Yamaha Fz6 N Service Manual

							
ABS (ANTI-LOCK BRAKE SYSTEM)
8-98
WARNING
EWA4S81009
Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close 
the brake hose lines. Check that the connections of the brake hose lines  from the brake master cylinder to the hydrau-
lic unit and to the front brake caliper from the hydraulic unit are correct.
WARNING
EWA4S81010
The front brake will not function properly if the connections are reversed.
 Front brake hose “1” inlet: from the front brake master cylinder
 Front brake hose “2” outlet: to the front brake caliper
NOTE:
 If the front brake hose inlet and outlet connections are reversed on the hydraulic unit, the brake  lever is pulled to full stroke without respondi ng and will be pushed back slowly without pulsating 
when the final check in [D-6] is performed.
 If the front and rear brake hose connections are reversed on the hydraulic unit, the pulsating action  in the brake lever and brake pedal will be performed in the reverse order when the final check in 
[D-6] is performed.
5. Hydraulic unit solenoid coupler terminal  Check if the front and rear hydraulic unit solenoid  coupler terminals (hydraulic unit and wire har-
ness [ABS]) are reversed.
6. Hydraulic unit If the malfunction is not corrected after performing steps 1 to 5, replace the hydraulic unit. Be 
sure to connect the brake hoses and couplers correctly and securely. Check the hydraulic unit 
operation. (Refer to [D-6] FINAL CHECK on page 8-104.)
Malfunction code 42 (Rear wheel not recover from the locking tendency even though the sig-
nal is continuously transmitted from the ABS ECU to release the hydraulic state [when the
battery voltage is normal].)
Check the following:
1. Rotation of the rear wheel  Check that there is no brake drag on the rear wheel and make sure it rotates smoothly.
 Check for brake disc distortion.
2. Brake master cylinder and brake caliper Terminal color
Solenoid side Wire harness side (ABS)
Front Red, Green Red, White/Blue Rear Red, Blue Red, White/Green 
						

							
ABS (ANTI-LOCK BRAKE SYSTEM)
8-99
 Check that the brake fluid pressure is correctly transmitted to the brake disc when the brake pedal is operated and that the pressure decreases when the pedal is released.
3. Brake fluid  Visually check the brake fluid in the brake master cylinder reservoir and check the fluid for water,  foreign materials, solidification and contamination.
 Check for air in the brake hose lines.
4. Brake hose lines  Check the brake hose lines for kinks and deterioration (particularly between the hydraulic unit 
and the rear brake caliper).
WARNING
EWA4S81011
Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close 
the brake hose lines.
 Check that the connections of the brake hose lines  from the brake master cylinder to the hydrau-
lic unit and to the rear brake caliper from the hydraulic unit are correct.
WARNING
EWA4S81012
The rear brake will not function properly if the connections are reversed.
 Rear brake hose “1” inlet: from the rear brake master cylinder
 Rear brake hose “2” outlet: to the rear brake caliper
NOTE:
 If the rear brake hose inlet and outlet connections are reversed on the hydraulic unit, the brake  pedal is pressed down to full stroke without  responding and will be pushed back slowly without 
pulsating when the final check is performed.
 If the front and rear brake hose connections are reversed on the hydraulic unit, the pulsating action  in the brake lever and brake pedal will be performed in the reverse order when the final check is 
performed.
5. Hydraulic unit solenoid coupler terminal  Check if the front and rear hydraulic unit solenoid  coupler terminals (hydraulic unit and wire har-
ness [ABS]) are reversed.
6. Hydraulic unit If the malfunction is not corrected after performing steps 1 to 5, replace the hydraulic unit. Be 
sure to connect the brake hose lines and coupler s correctly and securely. Check the hydraulic 
unit operation. (Refer to [D-6] FINAL CHECK on page 8-104.) Terminal color
Solenoid side Wire harness side (ABS)
Front Red, Green Red, White/Blue Rear Red, Blue Red, White/Green 
						

							
ABS (ANTI-LOCK BRAKE SYSTEM)
8-100
Malfunction code 51 (Front wheel will not recover from the locking tendency even though the
signal is continuously transmitted from the ABS ECU to release the hydraulic state [when the
battery voltage is low].)
Check the following:
1. Rotation of the front wheel
Refer to “Malfunction code 41”.
2. Brake master cylinder and brake caliper Refer to “Malfunction code 41”.
3. Brake fluid Refer to “Malfunction code 41”.
4. Brake hose lines
Refer to “Malfunction code 41”.
5. Hydraulic unit solenoid coupler terminals Refer to “Malfunction code 41”.
6. Hydraulic unit Refer to “Malfunction code 41”.
7. Battery voltage
Measure the battery voltage.
Malfunction code 52 (Rear wheel will not recover from the locking tendency even though the
signal is continuously transmitted from the ABS ECU to release the hydraulic state [when the
battery voltage is low].)
Check the following:
1. Rotation of the rear wheel Refer to “Malfunction code 42”.
2. Brake master cylinder and brake caliper Refer to “Malfunction code 42”.
3. Brake fluid
Refer to “Malfunction code 42”.
4. Brake hose lines Refer to “Malfunction code 42”.
5. Hydraulic unit solenoid coupler terminals Refer to “Malfunction code 42”.
6. Hydraulic unit
Refer to “Malfunction code 42”.
7. Battery voltage Measure the battery voltage. 
						

