Yamaha FZS6W 07 User Manual

							
ELECTRICAL COMPONENTS
8-70
NOTE:
Voltage should be measured 30 minutes after 
the machine is stopped.
b. Connect a charged and AMP meter to the battery and start charging.
NOTE:
Set the charging voltage at 16–17 V. If the set-
ting is lower, charging  will be insufficient. If too 
high, the battery will be over-charged.
c. Make sure that the current is higher than 
the standard charging current written on 
the battery.
NOTE:
If the current is lower than the standard charg-
ing current written on the battery, set the 
charging voltage adjust dial at 20–24 V and 
monitor the amperage for 3–5 minutes to 
check the battery.
d. Adjust the voltage so that the current is at the standard charging level.
e. Set the time according to the charging time  suitable for the open-circuit voltage.
Refer to “Battery condition checking steps”.
f. If charging requires more than 5 hours, it is  advisable to check the charging current 
after a lapse of 5 hours. If there is any 
change in the amperage, readjust the volt-
age to obtain the standard charging cur-
rent.
g. Measure the battery open-circuit voltage  after leaving the battery unused for more 
than 30 minutes.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant voltage
charger
a. Measure the open-circuit voltage prior to 
charging.
NOTE:
Voltage should be measured 30 minutes after 
the machine is stopped.
b. Connect a charger and AMP meter to the battery and start charging.
c. Make sure that the current is higher than  the standard charging current written on 
the battery.
NOTE:
If the current is lower than the standard charg-
ing current written on the battery, This type of 
battery charger cannot charge the MF battery. 
A variable voltage charger is recommended.
d. Charge the battery until the battery’s charg-
ing voltage is 15 V.
NOTE:
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage after leaving the battery unused for more 
than 30 minutes.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:Battery
7. Connect:
Battery leads(to the battery terminals)
CAUTION:
ECA13630
First, connect the positive battery lead “1”, 
and then the negative battery lead “2”.
8. Check: Battery terminals
Dirt  → Clean with a wire brush.
Loose connection  → Connect properly.
 Reach the standard charging current
Battery is good.
 Does not reach the standard charging cur-
rent
Replace the battery.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery. 
						

							
ELECTRICAL COMPONENTS
8-71
9. Lubricate: Battery terminals
10. Install:  Fuel tank
 Front cowling inner panel
Seat
EAS28040
CHECKING THE RELAYS
Check each switch for continuity with the 
pocket tester. If the continuity reading is incor-
rect, replace the relay.
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester ( Ω ×  1) and bat-
tery (12 V) to the relay terminal as shown.
Check the relay operation.
Out of specification  → Replace.
Relay unit (starting circuit cut-off relay) Relay unit (fuel pump relay)
Headlight relay
Recommended lubricant
Dielectric grease
Pocket tester90890-03112
Analog pocket tester YU-03112-C
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Relay operationContinuity/No continuity 
(between “3” to “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity/No continuity 
(between “3” to “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
ResultContinuity/No continuity 
(between “3” to “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
ResultContinuity/No continuity 
(between “3” to “4”) 
						

							
ELECTRICAL COMPONENTS
8-72
Radiator fan motor
EAS4S81032
CHECKING THE TURN SIGNAL/HAZARD 
RELAY
1. Check: Turn signal/hazard relay input voltage
Out of specification  → The wiring circuit 
from the main switch to the turn signal/haz-
ard relay coupler is faulty and must be 
repaired.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the  turn signal/hazard relay terminal as shown. b. Turn the main switch to “ON”.
c. Measure the turn signal/hazard relay input 
voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
 Turn signal/hazard relay output voltageOut of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the 
turn signal/hazard relay terminal as shown.
b. Turn the main switch to “ON”.
c. Measure the turn signal/hazard relay out- put voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28050
CHECKING THE RELAY UNIT (DIODE)
1. Check: Relay unit (diode)Out of specification  → Replace.
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity/No continuity 
(between “3” to “4”)
Turn signal/hazard relay input
voltageDC 12 V
Pocket tester90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe  →
Brown/Green “1”
 Negative tester probe  →
Ground
Turn signal/hazard relay output
voltage DC 12 V
Pocket tester90890-03112
Analog pocket tester
YU-03112-C
 Positive tester probe  →
Brown/White “1”
 Negative tester probe  →
Ground 
						

