Yamaha Fz6 N Service Manual

							
ELECTRICAL COMPONENTS
8-108
1. Coolant temperature sensor
2. Throttle position sensor
3. Intake air temperature sensor
4. Fuel pump
5. Intake air pressure sensor
6. ECU (engine control unit)
7. ABS ECU (FZ6-NA/FZ6-NAHG/FZ6-SA/FZ6-SAHG)
8. Lean angle sensor
9. Starting circuit cut-off relay
10.Rear wheel sensor
11.Dimmer relay
12.Radiator fan motor relay
13.Turn signal relay
14.Hydraulic unit
15.Rectifier/regulator
16.Front wheel sensor 
						

							
ELECTRICAL COMPONENTS
8-109
EAS27980
CHECKING THE SWITCHES 
						

							
ELECTRICAL COMPONENTS
8-110
1. Main switch
2. Horn switch
3. Dimmer switch (FZ6-S/FZ6-NA/FZ6-SA/FZ6-SHG(W)/FZ6-SAHG)
4. Dimmer switch (FZ6-N/FZ6-NHG(W)/FZ6- NAHG)
5. Pass switch (FZ6-S/FZ6-NA/FZ6-SA/FZ6- SHG(W)/FZ6-SAHG)
6. Pass switch (FZ6-N/FZ6-NHG(W)/FZ6- NAHG)
7. Turn signal switch
8. Hazard switch
9. Clutch switch
10.Sidestand switch
11.Engine stop switch
12.Front brake light switch
13.Start switch
14.Oil level switch
15.Neutral switch
16.Rear brake light switch
17.Fuse
18.Left handlebar switch lead coupler (FZ6-S/ FZ6-SA/FZ6-SHG(W)/FZ6-SAHG)
19.Left handlebar switch lead coupler (FZ6-N/ FZ6-NA/FZ6-NHG(W)/FZ6-NAHG) 
						

							
ELECTRICAL COMPONENTS
8-111
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check 
the wiring connections and if necessary, replace the switch.
CAUTION:
ECA14370
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes 
from the opposite end of the coupler, taking care not to loosen or damage the leads.
NOTE:
 Before checking for continuity, set the pocket tester to “0” and to the “Ω ×  1” range.
 When checking for continuity, switch back and forth between the switch positions a few times.
The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illus-
tration similar to the one on the left.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in 
the top row in the switch illustration.
NOTE:
“ ” indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the 
respective switch position).
The example illustration on the left shows that:
There is continuity between black and black/white when the switch is set to “OFF”.
There is continuity between red and brown when the switch is set to “ON”.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C 
						

							
ELECTRICAL COMPONENTS
8-112
EAS27990
CHECKING THE BULBS AND BULB SOCK-
ETS
Check each bulb and bulb socket for damage 
or wear, proper connections, and also for conti-
nuity between the terminals.
Damage/wear → Repair or replace the bulb, 
bulb socket or both.
Improperly connected  → Properly connect.
No continuity  → Repair or replace the bulb, 
bulb socket or both.
Types of bulbs
The bulbs used on this vehicle are shown in 
the illustration.
 Bulbs “a” is used for the headlight and usu- ally use a bulb holder that must be detached 
before removing the bulb.
 Bulbs “b” and “c” are used for turn signal and  tail/brake lights and can be removed from the 
socket by pushing and turning the bulb coun-
terclockwise.
 Bulbs “d” is used for auxiliary light and 
license plate lights and can be removed from 
the socket by carefully pulling them out. Checking the condition of the bulbs
The following procedure applies to all of the 
bulbs.
1. Remove:
Bulb
WARNING
EWA13320
Since the headlight bulb gets extremely 
hot, keep flammable products and your 
hands away from the bulb until it has 
cooled down.
CAUTION:
ECA14380
 Be sure to hold the socket firmly when removing the bulb. Never pull the lead, 
otherwise it may be pulled out of the ter-
minal in the coupler.
 Avoid touching the glass part of the head- light bulb to keep it free from oil, other-
wise the transparency of the glass, the 
life of the bulb, and the luminous flux will 
be adversely affected. If the headlight 
bulb gets soiled, thoroughly it with a cloth 
moistened with alcohol or lacquer thin-
ner.
2. Check:  Bulb (for continuity) (with the pocket tester)
No continuity  → Replace.
NOTE:
Before checking for continuity, set the pocket 
tester to “0” and to the “ Ω ×  1” range.
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a. Connect the positive tester probe to termi-
nal “1” and the negative tester probe to ter-
minal “2”, and check the continuity.
Pocket tester90890-03112
Analog pocket tester YU-03112-C 
						

