charging YAMAHA WR 450F 2016 User Guide
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2016, Model line: WR 450F, Model: YAMAHA WR 450F 2016Pages: 426, PDF Size: 10.86 MB
Page 345 of 426
CHARGING SYSTEM
9-15
EAS27240
Page 348 of 426
LIGHTING SYSTEM
9-18
EAS2GC1367TROUBLESHOOTING
Any of the following fail to light: headlight or meter light.
TIP
Before troubleshooting, remove the following part (s):
1. Seat
2. Side cover (left)
3. Air scoop (left/right)
4. Fuel tank1. Check the each bulbs condition. Refer to “CHECKING THE BULBS
AND BULB SOCKETS” on page 9-
67. NG
Replace the bulb (s).
OK
2. Check the fuse. Refer to “CHECKING THE FUSES”
on page 9-68. NG
Replace the fuse(s).
OK
3. Check the battery. Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-69. NG
• Clean the battery terminals.
• Recharge or replace the battery.
OK
4. Check the main relay. Refer to “CHECKING THE RE-
LAYS” on page 9-72. NG
Replace the main relay.
OK
5. Check the headlight relay. Refer to “CHECKING THE RE-
LAYS” on page 9-72. NG
Replace the headlight relay.
OK
6. Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-16. NG
Properly connect or repair the lighting sys-
tem’s wiring.
OK
Replace the ECU, meter assembly, or
taillight.
Page 352 of 426
SIGNALING SYSTEM
9-22
EAS2GC1369TROUBLESHOOTING
• The speedometer does not operate normally.
• The fuel indicator light does not come on.
TIP
Before troubleshooting, remove the following part (s):
1. Seat
2. Side cover (left/right)
3. Air scoop (left/right)
4. Fuel tank
Check the signaling system
The speedometer fails to operate.
1. Check the fuse.Refer to “CHECKING THE FUSES”
on page 9-68. NG
Replace the fuse(s).
OK
2. Check the battery. Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-69. NG
• Clean the battery terminals.
• Recharge or replace the battery.
OK
3. Check the main relay. Refer to “CHECKING THE RE-
LAYS” on page 9-72. NG
Replace the main relay.
OK
4. Check the entire signaling system’s wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-20. NG
Properly connect or repair the signaling
system’s wiring.
OK
This circuit is OK.
1. Check the speed sensor. Refer to “CHECKING THE SPEED
SENSOR” on page 9-77. NG
Replace the speed sensor.
OK
2. Check the entire signaling system’s wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-20. NG
Properly connect or repair the signaling
system’s wiring.
OK
Replace the meter assembly.
Page 356 of 426
COOLING SYSTEM
9-26
EAS2GC1372TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP
Before troubleshooting, remove the following part(s):
1. Seat
2. Side cover (left)
3. Air scoop (left/right)
4. Fuel tank1. Check the fuse. Refer to “CHECKING THE FUSES”
on page 9-68. NG
Replace the fuse(s).
OK
2. Check the battery. Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-69. NG
• Clean the battery terminals.
• Recharge or replace the battery.
OK
3. Check the main relay. Refer to “CHECKING THE RE-
LAYS” on page 9-72. NG
Replace the main relay.
OK
4. Check the radiator fan motor. Refer to “CHECKING THE RADIA-
TOR FAN MOTOR” on page 9-78. NG
Replace the radiator fan motor.
OK
5. Check the radiator fan motor relay. Refer to “CHECKING THE RE-
LAYS” on page 9-72. NG
Replace the radiator fan motor relay.
OK
6. Check the coolant temperature sen- sor.
Refer to “CHECKING THE COOL-
ANT TEMPERATURE SENSOR”
on page 9-78. NG
Replace the coolant temperature sensor.
OK
7. Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-16. NG
Properly connect or repair the cooling sys-
tem’s wiring.
OK
Replace the ECU.
Page 381 of 426
FUEL INJECTION SYSTEM
9-51
Fault code No.46
Item Charging voltage is abnormal.
