Yamaha Fz6 N Service Manual

							
8
ELECTRICAL SYSTEM
IGNITION SYSTEM....................................................................................... 8-1
CIRCUIT DIAGRAM............. ................................................................... 8-1
TROUBLESHOOTING ............................................................................ 8-3
ELECTRIC STARTING SYSTEM .................................................................. 8-5
CIRCUIT DIAGRAM............. ................................................................... 8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......................... 8-7
TROUBLESHOOTING ............................................................................ 8-8
CHARGING SYSTEM ................................................................................. 8-11
CIRCUIT DIAGRAM............. ................................................................. 8-11
TROUBLESHOOTING .......................................................................... 8-13
LIGHTING SYSTEM ................................................................................... 8-15
CIRCUIT DIAGRAM............. ................................................................. 8-15
TROUBLESHOOTING .......................................................................... 8-17
SIGNALING SYSTEM ................................................................................. 8-19
CIRCUIT DIAGRAM............. ................................................................. 8-19
TROUBLESHOOTING .......................................................................... 8-21
COOLING SYSTEM .................................................................................... 8-27
CIRCUIT DIAGRAM............. ................................................................. 8-27
TROUBLESHOOTING .......................................................................... 8-29
FUEL INJECTION SYSTEM ....................................................................... 8-31
CIRCUIT DIAGRAM............. ................................................................. 8-31
ECU SELF-DIAGNOSTIC FUNCTION ................................................. 8-33
FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS 
OPERATION CONTROL) ..................................................................... 8-34
TROUBLESHOOTING METHOD ......................................................... 8-36
DIAGNOSTIC MODE ............................................................................ 8-37
TROUBLESHOOTING DETAILS .......................................................... 8-43
FUEL PUMP SYSTEM ................................................................................ 8-57
CIRCUIT DIAGRAM............. ................................................................. 8-57
TROUBLESHOOTING .......................................................................... 8-59
IMMOBILIZER SYSTEM ............................................................................. 8-61
CIRCUIT DIAGRAM............. ................................................................. 8-61
GENERAL INFORMATION ................................................................... 8-63
PART REPLACEMENT AND KEY CODE REGISTRATION 
REQUIREMENTS ................................................................................. 8-63
TROUBLESHOOTING .......................................................................... 8-67
SELF-DIAGNOSIS FAULT CODE INDICATION.................................... 8-67 
						

