Yamaha FZ6-N 2004 Service Manual Download Page 32

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CONNECTING RODS AND PISTONS

ENG

NOTE:

CAUTION:

NOTE:

EAS00393

REMOVING THE CONNECTING RODS AND
PISTONS

The following procedure applies to all of the
connecting rods and pistons.
1. Remove:

connecting rod cap

big end bearings

Identify the position of each big end bearing so
that it can be reinstalled in its original place.

2. Remove:

piston pin clips

piston pin

piston

Do not use a hammer to drive the piston pin
out.

For reference during installation, put identifica-
tion marks on the piston crown.

Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set

Piston pin puller set

90890-01304, YU-01304

3. Remove:

top ring

2nd ring

oil ring

When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.

Summary of Contents for FZ6-N 2004

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Page 3: ...t is necessary to use this Supplementa ry Service Manual together with the following manual FZ6 S S 2004 SERVICE MANUAL 5VX1 AE1 FZ6 N S 2004 SUPPLEMENTARY SERVICE MANUAL E2003 by Yamaha Motor Co Ltd First Edition December 2003 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...mprove all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following ...

Page 5: ...he top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s ap pears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number i...

Page 6: ...trical system 9 Troubleshooting Symbols 10 to 17 indicate the following 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit clearance 16 Engine speed 17 Electrical data Symbols 18 to 23 in the exploded diagrams indi cate the types of lubricants and lubrication points 18 Engine oil 19 Gear oil 20 Molybdenum disulfide oil 21 Wheel beari...

Page 7: ...BULBS 21 ADJUSTING THE HEADLIGHT BEAMS 22 ENGINE CONNECTING RODS AND PISTONS 23 REMOVING THE CONNECTING RODS AND PISTONS 24 CHECKING THE BIG END BEARINGS for EUR 25 CHECKING THE BIG END BEARINGS for OCE 28 INSTALLING THE CONNECTING ROD AND PISTON for EUR 32 INSTALLING THE CONNECTING ROD AND PISTON for OCE 35 COOLING SYSTEM RADIATOR 39 THERMOSTAT 41 WATER PUMP 42 ELECTRICAL SYSTEM CHECKING THE SWIT...

Page 8: ...SIGNALING SYSTEM 57 CIRCUIT DIAGRAM 57 TROUBLESHOOTING 59 CHECKING THE SIGNALING SYSTEM 59 FZ6 N S 2004 WIRING DIAGRAM ...

Page 9: ... oil and a full fuel tank Maximum load except motorcycle 201 kg 443 lb 196 kg 432 lb SSS SSS ELECTRICAL SPECIFICATIONS Item Standard Limit Bulbs voltage wattage quantity Headlight Auxiliary light Tail brake light Turn signal light Licence light Meter light 12V 60 W 55 W 1 12 V 5 W 1 12 V 5 W 21 W 1 12 V 10 W 4 12 V 5 W 1 EL SSS SSS SSS SSS SSS SSS Starting circuit cut off relay Model manufacture G...

Page 10: ..._ 11 150_ Connecting rod caps for OCE Bolt M7 8 15 120_ 1 5 120_ 11 120_ CHASSIS TIGHTENING TORQUES Item Thread Tightening Remarks Item size Nm mSkg ftSlb Remarks Radiator cover and radiator M6 8 0 8 7 2 Horn bracket and frame M6 7 0 7 5 1 Front frame and rear frame upper M10 41 4 1 30 Front frame and rear frame lower M10 41 4 1 30 To repair make sure to apply the liquid fixing agent to the bolt w...

Page 11: ... 3 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator 2 Oil cooler COOLING SYSTEM DIAGRAMS ...

Page 12: ... 4 COOLING SYSTEM DIAGRAMS SPEC 1 Water pump 2 Oil cooler 3 Radiator ...

Page 13: ... 5 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator 2 Thermostat ...

Page 14: ...an dlebar switch lead and clutch cable in order through the frame hole from the inner side of the vehicle D To the headlight and speedometer E Pass the right handlebar switch lead and throttle cable clutch cable through the meter cover hole F Install the clamp in the direction as shown in the il lustration 1 Left handlebar switch lead 2 Main switch and immobilizer lead 3 Clutch cable 4 Throttle ca...

