2004 YAMAHA TT600RE Service Manual

ELECELECTRICAL STARTING SYSTEM
7-25
IT RUNS
IT FAILS TO RUN The starter is defective. Repair or replace.
IT FAILS TO RUNThe starter relay is defective. Replace.
3. Starter
•Connect the positive terminal of the bat-
tery (1) and the starter cable (2) using a
connection cable (3) *.
•Check the functioning of the starter.
WARNING
• A wire that is used as a jumper lead must have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
burn.
• This check is likely to produce sparks, therefore make sure that no flammable
gas or fluid is in the vicinity.
*
*
4. Starter relay.
•Disconnect the starter relay connector.
•Connect the battery and frame to the
starter relay connector, using a connec-
tion cable (1) as shown.
Battery terminal (+) (2) ➔
Red/Black terminal (3)
Frame ➔Blue/White terminal (4)
•Check the functioning of the starter.
*
IT RUNS
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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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\f


 
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ELECELECTRICAL STARTING SYSTEM
7-27
*
*
CORRECT
7. 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)
8. 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.


 






 


INCORRECT
The sidestand switch is defective. Replace.
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*
9. 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.
 

 


CORRECT
7-28
ELECELECTRICAL STARTING SYSTEM
INCORRECT
The start switch is defective. Replace the right
handlebar switch.
10. Start switch.
•Disconnect the start switch connector
from the harness.
•Connect the pocket tester ( Ωx 1) to the
handlebar switch terminal.
•Check the start switch component for con-
tinuity between “Blue/White (1)” and
“Black/Yellow (2)”.
Refer to “SWITCH CHECK” in Chapter 3.
CORRECT
 
! "



# 



*
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ELEC
7-29
ELECTRICAL STARTING SYSTEM
11. Harness connections.
Check the connections of the entire starter
system.
See the “ELECTRIC CIRCUIT DIAGRAM”.UNCERTAIN CONNECTIONS
Correct.
*
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ELECTRICAL STARTING SYSTEM
7-30
ELEC
STARTER MOTOR
(1) Brushes
(2) Armature
(3) Stator
(4) O-Ring BRUSH LENGHT LIMIT
5 mm (0.20 in)
COMMUTATOR WEAR LIMIT:
27 mm (1.06 in)
MICA UNDERCUT:
0.7 mm (0.027 in)
ARMATURE COIL RESISTANCE:
0.03 ~ 0.04 Ωat 20°C (68°F)
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ELECELECTRICAL STARTING SYSTEM
Removal
1. Remove:
•The starter motor Refer to the “ENGINE REMOVAL” sec-
tion in CHAPTER 5.
Inspection and repair
1. Inspect:
•Manifold Dirty ➔Clean with sandpaper no. 600.
2. Measure:
•Diameter of the commutator Out of specification ➔Replace the motor.
3. Measure:
•The mica undercut (b).
Out of specification ➔Level the undercut
to the correct value using a hacksaw.
Wear limit of commutator (a): 27 mm
Mica undercut (b):0.7 mm
NOTE:
The mica insulation of the commutator must have
an undercut to ensure proper functioning of the
commutator.
Disassembly
1. Remove:
•Circlip (1)
•Drive gear (2)
•Screws (3)
•Rear bracket (4)
•Washers (5)
•Brushes housing (6)
•Brushes (7)
•Front bracket (8)
•Washers (9)
•Armature (10)
•Stator (11)
7-31
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ELECTRICAL STARTING SYSTEM
7-32
ELEC
4. Inspect:
•Armature coils (insulation/continuity). Out of specification ➔Replace the
motor.
5. Measure:
•Brush lenght
Out of specification ➔Replace all brus-
hes at once.
6. Inspect:
•Brush spring strength
Worn out ➔Replace all springs at once.
7. Inspect:
•Bearings (1)
•Oil seal (2)
•O-Rings
•Bush (3)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
How to inspect the excitation coils:
•Connect the pocket tester and check continuity (1) and insulation (2).
•Check the armature resistance:
•If the resistance is not correct, replace
the starter motor.
Armature coil resistance: Continuity check (1):0 Ω at 20°C (68°F)
Insulation check (2): Over 1 M Ωat 20°C (68°F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Brush spring strength:
8.82 N (899 gf)
Brush lenght limit (a): 5.0 mm
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