							
ABS (ANTI-LOCK BRAKE SYSTEM)........................................................ 8-71
ABS CIRCUIT DIAGRAM .... ................................................................. 8-71
ABS COMPONENTS CHART ............................................................... 8-73
ABS CONNECTOR LOCATION  CHART .............................................. 8-75
ABS ECU AND ABS MOTOR RE LAY ................................................... 8-77
[D-1] MAINTENANCE OF THE ABS ECU ............................................ 8-78
[D-2] MAINTENANCE OF THE ABS MOTOR RELAY .......................... 8-78
ABS TROUBLESHOOTING OUTL INE ................................................. 8-78
BASIC INSTRUCTION FOR TROU BLESHOOTING............................ 8-79
BASIC PROCESS FOR TROUBL ESHOOTING ................................... 8-81
[A] ABS MALFUNCTION CHECK USING THE ABS WARNING 
LIGHT ................................................................................................... 8-82
[B] DETAILED ABS MALFUNCT ION CHECK....................................... 8-82
[B-1] THE ABS WARNING LIGHT DOES NOT COME ON .................. 8-82
[B-2] THE ABS WARNING LIGHT REMAINS ON ................................ 8-82
[B-3] THE ABS WARNING LIGHT FLASHES ....................................... 8-83
[B-4] MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS 
(PAST MALFUNCTION)........................................................................ 8-83
[B-5] MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS 
(PRESENT MALFUNCTION) ............................................................... 8-85
[C] DETERMINING THE CAUSE AND LOCATION OF 
THE MALFUNCTION ............................................................................ 8-86
[C-1] ONLY THE ABS WARNING LIGHT DOES NOT 
COME ON WHEN THE MAIN SWITCH IS SET TO “ON” .................... 8-86
[C-2] ABS WARNING LIGHT AND ALL OTHER INDICATORS 
DO NOT COME ON .............................................................................. 8-86
[C-3] ABS WARNING LIGHT FLASHES............................................... 8-87
[C-4] ABS WARNING LIGHT FLASHES EVERY 0.5 SECOND ........... 8-87
[C-5] DIAGNOSIS BY THE MALFUNCTION CODE ............................. 8-87
[D-6-4] DELETING THE MALFUNCTION CODE ............................... 8-101
[D-6-6] DELETE FUNCTION TEST .................................................... 8-103
[D-6] FINAL CHECK ........................................................................... 8-104
ELECTRICAL COMPONENTS ................................................................. 8-105
CHECKING THE SWITCHES ............................................................. 8-109
CHECKING THE BULBS AND BULB SOCKETS ............................... 8-112
CHECKING THE LEDS ...................................................................... 8-113
CHECKING THE FUSES.................................................................... 8-113
CHECKING AND CHARGING THE BATTERY ................................... 8-114
CHECKING THE RELAYS .................................................................. 8-117
CHECKING THE ABS MOTOR RELAY .............................................. 8-118
CHECKING THE SOLENOID VALVES AND MOTOR ........................ 8-119
CHECKING THE TURN SIGNAL/HAZARD RELAY ........................... 8-120
CHECKING THE RELAY UNIT (DIODE) ............................................ 8-120
CHECKING THE SPARK PLUG CAPS .............................................. 8-121
CHECKING THE IGNITION COILS .................................................... 8-121
CHECKING THE CRANKSHAFT POSITION SENSOR ..................... 8-122
CHECKING THE LEAN ANGLE SENSOR ......................................... 8-123
CHECKING THE WHEEL SENSOR ................................................... 8-123
CHECKING THE STARTOR MOTOR OPERATION ........................... 8-124
CHECKING THE STATOR COIL ......................................................... 8-124
CHECKING THE RECTIFIER/REGULATOR ...................................... 8-124
CHECKING THE HORN ..................................................................... 8-125 
						

							
CHECKING THE ENGINE OIL LEVEL GAUGE ................................. 8-125
CHECKING THE FUEL SENDER ...................................................... 8-126
CHECKING THE SPEED SENSOR ................................................... 8-126
CHECKING THE RADIATOR FAN MOTOR........................................ 8-127
CHECKING THE COOLANT TEMPERATURE SENSOR .................. 8-127
CHECKING THE THROTTLE POSITION SENSOR........................... 8-128
CHECKING THE FUEL PUMP ........................................................... 8-128
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ................. 8-129
CHECKING THE INTAKE AIR PRESSURE SENSOR ....................... 8-129
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ................ 8-130 
						