Page 15: ...ole located on the right side of the frame Route the throttle cable above the wire harness C Route the horn lead inner side of the coolant reser voir tank hose D Clamp the horn lead and radiator hose the external side only Horn lead should be positioned inside of the hose Install the clamp in the direction pointing its detent pawl to the downside E Route the right handlebar switch lead under the b...

Page 16: ...reather hose fuel tank drain hose and coolant res ervoir tank breather hose to be lower than the clamp position of the muffler stay Any order to take out the fuel tank breather hose and fuel tank drain hose can be accepted J Pass the fuel tank breather hose fuel tank drain hose coolant reservoir tank breather hose and brake right switch lead through the guide of the stay assembly 2 K Clamp the tai...

Page 17: ...d 25 Oil level gauge lead 26 Sidestand switch lead 27 A C magneto lead 28 Speed sensor lead 1 Left handlebar switch lead 2 Main switch and immobilizer lead 3 Meter lead and left handlebar switch lead 4 Clutch cable 5 Battery negative lead coupler 6 Starter relay lead 7 Battery negative lead 8 Fuel tank drain hose 9 Rectifier regulator 10 Turn signal relay 11 Radiator fan motor relay 12 Dimmer rela...

Page 18: ...d but make sure that the leads are not crossed N Clamp the rear turn signal lead and license plate light lead to the frame Hook the clamp to the brack et Pull out the lead sufficiently to the frame side and route it along with the side of the back stay Cut the tip of the clamp to be between 1 and 5 mm 0 04 and 0 20 in upward O Clamp the rear turn signal lead and license plate light lead to the fra...

Page 19: ... to visually check the bend R section Y Point the tip of the clamp to the inner side of the ve hicle body Z Make sure to pass the neutral switch lead through the hole of the flap AA Clamp the seat lock wire to the frame as shown in the illustration Secure the clamp to the weld of the cross member with the frame Position the binding section in front of the vehicle body and cut the tip to be between...

Page 20: ...e 24 Cover 2 25 Spark plug lead 26 Air cut off valve hose 1 Right handlebar switch lead 2 Throttle cables 3 Battery positive lead 4 Coolant reservoir tank hose 5 Battery cover 6 Connecter cover 7 Fuel tank breather hose 8 Brake fluid reservoir hose 9 Lean angle cut off switch 10 Fuse box 11 Rear turn signal light lead right 12 License plate light lead 13 Rear turn signal light lead left CABLE ROUT...

Page 21: ...ected part of the tip to the inner side of the vehicle H Pass the radiator hose coolant reservoir hose wire harness and starter motor lead in order through the lower side of the vehicle I Set the 4 pin coupler in the connector cover after wiring it J To the sidestand switch K To the speed sensor L To the A C magneto M To the oil level gauge N To the rear brake light switch O To the neutral switch ...

Page 22: ...e air cut off valve hose AN Route the spark plug lead 4 by the front side of the spark plug leads 2 and 3 CABLE ROUTING SPEC W Attach the rectifier regulator lead to the clamp of the rectifier bracket X To the engine ground Y To the fuel injection Z To the fuel pump AA Route the clutch cable under the fuel injection lead AB Pass the clutch cables through the clamp and then install the clamp to the...

Page 23: ... 15 CABLE ROUTING SPEC AO Route the spark plug leads 2 and 3 behind the air cut off valve hose ...

Page 24: ...tion Working groves should not be used at the time of work E It prevents that this portion falls out 2 The clamp is attached from the bottom after the work of 1 It checks being completely equipped with and section A B C 1 Fuel pump assembly 2 Fuel tank breather hose 3 Fuel tank drain hose 4 Fuel hose 5 Clip 6 Clamp A Air opening B Install the O ring with its lip pointed upward C Fuel tank breather...

