Yamaha Fz6n Manual
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8-23 STARTER MOTORELEC 3.4 Nm (0.34 mkg, 2.5 ftlb) NOTE: 3. Install: starter motor yoke 1 O-ring 2 New front cover 3 rear cover 4 bolts 5 Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers.
8-24 2A.C. magneto 3Rectifier / regulator 6Fuse (main) 9Battery CHARGING SYSTEMELEC EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM
8-25 NOYES 3. Charging voltage Set the engine tachometer to the ignition coil of cylinder #1. Connect the pocket tester (DC 20 V) to the battery as shown. The charging circuit is OK. Positive tester probe positive battery terminal Negative tester probe negative battery terminal Start the engine and let it run at approxi- mately 5,000 r / min. Measure the charging voltage. Charging voltage 14 V at 5,000 r / min Is the charging voltage within specification? EAS00775 YESNO Clean the battery terminals. Recharge or re- place the battery. Make sure the battery is fully charged. NOTE: Minimum open-circuit voltage 12.8 V or more at 20C (68F) Is the battery OK? CHARGING SYSTEMELEC NOTE: YESNO 1. Main fuse Check the main fuse for continuity. Refer to “CHECKING THE FUSES” in chap- ter 3. Is the main fuse OK? Replace the fuse. 2. Battery Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. EAS00739 EAS00774 TROUBLESHOOTING The battery is not being charged. Check: 1. main fuse 2. battery 3. charging voltage 4. stator coil lead 5. stator coil resistance 6. wiring connections (of the entire charging system) Before troubleshooting, remove the following part(s): 1. seat 2. front cowling inner panel (left and right) 3. fuel tank Troubleshoot with the following special tool(s). Pocket tester 90890-03112, YU-3112 EAS00738
8-26 CHARGING SYSTEMELEC YESNO 5. Stator coil resistance Remove the generator cover. Connect the pocket tester (Ω 1) to the sta- tor coils as shown. Replace the stator coil assembly. EAS00776 Positive tester probe white Negative tester probe white Positive tester probe white Negative tester probe white1 1 2 3 Measure the stator coil resistances. Stator coil resistance 0.22 0.34 Ω at 20C (68F) Is the stator coil OK? YESNO 6. Wiring Check the wiring connections of the entire charging system. Refer to “CIRCUIT DIAGRAM”. Is the charging system’s wiring properly con- nected and without defects? Properly connect or repair the charging system’s wiring. EAS00779 Replace the rectifi- er / regulator. 4. Stator coil lead Disconnect stator coil lead coupler. Connect the pocket tester (Ω 1) to the sta- tor coil lead coupler as shown. Positive tester probe white Negative tester probe ground 3 Positive tester probe white Negative tester probe ground 1 Positive tester probe white Negative tester probe groundNo continuity 2 YESNO Replace the stator coil lead. Are the tester readings correct?
8-27 LIGHTING SYSTEMELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM
8-28 LIGHTING SYSTEMELEC 1Main switch 6Fuse (main) 9Battery 20ECU 35High beam indicator light 46Fuse (headlight) 47Fuse (ignition) 48Fuse (tail) 51License plate light 52Tail / brake light 55Dimmer switch 60Dimmer relay 61Headlight (high beam) 62Headlight (low beam) 65Front turn signal / position light (right) 66Front turn signal / position light (left)
8-29 YESNO Clean the battery terminals. Recharge or re- place the battery. EAS00749 3. Main switch Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the main switch OK? YESNO Replace the main switch. EAS00784 YESNO 4. Dimmer switch Check the dimmer switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the dimmer switch OK? The dimmer switch is faulty. Replace the left handlebar switch. Minimum open-circuit voltage 12.8 V or more at 20C (68F) Is the battery OK? LIGHTING SYSTEMELEC NOTE: YESNO 1. Main, headlight, ignition and tail fuses Check the main, tail, ignition and headlight fuses for continuity. Refer to “CHECKING THE FUSES” in chap- ter 3. Are the main, tail, ignition and headlight fuses OK? Replace the fuse(s). 2. Battery Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. EAS00739EAS00781 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, licence light or meter light. Check: 1. main, tail, ignition and headlight fuses 2. battery 3. main switch 4. dimmer switch 5. dimmer relay 6. wiring connections (of the entire lighting system) Before troubleshooting, remove the following part(s): 1. seat 2. front cowling inner panel (left and right) 3. fuel tank 4. side cover Troubleshoot with the following special tool(s). Pocket tester 90890-03112, YU-3112 EAS00738
8-30 Does the dimmer relay have continuity be- tween red / yellow and green? NOYES Replace the dimmer relay. Positive tester probe red / yellow Negative tester probe green 1 2 3 4 5. Dimmer relay Disconnect the dimmer relay from the cou- pler. Connect the pocket tester (Ω 1) and bat- tery (12 V) to the dimmer relay as shown. Positive battery lead red / yellow Negative battery lead yellow / black EAS00787 YESNO 6. Wiring Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the lighting system’s wiring properly con- nected and without defects? Properly connect or repair the lighting system’s wiring. Check the condition of each of the lighting system’s circuits. Refer to “CHECK- ING THE LIGHTING SYSTEM”. LIGHTING SYSTEMELEC
8-31 High beam indicator light (LEDs) Positive tester probe yellow Negative tester probe black / white YESNO 1. Headlight bulb and socket Check the headlight bulb and socket for con- tinuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. Are the headlight bulb and socket OK? Replace the head- light bulb, socket or both. YESNO 2. Voltage Connect the pocket tester (DC 20 V) to the headlight and meter assembly couplers as shown. The wiring circuit from the main switch to the headlight cou- pler is faulty and must be repaired. When the dimmer switch is set to “ ” When the dimmer switch is set to “ ” Headlight coupler (wire harness side) Low beam Headlight Positive tester probe black Negative tester probe black / green 1 2 Meter assembly coupler (wire harness side) Turn the main switch to “ON”. Start the engine. Set the dimmer switch to “ ” or “ ”. Measure the voltage (DC 12 V) of black / green or black / yellow on the headlight coupler (wire harness side). Is the voltage within specification? 2 This circuit is OK. A B Headlight Positive tester probe black Negative tester probe black / yellow A Headlight coupler (wire harness side) High beam B 5 6 3 4 4 LIGHTING SYSTEMELEC EAS00788 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on.
8-32 LIGHTING SYSTEMELEC YESNO 1. License plate light bulb and socket Check the license plate light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. Are the license plate light bulb and socket OK? Replace the license plate light bulb, sock- et or both. EAS007922. The license plate light fails to come on. YESNO 2. Voltage Connect the pocket tester (DC 20 V) to the license plate light coupler (wire harness light side) as shown. The wiring circuit from the main switch to the license plate light coupler is faulty and must be re- paired. Positive tester probe blue Negative tester probe black 1 2 Turn the main switch to “ON”. Measure the voltage (DC 12 V) of blue on the license plate light coupler (wire harness side). Is the voltage within specification? 1 This circuit is OK.