Yamaha FZS6W 07 User Manual

							
ELECTRICAL COMPONENTS
8-80
b. Check the throttle position sensor maxi-mum resistance.
Out of specification  → Replace the throttle 
position sensor.
c. Connect the pocket tester ( Ω ×  1k) to the 
throttle position sensor as shown.
d. While slowly turning the throttle position  sensor shaft, check that  the throttle posi-
tion sensor resistance is within the speci-
fied range.
The resistance does not change or it 
changes abruptly  → Replace the throttle 
position sensor.
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3. Install:  Throttle position sensor
NOTE:
When installing the throttle position sensor, 
adjust its angle properly. Refer to ADJUST-
ING THE THROTTLE POSITION SENSOR 
on page 7-6.
EAS28350
CHECKING THE FUEL PUMP
WARNING
EWA13850
Gasoline is extremely flammable and under 
certain circumstances there can be a dan-
ger of an explosion or fire. Be extremely 
careful and note the following points:
 Stop the engine before refueling.
 Do not smoke, and keep away from open 
flames, sparks, or any other source of 
fire.
 If you do accidentally spill gasoline, wipe  it up immediately with dry rags.
 If gasoline touches the engine when it is  hot, a fire may occur. Therefore, make 
sure the engine is completely cool before 
performing the following test.
1. Disconnect:  Fuel pump coupler
(from the wire harness)
2. Check:  Fuel pump resistance
Out of specification  → Replace.
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a. Connect the pocket tester ( Ω ×  1) to the 
fuel pump coupler as shown.
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
 Tester positive lead  →
Blue “1”
 Tester negative lead  →
Black/Blue “2”
Resistance 4.0–6.0 k Ω
 Tester positive lead  →
Ye l l o w  “ 3 ”
 Tester negative lead  →
Black/Blue “2”
Throttle position sensor resis-
tance 0 to 3.5–6.5 k Ω at 20 °C (68 °F)
Fuel pump resistance
0.2–3.0  Ω at 20 °C (68 °F)
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe Red/blue “1”
 Negative tester probe
Black “2” 
						

							
ELECTRICAL COMPONENTS
8-81
b. Measure the fuel pump resistance.
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EAS28370
CHECKING THE AIR INDUCTION SYSTEM 
SOLENOID
1. Check: Air induction system solenoid resistanceOut of specification  → Replace.
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a. Remove the air induc tion system solenoid 
coupler from the wire harness.
b. Connect the pocket tester ( Ω ×  1) to the air 
induction system so lenoid terminal as 
shown.
c. Measure the air induc tion system solenoid 
resistance.
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EAS28410
CHECKING THE INTAKE AIR PRESSURE 
SENSOR
1. Check:  Intake air pressure sensor output voltage
Out of specification  → Replace.
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a. Connect the pocket tester (DC 20 V) to the 
intake air pressure sensor coupler (wire 
harness side) as shown.
b. Set the main switch to “ON”.
c. Measure the intake air pressure sensor  output voltage.
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EAS28420
CHECKING THE INTAKE AIR TEMPERA-
TURE SENSOR
1. Remove: Intake air temperature sensor
(from the air filter case.)
WARNING
EWA14110
 Handle the intake air temperature sensor with special care.
 Never subject the intake air temperature  sensor to strong shocks. If the intake air 
temperature sensor is dropped, replace it.
Air induction system solenoid
resistance
18–22  Ω at 20 °C (68 °F)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
 Positive tester probe Brown/Red “1”
 Negative tester probe Red/White “2”
Intake air pressure sensor out-
put voltage
3.75–4.25 V
Pocket tester90890-03112
Analog pocket tester YU-03112-C
 Positive tester probe Pink/White “1”
 Negative tester probe
Black/Blue “2” 
						

							
ELECTRICAL COMPONENTS
8-82
2. Check: Intake air temperature sensor resistanceOut of specification  → Replace.
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a. Connect the pocket tester ( Ω ×  100) to the 
intake air temperature sensor terminal as 
shown.
b. Measure the intake air temperature sensor  resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Intake air pressure sensor
resistance
2.2–2.7 k Ω at 20 °C (68 °F)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
 Positive tester probe Brown/White “1”
 Negative tester probe Balck/Blue “2” 
						