Page 25: ... tank hose inside of the clamp H Insert in certainly I To the fuel tank drain tube left J Air opening K There should be no slacking of the hose when it is routed 1 Coolant breather hose 2 Coolant reservoir tank 3 Coolant reservoir tank hose 4 Clamp 5 Fuel tank drain hose A Front side B Pass the coolant reservoir tank hose hangs down downward from back of the bolt C Insert this portion securely ...

Page 26: ...ap Ǹ Ǹ See page 3 22 S Replace Ǹ Ǹ 3 Valves See page 3 10 S Check valve clearance S Adjust Every 40 000 km 4 Air filter element See page 3 32 S Replace Ǹ 5 Clutch See page 3 31 S Check operation S Adjust Ǹ Ǹ Ǹ Ǹ Ǹ 6 Front brake S Check operation fluid level and vehicle for fluid leakage Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 6 See page 3 41 43 45 S Replace brake pads Whenever worn to the limit 7 Rear brake S Check operation...

Page 27: ... km and after washing the motorcycle or riding in the rain 24 Front and rear brake switches See page 3 45 See page 8 4 S Check operation Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 25 Moving parts and cables See page 3 57 S Lubricate Ǹ Ǹ Ǹ Ǹ Ǹ 26 Throttle grip housing and cable See page 3 19 S Check operation and free play S Adjust the throttle cable free play if necessary S Lubricate the throttle grip housing and cable Ǹ Ǹ Ǹ Ǹ ...

Page 28: ...he cowlings Seat Rear cowling Frame side cover 1 2 Remove the parts in the order listed Refer to SEAT For installation reverse the removal procedure 23 Nm 2 3 mSkg 17 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 23 Nm 2 3 mSkg 17 ftSlb COWLINGS CHK ADJ COWLINGS ...

Page 29: ...le products and your hands away from the bulb until it has cooled down 4 Install Sheadlight bulb New Secure the new headlight bulb with the head light bulb holder Avoid touching the glass part of the head light bulb to keep it free from oil otherwise 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 clea...

Page 30: ...eadlights 1 Adjust Sheadlight beam vertically a Turn the adjusting screw 1 in direction a or b Direction Headlight beam is raised Direction Headlight beam is lowered 2 Adjust Sheadlight beam horizontally a Turn the adjusting knob 2 in direction a or b Direction Headlight beam moves to the right Direction Headlight beam moves to the left ...

Page 31: ...ig end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring Oil ring 4 4 4 8 4 4 4 4 4 4 Remove the parts in the order listed Refer to CRANKCASE For installation reverse the removal procedure 15 Nm 1 5 mSkg 11 ftSlb 120_ 15 Nm 1 5 mSkg 11 ftSlb 150_ CONNECTING RODS AND PISTONS ENG EAS00252 ENGINE CONNECTING RODS AND PISTONS ...

Page 32: ...ton pin 2 Spiston 3 Do not use a hammer to drive the piston pin out SFor reference during installation put identifica tion marks on the piston crown SBefore removing the piston pin deburr the pis ton pin clip groove and the piston pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 Piston pin puller set 90890 01304 YU ...

Page 33: ... the big end bearings crankshaft pins and the inside of the connecting rod halves b Install the big end upper bearing into the con necting rod and the big end lower bearing into the connecting rod cap Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod hal...

Page 34: ...further to reach the specified angle 150_ When the nut is tightened more than the spe cified angle do not loosen the nut and then retighten it Replace the bolt with a new one and perform the procedure again SDo not use a torque wrench to tighten the nut to the specified angle STighten the nut until it is at the specified angles When using a hexagonal nut note that the angle from one corner to anot...

Page 35: ...ds are used to determine the replacement big end bearing sizes S P1 X P4 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 2 re spectively then the bearing size for P1 is P1 connecting rod P1 crankshaft 5 2 3 brown BIG END BEARING COLOR CODE 1 Blue 2 Black 3 Brown 4 Green ...

Page 36: ... the big end bearings crankshaft pins and the inside of the connecting rod halves b Install the big end upper bearing into the con necting rod and the big end lower bearing into the connecting rod cap Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod hal...

Page 37: ...nnecting rod and connecting rod cap once using a single unit of the connecting rod i Tighten the connecting rod bolt while check ing that the sections shown a and b are flush with each other by touching the surface SSide machined face a SThrusting faces 4 places at front and rear b To install the big end bearing care should be taken not to install it at an angle and the position should not be out ...

