Yamaha YFM660 01 User Manual
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8 - 30 –+ELECSIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the tail/brake light fails to come on: CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for continu- ity. NO CONTINUITY Replace the bulb and/or bulb socket. CONTINUITY 2.Brake switches Refer to “CHECKING THE SWITCH”. NO CONTINUITY Replace the brake switch. 3.Voltage Connect the pocket tester (DC 20V) to the bulb socket coupler. Tester (+) lead → Yellow terminal 1 Tester (–) lead → Black terminal 2 MEETS SPECIFICATION Turn the main switch to “ON”. Turn the lights switch to “LO” or “HI”. Check the voltage (12 V) of the “Yellow” lead on the bulb socket connector. This circuit is not faulty. OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty, repair it.
8 - 31 –+ELECSIGNAL SYSTEM EB806024 2.If the neutral indicator light fails to come on: CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for continu- ity. NO CONTINUITY Replace the bulb and/or bulb socket. CONTINUITY 2.Neutral switch Refer to “CHECKING THE SWITCH”. NO CONTINUITY Replace the neutral switch. 3.Voltage Connect the pocket tester (DC 20V) to the bulb socket coupler. Tester (+) lead → Brown terminal 1 Tester (–) lead → Sky blue terminal 2 MEETS SPECIFICATION Turn the main switch to “ON”. Check the voltage (12 V). This circuit is not faulty. OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty, repair it.
8 - 32 –+ELECSIGNAL SYSTEM 3.If the reverse indicator light fails to come on: CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for continu- ity. NO CONTINUITY Replace the bulb and/or bulb socket. CONTINUITY 2.Reverse switch Refer to “CHECKING THE SWITCH”. NO CONTINUITY Replace the reverse switch. 3.Voltage Connect the pocket tester (DC 20V) to the bulb socket coupler. Tester (+) lead → Brown terminal 1 Tester (–) lead → Green/Blue terminal 2 MEETS SPECIFICATION Turn the main switch to “ON”. Check the voltage (12 V). This circuit is not faulty. OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty, repair it.
8 - 33 –+ELECSIGNAL SYSTEM 4.If the coolant temperature warning light does not come on when the start switch is pushed on, or if the coolant temperature warning light does not come on when the temperature is high (more than 117 ~ 123 °C (242.6 ~ 253.4 °F)): CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for continu- ity. NO CONTINUITY Replace the bulb and/or bulb socket. GOOD CONDITION 2.Thermo switch 2 Remove the thermo switch from the ther- mostat housing. Connect the pocket tester (Ω × 1) to the thermo switch 1 . Immerse the thermo switch in coolant 2 . Check the thermo switch for continuity. While heating the coolant use a thermome- ter 3 to record the temperatures. Test stepWater temperature Good condition Thermo switch 10 ~ 115 ± 3 °C (32 ~ 239 ± 5.4 °F) × 2More than 120 ± 3 °C (248 ± 5.4 °F) 3*120 ± 3 to 115 ± 3 °C (248 ± 5.4 to 239 ± 5.4 °F) 4*Less than 115 ± 3 °C (239 ± 5.4 °F) × Tests 1 & 2; Heat-up tests Tests 3* & 4*; Cool-down tests : Continuity × : No continuity T R.. Thermo switch: 2.8 Nm (2.8 m kg, 20 ft lb) Three bond sealock ® #10 WARNING Handle the thermo switch with special care. Never subject it to a strong shock or allow it to be dropped. Should it be dropped, it must be replaced. * BAD CONDITION Replace the thermo switch 2.
