2004 YAMAHA TT600RE relay

LIGHT SYSTEM
7-42
ELEC
The diagram shows the light 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
(18) Left handlebar switch
(20) Diode
(21) Pass switch
3631
222118
26
28
20
$
&
(22) Dimmer switch
(26) Headlight
(28) Relay assy
(31) Tail/stop light
(32) Meter
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ELECLIGHT SYSTEM
7-43
DIAGNOSTICS THE HIGH BEAM LIGHT, PARKING INDICATOR LIGHT, REAR LIGHT, FRONT PARKING LIGHT AND/OR INSTRUMENT LIGHTS FAIL TO TURN ON.
Procedure
Inspect:
1. Fuse
2. Battery
3. Main switch 4. Dipped/high beam light and dimmer switch
5. Relay assy
6. Harness connections (full system of connec- tions)
NOTE:
•Before starting inspections, remove the following parts:
1. Seat
2. Rear cowling
3. Cowling (headlight)
4. Tail light cover
•To check for defects 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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ELECLIGHT SYSTEM
7-45
*
CORRECT
DEFECTIVE CONNECTIONS Repair.6. Harness connections.
•Check the connections of the entire light
system.
Check the conditions of each circuit for the
entire light system.
See the “ELECTRIC CIRCUIT DIAGRAM”.
5. Starter circuit cut-off relay.
•Connect the pocket tester (DC 20V) and
the battery (12V) to the cut-off relay con-
nector terminal of the starter circuit.
Battery terminal (+) ➔
White/Black terminal (1)
Battery terminal (–) ➔Black terminal (2)
Tester terminal (+) ➔Brown terminal (3)
Tester terminal (–) ➔Earth
DISCONTINUITY
The starter circuit cut-off relay is defective.
Replace.
•Turn the main switch to ON.
•Check the voltage (12V) on the
“Brown/Blue” and “Brown” cable to the
connector terminal of the starter circuit
cut-off relay.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
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LIGHT SYSTEM
7-46
ELEC
LIGHT SYSTEM INSPECTION NOTE:
To proceed to the control of the light system, start the engine and then stop it by the emergency engine
stop switch. In this way the light relay remains excited and it is possible to check the light system.
1. The front headlight and the high beam light fail to turn on.
CONTINUITY
DISCONTINUITY
Replace the bulb and/or the bulbholder.1. Bulb and bulbholder.
•Check the continuity of the bulb and bulb-
holder.
Refer to “BULB INSPECTION” section.
2. Voltage.
•Connect the pocket tester (DC 20V) to the
front headlight connectors and the high
beam switch.
Headlight: Tester terminal (+) ➔
Green (2) or Yellow (1) cable
Tester terminal (–) ➔Black cable (3)
High beam light: Tester terminal (+) ➔Yellow cable (4)
Tester terminal (–) ➔Black cable (5)
[A] When the lights switch (commutator) is at
position “HI”.
[B] When the lights switch (commutator) is at position “LO”.
OUT OF SPECIFICATION
The circuit from the main switch to the bulbhol-
der connector is defective. Repair.
A
B
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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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ELECSIGNAL SYSTEM
7-59
•Check the switch component for conti-
nuity between “Brown/White (1)” and
“Brown/Black (2)” and “Brown/White (1)”
and “Green/Black (3)”.
Refer to “SWITCH CHECK” section.
CORRECT
3. Direction indicator lamp relay.
•Connect the pocket tester (DC 20V) to the
indicator lamp relay.
Tester terminal (+) ➔Brown terminal (1)
Tester terminal (–) ➔Earth
•Turn the main switch to ON.
•Check the voltage (12V) on the “Brown”
cable to the indicator lamp relay terminal.
OUT OF SPECIFICATION
The circuit from the main switch to the lamp re-
lay connector is defective. Repair.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
*



 








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INCORRECT
The direction indicator switch is defective.
Replace.
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SIGNAL SYSTEM
7-60
ELEC
OUT OF SPECIFICATION The direction indicator lamp relay is defective.
Replace.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
* *
4. Voltage.
•Connect the pocket tester (DC 20V) to the
bulbholder connector.
Tester terminal (+) ➔
Brown/White terminal (1)
Tester terminal (–) ➔Earth
•Turn the main switch to ON.
•Check the voltage (12V) on the “Blue”
cable to the bulbholder connector.
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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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