Page 38: ...ther to reach the specified angle 120_ p After the installation check that the section show a is flush with each other by touching the surface SSide machined face a SWhen the bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and per form the procedure again SIf they are not flush with each other remove the connecting rod bo...

Page 39: ... big end bearings 2 Select Sbig end bearings P1 X P4 SThe numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes S P1 X P4 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 2 re spectively then the bearing size for P1 is P...

Page 40: ... manufacturer s marks or numbers a face up 2 Install Spiston 1 onto the respective connecting rod 2 Spiston pin 3 Spiston pin clip New 4 SApply engine oil onto the piston pin SMake sure that the Y mark a on the connect ing rod faces left when the arrow mark b on the piston is pointing up Refer to the illustra tion SReinstall each piston into its original cylinder numbering order starting from the ...

Page 41: ... big end bearings with the notches in the connecting rods and connecting rod caps SBe sure to reinstall each big end bearing in its original place SWhile compressing the piston rings with one hand install the connecting rod assembly into the cylinder with the other hand SMake sure that the Y marks a on the con necting rods face towards the left side of the crankshaft SMake sure that the characters...

Page 42: ...ghten the nut further to reach the specified angle 150_ When the nut is tightened more than the spe cified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and perform the procedure again SDo not use a torque wrench to tighten the nut to the specified angle STighten the nut until it is at the specified angles When using a hexagonal nut note that the angle from one...

Page 43: ... manufacturer s marks or numbers a face up 2 Install Spiston 1 onto the respective connecting rod 2 Spiston pin 3 Spiston pin clip New 4 SApply engine oil onto the piston pin SMake sure that the Y mark a on the connect ing rod faces left when the arrow mark b on the piston is pointing up Refer to the illustra tion SReinstall each piston into its original cylinder numbering order starting from the ...

Page 44: ... end bearings Sconnecting rod big end inner surface with the recommended lubricant Recommended lubricant Engine oil 6 Install Sbig end bearings Sconnecting rod cap onto the connecting rod SAlign the projections on the big end bearings with the notches in the connecting rods and connecting rod caps SMake sure that the characters a on both the connecting rod and connecting rod cap are aligned ...

Page 45: ...sh with each other by touching the surface SSide machined face a SThrusting faces 4 places at front and rear b To install the big end bearing care should be taken not to install it at an angle and the position should not be out of alignment e Loosen the connecting rod bolt remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in th...

Page 46: ...ed angle 120_ e After the installation check that the section shown a is flush with each other by touching the surface SSide machined face a SWhen the bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and per form the procedure again SIf they are not flush with each other remove the connecting rod bolt and big end bear ing ...

Page 47: ...tlet hose Radiator inlet hose and protector Oil cooler outlet hose Radiator Radiator cap 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS Refer to FUEL TANK in chapter 3 Refer to AIR FILTER CASE in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Disconnect Disconnect Disconnect 10 Nm 1 0 mSkg 7 2 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSk...

Page 48: ... 40 RADIATOR COOL Order Job Part Q ty Remarks 9 Radiator fan 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb ...

Page 49: ...se and protector Thermostat cover Thermostat 1 1 1 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS Refer to FUEL TANK Refer to AIR FILTER CASE in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Refer to THROTTLE BODIES in chapter 7 For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ftSlb THERMOSTAT COOL EAS00460 THERMOSTAT ...

Page 50: ...1 1 Remove the parts in the order listed It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil Drain Refer to CHANGING THE COOLANT in chapter 3 Disconnect Disconnect For installation reverse the removal procedure NOTE 10 Nm 1 0 mSkg 7 2 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb WATER PUMP COOL EAS00468 WATER PUMP ...

Page 51: ...nd switch 8 Engine stop switch 9 Front brake light switch 10 Start switch CHECKING THE SWITCHES ELEC EAS00731 ELECTRICAL SYSTEM CHECKING THE SWITCHES Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the sw...

