2004 YAMAHA TT600RE ignition

IGNITION SYSTEM
7-14
ELEC
3. Spark plug.
•Check the conditions of the spark plug.
•Check the type of spark plug used.
•Check the electrodes gap.
Standard spark plug: DPR8EA-9 (NGK), DPR9EA-9
4. Amplitude of the ignition spark.
•Detach the spark plug cap from the spark
plug.
•Connect the dynamic spark tester (1) as
shown in the figure.
(2) Spark plug cover (3) Spark plug
•Turn the main switch ON.
•Check the amplitude of the ignition spark.
•Start the engine and increase the ampli-
tude until the ignition becomes discontin-
uous.
Electrodes gap: DPR8EA-9, DPR9EA-9 (NGK)
0.8 ~ 0.9 mm
YES
OUT OF SPECIFICATION
Correct the electrodes gap or replace the spark
plug.
Spark amplitude if the ignition
system is efficient: 6.0 mm
THE IGNITION SYSTEM IS INEFFICIENT
OR THERE IS NO SPARK
IN COMPLIANCE WITH SPECIFICATIONS
Minimum spark amplitude.
*
*
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ELECIGNITION SYSTEM
7-15
IN COMPLIANCE
WITH SPECIFICATIONS
5. Spark plug cap resistance.
•Remove the spark plug cap.
•Connect the pocket tester ( Ωx 1k) to the
spark plug cap.
•Check that the spark plug cap has the
specified resistance.
OUT OF SPECIFICATION
The spark plug cap is defective.
Replace.
Resistance of spark plug cap: 10 k Ωat 20°C (68°F)
6. Ignition winding resistance.
•Disconnect the ignition coil cables from
the wire harness.
•Connect the pocket tester ( Ωx 1) to the
ignition coil.
Tester terminal (+) ➔Pole (+)
Tester terminal (–) ➔Pole (–)
•Check that the primary coil has the speci-
fied resistance.
*
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IGNITION SYSTEM
7-16
ELEC
•Connect the pocket tester ( Ωx 1) to the
ignition coil.
Tester terminal (+) ➔Spark plug cable (1)
Tester terminal (–) ➔Pole (+)
•Check that the secondary coil has the
specified resistance
Secondary winding resistance: 13 k Ω ±
±

20% at 20°C (68°F)
(Spark plug cable – Terminal (–))
BOTH RESISTANCE
VALUES ARE CORRECT
OUT OF SPECIFICATION
The ignition coil is defective.
Replace.
*
Primary winding resistance: 4 Ω ±
±
15% at 20°C (68°F)
(Terminal (+) – Terminal (–))
7. 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.





 


  
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ELECIGNITION SYSTEM
7-17
*
CORRECT
8. 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)
CORRECT
INCORRECT
The emergency stop engine switch is defective.
Replace the right handlebar switch.
INCORRECT
The sidestand switch is defective. Replace.
*
9. Sidestand switch.
•Disconnect the sidestand switch connec-
tor (Black and Black) from the wire har-
ness.
•Connect the pocket tester ( Ωx 1) to the
sidestand switch cables. Refer to “SWITCH CHECK” in Chapter 3.
Tester terminal (+) ➔Black cable (1)
Tester terminal (–) ➔Black cable (2)





 
 



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IGNITION SYSTEM
7-18
ELEC
*
10. Neutral switch.
•Disconnect the neutral switch cable (Sky
blue).
•Connect the pocket tester ( Ωx 1) to the
neutral switch cables. Refer to “SWITCH CHECK” in Chapter 3.
Tester terminal (+) ➔Sky blue cable (1)
Tester terminal (–) ➔Earth
CORRECT
INCORRECT
The neutral switch is defective. Replace.
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"#
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11. Clutch switch.
•Disconnect the clutch switch connector
from the harness.
•Connect the pocket tester ( Ωx 1) to the
clutch switch cable.
•Check the clutch switch component for
continuity between “Black (1)” and “Black
(2)”.
Refer to “SWITCH CHECK” in Chapter 3.
INCORRECT
The clutch switch is defective. Replace.
!$ %&!'