							
ELECTRICAL COMPONENTS
8-83 
						

							
9
TROUBLESHOOTING
TROUBLESHOOTING.................................................................................. 9-1
GENERAL INFORMATION ..................................................................... 9-1
STARTING FAILURES ............................................................................ 9-1
INCORRECT ENGINE IDLING  SPEED ................................................. 9-1
POOR MEDIUM-AND-HIGH-SPEED  PERFORMANCE ........................ 9-2
FAULTY GEAR SHIFTING ...................................................................... 9-2
SHIFT PEDAL DOES NOT MOVE .......................................................... 9-2
JUMPS OUT OF GEAR .......................................................................... 9-2
FAULTY CLUTCH ................................................................................... 9-2
OVERHEATING ...................................................................................... 9-2
OVERCOOLING ..................................................................................... 9-3
POOR BRAKING PERFORMANCE ....................................................... 9-3
FAULTY FRONT FORK LEGS ................................................................ 9-3
UNSTABLE HANDLING .......................................................................... 9-3
FAULTY LIGHTING OR SIGNALING SYSTEM ...................................... 9-4 
						

							
TROUBLESHOOTING
9-1
EAS28450
TROUBLESHOOTING
EAS28460
GENERAL INFORMATION
NOTE:
The following guide for troubleshooting does 
not cover all the possible causes of trouble. It 
should be helpful, however, as a guide to basic 
troubleshooting. Refer to the relative proce-
dure in this manual for checks, adjustments, 
and replacement of parts.
EAS28470
STARTING FAILURES
Engine
1. Cylinder(s) and cylinder head(s) Loose spark plug
 Loose cylinder head or cylinder
 Damaged cylinder head gasket
 Damaged cylinder gasket
 Worn or damaged cylinder
 Incorrect valve clearance
 Improperly sealed valve
 Incorrect valve-to-valve-seat contact
 Incorrect valve timing
 Faulty valve spring
 Seized valve
2. Piston(s) and piston ring(s)
 Improperly installed piston ring
 Damaged, worn or fatigued piston ring
 Seized piston ring
 Seized or damaged piston
3. Air filter  Improperly installed air filter
 Clogged air filter element
4. Crankcase and crankshaft  Improperly assembled crankcase
 Seized crankshaft
Fuel system
1. Fuel tank  Empty fuel tank
 Clogged fuel filter
 Clogged fuel tank drain hose
 Deteriorated or contaminated fuel
2. Fuel pump  Faulty fuel pump
 Faulty fuel pump relay
3. Throttle body(-ies)  Deteriorated or contaminated fuel
 Sucked-in air Electrical system
1. Battery
 Discharged battery
 Faulty battery
2. Fuse(s)  Blown, damaged or incorrect fuse
 Improperly installed fuse
3. Spark plug(s)  Incorrect spark plug gap
 Incorrect spark plug heat range
 Fouled spark plug
 Worn or damaged electrode
 Worn or damaged insulator
 Faulty spark plug cap
4. Ignition coil(s)  Cracked or broken ignition coil body
 Broken or shorted primary or secondary 
coils
 Faulty spark plug lead
5. Ignition system  Faulty ECU
 Faulty crankshaft position sensor
6. Switches and wiring  Faulty main switch
 Faulty engine stop switch
 Broken or shorted wiring
 Faulty neutral switch
 Faulty start switch
 Faulty sidestand switch
 Faulty clutch switch
 Improperly grounded circuit
 Loose connections
7. Starting system  Faulty starter motor
 Faulty starter relay
 Faulty starting circuit cut-off relay
 Faulty starter clutch
EAS28490
INCORRECT ENGINE IDLING SPEED
Engine
1. Cylinder(s) and cylinder head(s)
 Incorrect valve clearance
 Damaged valve train components
2. Air filter  Clogged air filter element
Fuel system
1. Throttle body(-ies)  Damaged or loose throttle body joint
 Improperly synchronized carburetors
 Improperly adjusted engine idling speed (throttle stop screw) 
						

