2004 YAMAHA TT600RE battery

ELECCHARGING SYSTEM
7-37
DIAGNOSTICS THE BATTERY IS NOT BEING CHARGED
Procedure
Inspect:
1. Fuse
2. Battery
3. Charging voltage 4. Stator winding resistance
5. Harness connection (whole connection system)
NOTE:
Before starting inspections, remove the following parts: 1. Seat
2. Rear cowling
•To check for defects use the following special tools.
Inductive rev counter: P/N. 90890-03113
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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CHARGING SYSTEM
7-38
ELEC
3. Charging voltage
•Connect the inductive rev counter to the
spark plug cable.
•Connect the pocket tester (DC 20V) to the
battery, as shown.
Tester terminal (+) ➔ Battery terminal (+)
Tester terminal (-) ➔Battery terminal (-)
•Start the engine and rev to about 5,000 rpm.
•Check the charging voltage.
Charging voltage:
14.0V at 5,000 rpm
4. Stator coil resistance.
•Disconnect the AC generator connector
from the harness.
•Connect the pocket tester ( Ωx 1) to the sta-
tor coils.
Stator coils (1)
Tester terminal (+) ➔White cable (1)
Tester terminal (-) ➔White cable (2))
*
NOTE:
Use a fully charged battery.
OUT OF SPECIFICATIONS
IN COMPLIANCE WITH
SPECIFICATIONS
Replace the battery.
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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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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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$
$
$%
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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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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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