Page 52: ...idestand switch 13 Neutral switch 17 Lean angle cut off switch 18 Crankshaft position sensor 21 ECU 28 Ignition coil 1 and 4 29 ignition coil 2 and 3 30 Spark plug 43 Engine stop switch 50 Fuse ignition 57 Clutch switch IGNITION SYSTEM ELEC EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 53: ...ITION SYSTEM ELEC NOTE YES NO 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK Replace the fuse s EAS00737 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check 1 main and ignition fuses 2 battery 3 spark plugs 4 ignition spark gap 5 spark plug cap resistanc...

Page 54: ...owing procedure applies to all of the spark plug caps SRemove the spark plug cap from the spark plug lead SConnect the pocket tester Ω 1k to the spark plug cap as shown SMeasure the spark plug cap resistance YES NO Spark plug cap resistance 10 kΩ at 20_C 68_F SIs the spark plug cap OK Replace the spark plug cap EAS00747 6 Ignition coil resistance The following procedure applies to all of the ignit...

Page 55: ...sure the crankshaft position sensor re sistance EAS00748 Crankshaft position sensor resis tance 248 X 372 Ω at 20_C 68_F between gray and black SIs the crankshaft position sensor OK YES NO Replace the crank shaft position sen sor EAS00749 8 Main switch SCheck the main switch for continuity Refer to CHECKING THE SWITCHES SIs the main switch OK YES NO Replace the main switch EAS00750 9 Engine stop s...

Page 56: ...Check the starting circuit cut off relay for continuity Positive tester probe blue yellow Negative tester probe sky blue 1 2 EAS00753 Positive tester probe blue yellow Negative tester probe blue green Continuity 1 3 Positive tester probe sky blue Negative tester probe blue yellow 2 1 Positive tester probe blue green Negative tester probe blue yellow No continuity 3 1 YES NO Replace the starting ci...

Page 57: ...54 15 Wiring SCheck the entire ignition system s wiring Refer to CIRCUIT DIAGRAM SIs the ignition system s wiring properly con nected and without defects YES NO Properly connect or repair the ignition system s wiring Replace the ECU ...

Page 58: ... 50 LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 59: ...witch 7 Fuse main 10 Battery 21 ECU 37 High beam indicator light 49 Fuse headlight 50 Fuse ignition 51 Fuse park 54 License plate light 55 Tail brake light 58 Pass switch 59 Dimmer switch 64 Dimmer relay 65 Auxiliary light 66 Headlight ...

Page 60: ...NG SYSTEM ELEC NOTE YES NO 1 Main headlight ignition and park fuses SCheck the main park ignition and headlight fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main park ignition and headlight fuses OK Replace the fuse s 2 Battery SCheck the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 EAS00739 EAS00781 TROUBLESHOOTING Any of the followin...

Page 61: ...ter Ω 1 and bat tery 12 V to the dimmer relay as shown Positive battery lead red yellow Negative battery lead yellow black EAS00787 YES NO 7 Wiring SCheck the entire lighting system s wiring Refer to CIRCUIT DIAGRAM SIs the lighting system s wiring properly con nected and without defects Properly connect or repair the lighting system s wiring Check the condition of each of the lighting system s ci...

Page 62: ...repaired When the dimmer switch is set to When the dimmer switch is set to Headlight coupler wire harness side Low beam Headlight Positive tester probe green Negative tester probe black 1 2 Meter assembly coupler wire harness side STurn the main switch to ON SStart the engine SSet the dimmer switch to or SMeasure the voltage DC 12 V of green or yellow on the headlight coupler wire harness side SIs...

Page 63: ...ltage DC 12 V of blue on the license plate light coupler wire harness side SIs the voltage within specification 1 This circuit is OK YES NO 1 Tail brake light bulb and socket SCheck the tail brake light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS SAre the tail brake light bulb and socket OK Replace the tail brake light bulb socket or both EAS00790 3 The tail brake l...

Page 64: ... to the left handlebar switch is faulty and must be repaired Positive tester probe blue red Negative tester probe black 1 2 STurn the main switch to ON SMeasure the voltage DC 12 V of black on the left handlebar switch wire harness side SIs the voltage within specification 2 YES NO 3 Voltage SConnect the pocket tester DC 20 V to the auxiliary light coupler wire harness side as shown Replace the le...

