Yamaha Fz6n Manual
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6-14 WATER PUMPCOOL NOTE: CAUTION: NOTE: EAS00473 CHECKING THE WATER PUMP 1. Check: water pump housing 1 water pump cover 2 impeller 3 rubber damper 4 rubber damper holder 5 water pump seals oil seal Cracks / damage / wear Replace. 2. Check: bearing Rough movement Replace. 3. Check: water pump outlet hose radiator outlet hose Cracks / damage / wear Replace. EAS00475 ASSEMBLING THE WATER PUMP 1. Install: bearing oil seal New 1 (into the water pump housing 2) Before installing the oil seal, apply tap water or coolant onto its out surface. Install the oil seal with a socket that matches its outside diameter. 2. Install: water pump seal New 1 Never lubricate the water pump seal surface with oil or grease. Install the water pump seal with the special tools. Before installing the water pump seal, apply Yamaha bond No.1215 or Quick Gasket 2 to the water pump housing 3.
6-15 WATER PUMPCOOL NOTE: CAUTION: 10 Nm (1.0 mkg, 7.2 ftlb) Mechanical seal installer 90890-04078, YM-33221 4 Middle driven shaft bearing driver 90890-04058, YM-04058 5 Quick Gasket ACC-11001-05-01 Yamaha bond #1215 90890-85505 APush down. 3. Install: rubber damper New 1 rubber damper holder New 2 Before installing the rubber damper, apply tap water or coolant onto its outer surface. 4. Measure: impeller shaft tilt Out of specification Repeat steps (3) and (4). Make sure the rubber damper and rubber damper holder are flush with the impeller. Impeller shaft tilt limit 0.15 mm (0.006 in) 1Straightedge 2Impeller 5. Install: impeller shaft circlip New O-ring New water pump cover
6-16 WATER PUMPCOOL 10 Nm (1.0 mkg, 7.2 ftlb) NOTE: NOTE: INSTALLING THE WATER PUMP 1. Install: O-ring New copper washer New water pump assembly Align the projection a at the oil pump shaft and water pump shaft groove b. 2. Install: water pump outlet hose 1 radiator outlet hose 2 Install the radiator outlet hose with white a mark positioned outside. Install the hose clamp with its screw head pointed to the inner side. 3. Fill: cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 4. Check: cooling system Leaks Repair or replace any faulty part. 5. Measure: radiator cap opening pressure Below the specified pressure !I! Replace the radiator cap. Refer to “CHECKING THE RADIATOR”.
7-1 FUEL INJECTION SYSTEMFI 1Ignition coil 2Air filter case 3Intake air temperature sensor 4Fuel delivery hose 5Fuel tank 6Fuel pump 7Intake air pressure sensor 8Throttle position sensor 9Fuel injector 10Catalytic converter 11Crankshaft position sensor 12Coolant temperature sensor 13Spark plug 14Pressure regulator 15Battery 16ECU 17Fuel injection system relay 18Engine trouble warning light 19Lean angle cut-off switch FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM
7-2 7 FUEL INJECTION SYSTEMFI WIRING DIAGRAM 1Main switch 5Fuse (fuel injection) 6Fuse (main) 9Battery 10Starting circuit cut-off relay 11Sidestand switch 12Neutral switch 13Fuel pump 14Throttle position sensor 15Intake air pressure sensor 16Lean angle cut-off switch 17Crankshaft position sensor 18Intake air temperature sensor 19Coolant temperature sensor 20ECU 21Cylinder #1-injector 22Cylinder #2-injector 23Cylinder #3-injector 24Cylinder #4-injector 26Speed sensor 27Ignition coil #1 and #4 28Ignition coil #2 and #3 29Spark plug 32Engine trouble warning light 34Multi-function meter 40Engine stop switch 47Fuse (ignition)
7-3 41: Lean angle cut-off switch (open or short circuit) 50: ECU internal malfunction (memory check error) FUEL INJECTION SYSTEMFI EAS00899 ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is stored in the memory of the ECU. To inform the rider that the fuel injection system is not functioning, the engine trouble warning light flashes when the start switch is being pushed to start the engine. If a malfunction is detected in the system by the self-diagnostic function, this mode provides an ap- propriate substitute characteristic operation, and alerts the rider of the detected malfunction by illumi- nating an engine trouble warning light. After the engine has been stopped, the lowest fault code number appears on the LCD meter. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is deleted. EAS00900 Engine trouble warning light indication and FI system operating condition Warning light indication ECU’s operationFI operationVehicle operation Flashing*Warning provided when unable to start engineOperation stoppedUnable Remains ONMalfunction detectedOperated with substitute characteristics in accordance with the description of the malfunctionAble / Unable depend- ing on the self-diag- nostic fault code * The warning light flashes when any one of the conditions listed below is present and the start switch is pushed. 12: Crankshaft position sensor 19: Sidestand switch (open circuit in wire to ECU) 30: Lean angle cut-off switch (latch up detected) EAS00901 Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned “ON” and when the start switch is being pushed. If the warning light does not come on under these condi- tions, the warning light bulb may be defective.