							
ABS (ANTI-LOCK BRAKE SYSTEM)
8-101
Malfunction code 61 (front), 62 (rear) (Sensor power supply is low)
1. Battery voltage lowCharge, check or replace the battery.
2. Battery terminal is disconnected.
Malfunction code 63 (front), 64 (r ear) (Sensor power supply failure)
1. GND short-circuit of the wire harness Remove the ABS ECU coupler and wheel sensor coupler and check the conductivity between 
the wire harness and GND.
If short-circuit is detected, replace the wire  harness because the cause is the wire harness fail-
ure.
*Continuity between: “A”–“C”, “B”–“C”
2. Wheel sensor malfunction Check the conductivity between the wheel sensor leads (white) and GND.
If short-circuit is detected, replace the wheel s ensor because the cause is the wheel sensor fail-
ure.
3. Battery terminal is disconnected.
4. When the items 1 to 3 are normal, replace the ABS ECU.
EAS4S81027
[D-6-4] DELETING THE MALFUNCTION CODE
1. Connect the test coupler adapter “1” to the te st coupler “2”. Refer to “[B-5] MALFUNCTION 
CHECK BY THE ABS SELF DIAGNOSIS (PRESENT MALFUNCTION)”
1. ABS ECU
2. Front wheel sensor
3. Rear wheel sensor
4. Blue 5. Black
6. Yellow/White
7. White
8. Gray 
						

							
ABS (ANTI-LOCK BRAKE SYSTEM)
8-102
2. Turn the main switch on. The multi-function display indicates previously recorded malfunction codes.
NOTE:
The ABS error code is not displayed dur ing the diagnosis of the fuel injection.
3. Turn the engine stop switch off.
CAUTION:
ECA4S81019
If the starter switch is pushed without turning the engine stop switch off, it may damage the 
starting motor gears or other parts, therefore be sure to turn it off.
4. Push the starter switch more than 10 times in 4 seconds to delete the malfunction codes.
NOTE:
If the malfunction codes cannot be cleared, the disc onnection of the starter switch monitor leads 
could be a cause.
5. Turn the main switch off.
6. Turn the main switch on again.
 Check that the ABS warning light goes on for 2 seconds, then goes out for 3 seconds and starts  flashing.
7. Turn the main switch off.
8. Disconnect the test coupler adapter from the test  coupler, and install the protective cap with the 
test coupler adapter. Deleting t he malfunction code is now finished.
NOTE:
Do not forget to install the protective cap.
CAUTION:
ECA4S81020
Since the ECU remains in the memory until the malfunction code is deleted, always delete 
the malfunction code when the service work is finished.
a. ABS warning light
b. ON
c. Main switch on
d. Main switch off e. Flashing
f. 2 seconds
g. 3 seconds
h. 0.5 seconds 
						

							
ABS (ANTI-LOCK BRAKE SYSTEM)
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EAS4S81033
[D-6-6] DELETE FUNCTION TEST
1. Place the vehicle on the sidestand.
2. Set the main switch to “OFF”.
3. Connect the test coupler adapter to the test coupler.
4. Set the main switch to “ON”.
5. Check: ECU voltage Connect the pocket tester (DC 20 V) to the ECU coupler.
Tester positive probe  → Brown/White “1”
Tester negative probe  → Black/White “2”
Lower than 12.8 V  → Charge or replace the battery.
6. Check:  ECU-to-start-switch-lead continuity
Connect the pocket tester ( Ω ×  1) to the ECU coupler and start switch coupler.
Tester positive probe  → White/Blue “1” (start switch)
Tester negative probe  → Green/White “2” (ECU)
No continuity  → Replace or repair the wire harness.
7. Check:  ECU voltage Connect the pocket tester (DC 20 V) to the ECU coupler.
Tester positive probe  → Green/Blue “2”
Tester negative probe  → Black/White “1”
Push the start switch.
Out of specification  → Replace the handlebar switch.
Battery voltage
Higher than 12.8 V
Start switch ON: less than 1 V
Start switch OFF: more than 12
V 
						

							
ABS (ANTI-LOCK BRAKE SYSTEM)
8-104
8. If the above-mentioned check are within specification, replace the ECU.
EAS4S81028
[D-6] FINAL CHECK
Checking procedures
1. Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir.Refer to CHECKING THE BRAKE FLUID LEVEL on page 3-24.
2. Check the wheel sensor housings and wheel sensors for proper installation. Refer to INSTALLING THE FRONT WHEEL on page 4-14 and INSTALLING THE REAR 
WHEEL on page 4-22.
3. Perform hydraulic unit operation test 1 or 2. Refer to HYDRAULIC UNIT OPERATION TEST on page 4-56.
4. Delete the malfunction codes. Refer to [D-6-4] DELETING THE MALFUNCTION CODE on page 8-101.
5. Perform a trial run.
Refer to [D-6-5] TRIAL RUN on page 4-59. 
						

							
ELECTRICAL COMPONENTS
8-105
EAS27970
ELECTRICAL COMPONENTS 
						

							
ELECTRICAL COMPONENTS
8-106
1. Main switch
2. Front brake light switch
3. Starter relay
4. Battery
5. ABS motor relay (FZ6-NA/FZ6-NAHG/FZ6-SA/FZ6-SAHG)
6. Fuse box
7. Rear brake light switch
8. Neutral switch
9. Sidestand switch
10.Oil level switch
11.Radiator fan motor
12.Horn
13.Ignition coil 
						

							
ELECTRICAL COMPONENTS
8-107