Page 65: ... 57 57 SIGNALING SYSTEM ELEC EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM ...

Page 66: ... 36 Multi function meter 38 Turn signal indicator light 39 Oil level switch 42 Front brake light switch 48 Fuse signal 50 Fuse ignition 51 Fuse park 52 Turn signal relay 53 Rear brake light switch 55 Tail brake light 60 Hazard switch 61 Turn signal switch 62 Horn switch 63 Horn 67 Rear turn signal light right 68 Rear turn signal light left 69 Front turn signal light right 70 Front turn signal ligh...

Page 67: ...IGHTING SYSTEM SIGNALING SYSTEM ELEC NOTE YES NO 1 Backup main ignition signal and park fuses SCheck the backup main ignition signal and park fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the backup main ignition signal and park fuses OK Replace the fuse s 2 Battery SCheck the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circui...

Page 68: ...urn the main switch to ON SPull in the brake lever or push down on the brake pedal SMeasure the voltage DC 12 V of yellow on the tail brake light coupler wire harness side SIs the voltage within specification 2 YES NO 2 Voltage SConnect the pocket tester DC 20 V to the horn connector at the horn terminal as shown The wiring circuit from the main switch to the horn connec tor is faulty and must be ...

Page 69: ...ground Positive tester probe brown green 1 STurn the main switch to ON SMeasure the voltage DC 12 V on brown green at the turn signal relay coupler wire harness side SIs the voltage within specification 1 YES NO The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be re paired YES NO 4 Voltage SConnect the pocket tester DC 20 V to the turn signal relay couple...

Page 70: ...ity Refer to CHECKING THE LEDs SAre the neutral indicator light OK EAS00801 4 The neutral indicator light fails to come on YES NO Replace the meter assembly YES NO 2 Neutral switch SCheck the neutral switch for continuity Refer to CHECKING THE SWITCHES SIs the neutral switch OK Replace the neutral switch When you switch the positive and negative tester probes the readings in the above chart will b...

Page 71: ... the tester readings correct YES NO 1 Oil level warning light LEDs SCheck the oil level warning light for continu ity When the main switch is turn to ON the oil level warning light is come on SAre the oil level warning light OK Replace the meter assembly EAS00802 5 The oil level warning light fails to come on YES NO 2 Oil level switch SDrain the engine oil and remove the oil level switch from the ...

Page 72: ... EAS00803 6 The fuel level warning light fails to come on 1 Fuel sender SDrain the fuel from the fuel tank and remove the fuel pump from the fuel tank SDisconnect the fuel sender coupler from the wire harness SConnect the pocket tester Ω 10 to the fuel sender terminals as shown Tester positive probe green white Tester negative probe black 1 2 Fuel sender resistance Full position of the float 20 X ...

Page 73: ...ring circuit from the main switch to the meter assem bly coupler is faulty and must be re paired Positive tester probe green white Negative tester probe black white 1 2 STurn the main switch to ON SMeasure the voltage DC 12 V of green white and black white at the meter assembly coupler SIs the voltage within specification This circuit is OK 1 2 ...

Page 74: ...ensor 19 Intake air temperature sensor 20 Coolant temperature sensor 21 ECU 22 Cylinder 1 injector 23 Cylinder 2 injector 24 Cylinder 3 injector 25 Cylinder 4 injector 26 Air cut off valve 27 Speed sensor 28 Ignition coil 1 and 4 29 Ignition coil 2 and 3 30 Spark plug 31 Meter assembly 32 Immobilizer indicator light 33 Oil level warning light 34 Engine trouble warning light 35 Neutral indicator li...

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Page 77: ...en Br L Brown Blue Br R Brown Red Br W Brown White G B Green Black G L Green Blue G W Green White G Y Green Yellow Gy B Gray Black L B Blue Black L G Blue Green L R Blue Red L W Blue White L Y Blue Yellow O B Orange Black O R Orange Red P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow W L White Blue W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Yellow B...

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