Yamaha Fz6 N Service Manual
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FEATURES 1-22 2.Pressurized statePort D “11” is closed by the “pressurization” signal transmitted from the ABS ECU. Before this occurs, the spool of the flow control valve has compressed the return spring and closed port B “9”. Brake fluid that has entered through port A “7” is further restricted by the orifice “10” and the brake fluid is sent to the brake calipers via port A “7” and port C “13”. At this time, the brake is pressur- ized at a constant speed regardless of the brake fluid pressure level since restriction of port A “7” changes so that a constant pressure differenc e is maintained between chamber A “20”and cham- ber B “21” of the flow control valve. 1. Brake master cylinder 2. Brake light switch 3. ABS motor 4. Hydraulic pump 5. Buffer chamber 6. Flow control valve 7. Port A 8. Spool 9. Port B 10.Orifice 11.Port D 12.Solenoid valve 13.Port C 14.Brake caliper 15.ABS ECU 16.ABS warning light 17.Brake fluid pressure 18.Time 19.Repressurizing
FEATURES 1-23 EAS4S81010 ABS SELF-DIAGNOSIS FUNCTION ABS warning light The ABS warning light “1” comes on when a malfunction is detected by the ABS self-diagnosis. It is located in the meter assembly. 1. Brake master cylinder 2. Brake light switch 3. ABS motor 4. Hydraulic pump 5. Buffer chamber 6. Flow control valve 7. Port A 8. Spool 9. Port B 10.Orifice 11.Port D 12.Solenoid valve 13.Port C 14.Brake caliper 15.ABS ECU 16.ABS warning light 17.Brake fluid pressure 18.Time 19.Repressurizing 20.Chamber A 21.Chamber B A. FZ6-NA/FZ6-SA B. FZ6-NAHG/FZ6-SAHG
FEATURES 1-24 Instances when the ABS warning light comes on 1.The ABS warning light comes on when the main switch is turned to “ON”.The ABS warning light comes on for 2 seconds whil e the ABS is performing a self-diagnosis, then goes off if there are no problems. 2.The ABS warning light comes on while riding. If the ABS warning light comes on while riding, a malfunction has been detected in the ABS. The ABS hydraulic control will not be performed. The ABS wi ll have recourse to manual braking if this occurs. 3.The ABS warning light flashes while riding. If the ABS warning light flashes while riding, ther e is no problem with the function of the ABS. However, the ABS ECU input has unstable factors. (For details, refer to ABS TROU BLESHOOTING OUTLINE on page 8-78.) NOTE: The ABS warning light comes on or flashes if the vehicle is ridden with the test coupler adapter connected to the ABS test coupler. The ABS warning light comes on during the engine cranking when the starter switch is pressed and starting circuit cut-off relay is turned “ON”. a. ABS warning light b. Main switch “OFF” c. Main switch “ON” d. Goes off e. Comes on for 2 seconds f. Preparation a. ABS warning light b. Comes on
FEATURES 1-25 4.The ABS warning light “1” flashes and a malfunction code “2” is indicated on the multi-function dis- play when the test coupler adapter “3” is connected to the ABS test coupler “4” for troubleshooting the ABS. The ABS test coupler can be accessed by removing the left inner panel (front cowling). When the test coupler adapter is connect ed to the ABS test coupler, the ABS warning light starts flashing and the multi-function display indicates all the malfunction codes recorded in the ABS ECU. NOTE: The ABS warning light comes on or flashes if the vehicle is ridden with the test coupler adapter con- nected to the ABS test coupler. a. ABS warning light b. Comes on c. Goes off d. Preparation Test coupler adapter 90890-03149 A. FZ6-NA/FZ6-SA B. FZ6-NAHG/FZ6-SAHG
FEATURES 1-26 Diagnosis indication The place where the ABS diagnosis code is displayed is also used for the indication of the FI diag- nosis code, odometer, trip meter and fuel trip. As the priority level of indication, the diagnosis code for FI is the first and the diagnosis code for ABS is the second. Accordingly, the ABS diagnosis code is no t displayed during the diagnosis for FI. NOTE: It shall not be in the diagnosis mode for FI. EAS4S81011 ABS WARNING LIGHT AND OPERATION ABS warning light When the main switch is turned to “ON”, the ABS warning light comes on for 2 seconds, then goes off. If the ABS warning light comes on while riding, stop th e vehicle, and then turn the main switch to “OFF”, then back to “ON”. The ABS operation is normal if the ABS warning light comes on for 2 seconds, then goes off. The ABS operation is normal if the ABS warning light flashes. Even if the ABS warning light remains on and does not go off, or if it comes on after riding, conven- tional braking performance of the vehicle is maintained. ABS function A brake system in which the hydraulic control has been performed by the ABS alerts a rider that the wheels had a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal. When the ABS is activated, t he grip between the road surface and tires is close to the limit. The ABS cannot prevent wheel lock* on slippery surface such as ice, when it is caused by engine braking, even if the ABS is activated. The ABS is not designed to shorten the braking distance or improve the cornering performance. Depending on the road conditions, the braking dist ance may be longer compared to that of vehi- cles not equipped with ABS. Therefore, ride at a safe speed and keep a safe distance between yourself and other vehicles.
FEATURES 1-27 The braking of the vehicle, even in the worst case, is principally executed when the vehicle is advancing straight ahead. During a turn, sudden braki ng is liable to cause a loss of traction of the tires. Even vehicles equipped wi th ABS cannot be prevented from falling over if braked suddenly. The ABS does not work when the main switch is turned to “OFF”. The conventional braking func- tion can be used. * Wheel lock: A condition that occurs when the rotation of one or both of the wheels has stopped, but the vehicle continues to travel.
IMPORTANT INFORMATION 1-28 EAS20180 IMPORTANT INFORMATION EAS20190 PREPARATION FOR REMOVAL AND DISAS- SEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to SPECIAL TOOLS on page 1-31. 3. When disassembling, always keep mated parts together. This includes gears, cylin- ders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During disassembly, clean all of the parts and place them in trays in the order of dis- assembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. EAS20210 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket sur- faces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease. EAS20220 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates “1” and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. 1. Oil 2. Lip 3. Spring 4. Grease
IMPORTANT INFORMATION 1-29 EAS20230 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals “1”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appro- priate. CAUTION: ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfaces. EAS20240 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip “1”, make sure the sharp-edged corner “2” is positioned opposite the thrust “3” that the circlip receives.
CHECKING THE CONNECTIONS 1-30 EAS20250 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: Lead Coupler Connector 2. Check: Lead Coupler Connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect several times. 3. Check: All connections Loose connection → Connect properly. NOTE: If the pin “1” on the terminal is flattened, bend it up. 4. Connect: Lead Coupler Connector NOTE: Make sure all connections are tight. 5. Check: Continuity (with the pocket tester) NOTE: If there is no continuity, clean the terminals. When checking the wire harness, perform steps (1) to (3). As a quick remedy, use a contact revitalizer available at most part stores. Pocket tester 90890-03112 Analog pocket tester YU-03112-C
SPECIAL TOOLS 1-31 EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. NOTE: For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”. For others, use part number starting with “90890-”. Tool name/Tool No. Illustration Reference pages Flywheel puller 90890-01362 Heavy duty puller YU-33270-B 5-30 Flywheel puller attachment 90890-04089 Crankshaft protector YM-33282 5-30 Sheave holder 90890-01701 Primary clutch holder YS-01880-A 5-30, 5-31, 5- 32, 5-34 Piston pin puller set 90890-01304 Piston pin puller YU-01304 5-62 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 6-3 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 6-3