							
IGNITION SYSTEM
8-1
EAS27090
IGNITION SYSTEM
EAS27110
CIRCUIT DIAGRAM
ChB
P
G/L Y/L R/GLgB/W
G/L
Y/L
R/GLgB/W
R/B
R/LG/BR/LG/BR/LG/B
R/B R/L
G/B
R/B23R/L
R/L
R/LR/BR/L24
25
26
27
R/WBr/RR/W
Br/R
15L
Y
B/L
D
G/W
G/WD
Br/W Br/W D
P/W P/W D
B/L B/L
B/LBr/W
LB/LP/W
16
2021
B/LG/WB/L B/L
L
A
B/W A
Y/L D
YY
C
LL C
R/L
C G/B
C
R/B
B/L
22
R/L
B/L
G/WBr/WYP/WB/L
G/WBr/WYP/WB/L
18
L
L
P/W
P/W
R/B
R/L
G/B
L
B/Y
B/LY/GL
B/R
Y/B
B/L
W/Y
W/Y B/L
B/L
L G/Y
R/B R/L
G/B L
B/L
W/Y
L
B/L
29
30 31
31
Y/L
19Gy
B
Gy B/L
28
R/B
17B
B
L
W
R/W P/BGy/GB/L
R/B
W L/Y
B/L
Y/L R/L
Y/G Y/G L/Y
R/W
Gy
Gy
Y
Y
Br/W
Br/W
G/W
G/W
R/WL/R
B/YBB/GG/WW
Ch
Dg
B BBr/R R/B R/B
G/B G/B
L/W
P/B P/B
Gy/G
Gy/G
L
O/B O/B
Gy/B Gy/B
B/W
R/W
B/W
YW/YG/WGy/GB/LB/RB/YL/Y
Y/LP/BBG/Y
R/BGy/B Br/W
Y/GP/WLB/W
R/WR/LL/WGyBr/RBY/BG/BO/B
Ch32 33
34
36
37
37 38
39
40 35
B
L/R
B W
W
B
R/W
R/W
B
G/W
G/W A
L/RBL/RB
B
R/GR/G
B/W Y/L
B B/GB
B/Y B
DgAG/LG/L
A
Dg
B
Ch B
Lg
Lg
B/Y
50
53
OFF
RUN
65
FREE
PUSH
R/Y
55
B
B
7
BB10G/YL/W
R/WR/BB
Br
G/YW/L R/WR/BBBr R
R/WL/W
9
66R
L/G L/G
R/W
R/W
57
B
Br/L
52
Y
L
B HI
LO
W/L
W/L
Y/B
Br
BrOFF
ON
8
L
N
R
51
YL BL
L/W
Br/L
Br/L
OFFON ON
Y Y
B
Dg
Y
L/B
Br/WR/Y
Ch
L/Y
G
BB/YBrR/YGY/B
R/Y
R/Y
Dg Y
L/BBr/WR/Y
ChB/RBB/YBr
13
B
BBrYBr
G/Y
5B
R
R
L/W
L/W
R/B
B72B/Y
B/Y
12B
BL/GB
59 60 61 62 63 64
58
B/R
B/R11
R/Y
R/Y54
Ch
B
73
R
Y
Y
L/BDg
B
Br/WBr/G
Br/GBr/GBr/W
Br/WCh
Ch Dg
Dg
Ch Dg
BG/W
R/W
B
R/L
G
G
B
B
L/YB/Y
Dg B
W
Br
B R/W
Sb Sb
R/L R/L
41
56
L/R
R/L
W/L
R/B
L/W
R
Lg
B/Y
Sb
B/R
L/GR/WL/YL/W
Br/R
WB R/B
L/Y
SbSb
R/W
B
14
BL
W W G/W
G/W G/L Lg
Lg
70Ch
B Ch
B
68 67
69
67 71
B
B B
B L/R
Dg
B
Dg
B
L/R
BB
BB B/Y B
B/G B
BB/G
B/Y
Dg
Ch
B R
R
R
Br/BBr/B
2W
W
W WW
W
4R
WW
WW
WW
42 43
45
44 46R
Br/LBB1
47
R/G
BB3
BB4
BB
BB
Br/L
BB
BB
B2 B1
Br/BLG/Y
R/W
BB
B2
BB2
BB3
BB1
BB4Br/RB
48
R/W
3
B
L B
L
L
L
B
G/Y R/W
R
Br/L
BBB
R/GY/LG/L R/W
R
B
W
W
W
B
6
BB2 B2Y/L
B
B2R/GY/LLgR/WBr/RBr/R
ON
OFF1
49
G/L
R/G
R/G
R/WL/RYBG-G/WWChDg
B/L
WIRE SUB LEAD2D
MAIN HARNESS WIRE SUB LEAD1
C
MAIN HARNESS CORD HEAD LIGHT2
B
MAIN HARNESS
CORD HEAD LIGHT1A
MAIN HARNESS
OFF
Lg WB/WG/WY/L
Dg
G/L R/WChR/GB/Y Lg
W
B/WG/WY/L
Dg
G/LR/WChR/GY 
						

							
IGNITION SYSTEM
8-2
1. Main switch
7. Main fuse
10.Battery
11.Starting circuit cut-off relay
12.Sidestand switch
13.Neutral switch
18.Lean angle sensor
19.Crankshaft position sensor
22.ECU (engine control unit)
29.Cylinder-#1/#4 ignition coil
30.Cylinder-#2/#3 ignition coil
31.Spark plugs
45.Engine stop switch
52.Ignition fuse
59.Clutch switch 
						

