2004 YAMAHA TT600RE brake light

ELECSWITCH CHECK
7-5

 






SWITCH CHECK
Check the continuity between the switch terminals
to verify whether connections are correct.
To check the switch, read the following points.
SWITCH CONNECTION
The table shown here contains the connections
between the switch terminals (eg main switch,
handlebar switches, brake switch, light switch etc).
The column on the far left shows the positions of
the main switch and the top line indicates the
colours of the cables connected with the terminals
of the switch itself.
“o––––o” indicates the terminals between which
there is electrical continuity, ie a closed circuit on
the respective switch positions.
For example, in this table:
“R” and “Br” are continuous when the switch is at
ON.
“L” and “R/B” are continuous when the switch is at
ON.
“R” and “L” are continuous when the switch is at
PARK.
Terminals are not continuous when the switch is at
OFF.
MAIN SWITCH INSPECTION
Before inspecting the switch, see the connection
table shown above and check the terminal con-
nections (closed circuit) by the colour combination.
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LIGHT INSPECTION
7-8
ELEC
LIGHT INSPECTION (HEADLIGHTS,
TAIL LIGHT AND BRAKE LIGHTS,
DIRECTION INDICATOR LIGHTS,
INSTRUMENT LIGHTS, ETC)
Check the continuity between the bulb terminals to
see that they are undamaged.
BULB TYPES
The bulbs used are classified as shown to the left
according to type of attachment.
(B) is H4 type halogen bulb (12V - 55/60W) and it
is used for headlight.
Avoid touching the glass part of a bulb. Keep it
free from oil; otherwise, the transparency of
the glass, life of the bulb, and luminous flux will
be adversely affected. If oil gets on a bulb,
thoroughly clean it with a cloth moistened with
alcohol or lacquer thinner.
(A) and (C) are used mainly for headlights.
(D) is used mainly for direction indicator lights and
the rear and braking lights.
(E) and (F) are used especially for instrument and
other indication lights.
BULB INSPECTION
1. Remove the bulb.
NOTE:
•Bulbs of type (B) and (C) use special supports
(bulbholders). Remove the bulbholder before
removing the bulb. Most of these bulbholders
may be removed by turning in an anticlockwise
direction.
•Most bulbs of type (A), (D) and (E) may be
removed from their housing by pushing them
and turning them in an anticlockwise direction.
•Bulbs of type (F) may be removed simply by
pulling them out.
CAUTION:
A
F
CB
ED
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SIGNAL SYSTEM
7-52
ELEC
The diagram shows the signal system circuit inside the electric system of the motorcycle. NOTE:
For the colour codes and complete legend, see page 7-2.
(3) Battery
(6) Fuse
(7) Main switch
(11) Diode
(14) Neutral switch
(15) Diode
(18) Left handlebar switch
(19) Horn switch (23) Flasher switch
(24) Horn
(25) Flasher relay
(27) Flasher light
(29) Front brake switch
(30) Rear brake switch
(31) Tail/stop light
(32) Meter
&
(
'
&
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$
$
$%
*$
'*
(+
&
&
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ELECSIGNAL SYSTEM
7-53
DIAGNOSTICS
•THE FLASHER LIGHTS, BRAKE LIGHT AND/OR WARNING LIGHTS FAIL TO TURN ON.
•THE HORN FAILS TO SOUND.
Procedure
Check:
1. Fuse
2. Battery
3. Main switch
4. Harness connections (entire system of con- nections)
NOTE:
•Before starting inspections, remove the following parts:
1. Seat
2. Rear cowling
3. Cowling (headlight)
4. Tail light cover
•To check for operating faults use the following special tools.
Pocket tester: P/N. 90890-03112
1. Fuse
•Check the fuse for continuity.
Refer to “CHECKING THE FUSES” in
Chapter 3.
•Is the fuse OK?
YES
2. Battery.
•Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in Chapter 3.
Min. open-circuit voltage:
12.8 V or more at 20°C (68°F)
•Is the battery OK?
NO
Replace the fuse.
NO
•Clean the battery terminals.
•Recharge or replace the battery.
YES
*
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ELECSIGNAL SYSTEM
7-57
CONTINUITY
DISCONTINUITY Replace the bulb and/or bulbholder.1. Bulb and bulbholder.
•Check the continuity of the bulb and bulb-
holder.
Refer to “BULB INSPECTION” section.
2. The rear stop light fails to turn on.
2. Brake switch.
•Disconnect the brake switch cables and
the connector from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
