2004 YAMAHA TT600RE battery

INSP
ADJ
CHECKING AND CHARGING THE BATTERY
3-49
Open-circuit voltage (V)
WARNING
Do not quick charge a battery.
•Never remove the MF battery sealing caps.
•Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
•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
remove it from the motorcycle (if charging
has to be done with the battery mounted
on the motorcycle, disconnect the nega-
tive 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 that 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 MF battery stabi-
lizes about 30 minutes after charging has
been completed. Therefore, wait 30 min-
utes after charging is completed before
measuring the open-circuit voltage.
CAUTION:
Condition of charge in battery (%)Ambient
temperature
20 °C
Open-circuit voltage (V)
Check the open-circuit
voltage Ambient
temperature 20 °C Charging 14
13
12
11
10
100 75 50 30 2520 00 10 20 30 40 50 60 Time (minutes) 18
17
16
15
14
13
12
11
10
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CHECKING AND CHARGING THE BATTERY
3-50
INSP
ADJ
Charging method using a variable-current (voltage) type charger
ChargerNOTE:Voltage should be measured 30 minutesafter the machine is stopped.
NOTE:
Set the charging voltage at 16 ~ 17 V (if
the setting is lower, charging will be
insufficient. If too high, the battery will be
over-charged.)
AMP
meterMeasure the open-circuit
voltage prior to charging.
Connect a charger and AMP
meter to the battery and start
charging.
Make sure the current is
higher than the standard
charging current written on
the battery.
By turning the charging voltage
adjust dial, set the charging
voltage at 20 ~ 25 V.
Monitor the amperage for 3 ~ 5
minutes to check if the standard
charging current is reached.Adjust the voltage so that
current is at standard charg-
ing level.
Set the timer according to
the charging time suitable for
the open-circuit voltage.
Refer to "Battery condition
checking steps."If the current does
not exceed standard
charging current af-
ter 5 minutes, re-
place the battery.
In case that charging requires more than 5 hours, it is advisable to check
the charging current after a lapse of 5 hours.
If there is any charge in the amperage, readjust the voltage to obtain the
standard charging current.
Measure the battery open-circuit voltage after having left the battery un-
used for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
YES
YESNO
NO
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INSP
ADJ
CHECKING AND CHARGING THE BATTERY
3-51
Charging method using a constant-voltage type charger
Measure the open-circuit
voltage prior to charging.
Connect a charger and AMP
meter to the battery and start
charging.
Make sure the current is
higher than the standard
charging current written on
the battery.
Charge the battery until the battery’s
charging voltage is 15 V.This type of battery charger cannot
charge the MF battery. A variable volt-
NOTE:Voltage should be measured 30 min-utes after the machine is stopped.
Measure the battery open-circuit volt-
age after having left the battery unused
for more than 30 minutes.
12.8 V or more --- Charging is com-
plete.
12.7 V or less --- Recharging is re-
quired.
Under 12.0 V --- Replace the battery.
NOTE:Set the charging time at 20 hours (max-imum).
NO
YES
Charging method using a constant-current type charger
This type of battery charger cannot charge the MF battery.
Charger
AMP meter
Voltmeter
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CHECKING AND CHARGING THE BATTERY
3-52
INSP
ADJ
6. Connect:
•Battery leads
(to the battery terminals)
First, connect the positive lead 2, then the
negative lead 1.
7. Check:
•Battery terminals
Dirt ➔Clean with a wire brush.
Loose connection ➔Connect properly.
8. Lubricate:
•Battery terminals
CAUTION:
9. Install:
•Panel
•Seat



Recommended lubricant
Dielectric grease
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CHASREAR SHOCK ABSORBER
4-69
Order Job name/Part name Q.ty Remarks Shock absorber removal Remove the parts in order.
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
Seat Refer to “SEAT, FUEL TANK AND REAR
Fuel tank
Rear cowling COWLING” section in Chapter 3.
Battery leads 2 Disconnect. NOTE:
First, disconnect the negative lead, then the
positive lead.
1 Muffler 1
2 Exhaust pipe assembly 1 Refer to “REAR SHOCK ABSORBER RE-
3 Rear frame 1 MOV AL” section.
4 Brake fluid reserve tank 1 Secure the brake fluid tank to the frame in
5 Air filter case 1 an upright position to avoid air entering the hydraulic system.
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CHASREAR SHOCK ABSORBER
4-73
SHOCK ABSORBER REMOVAL
WARNING
Support the motorcycle securely to prevent it
from falling over.
1. Park the motorcycle on a level surface.
2. Remove:
•Seat
•Rear cowling
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING” in CHAPTER 3.
3. Disconnect:
•Battery leads
8. Remove:
•Upper mounting bolt (1)
•Rear shock absorber
1
NOTE:
First, disconnect the negative lead, then the posi-
tive lead.
4. Remove:
•Exhaust pipe assembly
•Rear frame
•Air filter case
5. Raise the rear wheel placing a suitable sup- port under the engine.
6. Remove:
•Rear wheel
Refer to “REAR WHEEL REMOVAL” sec-
tion.
7. Remove:
•Shock absorber fastening nut (1)
•Lower mounting bolt
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ENGINE REMOVAL
5-2
ENG
Order Job name/Part name Q.ty Remarks Drain the engine oil (refer to “ENGINE OIL
REPLACEMENT” section in CHAPTER
3). Remove the seat, the fuel tank and
the rear cowling (refer to “SEAT, FUEL
TANK AND REAR COWLING” section in
CHAPTER 3).
1 Battery leads connector 1 Disconnect.
2 Muffler 1
3 Exhaust pipe 1
4 Engine protector 1
5 Shift pedal 1
6 Drive sprocket crankcase cover 1
7 Drive sprocket 1 Displace the drive chain.
8 Clutch cable 1 Disconnect.
9 Plug cap 1 Disconnect.
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ELECTRICAL CIRCUIT DIAGRAM
7-2
ELEC
B Black B/Y Black/Yellow
Br Brown Br/B Brown/Black
Ch Chocolate Br/W Brown/White
Dg Deep green G/B Green/Black
G Green G/R Green/Red
Gy Grey G/W Green/White
L Blue G/Y Green/Yellow
Or Orange L/R Blue/Red
P Pink L/W Blue/White
R Red L/Y Blue/Yellow
Sb Sky-blue R/B Red/Black
W White R/W Red/White
Y Yellow R/Y Red/Yellow
B/R Black/Red W/L White/Blue
B/W Black/White Y/R Yellow/Red
(1) AC generator/Pickup coil
(2) Rectifier/Regulator
(3) Battery
(4) Starter relay
(5) Starting motor
(6) Fuse
(7) Main switch
(8) Right handlebar switch
(9) Engine stop switch
(10) Starter switch
(11) Diode
(12) Clutch switch
(13) Sidestand switch
(14) Neutral switch
(15) Diode
(16) Ignitor unit
COLOUR CODE (17) Ignition coil
(18) Left handlebar switch
(19) Horn switch
(20) Diode
(21) Pass switch
(22) Dimmer switch
(23) Flasher switch
(24) Horn
(25) Flasher relay
(26) Headlight
(27) Flasher light
(28) Relay assy
(29) Front brake switch
(30) Rear brake switch
(31) Tail/stop light
(32) Meter
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