							
IGNITION SYSTEM
8-3
EAS27140
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
NOTE:
 Before troubleshooting, remove the following part(s):
1.Seat
2.Fuel tank
3.Side cowlingsNG→
OK ↓
NG→
OK ↓
NG→
OK ↓
NG→
OK ↓
NG→
OK ↓
NG→
OK ↓
NG→
OK ↓
1. Check the fuses.
(Main and ignition)
Refer to CHECKING THE 
FUSES on page 8-113. Replace the fuse(s).
2. Check the battery. Refer to CHECKING AND 
CHARGING THE BATTERY on 
page 8-114.  Clean the battery terminals.
 Recharge or replace the battery.
3. Check the spark plugs. Refer to CHECKING THE SPARK 
PLUGS on page 3-11. Re-gap or replace the spark plugs.
4. Check the spark plug caps. Refer to CHECKING THE SPARK 
PLUG CAPS on page 8-121. Replace the spark plug caps.
5. Check the ignition coils. Refer to CHECKING THE IGNI-
TION COILS on page 8-121. Replace the ignition coils.
6. Check the crankshaft position  sensor.
Refer to CHECKING THE 
CRANKSHAFT POSITION SEN-
SOR on page 8-122. Replace the crankshaft position sen-
sor.
7. Check the main switch. Refer to CHECKING THE 
SWITCHES on page 8-109. Replace the main switch. 
						

							
IGNITION SYSTEM
8-4
NG→
OK ↓
NG→
OK ↓
NG→
OK ↓
NG→
OK ↓
NG→
OK ↓
NG→
OK ↓
NG→
OK ↓
8. Check the engine stop switch.
Refer to CHECKING THE 
SWITCHES on page 8-109. Replace the right handlebar switch.
9. Check the neutral switch. Refer to CHECKING THE 
SWITCHES on page 8-109. Replace the neutral switch.
10. Check the sidestand switch. Refer to CHECKING THE 
SWITCHES on page 8-109. Replace the sidestand switch.
11. Check the clutch switch. Refer to CHECKING THE 
SWITCHES on page 8-109. Replace the clutch switch.
12. Check the starting circuit cut-off  relay.
Refer to CHECKING THE 
RELAYS on page 8-117. Replace the starting circuit cut-off 
relay.
13. Check the lean angle sensor. Refer to CHECKING THE LEAN 
ANGLE SENSOR on page 8-123. Replace the lean angle sensor.
14. Check the entire ignition system’s  wiring.
Refer to CIRCUIT DIAGRAM on 
page 8-1. Properly connect or repair the ignition 
system’s wiring
Replace the ECU (engine control 
unit). 
						