							
TROUBLESHOOTING
9-2
 Improper throttle cable free play
 Flooded throttle body
 Faulty air induction system
Electrical system
1. Battery  Discharged battery
 Faulty battery
2. Spark plug(s)  Incorrect spark plug gap
 Incorrect spark plug heat range
 Fouled spark plug
 Worn or damaged electrode
 Worn or damaged insulator
 Faulty spark plug cap
3. Ignition coil(s)
 Broken or shorted primary or secondary coils
 Faulty spark plug lead
 Cracked or broken ignition coil
4. Ignition system  Faulty ECU
 Faulty crankshaft position sensor
EAS28510
POOR MEDIUM-AND-HIGH-SPEED PER-
FORMANCE
Refer to STARTING FAILURES on page 9-1.
Engine
1. Air filter
 Clogged air filter element
Fuel system
1. Fuel pump  Faulty fuel pump
EAS28530
FAULTY GEAR SHIFTING
Shifting is difficult
Refer to “Clutch drags”.
EAS28540
SHIFT PEDAL DOES NOT MOVE
Shift shaft
 Improperly adjusted shift rod
 Bent shift shaft
Shift drum and shift forks
 Foreign object in a shift drum groove
 Seized shift fork
 Bent shift fork guide bar
Transmission
 Seized transmission gear  Foreign object between transmission gears
 Improperly assembled transmission
EAS28550
JUMPS OUT OF GEAR
Shift shaft
 Incorrect shift pedal position
 Improperly returned stopper lever
Shift forks
 Worn shift fork
Shift drum
 Incorrect axial play
 Worn shift drum groove
Transmission
 Worn gear dog
EAS28560
FAULTY CLUTCH
Clutch slips
1. Clutch
 Improperly assembled clutch
 Improperly adjusted clutch cable
 Loose or fatigued clutch spring
 Worn friction plate
 Worn clutch plate
2. Engine oil  Incorrect oil level
 Incorrect oil viscosity (low)
 Deteriorated oil
Clutch drags
1. Clutch  Unevenly tensioned clutch springs
 Warped pressure plate
 Bent clutch plate
 Swollen friction plate
 Bent clutch push rod
 Damaged clutch boss
 Burnt primary driven gear bushing
 Match marks not aligned
2. Engine oil  Incorrect oil level
 Incorrect oil viscosity (high)
 Deteriorated oil
EAS28600
OVERHEATING
Engine
1. Clogged coolant passages Cylinder head(s) and piston(s)
 Heavy carbon buildup 
						

							
TROUBLESHOOTING
9-3
2. Engine oil Incorrect oil level
 Incorrect oil viscosity
 Inferior oil quality
Cooling system
1. Coolant  Low coolant level
2. Radiator  Damaged or leaking radiator
 Faulty radiator cap
 Bent or damaged radiator fin
3. Water pump
 Damaged or faulty water pump
 Thermostat
 Thermostat stays closed
Oil cooler
 Clogged or damaged oil cooler
 Hose(s) and pipe(s)
 Damaged hose
 Improperly connected hose
 Damaged pipe
 Improperly connected pipe
Fuel system
1. Throttle body(-ies)  Damaged or loose throttle body joint
2. Air filter
 Clogged air filter element
Chassis
1. Brake(s)  Dragging brake
Electrical system
1. Spark plug(s)  Incorrect spark plug gap
 Incorrect spark plug heat range
2. Ignition system  Faulty ECU
3. Cooling system  Faulty radiator fan motor relay
 Faulty coolant temperature sensor
 Faulty ECU
EAS28610
OVERCOOLING
Cooling system
1. Thermostat Thermostat stays open
EAS28620
POOR BRAKING PERFORMANCE
 Worn brake pad  Worn brake disc
 Air in hydraulic brake system
 Leaking brake fluid
 Faulty brake caliper kit
 Faulty brake caliper seal
 Loose union bolt
 Damaged brake hose
 Oil or grease on the brake disc
 Oil or grease on the brake pad
 Incorrect brake fluid level
EAS28660
FAULTY FRONT FORK LEGS
Leaking oil
 Bent, damaged or rusty inner tube
 Cracked or damaged outer tube
 Improperly installed oil seal
 Damaged oil seal lip
 Incorrect oil level (high)
 Loose damper rod assembly bolt
 Damaged damper rod assembly bolt copper 
washer
 Cracked or damaged cap bolt O-ring
Malfunction
 Bent or damaged inner tube
 Bent or damaged outer tube
 Damaged fork spring
 Worn or damaged outer tube bushing
 Bent or damaged damper rod
 Incorrect oil viscosity
 Incorrect oil level
EAS28670
UNSTABLE HANDLING
1. Handlebar  Bent or improperly installed handlebar
2. Steering head components  Improperly installed upper bracket
 Improperly installed lower bracket(improperly tightened ring nut)
 Bent steering stem
 Damaged ball bearing or bearing race
3. Front fork leg(s)  Uneven oil levels (both front fork legs)
 Unevenly tensioned fork spring (both front fork legs)
 Broken fork spring
 Bent or damaged inner tube
 Bent or damaged outer tube
4. Swingarm  Worn bearing or bushing
 Bent or damaged swingarm
5. Rear shock absorber assembly(-ies) 
						