							
ELECTRICAL COMPONENTS
8-113
b. Connect the positive tester probe to termi-nal “1” and the negative tester probe to ter-
minal “3”, and check the continuity.
c. If either of the readings indicate no continu- ity, replace the bulb.
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Checking the condition of the bulb sockets
The following procedure applies to all of the 
bulb sockets.
1. Check:
 Bulb socket (for continuity) (with the pocket tester)
No continuity  → Replace.
NOTE:
Check each bulb socket for continuity in the 
same manner as described in the bulb section; 
however, note the following.
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a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the 
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any  of the readings indicate no continuity, 
replace the bulb socket.
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EAS4S81029
CHECKING THE LEDS
The following procedures applies to all of the 
LEDs.
1. Check: LED (for proper operation)
Improper operation  → Replace.
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a. Disconnect the meter assembly coupler 
(meter assembly side). b. Connect two jumper leads “1” from the bat-
tery terminals to the  respective coupler ter-
minal as shown.
WARNING
EWA4S81013
 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.
c. When the jumper leads are connected to  the terminals the respective LED should 
illuminate.
Does not light  → Replace the meter 
assembly.
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EAS28000
CHECKING THE FUSES
The following procedure applies to all of the 
fuses.
CAUTION:
ECA13680
To avoid a short circuit, always set the main 
switch to “OFF” when checking or replac-
ing a fuse.
1. Remove: Seat
 Front cowling inner panel
 Fuel tank (with ABS)
2. Check: Fuse
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a. Connect the pocket tester to the fuse and  check the continuity.
NOTE:
Set the pocket tester selector to “ Ω ×  1”.
Pocket tester
90890-03112
Analog pocket tester YU-03112-C 
						

							
ELECTRICAL COMPONENTS
8-114
b. If the pocket tester indicates “∞”, replace 
the fuse.
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3. Replace:  Blown fuse
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a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage  rating.
c. Set on the switches to verify if the electrical 
circuit is operational.
d. If the fuse immediately blows again, check  the electrical circuit.
WARNING
EWA13310
Never use a fuse with an amperage rating 
other than that specified. Improvising or 
using a fuse with the wrong amperage rat-
ing may cause extensive damage to the 
electrical system, cause the lighting and 
ignition systems to malfunction and could 
possibly cause a fire.
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4. Install:
 Fuel tank (with ABS)
 Front cowling inner panel
Seat
EAS28030
CHECKING AND CHARGING THE BATTERY
WARNING
EWA13290
Batteries generate explosive hydrogen gas 
and contain electrolyte which is made of 
poisonous and highly caustic sulfuric acid. 
Therefore, always follow these preventive 
measures:
 Wear protective eye gear when handling or working near batteries.
 Charge batteries in a well-ventilated area.
 Keep batteries away from fire, sparks or  open flames (e.g., welding equipment, 
lighted cigarettes).
 DO NOT SMOKE when charging or han-
dling batteries.
 KEEP BATTERIES AND ELECTROLYTE  OUT OF REACH OF CHILDREN.
 Avoid bodily contact with electrolyte as it 
can cause severe burns or permanent eye 
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
 Skin — Wash with water.
 Eyes — Flush with water for 15 minutes 
and get immediate medical attention.
INTERNAL
 Drink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg 
or vegetable oil. Get immediate medical 
attention.
CAUTION:
ECA13660
 This is a sealed battery. Never remove the sealing caps because the balance 
between cells will not be maintained and 
battery performance will deteriorate.
 Charging time, charging amperage and  charging voltage for an MF battery are dif-
ferent from those of conventional batter-
ies. The MF battery should be charged as 
explained in the charging method illustra-
tions. If the battery is overcharged, the 
electrolyte level will drop considerably. 
Therefore, take special care when charg-
ing the battery.
Pocket tester 90890-03112
Analog pocket tester
YU-03112-C
Fuses Amperage 
rating Q’ty
Main 30 A 1
Headlight 20 A 1 Signal 10 A 1
Ignition 10 A 1 Tail 10 A 1
Radiator fan motor 20 A 1
Fuel injection system 10 A 1 Backup 10 A 1
ABS (with ABS) 10 A 1
ABS motor (with ABS) 30 A 1 Reserve 10 A 1
Reserve 20 A 1
Reserve 30 A 1 
						

