2004 YAMAHA TT600RE Service Manual

CARBURETOR ASSEMBLY
6-12
CARB
Primary carburetor
1. Install:
•Needle jet (1)
•Connecter comp. (2)
NOTE:
Check that the connecter comp. (1) is in the posi-
tion shown in the figure.
2. Install:
•Throttle valve
3. Install:
•Spring
•Throttle shaft
NOTE:
Assemble the spring as shown in the illustration.
4. Install:
•Screw (connecter comp.)
NOTE:
Turn the throttle shaft clockwise (1/2 turn) to pre-
load the spring and then, holding it in position,
assemble the screw (connecter comp.).
Screw (connecter camp.): 2 Nm (0.2 mkg)
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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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CARBURETOR ASSEMBLY
6-14
CARB
10. Install:
•Float pin (1)
NOTE:
Assemble the float pin in the opposite direction to
the arrow.
11. Measure:
•Float height (a)
Out of specification ➔Adjust.
Float height: 27.0 - 29.0 mm
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Measurement and adjustment:
•Hold the carburetor upside down.
•Measure the distance from the joint plane of
the float chamber (without the gasket) and the
top of the float.
NOTE:
The float arm must rest on the neeedle valve
without being pressed.
•If the float height is out of tolerance, check the
valve seat and the needle valve.
•If either is worn, replace both.
•If both are perfect, adjust the float height by
bending the wing tab of the float itself (1).
•Recheck the float height.
12. Install:
•Float chamber
Screw (float chamber): 2 Nm (0.2 mkg)
13. Adjust:
•Pilot air screw (1)
Adjustment:
•Turn the screw until it is slightly locked.
•Unscrew by 3 and 1/2 turns.
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CARBCARBURETOR ASSEMBLY
6-15
14. Install:
•Primary carburetor
•Secondary carburetor
15. Install:
•Support plate (front) (1)
•Support plate (rear) (2) Screw (support plate): 3.5 Nm (0.35 mkg)
16. Adjust:
•Synchronisation of secondary carburetor
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Adjustment:
•Move the primary throttle valve (1) to a height
of 7.0 mm as shown in the figure.
•Tighten or loosen the synchronisation screw
(1) until the secondary throttle valve (2) starts
to open.
•Check that the secondary throttle valve is
open horizontally (a)=(b) when the primary
throttle valve is completely open
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CARBURETOR ASSEMBLY
6-16
CARB
FUEL LEVEL ADJUSTMENT (CARBURE-
TOR INSTALLED
1. Place the motorcycle on a level surface.
2. Make sure that the carburetor is in a horizon- tal position by placing a hydraulic jack under
the engine.
Fuel level gauge: P/N. 90890-01312
4. Loosen drain screw (2) and heat the engine.
5. Measure:
•Fuel level (a)
Out of specification ➔Adjust.
Fuel level: 6.0 ~ 8.0 mm
Under the edge of the carburetor
body.
6. Adjust:
•Fuel level
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Fuel level adjustment:
•Remove carburetor assembly.
•Inspect valve seat and needle valve set.
•If either of the two is worn, replace both.
•If both are perfect, adjust float height by bend-
ing the wing tab of the float itself (1).
•Recheck the fuel level.
3. Connect the fuel level gauge (1) to the carbu- rettor nipple.
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7
ELEC
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ELEC
CHAPTER 7
ELECTRICAL
ELECTRICAL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
COLOUR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
SWITCH CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
MAIN SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
LIGHT INSPECTION (HEADLIGHTS, TAIL LIGHT AND BRAKE LIGHTS,
DIRECTION INDICATOR LIGHTS, INSTRUMENT LIGHTS, ETC) . . . . . . . . . . . . . . . . . 7-8
BULB TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
BULB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
ELECTRICAL STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
STARTING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
LIGHT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
LIGHT SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46
SIGNALLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
SIGNAL SYSTEM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
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ELEC
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