							
ELECTRICAL COMPONENTS
8-73
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the relay unit coupler from the wire harness.
b. Connect the pocket tester ( Ω ×  1) to the 
relay unit terminal as shown.
c. Check the relay unit (diode) for continuity.
d. Check the relay unit (diode) for no continu-
ity.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28070
CHECKING THE SPARK PLUG CAPS
The following procedure applies to all of the 
spark plug caps.
1. Check: Spark plug cap resistanceOut of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the spark plug cap from the spark 
plug lead.
b. Connect the pocket tester ( Ω ×  1k) to the 
spark plug cap as shown.
c. Measure the spark plug cap resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
Continuity
Positive tester probe  → Sky
blue “1”
Negative tester probe  →
Black/Yellow “2”
No continuity
Positive tester probe  → Black/
Yellow “2”
Negative tester probe  → Sky
blue “1”
Continuity Positive tester probe  → Sky
blue “1”
Negative tester probe  →
Black/Red “3”
No continuity Positive tester probe  → Black/
Red “3”
Negative tester probe  → Sky
blue “1”
Continuity
Positive tester probe  → Sky
blue “1”
Negative tester probe  → Light
green “4”
No continuity Positive tester probe  → Light
green “4”
Negative tester probe  → Sky
blue “1”
Continuity Positive tester probe  → Blue/
Green “5”
Negative tester probe  →
Black/Red “3”
No continuity
Positive tester probe  → Black/
Red “3”
Negative tester probe  → Blue/
Green “5”
Resistance 10.0 k Ω
Pocket tester
90890-03112
Analog pocket tester YU-03112-C 
						

							
ELECTRICAL COMPONENTS
8-74
EAS28100
CHECKING THE IGNITION COILS
The following procedure applies to all of the 
ignition coils.
1. Check: Primary coil resistanceOut of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the igniti on coil connectors 
from the ignition coil terminals.
b. Connect the pocket tester ( Ω ×  1) to the 
ignition coil as shown.
c. Measure the primary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:  Secondary coil resistanceOut of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark  plug cap from the 
ignition coil.
b. Connect the pocket tester ( Ω ×  1k) to the 
ignition coil as shown. c. Measure the secondary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
 Ignition spark gapOut of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the 
spark plug.
b. Connect the ignition checker/dynamic 
spark tester “1” as shown.
c. Set the main switch to “ON”.
d. Measure the ignition spark gap “a”.
Primary coil resistance 1.53–2.07  Ω at 20 °C (68 °F)
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe Red/black
 Negative tester probe
Orange/Black (Gray/Black)
Secondary coil resistance12.0–18.0 k Ω at 20 °C (68 °F)
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
 Negative tester probe Spark plug lead “1”
 Positive tester probe
Spark plug lead “2”
Minimum ignition spark gap6.0 mm (0.24 in)
Ignition checker90890-06754
Opama pet-4000 spark checker YM-34487
2. Spark plug cap 
						

							
ELECTRICAL COMPONENTS
8-75
e. Crank the engine by pushing the starter switch and gradually increase the spark 
gap until a misfire occurs.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28120
CHECKING THE CRANKSHAFT POSITION 
SENSOR
1. Disconnect: Crankshaft position sensor coupler
(from the wire harness)
2. Check:  Crankshaft position sensor resistance
Out of specification  → Replace the crank-
shaft position sensor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester ( Ω ×  100) to the 
crankshaft position sensor coupler as 
shown.
b. Measure the crankshaft position sensor  resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28130
CHECKING THE LEAN ANGLE SENSOR
1. Remove: Lean angle sensor
(from the bracket.)
2. Check:  Lean angle sensor output voltage
Out of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the lean angle sensor coupler to 
the wireharness.
b. Connect the pocket tester (DC 20 V) to the  lean angle sensor coupler as shown.
c. When turn the lean angle sensor to 65 °.
d. Measure the lean angle sensor out put volt- age.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS4S81035
CHECKING THE STARTOR MOTOR OPERA-
TION
1. Check: Starter motor operation
Does not operate  → Perform the electric 
starting system troubleshooting, starting 
with step 5.
Refer to TROUBLESHOOTING on page 
9-1.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive battery terminal “1”  and starter motor lead “2” with a jumper 
lead “3”.
WARNING
EWA13810
 A wire that is used as a jumper lead must have at least the same capacity of the bat-
tery, otherwise the jumper lead may burn.
Crankshaft position sensor
248–372  Ω at 20 °C (68 °F)
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe Gray “1”
 Negative tester probe
Black “2”
Lean angle sensor output volt-
age65 °: 1.0–4.0 V
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe Yellow/Green “1”
 Negative tester probe
Black/Blue “2” 
						

							
ELECTRICAL COMPONENTS
8-76
 This check is likely to produce sparks, therefore, make sure no flammable gas or 
fluid is in the vicinity.
b. Check the starter motor operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:  Stator coil resistanceOut of specification  → Replace the stator 
coil.
EAS28150
CHECKING THE STATOR COIL
1. Disconnect:
 Stator coil coupler(from the wire harness)
2. Check:  Stator coil resistanceOut of specification  → Replace the stator 
coil.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester ( Ω ×  1) to the 
stator coil coupler as shown. b. Measure the stator coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28170
CHECKING THE RECTIFIER/REGULATOR
1. Check:
 Charging voltageOut of specification  → Replace the rectifier/
regulator.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the engine tachometer to the ignition  coil of cylinder #1.
b. Connect the pocket tester (AC 20 V) to the  rectifier/regulator coupler as shown.
c. Start the engine and let it run at approxi- mately 5000 r/min.
d. Measure the rectifier/regulator input volt- age.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Stator coil resistance
0.22–0.34  Ω at 20 °C (68 °F)
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe White “1”
 Negative tester probe White “2”
 Positive tester probe White “1”
 Negative tester probe White “3”
 Positive tester probeWhite “2”
 Negative tester probe White “3”
Charging voltage
above 14 V at 5000 r/min
Pocket tester90890-03112
Analog pocket tester
YU-03112-C
 Positive tester probe Red “1”
 Negative tester probe Black “2” 
						

