Yamaha FZS6W 07 User Manual
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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. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4S81029 CHECKING THE LEDS The following procedures applies to all of the LEDs. 1. Check: LED (for proper operation) Improper operation → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Replace: Blown fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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%