2004 YAMAHA TT600RE check engine

ENGINE REASSEMBLY
5-78
ENG
9. Install:
•Carburetor Screw (clamp): 2 Nm (0.2 mkg)
Screw (seat): 10 Nm (1.0 mkg)
See section “CARBURETOR-INSTALLA-
TION” in CHAPTER 6.
10. Adjust:
•Throttle cable free play
Free play: 3 ~ 5 mm
Engine idle speed:1.150 ~ 1.450 rpm
See section “THROTTLE CABLE FREE
PLAY ADJUSTMENT” in CHAPTER 3.
11. Install:
•Fuel tank
Do not start the engine until it is filled with oil.
CAUTION:
12. Fill with:
•Engine oil Amount of oil (total): 3.0 litres
13. Check:
•Engine idle speed
See section “IDLE SPEED ADJUST-
MENT” in CHAPTER 3.
14. Install:
•Seat
See section “ENGINE OIL REPLACE-
MENT” in CHAPTER 3.
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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
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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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ELECIGNITION SYSTEM
7-13
DIAGNOSTICS IF THE IGNITION SYSTEM WERE TO STOP WORKING (NO OR INTERMITTENT SPARK)
Procedure
Check:
1. Fuse
2. Battery
3. Spark plug
4. Amplitude of ignition spark
5. Spark plug cap resistance
6. Ignition winding resistance 7. Main switch
8. Engine stop switch
9. Sidestand switch
10. Neutral switch
11. Clutch switch
12. Pick-up coil resistance
13. Wiring connections (whole connection sys- tem)
NOTE:
Before making the inspections mentioned, remove the following parts:
1. Seat
2. Rear cowling 3. Fuel tank
4. Cowling (headlight)
•To check functioning defects use the following special tools.
Dinamic spark tester: P/N. 90890-06754
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:
2.8 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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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
7-17
*
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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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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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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