Download pdf - ELEC IGNITION SYSTEM - JustAnswerww2.justanswer.com/uploads/keysync/2012-02-13_024320_1300ignitio… · 13.02.2012 · ELEC – + IGNITION SYSTEM IGNITION SPARK GAP ... 90890-06754

7-13

E

– +

ELEC IGNITION SYSTEM

IGNITION SPARK GAP

WARNING

• When checking the spark gap, do nottouch any of the connections of the sparkgap tester lead wires.

• When performing the spark gap test, takespecial care not to let sparks leak out ofthe removed spark plug cap.

• When performing the spark gap check,keep flammable gas or liquids away,since this test can produce sparks.

1. Check:

• Ignition spark gap

Below specification → Check the ECM

output peak voltage.

Check the ignition coil for resistance.

È For USA and Canada

É For Worldwide

Spark gap:10–11 mm (0.39–0.43 in)

Checking steps:

• Connect the spark plug cap to the sparkgap tester.

• Set the spark gap length on the adjustingknob.

Spark gap tester:YM-34487

Ignition tester:90890-06754

• Crank the engine and observe the igni-tion system spark through the dischargewindow.

È

É

0 5

OK

0 5 10

È

OK

É

7-14

E

– +


IGNITION SYSTEM PEAK VOLTAGE

WARNING

When checking the electrical components,

do not touch any of the connections of the

digital tester lead wires.

NOTE:• If there is no spark, or the spark is weak,

continue with the ignition system test.

• If a good spark is obtained, the problem is

not with the ignition system, but possibly with

the spark plug(s) or another component.

1. Measure:

• ECM output peak voltage

Below specification → Measure the

pickup coil output peak voltage.

NOTE:To crank the engine, connect the engine shut-

off cord (lanyard) to the engine shut-off switch,

and then press the start switch and engine

stop switch simultaneously.

ECM output peak voltage:Black/red (B/R) – Ground forcylinder #1Black/white (B/W) – Ground forcylinder #2Black/yellow (B/Y) – Ground forcylinder #3

r/minLoaded

Cranking 2,000 3,500

V 0.8 174 156

7-15

E

– +


2. Measure:

• Pickup coil output peak voltage

Below specification → Replace the

pickup coil.

Above specification → Replace the

ECM.





3. Measure:

• Lighting coil output peak voltage

Below specification → Replace the light-

ing coil.





Test harness (6 pins):YB-06849

Test harness SM6195021-6 (6 pins):

90890-06849

Pickup coil output peak voltage:White/red (W/R) – Black (B)White/black (W/B) – Black (B)White/yellow (W/Y) – Black (B)

r/minUnloaded Loaded


V 6.0 6.0 24 40

Lighting coil tester (3 pins):YB-06870

Test harness SMT250-3 (3 pins):90890-06870

Lighting coil output peak voltage:Green (G) – Green (G)

r/minUnloaded Loaded


V 9.0 7.5 12.5 12.5

7-16

E

– +

ELEC

4. Measure:

• Rectifier/regulator output peak voltage

Below specification → Replace the recti-

fier/regulator.

NOTE:• Do not use the peak voltage adapter to mea-

sure the output voltage.

• Disconnect the output lead of the tester har-

ness.

BATTERYRefer to “ELECTRICAL” in Chapter 3.

FUSERefer to “STARTING SYSTEM.”

SPARK PLUGSRefer to “POWER UNIT” in Chapter 3.

SPARK PLUG LEAD ASSEMBLY1. Check:

• Spark plug lead assembly

Cracks/damage → Replace.

Test harness (6 pins):YB-06848

Test harness FSW-6A (6 pins):90890-06848

Rectifier/regulator output peak voltage:

Red (R) – Black (B)

r/minUnloaded

3,500

V 14.5

2. Measure:

• Spark plug lead resistance

Out of specification → Replace.

Spark plug lead resistance:#1: 6.1–14.3 kΩ

#2: 4.5–10.9 kΩ

#3: 3.3–8.2 kΩ

IGNITION SYSTEM

7-17

E

– +

ELEC

IGNITION COIL1. Measure:

• Primary coil resistance


NOTE:When measuring a resistance of 10 Ω or less

with the digital tester, the correct measurement

cannot be obtained because of the tester’s

internal resistance.

Refer to “Low resistance measurement.”

Primary coil resistance:Black/white (B/W) – Body

0.26–0.36 Ω at 20 °C (68 °F)

2. Measure:

• Secondary coil resistance


Secondary coil resistance:Black/white (B/W) – Spark plug lead terminal

3.5–4.7 kΩ at 20 °C (68 °F)

ENGINE STOP SWITCH1. Check:

• Engine stop switch continuity


Engine stop switch continuity(black coupler)

Clip PositionLead color

White Black

InstalledFree

Push

RemovedFree

Push

IGNITION SYSTEM

7-18

E

– +


ENGINE TEMPERATURE SENSOR1. Measure:

• Engine temperature sensor resistance

(at the specified temperatures)

Out of specifications → Replace.