Fail-safe system Able/Unable to start engine
Able/Unable to drive vehicle
Diagnostic code No. —
Diagnostic tool display —
Procedure —
Item Probable cause of malfunc-
tion and check Maintenance jobConfirmation of service
completion
1 Connection of wire harness ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or bro-
ken terminals and locking
condition of the pins). Improperly connected
Connect the coupler securely
or repair/replace the wire har-
ness. Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not dis-
played
Service is finished.
Fault code number is dis-
played Go to item 2.
2 Wire harness continuity. Open or short circuit Re-
place the wire harness.
Between rectifier/regulator
coupler and ECU coupler.
red–red
Between battery terminal and
ECU coupler.
red–red Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not dis-
played
Service is finished.
Fault code number is dis-
played Go to item 3.
3 Defective AC magneto. Check the AC magneto. Refer to “CHARGING SYS-
TEM” on page 9-12.
Defective AC magneto Re-
place. Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not dis-
played
Service is finished.
Fault code number is dis-
played Go to item 4.
4 Malfunction in ECU. Replace the ECU.
Page 388 of 426
FUEL PUMP SYSTEM
9-58
EAS2GC1381TROUBLESHOOTING
The fuel pump fails to operate.
TIP
Before troubleshooting, remove the following part(s):
1. Seat
2. Side cover (left/right)
3. Air scoop (left/right)
4. Fuel tank1. Check the fuse. Refer to “CHECKING THE FUSES”
on page 9-68. NG
Replace the fuse(s).
OK
2. Check the battery. Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-69. NG
• Clean the battery terminals.
• Recharge or replace the battery.
OK
3. Check the engine stop switch. Refer to “CHECKING THE
SWITCHES” on page 9-64. NG
Replace the engine stop switch.
OK
4. Check fuel pressure. Refer to “CHECKING THE FUEL
PRESSURE” on page 8-5. NG
Replace the fuel pump.
OK
5. Check the fuel pump system wire harness connections.
Refer to “CIRCUIT DIAGRAM” on
page 9-56. NG
Properly connect or repair the fuel pump
system’s wiring.
OK
Replace the ECU.
Page 399 of 426
ELECTRICAL COMPONENTS
9-69
4. Install:• Seat
• Side cover (left/right)Refer to “GENERAL CHASSIS” on page 5-
1.
EAS2GC1386CHECKING AND CHARGING THE BATTERYEWA
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or han- dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical at-
tention.
ECA
NOTICE
• This is a VRLA (Valve Regulated Lead Ac-id) battery. Never remove the sealing caps
because the balance between cells will not
be maintained and battery performance
will deteriorate.
• Charging time, charging amperage and charging voltage for a VRLA (Valve Regu-
lated Lead Acid) battery are different from
those of conventional batteries. The VRLA
(Valve Regulated Lead Acid) battery
should be charged according to the appro-
priate charging method. If the battery is
overcharged, the electrolyte level will drop
considerably. Therefore, take special care
when charging the battery.
TIP
Since VRLA (Valve Regulated Lead Acid) bat-
teries are sealed, it is not possible to check the
charge state of the battery by measuring the
specific gravity of the electrolyte. Therefore, the
charge of the battery has to be checked by
measuring the voltage at the battery terminals.
1. Remove:• Side cover (left/right)
• SeatRefer to “GENERAL CHASSIS” on page 5-
1.
2. Disconnect: • Battery leads
(from the battery terminals)
ECA
NOTICE
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”.
3. Remove:• Battery
4. Check: • Battery charge
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a. Connect a pocket tester to the battery termi- nals.
TIP
• The charge state of a VRLA (Valve Regulated Lead Acid) battery can be checked by mea-
suring its open-circuit voltage (i.e., the voltage
when the positive battery terminal is discon-
nected).
• No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in the charts and the following example.
• Positive tester probe
positive battery terminal
• Negative tester probe
negative battery terminal
1
2
Page 400 of 426
ELECTRICAL COMPONENTS
9-70
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5. Charge:• Battery
(refer to the appropriate charging method)
EWA
WARNING
Do not quick charge a battery.
ECA
NOTICE
• Do not use a high-rate battery charger since it forces a high-amperage current
into the battery quickly and can cause bat-
tery overheating and battery plate dam-
age.