							
TROUBLESHOOTING
9-4
 Faulty rear shock absorber spring
 Leaking oil or gas
6. Tire(s)
 Uneven tire pressures (front and rear)
 Incorrect tire pressure
 Uneven tire wear
7. Wheel(s)  Incorrect wheel balance
 Deformed cast wheel
 Damaged wheel bearing
 Bent or loose wheel axle
 Excessive wheel runout
8. Frame
 Bent frame
 Damaged steering head pipe
 Improperly installed bearing race
EAS28710
FAULTY LIGHTING OR SIGNALING SYS-
TEM
Headlight does not come on
 Wrong headlight bulb
 Too many electrical accessories
 Hard charging
 Incorrect connection
 Improperly grounded circuit
 Poor contacts (main or light switch)
 Burnt-out headlight bulb
Headlight bulb burnt out
 Wrong headlight bulb
 Faulty battery
 Faulty rectifier/regulator
 Improperly grounded circuit
 Faulty main switch
 Faulty light switch
 Headlight bulb life expired
Tail/brake light does not come on
 Wrong tail/brake light bulb
 Too many electrical accessories
 Incorrect connection
 Burnt-out tail/brake light bulb
Tail/brake light bulb burnt out
 Wrong tail/brake light bulb
 Faulty battery
 Incorrectly adjusted rear brake light switch
 Tail/brake light bulb life expired
Turn signal does not come on
 Faulty turn signal switch
 Faulty turn signal relay
 Burnt-out turn signal bulb  Incorrect connection
 Damaged or faulty wire harness
 Improperly grounded circuit
 Faulty battery
 Blown, damaged or incorrect fuse
Turn signal blinks slowly
 Faulty turn signal relay
 Faulty main switch
 Faulty turn signal switch
 Incorrect turn signal bulb
Turn signal remains lit
 Faulty turn signal relay
 Burnt-out turn signal bulb
Turn signal blinks quickly
 Incorrect turn signal bulb
 Faulty turn signal relay
 Burnt-out turn signal bulb
Horn does not sound
 Improperly adjusted horn
 Damaged or faulty horn
 Faulty main switch
 Faulty horn switch
 Faulty battery
 Blown, damaged or incorrect fuse
 Faulty wire harness 
						

							
EAS28740
WIRING DIAGRAM
FZS6W/FZS6WC
1. Main switch
2. AC magneto
3. Rectifier/regulator
4. Backup fuse
5. Fuel injection system fuse
6. Main fuse
7. Starter relay
8. Starter motor
9. Battery
10. Starting circuit cut-off relay
11. Sidestand switch
12. Neutral switch
13. Fuel pump
14. Throttle position sensor
15. Intake air pressure sensor
16. O
2 sensor
17. Lean angle sensor
18. Crankshaft position sensor
19. Intake air temperature sensor
20. Coolant temperature sensor
21. ECU (engine control unit)
22. Injector #1
23. Injector #2
24. Injector #3
25. Injector #4
26. Air induction system solenoid
27. Speed sensor
28. Cylinder-#1/#4 ignition coil
29. Cylinder-#2/#3 ignition coil
30. Spark plug
31. Meter assembly
32. Fuel level warning light
33. Oil level warning light
34. Neutral indicator light
35. Tachometer
36. Multi-function meter
37. Engine trouble warning light
38. Coolant temperature warning  light
39. High beam indicator light
40. Left turn signal indicator light
41. Right turn signal indicator light
42. Meter light
43. Oil level switch
44. Right handlebar switch
45. Front brake light switch
46. Engine stop switch
47. Start switch
48. Radiator fan motor fuse
49. Radiator fan motor relay
50. Radiator fan motor
51. Signal fuse
52. Headlight fuse
53. Ignition fuse
54. Tail fuse
55. Turn signal relay
56. Rear brake light switch 57. License plate light
58. Tail/brake light
59. Left handlebar switch
60. Clutch switch
61. Dimmer switch
62. Hazard switch
63. Turn signal switch
64. Horn switch
65. Horn
66. Headlight relay
67. Headlight (high beam)
68. Headlight (low beam)
69. Front left turn signal light
70. Front right turn signal light
71. Rear left turn signal light
72. Rear right turn signal light
EAS4S81044
COLOR CODE
BBlack
Br Brown
Ch Chocolate
Dg Dark green
G Green
Gy Gray
LBlue
O Orange
PPink
RRed
Sb Sky blue
WWhite
YYellow
B/G Black/Green
B/L Black/Blue
B/R Black/Red
B/W Black/White
B/Y Black/Yellow
Br/G Brown/Green
Br/L Brown/Blue
Br/R Brown/Red
Br/W Brown/White
G/B Green/Black
G/R Green/Red
G/W Green/White
G/Y Green/Yellow
Gy/G Gray/Green
Gy/R Gray/Red
L/B Blue/Black
L/R Blue/Red
L/W Blue/White
L/Y Blue/Yellow
O/B Orange/Black
P/W Pink/White
R/B Red/Black
R/G Red/Green
R/L Red/Blue
R/W Red/White
R/Y Red/Yellow
Sb/W Sky blue/White
W/B White/Black
W/R White/Red
W/Y White/Yellow
Y/B Yellow/Black
Y/G Yellow/Green
Y/L Yellow/Blue
Y/R Yellow/Red