Engine temperature sensor resistance:

20 °C (68 °F): 54.2–69.0 kΩ 100 °C (212 °F): 3.12–3.48 kΩ

Measurement steps:

• Suspend the engine temperature sensorin a container filled with water.

• Slowly heat the water.• Measure the resistance when the speci-

fied temperatures are reached.

INTAKE AIR TEMPERATURE SENSOR1. Measure:

• Intake air temperature sensor resistance



Intake air temperature sensor resistance:

0 °C (32 °F): 5.4–6.6 kΩ 80 °C (176 °F): 0.29–0.39 kΩ

Measurement steps:

• Ice the intake air temperature sensor andmeasure the resistance when the speci-fied temperature is reached.

• Suspend the intake air temperature sen-sor in a container filled with water.

• Slowly heat the water.• Measure the resistance when the speci-

fied temperature is reached.

7-19

E

– +


COOLING WATER TEMPERATURE

SENSOR1. Measure:

• Cooling water temperature sensor

resistance



Cooling water temperature sensor resistance:

0 °C (32 °F): 24.0–37.1 kΩ 100 °C (212 °F): 0.87–1.18 kΩ 200 °C (392 °F): 104–153 Ω

Measurement steps:

• Ice the cooling water temperature sensorand measure the resistance when thespecified temperature is reached.

• Suspend the cooling water temperaturesensor in a container filled with oil.

• Slowly heat the oil.• Measure the resistance when the speci-

fied temperatures are reached.

EXHAUST TEMPERATURE SENSOR1. Measure:

• Exhaust temperature sensor resistance



Exhaust temperature sensor resistance:

300 °C (572 °F): 73–241 kΩ 600 °C (1,112 °F): 0.86–1.58 kΩ 900 °C (1,652 °F): 64–90 Ω

Measurement steps:

• Heat the exhaust temperature sensorusing an electric furnace or equivalent.

• Measure the resistance when the speci-fied temperatures are reached.

7-20

E

– +


MAIN AND FUEL PUMP RELAY1. Check:

• Main and fuel pump relay continuity


Checking steps:

• Connect the tester leads between mainand fuel pump relay terminals 5, 6, and7.

• Connect terminal 2 or 3 to the positivebattery terminal.

• Connect terminal 1 to the negative bat-tery terminal.

• Check that there is continuity betweenthe main and fuel pump relay terminals.

• Check that there is no continuity betweenthe main and fuel pump relay terminalsafter disconnecting terminal 1, 2, or 3.

• Connect the tester leads between mainand fuel pump relay terminals 6 and 8.

• Connect terminal 7 to the positive bat-tery terminal.

• Connect terminal 4 to the negative bat-tery terminal.

• Check that there is continuity betweenthe main and fuel pump relay terminals.

• Check that there is no continuity betweenthe main and fuel pump relay terminalsafter disconnecting terminal 4 or 7.

1234

5678

+ –

84

5

1

3276

+ –

84

5

1

3276

THROTTLE POSITION SENSOR1. Measure:

• Check the throttle position sensor output

voltage using the Yamaha Diagnostic

System.

Out of specification → Replace the

throttle bodies.

Throttle position sensor output voltage:

Pink (P) – Black/orange (B/O)0.793–0.807 V

7-21

E

– +


ATMOSPHERIC PRESSURE SENSOR1. Measure:

• Atmospheric pressure sensor output

voltage


È: Output voltage É: Vacuum pressure

NOTE:While the Yamaha Diagnostic System is oper-

ating, electric power is supplied to the atmo-

spheric pressure sensor.

Air pressure sensor tester (3 pins):

YB-06869Test harness EJ-II-3 (3 pins):

90890-06869Lower unit pressure/vacuum tester:

YB-35956-AVacuum/pressure pump gauge set:

90890-06756

Atmospheric pressure sensor output voltage:

Pink/green (P/G) – Black/orange (B/O)1 101.3 kPa

(1.01 kgf/cm2, 14.4 psi):a 4.00 V

2 50 kPa (0.5 kgf/cm2, 7.1 psi):b 1.97 V

3 20 kPa (0.2 kgf/cm2, 2.8 psi):c 0.79 V

Measurement steps:

• Disconnect the atmospheric pressuresensor.

• Connect the test harness (3 pins) to theatmospheric pressure sensor.

• Operate the Yamaha Diagnostic System.• Apply vacuum pressure to the atmo-

spheric pressure sensor and measurethe output voltage.

