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Yamaha Fz6n Manual

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    Page
    of 432
    							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. 
    						
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