate ly 5000 r/m in. d. Measure the rect ifie r/regu lator inp ut vo lta ge. ••••••••••••••••••\ •••••••••••••• 2. Chec k: • Rectif ier/r egulator output voltage O ut of specif icat ion 4 Rep lace the rectifi er/reg ulator. Regulated voltage (DC) 14.3-14.7 v TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a. Set the engine tac hometer to the ignit ion coil of cylinde r #1. b. Connec t the poc ket tes ter ( D C 20 V) to the ba ttery as shown. ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU- 03112 -C • Positive teste r probe 4 po sitive bat tery te rm inal 1 • Nega tive tester probe 4 negative batt ery te rminal 2 s, \*C c. Start the engine and le t it run at approx imate ly 5000 r/min. d . Measure the ch argi ng volta ge. ......... CHECKING THE HORN 1. C heck: • Hom res istance Ou1 of spe cific ati on 4 Rep la ce. Horn Coil resistance 1.01 -1.11 n TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a. Disco nnect th e horn lea ds from the horn ter mina ls. b. Con nect the digital circuit tester to the horn termina ls . Digital circuit tester 90890-03174 Model 88 Multimeter with tachom eter YU -A1927 • Positive teste r p robe Horn t erminal 1 • N ega tive tester probe Horn t erminal 2 8-103
c. Meas ure the horn resis tance. ••••••••••••••••••\ •••••••••••••• 2 . Ch eck: • Horn sound Fau lty sou nd --t Rep lace . EA S2$ 190 CHECKING THE ENGINE OIL LEVEL SWITCH 1. Drain: •Engine oil 2 . Remove: • Oil level swi tc h (from the oil pan) 3. Check: • Oil level switch resistance Oil level switch Oil level switch resistance (maxi mum level position) 484.o-536.o n Oil level switch resistance (mini mum level position) 114.0-126.0 n TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a. Connec t the pocket tester (n x 100) to t he oil level swi tc h term ina l as sh own. Pocket tester 90890-03112 Analog pocket tester YU -03112-C Mi nim um leve l position A • Posi tiv e tester probe Con nector (gray) 1 • N egative teste r probe B od y eart h 2 ELECTRICAL COMPONENTS Maxim um level p osi tion B • Positiv e tester probe Con nec tor (gray) 1 • Neg ative tester probe B od y ea rth 2 !ID 2 1 b. Measure the oil leve l switch resista nce. CHECKING THE FUEL SENDER 1 . Disc onne ct: • Fuel pum p co uple r (from the fuel pump) 2. Remov e: •Fue l ta nk 3. Rem ove: •Fue l pum p (fr om the fue l tank ) 4. Check: • Fue l sender res is tance Out of specificat ion --t Replace the fuel pump assemb ly . Sender unit resistance (full) 9.0-11.0 n Sender unit resistance (empty) 213.0-219.o n TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a. Con nect the pocket tes ter (0 x 10/100) to the fue l sen der termina ls as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112 -C • Positive tester probe --t Fuel sen der term ina l 1 • N egative tester prob e --t Fuel sender termina l 2 8-104
2 b. Move the fuel sender floa t to maxim um 3 and minimum 4 level pos ition. °° CHECKING THE FUEL METER/FUEL LEVEL WARNING LIGHT Th is model is eq uipped with a self -d iagnosis de v ice for the fuel level de tec tion ci rcuit. 1. Check : • Fue l m ete r/fuel le vel w arning ligh t 1 (Tum the ma in s witch to ON.) W arn ing light comes o n for a f ew seco nds th e n go es off 4 Warni ng ligh t is OK. Warni ng light does not com e on 4 R ep lace th e me ter asse mbly. Warni ng lig ht flashes eigh t times, then goes off for 3 sec onds in a re p eated cycle (mal functi on dete ct ed in fuel se nde r) 4 Rep lace the f u el pump assemb ly. 1 ELECTRICAL COMPONENTS ......... CHECKING THE OIL LEVEL WARNING LIGHT This model is equ ipped with a se lf - diagnosis de v ic e f or th e oil leve l dete cti on circui t. 1. Check: •Oil leve l warning light 1 (Tu m the main swi t ch to O N.) W arni ng ligh t comes on fo r a few seconds then goe s off 4 Warni ng ligh t is OK. W arni ng ligh t d oe s not co me on 4 Rep lace the meter assemb ly. Wa rni ng light flashes ten times, then goes off for 2.5 seconds in a re p eate d cycle (mal func tion detec ted in oil leve l switc h) 4 Replace the oil level switch . CHECKING THE SPEED SENSOR 1. Check: • Speed sensor outp ut voltage Out of spec ificat io n 4 Rep lace. 1 ~ Oulput voltage reading cycle 0.6 V to 4.8 V to 0.6 V to 4.8 V ••••••••••••••••••\ •••••••••••••• a. Con nect the tes t h arness S-press ure senso r (3P) 1 to th e spee d senso r coupler and wire harn ess as shown. b. Con nect th e pocket tester (DC 20 V) to the test harness S-press ure sensor (3P) . Pocket tester 90890-03112 Analog pocket tester YU-03112 -C Test harness S -pressure sensor (3P) 90890-03207 YU-03207 • Po sitive te s te r pr obe white/yellow (wire harn ess color) • Negat ive tester probe b la ck/blu e (wi re harness c olor) 8-105