							
ELECTRICAL COMPONENTS
8-115
NOTE:
Since MF batteries are sealed, it is not possi-
ble to check the charge state of the battery by 
measuring the specific gravity of the electro-
lyte. Therefore, the charge of the battery has to 
be checked by measuring the voltage at the 
battery terminals.
1. Remove: Seat
 Front cowling inner panel
 Fuel tank
2. Disconnect:  Battery leads (from the battery terminals)
CAUTION:
ECA13640
First, disconnect the negative battery lead 
“1”, and then positive battery lead “2”.
3. Remove: Battery
4. Check:  Battery charge
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a. Connect a pocket tester to the battery ter- minals.
NOTE:
 The charge state of an MF battery can be checked by measuring its open-circuit volt-
age (i.e., the voltage when the positive bat-
tery terminal is disconnected).
 No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown  in the charts and the following example.
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5. Charge:Battery (refer to the appropriate charging method 
illustration)
WARNING
EWA13300
Do not quick charge a battery.
CAUTION:
ECA13670
 Never remove the MF battery sealing caps.
 Do not use a high-rate battery charger  since it forces a high-amperage current 
into the battery quickly and can cause 
battery overheating and battery plate 
damage.
 If it is impossible to regulate the charging 
current on the battery charger, be careful 
not to overcharge the battery.
 When charging a battery, be sure to 
remove it from the vehicle. (If charging 
has to be done with the battery mounted 
on the vehicle, disconnect the negative 
battery lead from the battery terminal.)
 To reduce the chance of sparks, do not  plug in the battery charger until the bat-
tery charger leads are connected to the 
battery.
 Before removing the battery charger lead 
clips from the battery terminals, be sure 
to turn off the battery charger.
 Make sure the battery charger lead clips 
are in full contact with the battery termi-
nal and that they are not shorted. A cor-
roded battery charger lead clip may 
generate heat in the contact area and a 
weak clip spring may cause sparks.
 If the battery becomes hot to the touch at 
any time during the charging process, 
disconnect the battery charger and let the 
battery cool before reconnecting it. Hot 
batteries can explode!
 As shown in the following illustration, the  open-circuit voltage of an MF battery sta-
bilizes about 30 minutes after charging 
has been completed. Therefore, wait 30 
 Positive tester probe 
→
positive battery terminal
 Negative tester probe  →
negative battery terminal
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20–30% 
						

							
ELECTRICAL COMPONENTS
8-116
minutes after charging is completed 
before measuring the open-circuit volt-
age.
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Charging method using a variable-current
(voltage) charger
a. Measure the open-circuit voltage prior to charging.
NOTE:
Voltage should be measured 30 minutes after 
the machine is stopped.
b. Connect a charged and AMP meter to the battery and start charging.
NOTE:
Set the charging voltage at 16–17 V. If the set-
ting is lower, charging  will be insufficient. If too 
high, the battery will be over-charged.
c. Make sure that the current is higher than 
the standard charging current written on 
the battery.
NOTE:
If the current is lower than the standard charg-
ing current written on the battery, set the 
charging voltage adjust dial at 20–24 V and 
monitor the amperage for 3–5 minutes to 
check the battery.
d. Adjust the voltage so that the current is at the standard charging level.
e. Set the time according to the charging time  suitable for the open-circuit voltage.
Refer to “Battery condition checking steps”.
f. If charging requires more than 5 hours, it is  advisable to check the charging current 
after a lapse of 5 hours. If there is any 
change in the amperage, readjust the volt-
age to obtain the standard charging cur-
rent.
g. Measure the battery open-circuit voltage  after leaving the battery unused for more 
than 30 minutes.
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Charging method using a constant voltage
charger
a. Measure the open-circuit voltage prior to charging.
NOTE:
Voltage should be measured 30 minutes after 
the machine is stopped.
b. Connect a charger and AMP meter to the battery and start charging.
c. Make sure that the current is higher than 
the standard charging current written on 
the battery.
NOTE:
If the current is lower than the standard charg-
ing current written on the battery, This type of 
battery charger cannot charge the MF battery. 
A variable voltage charger is recommended.
d. Charge the battery until the battery’s charg-ing voltage is 15 V.
NOTE:
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage 
after leaving the battery unused for more 
than 30 minutes.
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6. Install:Battery
7. Connect: Battery leads (to the battery terminals)
CAUTION:
ECA13630
First, connect the positive battery lead “1”, 
and then the negative battery lead “2”.
 Reach the standard charging current
Battery is good.
 Does not reach the standard charging cur- rent
Replace the battery.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery. 
						

							
ELECTRICAL COMPONENTS
8-117
8. Check: Battery terminals Dirt  → Clean with a wire brush.
Loose connection  → Connect properly.
9. Lubricate:  Battery terminals
10. Install:  Fuel tank
 Front cowling inner panel
Seat
EAS28040
CHECKING THE RELAYS
Check each switch for continuity with the 
pocket tester. If the continuity reading is incor-
rect, replace the relay.
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester ( Ω ×  1) and bat-
tery (12 V) to the relay terminal as shown.
Check the relay operation.
Out of specification  → Replace. Relay unit (starting circuit cut-off relay)
Relay unit (fuel pump relay)
Recommended lubricant
Dielectric grease
Pocket tester90890-03112
Analog pocket tester YU-03112-C
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Relay operationContinuity/No continuity 
(between “3” to “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
ResultContinuity/No continuity 
(between “3” to “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
ResultContinuity/No continuity 
(between “3” to “4”)