2004 YAMAHA TT600RE stop start

CARBCARBURETOR DISASSEMBLY
6-7
2. Remove:
•Needle valve set/Valve seat (1)
•Main jet/Main nozzle 1 (2)
•Pilot jet (3)
•Pilot screw set (4)
•O-Ring (5)
3. Remove:
•Stop screw (1)
•Starter set (2)
4. Remove:
•Cover (1) (enrichment)
•Spring (2)
•Diaphragm (3)
5. Remove:
•Top cover (1)
•Cover gasket (2)
•Screw (3) (connecter comp.)
6. Remove:
•Throttle lever (1)
•Collar (2)
•Cable holder (3)
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CARBCARBURETOR INSPECTION
6-9
CARBURETOR INSPECTION
1. Inspect:
•Carburetor body
Soiled ➔Clean.
NOTE:
Use petroleum-based solutions to clean. Clean all
passages and jets with compressed air.
2. Inspect:
•Valve seat (1)
•Needle valve set (2)
Wear/Corrosion ➔Replace.
•O-Ring (3)
Damaged ➔Replace.
NOTE:
Always replace the needle valve set and the valve
seat together.
3. Inspect:
•Starter piston (1)
Wear/Damage ➔Replace
•Stop screw (2)
Damaged ➔Replace.
4. Inspect:
•Diaphragm (1) (piston valve)
•Diaphragm (2) (enrichment)
Damaged ➔Replace.
5. Inspect:
•Needle jet (1) (primary)
•Needle jet (2) (secondary)
Curvature/Wear ➔Replace.
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CARBCARBURETOR ASSEMBLY
6-13
5. Install:
•Cable holder
•Collar
•Throttle lever
NOTE:
Check that the throttle shaft lever (2) and the
adjuster bolt (3) are aligned when tightening the
throttle nut (1).
Screw (cable holder): 3 Nm (0.3 mkg)
Screw (top cover): 2 Nm (0.2 mkg)
Starter piston: 6 Nm (0.6 mkg)
Main nozzle 1: 2 Nm (0.2 mkg)
Screw (valve seat): 2 Nm (0.2 mkg)
6. Install:
•Top cover
7. Install:
•Diaphragm (1) (enrichment)
NOTE:
Make the diaphragm tab coincide with the gravity
enricher notch.
9. Install:
•Pilot screw set (1)
•Pilot jet (2)
•Main nozzle 1 (3)
•Main jet (primary) (4)
•Valve seat (5)
8. Install:
•Starter set
•Stop screw
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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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ELECTRICAL STARTING SYSTEM
7-22
ELEC
The diagram illustrates the electrical starting system-circuit inside the motorcycles electric system. NOTE:
For the colour code and legend, see page 7-2.
(3) Battery
(4) Starter relay
(5) Starting motor
(6) Fuse
(7) Main switch
(9) Engine stop switch (10) Starter switch
(11) Diode
(12) Clutch switch
(13) Sidestand switch
(14) Neutral switch
(15) Diode
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4
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ELECELECTRICAL STARTING SYSTEM
7-23
STARTING CIRCUIT OPERATION
The starting circuit on this model consists of the
starter motor, starter relay, and the starting circuit
cut-off relay. If the engine stop switch is on “RUN”
and the main switch is on “ON” (both switches are
closed), the starter motor can operate only if:
The starting circuit cut-off relay prevents the
starter from operating when neither of these con-
ditions have been met. In this instance, the start-
ing circuit cut-off relay is open so current cannot
reach the starter motor.
When at least one of the above conditions have
been met however, the starting circuit cut-off relay
is closed, and the engine can be started by press-
ing the starter switch.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE CLUTCH LEVER IS PULLED IN
1 Battery
2 Main switch
3 Engine stop switch
4 Starter relay
5 Starting circuit cut-off relay
6 Start switch
7 Starter motor
8 Neutral switch
9 Clutch switch
0 Sidestand switch
The transmission is in neutral (the neutral
switch is closed). or if
The clutch lever is pulled to the handlebar (the
clutch switch is closed) and the sidestand is up
(the sidestand switch is closed).
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ELECTRICAL STARTING SYSTEM
7-24
ELEC
DIAGNOSTICS THE STARTER FAILS TO WORK
Procedure
Inspect:
(1) Fuse
(2) Battery
(3) Starting motor
(4) Starter relay
(5) Main switch (6) Engine stop switch
(7) Sidestand switch
(8) Neutral switch
(9) Clutch switch
(10) Starter switch
(11) Harness connections
NOTE:
Before starting inspections, remove the following parts:
1. Seat
2. Rear cowling 3. Fuel tank
4. Cowling (headlight)
•To check for defects use the following special tools.
Pocket tester: P/N. 90890-03112
1. Fuse.
•Remove fuse.
•Connect the pocket tester ( Ωx 1) to the
fuse.
•Check the fuse for continuity.
Refer to “CHECKING THE FUSES” in
Chapter 3.
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)
CONTINUITY
DISCONTINUTY
Replace the fuse.
INCORRECT
•Clean the battery terminals.
•Recharge or replace the battery.
Refer to “BATTERY INSPECTION” in
Chapter 3.
*
CORRECT
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ELECTRICAL STARTING SYSTEM
7-26
ELEC
5. Main switch
•Disconnect the main switch connector
from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
main switch cables. Refer to “SWITCH CHECK” in Chapter 3.
CORRECT
INCORRECT
The main switch is defective. Replace.










6. Emergency stop engine switch.
•Disconnect the emergency stop engine
switch connector (Brown, Green/Yellow
and Red/Black) from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
switch cables. Refer to “SWITCH CHECK” in Chapter 3.
Tester terminal (+) ➔
Red/Black (1) cable
Tester terminal (–) ➔Brown cable (2)
INCORRECT
The emergency stop engine switch is defective.
Replace the right handlebar switch.
*
CORRECT
*




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