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Yamaha FZS6W 07 User Manual

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    Page
    of 394
    							
    ELECTRICAL COMPONENTS
    8-60
    1. Main switch
    2. Front brake light switch
    3. Starter relay
    4. Battery
    5. Fuse box
    6. Rear brake light switch
    7. Neutral switch
    8. Sidestand switch
    9. Oil level switch
    10.Radiator fan motor
    11.Horn
    12.Ignition coil 
    						
    							
    ELECTRICAL COMPONENTS
    8-62
    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. Lean angle sensor
    8. Starting circuit cut-off relay
    9. Dimmer relay
    10.Radiator fan motor relay
    11.Turn signal relay
    12.Rectifier/regulator 
    						
    							
    ELECTRICAL COMPONENTS
    8-63
    EAS27980
    CHECKING THE SWITCHES 
    						
    							
    ELECTRICAL COMPONENTS
    8-64
    1. Main switch
    2. Horn switch
    3. Dimmer switch
    4. Turn signal switch
    5. Hazard switch
    6. Clutch switch
    7. Sidestand switch
    8. Engine stop switch
    9. Front brake light switch
    10.Start switch
    11.Oil level switch
    12.Neutral switch
    13.Rear brake light switch
    14.Fuse
    15.Left handlebar switch lead coupler 
    						
    							
    ELECTRICAL COMPONENTS
    8-65
    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
    8-66
    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” is used for turn signal and tail/brake  lights and can be removed from the socket by 
    pushing and turning the bulb counterclock-
    wise.
     Bulbs “c” is used for  license plate light and 
    can be removed from their respective 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.
    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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    Pocket tester90890-03112
    Analog pocket tester YU-03112-C 
    						
    							
    ELECTRICAL COMPONENTS
    8-67
    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
     Right side cover
    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”.
    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.
    Pocket tester90890-03112
    Analog pocket tester YU-03112-C
    Pocket tester90890-03112
    Analog pocket tester YU-03112-C 
    						
    							
    ELECTRICAL COMPONENTS
    8-68
    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.
    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
    4. Install: Right side cover
    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.
    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
    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
    Reserve 10 A 1
    Reserve 20 A 1
    Reserve 30 A 1 
    						
    							
    ELECTRICAL COMPONENTS
    8-69
    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 
    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.
     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% 
    						
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