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*
CORRECT
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ELECIGNITION SYSTEM
7-19
*
12. Pick-up coil resistance.
•Disconnect the generator connector
(Green/White and Blue/Yellow).
•Connect the pocket tester ( Ωx 100) to
pick-up coil cables.
Tester terminal (+) ➔
Blue/Yellow cable (1)
Tester terminal (–) ➔
Green/White cable (2)
•Check that the pick-up coil resistance is as
specified.
Pick-up coil resistance: 230 Ω ±
±
20% at 20°C (68°F)
(Green/White - Blue/Yellow)
COMPLY WITH
SPECIFICATIONS
CORRECT
OUT OF SPECIFICATIONS
The pick-up coil is defective. Replace.
UNCERTAIN CONNECTIONS Correct.13. Wiring connections.
Check the connections of the entire ignition
system. Refer to “ELECTRICAL CIRCUIT
DIAGRAM” section.
The CDI unit is defective. Replace.
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FAILURE TO START/
DIFFICULTIES IN STARTING
8-2
TRBL
SHTG
?
Spark plug
Ignition coil
Ignition unit
Switches and cables PROBABLE CAUSES•Electrodes gap not correct
•Electrodes worn
•Feed cable interrupted
•Wrong thermal grading of spark plug
•Defective spark plug cap
•Primary or secondary winding interrupted
•High voltage cable defective
•Defective coil
•Defective unit
•Defective pick-up coil
•Woodruff key broken
Starter motor
•Starter motor defective
•Starter motor relay defective
•Diodes defectives
•Starter one-way bearing defective
•Main switch defective
•Emergency stop engine switch defective
•Harness with cable interrupted
•Neutral switch defective
•Sidestand switch defective
•Clutch switch defective
•Starter switch defective
ELECTRICAL SYSTEM
Cylinder and cylinder head
Piston and piston rings
Crankcase and valves, crankshaft PROBABLE CAUSES
•Spark plug tightening insufficiently
•Cylinder head or cylinder insufficiently tightened
•Cylinder head gasket broken
•Cylinder gasket broken
•Cylinder worn, damaged or seized
•Piston rings wrongly assembled
•Piston rings worn, yielded or broken
•Piston rings stuck together
•Piston seized or damaged
•Poor crankcase sealing
•Crankshaft oil seal edge damaged
•Poor valve sealing
•Valve and seat with insufficient contact
•Valve timing wrongly
•Valve spring broken
•Crankshaft seized
•Camshaft seized
POOR ENGINE COMPRESSION
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POOR PERFORMANCE AT IDLE SPEED/
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED
8-3
TRBL
SHTG
?
Carburetor
Electrical system
Valves PROBABLE CAUSES•The starter piston fails to return freely
•Pilot jet obstructed or loose
•Pilot jet obstructed
•Pilot air screw wrongly set
•Idle speed wrongly set
(throttle valve stop screw)
•Throttle cable free play wrongly set
•Carburetor flooded
•Valve clearance wrongly set
Air filter
•Air filter element obstructed
POOR PERFORMANCE AT IDLE SPEED
See “FAILURE TO START/DIFFICULTIES IN STARTING”.
(FUEL SYSTEM, ELECTRICAL SYSTEM, COMPRESSION SYSTEM and Valve clearance)
Carburetor
PROBABLE CAUSES
•Petrol contains water or impurities or is adulterated
•Infiltrations of air
•Deformation of float
•Defective diaphragm
• Needle valve worn or scratched
•Needle valve seat insufficiently sealed
•Needle stop position incorrect
•Fuel level set wrongly
•Main jet obstructed or loose
•Main nozzle obstructed or loose
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED
•Defective battery
•Defective spark plug
•Defective ignition unit
•Defective AC magneto
•Defective ignition coil
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