2004 YAMAHA TT600RE check oil

LIGHT INSPECTION
7-8
ELEC
LIGHT INSPECTION (HEADLIGHTS,
TAIL LIGHT AND BRAKE LIGHTS,
DIRECTION INDICATOR LIGHTS,
INSTRUMENT LIGHTS, ETC)
Check the continuity between the bulb terminals to
see that they are undamaged.
BULB TYPES
The bulbs used are classified as shown to the left
according to type of attachment.
(B) is H4 type halogen bulb (12V - 55/60W) and it
is used for headlight.
Avoid touching the glass part of a bulb. Keep it
free from oil; otherwise, the transparency of
the glass, life of the bulb, and luminous flux will
be adversely affected. If oil gets on a bulb,
thoroughly clean it with a cloth moistened with
alcohol or lacquer thinner.
(A) and (C) are used mainly for headlights.
(D) is used mainly for direction indicator lights and
the rear and braking lights.
(E) and (F) are used especially for instrument and
other indication lights.
BULB INSPECTION
1. Remove the bulb.
NOTE:
•Bulbs of type (B) and (C) use special supports
(bulbholders). Remove the bulbholder before
removing the bulb. Most of these bulbholders
may be removed by turning in an anticlockwise
direction.
•Most bulbs of type (A), (D) and (E) may be
removed from their housing by pushing them
and turning them in an anticlockwise direction.
•Bulbs of type (F) may be removed simply by
pulling them out.
CAUTION:
A
F
CB
ED
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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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ELECIGNITION SYSTEM
7-15
IN COMPLIANCE
WITH SPECIFICATIONS
5. Spark plug cap resistance.
•Remove the spark plug cap.
•Connect the pocket tester ( Ωx 1k) to the
spark plug cap.
•Check that the spark plug cap has the
specified resistance.
OUT OF SPECIFICATION
The spark plug cap is defective.
Replace.
Resistance of spark plug cap: 10 k Ωat 20°C (68°F)
6. Ignition winding resistance.
•Disconnect the ignition coil cables from
the wire harness.
•Connect the pocket tester ( Ωx 1) to the
ignition coil.
Tester terminal (+) ➔Pole (+)
Tester terminal (–) ➔Pole (–)
•Check that the primary coil has the speci-
fied resistance.
*
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IGNITION SYSTEM
7-16
ELEC
•Connect the pocket tester ( Ωx 1) to the
ignition coil.
Tester terminal (+) ➔Spark plug cable (1)
Tester terminal (–) ➔Pole (+)
•Check that the secondary coil has the
specified resistance
Secondary winding resistance: 13 k Ω ±
±

20% at 20°C (68°F)
(Spark plug cable – Terminal (–))
BOTH RESISTANCE
VALUES ARE CORRECT
OUT OF SPECIFICATION
The ignition coil is defective.
Replace.
*
Primary winding resistance: 4 Ω ±
±
15% at 20°C (68°F)
(Terminal (+) – Terminal (–))
7. 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.





 


  
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ELECIGNITION SYSTEM
7-19
*
12. Pick-up coil resistance.
•Disconnect the generator connector
(Green/White and Blue/Yellow).
•Connect the pocket tester ( Ωx 100) to
pick-up coil cables.
Tester terminal (+) ➔
Blue/Yellow cable (1)
Tester terminal (–) ➔
Green/White cable (2)
•Check that the pick-up coil resistance is as
specified.
Pick-up coil resistance: 230 Ω ±
±
20% at 20°C (68°F)
(Green/White - Blue/Yellow)
COMPLY WITH
SPECIFICATIONS
CORRECT
OUT OF SPECIFICATIONS
The pick-up coil is defective. Replace.
UNCERTAIN CONNECTIONS Correct.13. Wiring connections.
Check the connections of the entire ignition
system. Refer to “ELECTRICAL CIRCUIT
DIAGRAM” section.
The CDI unit is defective. Replace.
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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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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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ELECCHARGING SYSTEM
7-39
CORRECT
IN COMPLIANCE
WITH SPECIFICATIONS
OUT OF SPECIFICATIONS
Stator winding is defective. Replace.
UNCERTAIN CONNECTIONS Correct.
Stator coils (2)
Tester terminal (+) ➔White cable (1)
Tester terminal (-) ➔White cable (3)
•Check that the winding resistance of the
stator complies with specifications.
Stator coil resistance: White (1) – White (2)
0.65 Ω± 20% at 20°C (68°F)
White (1) – White (3) 0.65 Ω± 20% at 20°C (68°F)


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5. Wiring connections.
•Check the connections of the entire char-
ging system.
Refer to “ELECTRICAL CIRCUIT DIA-
GRAM” section.
The rectifier/regulator is defective. Replace.
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