8 - 34 –+ELECSIGNAL SYSTEM C0NTINUITY 3.Voltage Connect the pocket tester (DC 20V) to the bulb socket coupler. Tester (+) lead → Red/Black terminal 1 Tester (–) lead → White/Blue terminal 2 * MEETS SPECIFICATION Turn the main switch to “ON”. Check the voltage (12 V). OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty, repair it. CORRECT 4.Diode Remove the diode from the coupler. Connect the pocket tester (Ω × 1) to the diode terminals as shown. Check the diode for continuity as follows. Tester positive probe → Blue/Black 1 Tester negative probe → White/Blue 2Continu- ity Tester positive probe → White/Blue 2 Tester negative probe → Blue/Black 1No conti- nuity * OTE: When you switch the tester’s positive and negative probes, the readings in the left chart will be reversed. INCORRECT Replace the diode.
8 - 35 –+ELECSIGNAL SYSTEM C0NTINUITY CORRECT 5.Start switch Refer to “CHECKING THE SWITCH”. This circuit is not faulty. * INCORRECT Replace the handlebar switch (left).
8 - 36 –+ELECCOOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 3Main switch 4Battery 5Fuse DCircuit breaker (fan motor) EThermo switch 1 FFan motor
8 - 37 –+ELECCOOLING SYSTEM TROUBLESHOOTING Procedure Check: 1.Fuse 2.Battery 3.Main switch 4.Fan motor 5.Circuit breaker (fan motor)IF THE FAN MOTOR DOES NOT MOVE: 6.Thermo switch 1 7.Wiring connection (the entire cooling system) OTE: Remove the following part(s) before trouble- shooting. 1)Seat 2)Front fender Use the following special tool(s) for trouble- shooting. Pocket tester: P/N. YU-03112, 90890-03112 EB802011 CONTINUITY 1.Fuse Refer to “CHECKING THE SWITCH”. NO CONTINUITY Replace the fuse. EB802012 CORRECT 2.Battery Check the battery condition. Refer to “CHECKING THE BATTERY” in CHAPTER 3. Open-circuit voltage: 12.8 V or more at 20 °C (68 °F) INCORRECT Clean the battery terminals. Recharge or replace the battery. CORRECT 3.Main switch Refer to “CHECKING THE SWITCH”. * INCORRECT Replace the main switch.
8 - 38 –+ELECCOOLING SYSTEM C0NTINUITY TURNS 4.Fan motor Disconnect the fan motor coupler. Connect the battery (12 V) as shown. Battery (+) lead → Blue terminal 1 Battery (–) lead → Black terminal 2 Check the operation of the fan motor. * DOES NOT TURN Replace the fan motor. MEETS SPECIFICATION 5.Circuit breaker (fan motor) Remove the circuit breaker from the wire harness. Connect the pocket tester (Ω × 1) to the cir- cuit breaker. Circuit breaker resistance: Zero Ω at 20 °C (68 °F) * OUT OF SPECIFICATION Replace the circuit breaker.
8 - 39 –+ELECCOOLING SYSTEM C0NTINUITY GOOD CONDITION 6.Thermo switch 1 Remove the thermo switch from the radia- tor. Connect the pocket tester (Ω × 10) to the thermo switch 1 . Immerse the thermo switch in coolant 2 . Check the thermo switch for continuity. While heating the coolant use a thermome- ter 3 to record the temperatures. Test stepWater temperature Good condition Thermo switch 10 ~ 92 ± 3 °C (32 ~ 197.6 ± 5.4 °F) × 2More than 98 ± 3 °C (208.4 ± 5.4 °F) 3*98 ± 3 to 92 ± 3 °C (208.4 ± 5.4 to 197.6 ± 5.4 °F) 4*Less than 92 ± 3 °C (197.6 ± 5.4 °F) × Tests 1 & 2; Heat-up tests Tests 3* & 4*; Cool-down tests : Continuity × : No continuity T R.. Thermo switch: 28 Nm (2.8 m kg, 20 ft lb) Three bond sealock ® #10 * WARNING Handle the thermo switch with special care. Never subject it to a strong shock or allow it to be dropped. Should it be dropped, it must be replaced. * BAD CONDITION Replace the thermo switch 1.