7-4 FUEL INJECTION SYSTEMFI EAS00902 ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction. When an abnormal signal is received from a sensor, the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating, depending on the conditions. The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value, and the other in which the ECU directly operates an actuator. Details on the fail-safe actions are given in the table below. FAIL-SAFE ACTIONS TABLE Fault Code No.ItemSymptomFail-safe actionEngine startabilityVehicle drivability 12Crankshaft position sensorNo normal signals are received from the crankshaft position sensor.Stops the engine (by stopping the injection and ignition).UnableUnable 13 14Intake air pressure sensor (open or short circuit) (pipe system)Intake air pressure sensor-open or short circuit detected. Faulty intake air pressure sensor pipe system.Fixes the intake air pressure to 101.3 kpa. AbleAble 15 16Throttle position sensor (open or short circuit) (stuck)Throttle position sensor-open or short circuit detected. A stuck throttle position sensor is detected.Fixes the throttle position sensor to fully open. AbleAble 19Sidestand switch (open circuit in wire to ECU)Open circuit in the input line of ECU No.4 terminal is detected when the start switch is pressed.-- (No start)UnableUnable 21Coolant temperature sensorCoolant temperature sensor-open or short circuit detected.Fixes the coolant temperature to 60C.AbleAble 22Intake temperature sensorIntake temperature sensor-open or short circuit detected.Fixes the intake temperature to 20C.AbleAble 33Faulty ignitionOpen circuit detected in the primary lead of the ignition coil. (#1, #4)Cut the injection of other cylinder in the same group with the cylinder that the error is detected. (Example: when the #1 cylinder is defective cut the in- Able (depending on the num Able (depending on the num 34Open circuit detected in the primary lead of the ignition coil. (#2, #3)the #1 cylinder is defective cut the in- jection of #1 and #4 cylinders) Turn on the power to the air induction solenoid to always cut-off the air.on the num- ber of faulty cylinders)on the num- ber of faulty cylinders) 30 41Lean angle cut-off switch (latch up detected) (open or short circuit)The motorcycle has over turned. Lean angle cut-off switch-open or short circuit detected.Turns OFF the fuel injection system relay of the fuel system. UnableUnable 42Speed sensor, neutral switchNo normal signals are received from the speed sensor; or, an open or short circuit is detected in the neutral switch.Fixes the gear to the top gear.AbleAble 43 Fuel system voltage (monitor voltage)Supply power to the injector and fuel pump is not normal.Fixes the battery voltage to 12 V.Depending on the mal- function case.Depending on the mal- function case. 44 Error in writing the amount of CO adjustment on EEPROMAn error is detected while reading or writing on EEPROM (CO adjustment value).-- AbleAble 46Vehicle system power supply (Monitor voltage)Power supply to the FI system not normal--AbleAble 50ECU internal malfunction (memory check error)Faulty ECU memory. When this malfunction is detected, the code number might not appear on the meter.Shut down all functions except the communication with the meter.UnableUnable — Start unable warningRelay is not turned ON even if the crank signal is input while the start switch is turned ON. When the start switch is turned ON while an error is detected with the fault code of No.12, 19, 30, 41, 43 or 50.Engine trouble warning light flashes when the start switch is turned ON. UnableUnable