B/OP/G

È

a

b

c

3 2 1 É

7-22

E

– +


SLANT DETECTION SWITCH1. Check:

• Slant detection switch continuity


Position

Lead color

Blue/black (L/B)

Black/orange (B/O)

Normal operation È

Overturned É

UP

UP

È

É

7-23

E

– +

ELEC FUEL CONTROL SYSTEM

FUEL CONTROL SYSTEMWIRING DIAGRAM

33313029282720

2 5 6 7 8 10 14

262524232221 32

1 4 9 15 16 17 18 193 11 12 13

3534

Pu/Y

Pu/B

Pu/R

R/Y

L/B

B

P/G

P

B

24 :

25 :

26 :

27 :

28 :

29 :

30 :

31 :

33 :

Y

B/Y

B/G

B/O

B/L

O

L/R

O

P

2 :

5 :

6 :

7 :

8 :

10 :

14 :

20 :

23 :

B/O

B/O

B/O

P

B/O

B/O

B/L

B/O

B

B/O

P/G

B

B

WO

O

B

123 4 567 8

R

R

R

R

B

B

B

R/YR/Y

Pu/R

R/Y

Pu/B

R/Y

Pu/Y

B/O

B/O

R/Y

BB B

#1

#2

#3

B/O

L/B

P

B

L

Gy

P

B

L

B

B

L/B

O

P

B/G

B/O

B/O

B/Y

B/Y

B/Y

B/O

B/O

B/Y

B/Y

B/Y

Pu/R

Pu/B

B/O B/O

P

Pu/Y

G/R

R/YOG

B/G

G/B

G/YB/Y

Pu/R

B/Y

B/G

G/Y

B/OB/O

Pu/B Pu/Y

P

G/R

O

R/Y R/Y

B/G

B/O

B/O

L/B

B

L/B

OO

O

B

B B

R/Y

R/Y

R/Y

R/YR/Y

R

Br

BL/R

Y

L

R/Y

B/L

B/O

B

B

B/O

O

O

P/G

B/O

W

B

B

B

BB

L BB

B Gy

O

OOO

B/O

P

R/Y

R/Y

R/Y

R/Y

R/Y Pu/R

Pu/B

Pu/Y

R/Y

B/O

B/O

L/R

Y

B/O

1

2 3

4

6 7

8

9

0

A

B

C

DE

E

E

5

1 ECM

2 Main and fuel pump relay

3 Fuse (20 A)

4 Battery

5 Slant detection switch

6 Multifunction meter

7 Fuel sender

8 Fuel pump

9 Cooling water temperature sensor

0 Exhaust temperature sensor

A Atmospheric pressure sensor

B Throttle position sensor

C Intake air temperature sensor

D Engine temperature sensor

E Fuel injector

7-24

E

– +


WIRING DIAGRAM

33313029282720

2 5 6 7 8 10 14

262524232221 32

1 4 9 15 16 17 18 193 11 12 13

3534

Pu/Y

Pu/B

Pu/R

R/Y

L/B

B

P/G

P

B

24 :

25 :

26 :

27 :

28 :

29 :

30 :

31 :

33 :

Y

B/Y

B/G

B/O

B/L

O

L/R

O

P

2 :

5 :

6 :

7 :

8 :

10 :

14 :

20 :

23 :

B/O

B/O

B/O

P

B/O

B/O

B/L

B/O

B

B/O

P/G

B

B

WO

O

B

123 4 567 8

R

R

R

R

B

B

B

R/YR/Y

Pu/R

R/Y

Pu/B

R/Y

Pu/Y

B/O

B/O

R/Y

BB B

#1

#2

#3

B/O

L/B

P

B

L

Gy

P

B

L

B

B

L/B

O

P

B/G

B/O

B/O

B/Y

B/Y

B/Y

B/O

B/O

B/Y

B/Y

B/Y

Pu/R

Pu/B

B/O B/O

P

Pu/Y

G/R

R/YOG

B/G

G/B

G/YB/Y

Pu/R

B/Y

B/G

G/Y

B/OB/O

Pu/B Pu/Y

P

G/R

O

R/Y R/Y

B/G

B/O

B/O

L/B

B

L/B

OO

O

B

B B

R/Y

R/Y

R/Y

R/YR/Y

R

Br

BL/R

Y

L

R/Y

B/L

B/O

B

B

B/O

O

O

P/G

B/O

W

B

B

B

BB

L BB

B Gy

O

OOO

B/O

P

R/Y

R/Y

R/Y

R/Y

R/Y Pu/R

Pu/B

Pu/Y

R/Y

B/O

B/O

L/R

Y

B/O

1

2 3

4

6 7

8

9

0

A

B

C

DE

E

E

5

B : Black

Gy : Gray

L : Blue

O : Orange

P : Pink

R : Red

W : White

Y : Yellow

B/G : Black/green

B/L : Black/blue

B/O : Black/orange

B/Y : Black/yellow

L/B : Blue/black

L/R : Blue/red

P/G : Pink/green

Pu/B : Purple/black

Pu/R : Purple/red

Pu/Y : Purple/yellow

R/Y : Red/yellow

7-25

E

– +


FUEL PUMP1. Check:

• Fuel pump operating sound

No sound → Measure the fuel pressure.

Refer to “FUEL INJECTION SYSTEM”

in Chapter 4.

FUEL SENDER1. Measure:

• Fuel sender resistance


Float position

Resistance (Ω)

A 133.5–136.5

B 5–7