							
ELECTRICAL COMPONENTS
8-77
EAS28180
CHECKING THE HORN
1. Check: Horn resistanceOut of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the horn leads from the horn 
terminals.
b. Connect the pocket tester ( Ω ×  1) to the 
horn terminals.
c. Measure the horn resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:  Horn soundFaulty sound  → Adjust or replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a battery (12 V) to the horn.
b. Turn the adjusting screw in direction “a” or 
“b” until the specified horn sound is 
obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28190
CHECKING THE ENGINE OIL LEVEL 
GAUGE
1. Drain: Engine oil
2. Remove:
 Engine oil level gauge(from the oil pan)
3. Check:
 Engine oil level gauge resistance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester ( Ω ×  100) to the 
engine oil level gauge terminal as shown.
Horn resistance
1.01–1.11  Ω at 20 °C (68 °F)
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe Horn terminal “1”
 Negative tester probe Horn terminal “2”
Engine oil level gaugeMaximum level position resis-
tance 114–126  Ω at 20 °C (68 °F)
Minimum level position resis-
tance 484–536  Ω at 20 °C (68 °F)
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
Maximum level position “A”
 Positive tester probe Connector (white) “1”
 Negative tester probe Body earth “2”
Minimum level position “B”
 Positive tester probe Connector (white) “1”
 Negative tester probe Body earth “3” 
						

							
ELECTRICAL COMPONENTS
8-78
b. Measure the pickup coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28230
CHECKING THE FUEL SENDER
1. Remove: Fuel tank
2. Disconnect:  Fuel pump coupler
 Fuel sender coupler
(from the wire harness)
3. Remove:
 Fuel pump(from the fuel tank)
4. Check:
 Fuel sender resistanceOut of specification  → Replace the fuel 
pump assembly.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester ( Ω ×  10) to the 
fuel sender terminal as shown. b. Measure the fuel sender resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28240
CHECKING THE SPEED SENSOR
1. Check:
 Speed sensor output voltageOut of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the 
speed sensor coupler (wire harness side) 
as shown.
b. Set the main switch to “ON”.
c. Elevate the rear wheel and slowly rotate it.
d. Measure the voltage (DC 5 V) of White/Yel- low and Black/Blue. With each full rotation 
of the rear wheel, the voltage reading 
should cycle from 0.6 V to 4.8 V to 0.6 V to 
4.8 V.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Fuel sender resistance (full)20–26  Ω at 20 °C (68 °F)
Fuel sender resistance (empty) 134–140  Ω at 20 °C (68 °F)
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe Green/White “1”
 Negative tester probe
Black “2”
Output voltage reading cycle0.6 V–4.8 V–0.6 V–4.8 V
Pocket tester90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe White/Yellow “1”
 Negative tester probe
Black/Blue “2” 
						

							
ELECTRICAL COMPONENTS
8-79
EAS28250
CHECKING THE RADIATOR FAN MOTOR
1. Check: Radiator fan motorFaulty/rough movement  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the radiator fan motor coupler 
from the wire harness.
b. Connect the battery (DC 12 V) as shown.
c. Measure the radiator fan motor movement.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28260
CHECKING THE COOLANT TEMPERATURE 
SENSOR
1. Remove:  Coolant temperature sensor
WARNING
EWA14130
 Handle the coolant temperature sensor 
with special care.
 Never subject the coolant temperature  sensor to strong shocks. If the coolant 
temperature sensor is dropped, replace it.
2. Check:  Coolant temperature sensor resistance
Out of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester ( Ω ×  100) to the 
coolant temperature sensor “1” as shown. b. Immerse the coolant temperature sensor in 
a container filled with coolant “2”.
NOTE:
Make sure the coolant temperature sensor ter-
minals do not get wet.
c. Place a thermometer “3” in the coolant.
d. Slowly heat the coolant, and then let it cool to the specified temperature indicated in 
the table.
e. Check the coolant temperature sensor for 
continuity at the temperatures indicated in 
the table.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28300
CHECKING THE THROTTLE POSITION 
SENSOR
1. Remove: Throttle position sensor(from the throttle body)
2. Check:  Throttle position sensor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester ( Ω ×  1k) to the 
throttle position sensor as shown.
 Positive tester probe
Blue “1”
 Negative tester probe Black “2”
Coolant temperature sensor
5.21–6.37 k Ω at 0 °C (32 °F) 
0.29–0.35 k Ω at 80 °C (176 °F)
Pocket tester
90890-03112
Analog pocket tester YU-03112-C