							
ELECTRIC STARTING SYSTEM
8-5
EAS27160
ELECTRIC STARTING SYSTEM
EAS27170
CIRCUIT DIAGRAM
ChB
P
G/L Y/L R/GLgB/W
G/L
Y/L
R/GLgB/W
R/B
R/LG/BR/LG/BR/LG/B
R/B R/L
G/B
R/B23R/L
R/L
R/LR/BR/L24
25
26
27
R/WBr/RR/W
Br/R
15L
Y
B/L
D
G/W
G/WD
Br/W Br/W D
P/W P/W D
B/L B/L
B/LBr/W
LB/LP/W
16
2021
B/LG/WB/L B/L
L
A
B/W A
Y/L D
YY
C
LL C
R/L
C G/B
C
R/B
B/L
22
R/L
B/L
G/WBr/WYP/WB/L
G/WBr/WYP/WB/L
18
L
L
P/W
P/W
R/B
R/L
G/B
L
B/Y
B/LY/GL
B/R
Y/B
B/L
W/Y
W/Y B/L
B/L
L G/Y
R/B R/L
G/B L
B/L
W/Y
L
B/L
29
30 31
31
Y/L
19Gy
B
Gy B/L
28
R/B
17B
B
L
W
R/W P/BGy/GB/L
R/B
W L/Y
B/L
Y/L R/L
Y/G Y/G L/Y
R/W
Gy
Gy
Y
Y
Br/W
Br/W
G/W
G/W
R/WL/R
B/YBB/GG/WW
Ch
Dg
B BBr/R R/B R/B
G/B G/B
L/W
P/B P/B
Gy/G
Gy/G
L
O/B O/B
Gy/B Gy/B
B/W
R/W
B/W
YW/YG/WGy/GB/LB/RB/YL/Y
Y/LP/BBG/Y
R/BGy/B Br/W
Y/GP/WLB/W
R/WR/LL/WGyBr/RBY/BG/BO/B
Ch32 33
34
36
37
37 38
39
40 35
B
L/R
B W
W
B
R/W
R/W
B
G/W
G/W A
L/RBL/RB
B
R/GR/G
B/W Y/L
B B/GB
B/Y B
DgAG/LG/L
A
Dg
B
Ch B
Lg
Lg
B/Y
50
53
OFF
RUN
65
FREE
PUSH
R/Y
55
B
B
7
BB10G/YL/W
R/WR/BB
Br
G/YW/L R/WR/BBBr R
R/WL/W
9
66R
L/G L/G
R/W
R/W
57
B
Br/L
52
Y
L
B HI
LO
W/L
W/L
Y/B
Br
BrOFF
ON
8
L
N
R
51
YL BL
L/W
Br/L
Br/L
OFFON ON
Y Y
B
Dg
Y
L/B
Br/WR/Y
Ch
L/Y
G
BB/YBrR/YGY/B
R/Y
R/Y
Dg Y
L/BBr/WR/Y
ChB/RBB/YBr
13
B
BBrYBr
G/Y
5B
R
R
L/W
L/W
R/B
B72B/Y
B/Y
12B
BL/GB
59 60 61 62 63 64
58
B/R
B/R11
R/Y
R/Y54
Ch
B
73
R
Y
Y
L/BDg
B
Br/WBr/G
Br/GBr/GBr/W
Br/WCh
Ch Dg
Dg
Ch Dg
BG/W
R/W
B
R/L
G
G
B
B
L/YB/Y
Dg B
W
Br
B R/W
Sb Sb
R/L R/L
41
56
L/R
R/L
W/L
R/B
L/W
R
Lg
B/Y
Sb
B/R
L/GR/WL/YL/W
Br/R
WB R/B
L/Y
SbSb
R/W
B
14
BL
W W G/W
G/W G/L Lg
Lg
70Ch
B Ch
B
68 67
69
67 71
B
B B
B L/R
Dg
B
Dg
B
L/R
BB
BB B/Y B
B/G B
BB/G
B/Y
Dg
Ch
B R
R
R
Br/BBr/B
2W
W
W WW
W
4R
WW
WW
WW
42 43
45
44 46R
Br/LBB1
47
R/G
BB3
BB4
BB
BB
Br/L
BB
BB
B2 B1
Br/BLG/Y
R/W
BB
B2
BB2
BB3
BB1
BB4Br/RB
48
R/W
3
B
L B
L
L
L
B
G/Y R/W
R
Br/L
BBB
R/GY/LG/L R/W
R
B
W
W
W
B
6
BB2 B2Y/L
B
B2R/GY/LLgR/WBr/RBr/R
ON
OFF1
49
G/L
R/G
R/G
R/WL/RYBG-G/WWChDg
B/L
WIRE SUB LEAD2D
MAIN HARNESS WIRE SUB LEAD1
C
MAIN HARNESS CORD HEAD LIGHT2
B
MAIN HARNESS
CORD HEAD LIGHT1A
MAIN HARNESS
OFF
Lg WB/WG/WY/L
Dg
G/L R/WChR/GB/Y Lg
W
B/WG/WY/L
Dg
G/LR/WChR/GY 
						

							
ELECTRIC STARTING SYSTEM
8-6
1. Main switch
7. Main fuse
8. Starter relay
9. Starter motor
10.Battery
11.Starting circuit cut-off relay
12.Sidestand switch
13.Neutral switch
45.Engine stop switch
46.Start switch
52.Ignition fuse
59.Clutch switch 
						

							
ELECTRIC STARTING SYSTEM
8-7
EAS27180
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 cl utch 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 con-
ditions has been met. In this instance, the starting  circuit cut-off relay is open so current cannot 
reach the starter motor. When at least one of th e above conditions has been met the starting circuit 
cut-off relay is closed and the engine can be started by pressing the starter switch.
a. WHEN THE TRANSMISSION IS IN NEU- TRAL
b. WHEN THE SIDESTAND IS UP AND THE  CLUTCH LEVER IS PULLED TO THE 
HANDLEBAR
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Engine stop switch
6. Starting circuit cut-off relay
7. Diode
8. Clutch switch
9. Sidestand switch
10.Neutral switch
11.Start switch 12.Starter relay
13.Starter motor