Yamaha Fz6n Manual

8-13
IGNITION SYSTEMELEC
EAS00754
15. Wiring

Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.

Is the ignition system’s wiring properly con-
nected and without defects?
YESNO
Properly connect or
repair the ignition
system’s wiring.
Replace the ECU. 

8-14
1Main switch
6Fuse (main)
7Starter relay
8Starter motor
9Battery
10Starting circuit cut-off relay
11Sidestand switch
12Neutral switch
40Engine stop switch
41Start switch
47Fuse (ignition)
54Clutch switch
ELECTRIC STARTING SYSTEMELEC
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM 

8-15
ELECTRIC STARTING SYSTEMELEC
EAS00756
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
clutch switch is closed) and the sidestand is up
(the sidestand switch is closed).
The starting circuit cut-off relay...

8-16
YESNO
3. Starter motor

Connect the positive battery terminal   and
starter motor lead   with a jumper lead  .
Repair or replace the
starter motor. 
A wire that is used as a jumper lead
must have at least the same capacity or
more as that of the battery lead, other-
wise the jumper lead may burn.

This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.

Does the starter motor turn?
WARNING
1
23
EAS00758
YESNO 2. Battery

Check the condition of the battery....

8-17
4. Starting circuit cut-off relay

Disconnect the starting circuit cut-off relay
coupler from the wire harness.

Connect the pocket tester (Ω 
 1) and bat-
tery (12 V) to the starting circuit cut-off relay
coupler as shown.
YESNO
Replace the starting
circuit cut-off relay.
Positive tester probe 
 white / blue 
Negative tester probe 
 blue / white

Does the starting circuit cut-off relay have
continuity between white / blue and
blue / white?
1
2
3
4
EAS00759
Positive battery terminal 
 red / black...

8-18

Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.

Is the starting system’s wiring properly con-
nected and without defects?
EAS00766
12. Wiring
YESNO
Properly connect or
repair the starting
system’s wiring.
The starting system
circuit is OK.
11. Start switch

Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the start switch OK?
YESNO
Replace the right
handlebar switch.
EAS00764
10. Clutch switch

Check the clutch switch for continuity.
Refer to...

8-19
STARTER MOTORELEC
Order Job / Part Q’ty Remarks
1
2Removing the starter motor
Seat
Front cowling inner panel (left and right)
Fuel tank
Throttle bodies
Starter motor lead
Starter motor1
1Remove the parts in the order listed.
Refer to “SEAT” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “THROTTLE BODIES” in 
chapter 7.
For installation, reverse the removal 
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
5 Nm (0.5 m
kg, 3.6 ft
lb)
EAS00767
STARTER MOTOR 

8-20
STARTER MOTORELEC
Order Job / Part Q’ty Remarks
Disassembling the starter motor
O-ring
Front cover
Lock washer
Oil seal
Bearing
Washer set
Rear cover
Washer set
O-ring
Brush holder
Armature assembly
Starter motor yoke
O-ring1
1
1
1
1
1
1
1
2
1
1
1
2Disassembly the parts in the order listed.
For assembly, reverse the disassembly 
procedure.
1
2
3
4
5
6
7
8
9
10
11
12
3.4 Nm (0.34 m
kg, 2.5 ft
lb)
7.8 Nm (0.78 m
kg, 5.6 ft
lb)
13
EAS00768 

8-21
STARTER MOTORELEC
NOTE:
EAS00770
CHECKING THE STARTER MOTOR
1. Check:

commutator
Dirt 
 Clean with 600 grit sandpaper.
2. Measure:

commutator diameter 
a
Out of specification 
 Replace the starter
motor.
Commutator wear limit
27 mm (1.06 in)
3. Measure:

mica undercut 
a
Out of specification 
 Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commuta-
tor.
Mica undercut
0.7 mm (0.03 in)
The mica of the commutator must be undercut
to ensure proper...

8-22
STARTER MOTORELEC
NOTE: 5. Measure:

brush length 
a.
Out of specification 
 Replace the brushes
as a set.
Brush length wear limit
3.5 mm (0.14 in)
6. Measure:

brush spring force
Out of specification 
 Replace the brush
springs as a set.
Brush spring force
7.16  9.52 N
(730  971 gf, 25.77  34.27 oz)
7. Check:

gear teeth
Damage / wear 
 Replace the gear.
8. Check:

bearing

oil seal
Damage / wear 
 Replace the defective
part(s).
EAS00772
ASSEMBLING THE STARTER MOTOR
1. Install:

brush seat 
1
2....