7-5 FUEL INJECTION SYSTEMFI Communication error with the meter Er-1ECU internal malfunction (output signal error)No signals are received from the ECU.–UnableUnable Er-2ECU internal malfunction (output signal error)No signals are received from the ECU within the specified duration. –UnableUnable Er-3ECU internal malfunction (output signal error)Data from the ECU cannot be received correctly.–UnableUnable Er-4ECU internal malfunction (input signal error)Non-registered data has been received from the meter.–UnableUnable
7-6 Engine operation is not normal or the engine trouble warning light is on. * Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on. Check the fault code number displayed on the me- ter. Identify the system with the malfunction. (Refer to the “FAIL-SAFE ACTIONS TABLE”.) Identify the probable cause of malfunction. (Refer to the “Fault code table”.) Check and repair the probable case of malfunc- tion. Fault code No. YES Fault code No. NO Check and repair. (Refer to “TROU- BLESHOOTING DE- TAILS”.) Monitor the operation of the sensors and actuators in the diag- nostic mode. (Refer to “Diagnostic mode table” in chapter 7)Check and repair. (Refer to “TROU- BLESHOOTING DE- TAILS”.) Perform ECU reinstatement action. (Refer to “Re- instatement method” in “TROUBLESHOOTING DETAILS”.) Turn the main switch to “OFF”, turn the main switch back to “ON”, and then check if the fault code num- ber is still displayed. Erasing the malfunction history:* The malfunction history is stored even if the main switch is turned OFF. The malfunction history must be erased in the diagnostic mode. (Refer to the “Diagnostic mode table (Diagnostic code No.62)”)Repairs completed The engine trouble warning light does not come on. Check the operation of following sensors and ac- tuators in the diagnostic mode (Refer to “Diagnos- tic mode table” in chapter 7.) 01: Throttle position sensor (throttle angle) 30: Ignition coil #1, #4 31: Ignition coil #2, #3 36: Injector #1, #4 37: Injector #2, #3 48: Al system solenoid Malfunction of en- gineDefective sensor or actuator Check and repair the inner parts of engine. (Refer to Chapter 5)Check and repair the corresponding sensor or actua- tor. * Operated when the engine trouble warning light is on. Fault code number displayed Fault code number not displayed OK NG OK OK Check the engine condition. OK NG FUEL INJECTION SYSTEMFI EAS00904 TROUBLESHOOTING CHART
7-7 FUEL INJECTION SYSTEMFI NOTE: NOTE: EAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without con- necting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the en- gine stop switch to “OFF”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SE- LECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the but- tons for 8 seconds or more. All displays on the meter disappear except the clock and tripmeter displays. “dIAG” appears on the LCD meter. 4. Press the “SELECT” button to select the CO adjustment mode “Co” or the diagnostic mode “dIAG”. 5. After selecting “dIAG”, simultaneously press the “SELECT” and “RESET” buttons for 2 se- conds or more to execute the selection. 6. Select the diagnostic code number that ap- plies to the item that was verified with the fault code number by pressing the “SELECT” and “RESET” buttons. The diagnostic code number appears on the LCD meter (01-70). To decrease the selected diagnostic code number, press the “RESET” button. Press the “RESET” button for 1 second or longer to auto- matically decrease the diagnostic code num- bers. To increase the selected diagnostic code num- ber, press the “SELECT” button. Press the “SELECT” button for 1 second or longer to au- tomatically increase the diagnostic code num- bers.