• If it is impossible to regulate the charging current on the battery charger, be careful
not to overcharge the battery. • When charging a battery, be sure to re-
move it from the vehicle. (If charging has
to be done with the battery mounted on the
vehicle, disconnect the negative battery
lead from the battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the bat-
tery.
• Before removing the battery charger lead clips from the battery terminals, be sure to
turn off the battery charger.
• Make sure the battery charger lead clips are in full contact with the battery terminal
and that they are not shorted. A corroded
battery charger lead clip may generate
heat in the contact area and a weak clip
spring may cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
• As shown in the following illustration, the open-circuit voltage of a VRLA (Valve Reg-
ulated Lead Acid) battery stabilizes about
30 minutes after charging has been com-
pleted. Therefore, wait 30 minutes after
charging is completed before measuring
the open-circuit voltage.
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Charging method using a variable-cur-
rent (voltage) charger
a. Measure the open-circuit voltage prior to charging.
TIP
Voltage should be measur ed 30 minutes after
the engine is stopped.
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20–30%
A. Open-circuit voltage (V)
B. Charging time (hours)
C. Relationship between the open-circuit voltage
and the charging time at 20°C (68°F)
D. These values vary wit h the temperature, the
condition of the battery plates, and the electro-
lyte level.
A. Open-circuit voltage (V)
B. Charging condition of the battery (%)
C. Ambient temperature 20°C (68°F)
A. Open-circuit voltage (V)
B. Time (minutes)
C. Charging
D. Ambient temperature 20°C (68°F)
E. Check the open-circuit voltage.
Page 401 of 426
ELECTRICAL COMPONENTS
9-71
b. Connect a charger and ammeter to the bat-tery and start charging.
TIP
Set the charging voltage to 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 bat-
tery.
TIP
If the current is lower than the standard charg-
ing current written on the battery, set the charg-
ing voltage adjust dial at 20–24 V and monitor
the amperage for 3–5 minutes to check the bat-
tery.
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.
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 voltage to obtain
the standard charging current.
g. Measure the battery open-circuit voltage af-
ter leaving the battery unused for more than
30 minutes.
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Charging method using a constant volt-
age charger
a. Measure the open-circuit voltage prior to charging.
TIP
Voltage should be measured 30 minutes after
the engine is stopped.
b. Connect a charger and ammeter to the bat-tery and start charging.
c. Make sure that the current is higher than the
standard charging current written on the bat-
tery.
TIP
If the current is lower than the standard charg-
ing current written on the battery, this type of
battery charger cannot charge the VRLA (Valve
Regulated Lead Acid) battery. A variable volt-
age charger is recommended.
d. Charge the battery until the battery’s charg-ing voltage is 15 V.
TIP
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage af-ter leaving the battery unused for more than
30 minutes.
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6. Install:
• Battery terminals
7. Connect:
• Battery leads(to the battery terminals)
ECA
NOTICE
First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
8. Check:• Battery terminalsDirt Clean with a wire brush.
Loose connection Connect properly.
9. Lubricate: • Battery terminals
10.Install: • Seat
• Side cover (left/right)
Refer to “GENERAL CHASSIS” on page 5-
1.
• Standard charging current is reached
Battery is good.
• Standard charging current is not reached 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.
Recommended lubricantDielectric grease
2
1
Page 406 of 426
ELECTRICAL COMPONENTS
9-76
b. Check the starter motor operation.
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EAS28150CHECKING THE STATOR COIL
1. Disconnect:• Stator coil coupler(from the wire harness)
2. Check:
• Stator coil resistanceOut of specification Replace the stator
coil.
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a. Connect the pocket tester ( 1) to the sta-
tor coil coupler as shown. b. Measure the stator coil resistance.
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EAS2GC1395CHECKING THE RECTIFIER/REGULATOR
1. Check:
• Charging voltageOut of specification Replace the rectifier/
regulator.
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a. Set the digital tachometer to the ignition coil.
b. Connect the pocket tester (DC 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 charging voltage.
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Stator coil resistance 0.528–0.792 (W–W)
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 probe White “2”
• Negative tester probe
White “3”
No load regulated voltage 14.1–14.9 V
Digital tachometer 90890-06760
Digital tachometer YU-39951-B
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
• Positive tester probe Red “1”
• Negative tester probe
Black “2”
123
12