brake switch terminals.
•Check the switch component for conti-
nuity between “Green/Yellow (1)” and
“Brown (2)”, or “Black (3)” and “Black (4)”. Refer to “SWITCH CHECK” section.
[A] Front brake switch
[B] Rear brake switch
INCORRECT
The brake switch is defective. Replace.
*
ON (Step down)
OFF (Free) BB
BB
G/Y Br
34
2
G/Y RW
1
ON (Pull in) OFF (Free)
G/Y
Br
A
B
Br
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SIGNAL SYSTEM
7-58
ELEC
3. Voltage.
•Connect the pocket tester (DC 20V) to the
bulbholder connector.
Tester terminal (+) ➔Green/Yellow cable (1)
Tester terminal (–) ➔Black terminal (2)
•Turn the main switch to ON.
•The brake lever is pulled or the brake
pedal is pressed.
•Check the voltage (12V) on the
“Green/Yellow” cable of the bulbholder
connector.
OUT OF SPECIFICATION
The circuit from the main switch to the bulbhol-
der connector is defective. Repair.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
*
The circuit is efficient.
CONTINUITY
DISCONTINUITY
Replace the bulb and/or bulbholder.
3. The direction indicator light and/or the direc- tion indicator light fail to flash.
1. Bulb and bulbholder.
•Check the continuity of the bulb and bulb-
holder.
Refer to “BULB INSPECTION” section.
2. Direction indicator switch.
•Disconnect the left handlebar switch con-
nector from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
left handlebar switch cables.
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TRBL
SHTG
?
CHAPTER 8°
TROUBLESHOOTING
FAILURE TO START/DIFFICULTIES IN STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
POOR ENGINE COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
POOR PERFORMANCE AT IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED . . . . . . . . . . . . . . . . . 8-3
DIFFICULTIES IN SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
SHIFTING IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
THE SHIFT PEDAL FAILS TO MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
DISENGAGING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
CLUTCH SLIDES OR FAILS TO RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CLUTCH SLIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CLUTCH FAILS TO RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
DEFECTIVE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
POOR BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
OIL LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
MALFUNCTIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
UNSTABLE STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . 8-8
POOR HEADLIGHT ILLUMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
FREQUENT BURNING OF BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DIRECTION INDICATORS FAIL TO TURN ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DIRECTION INDICATORS FAIL TO TURN OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DELAYED TURNING ON OF INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
EXCESSIVE INDICATOR INTERMITTENCE FREQUENCY . . . . . . . . . . . . . . . . . . . 8-9
THE HORN FAILS TO WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
OVERHEATING OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
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DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS/ OVERHEATING OF ENGINE
8-9
TRBL
SHTG
?
PROBABLE CAUSES
•Indicator lamp relay defective
•Insufficient battery capacity
(battery almost flat)
•Incorrect bulb
•Main switch or direction indicator switch defec-
tive
DELAYED TURNING ON OF INDICATORS
PROBABLE CAUSES
•Battery flat
•Main switch or horn switch defective
•Horn wrongly set
•Defective horn
•Harness cut off
THE HORN FAILS TO WORK
OVERHEATING OF ENGINE
PROBABLE CAUSES
•Incorrect bulb
•Indicator lamp relay defective
EXCESSIVE INDICATOR
INTERMITTENCE FREQUENCY
Ignition system
Fuel feed system PROBABLE CAUSES
•Incorrect electrode gap of spark plug
•Spark plug thermal gradation wrong
•Ignition unit defective
•Incorrect carburetor main jet (incorrect setting)
•Incorrect fuel level
•Air filter element obstructed
Engine compression
•Excess of carbon deposits
Engine oil
•Incorrect oil level
•Incorrect oil viscosity
•Incorrect oil gradation
Brake
•Pads fail to return freely (remains blocked)
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