2004 YAMAHA TT600RE light

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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ELECSIGNAL SYSTEM
7-57
CONTINUITY
DISCONTINUITY Replace the bulb and/or bulbholder.1. Bulb and bulbholder.
•Check the continuity of the bulb and bulb-
holder.
Refer to “BULB INSPECTION” section.
2. The rear stop light fails to turn on.
2. Brake switch.
•Disconnect the brake switch cables and
the connector from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
brake switch terminals.
•Check the switch component for conti-
nuity between “Green/Yellow (1)” and
“Brown (2)”, or “Black (3)” and “Black (4)”. Refer to “SWITCH CHECK” section.
[A] Front brake switch
[B] Rear brake switch
INCORRECT
The brake switch is defective. Replace.
*
ON (Step down)
OFF (Free) BB
BB
G/Y Br
34
2
G/Y RW
1
ON (Pull in) OFF (Free)
G/Y
Br
A
B
Br
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SIGNAL SYSTEM
7-58
ELEC
3. Voltage.
•Connect the pocket tester (DC 20V) to the
bulbholder connector.
Tester terminal (+) ➔Green/Yellow cable (1)
Tester terminal (–) ➔Black terminal (2)
•Turn the main switch to ON.
•The brake lever is pulled or the brake
pedal is pressed.
•Check the voltage (12V) on the
“Green/Yellow” cable of the bulbholder
connector.
OUT OF SPECIFICATION
The circuit from the main switch to the bulbhol-
der connector is defective. Repair.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
*
The circuit is efficient.
CONTINUITY
DISCONTINUITY
Replace the bulb and/or bulbholder.
3. The direction indicator light and/or the direc- tion indicator light fail to flash.
1. Bulb and bulbholder.
•Check the continuity of the bulb and bulb-
holder.
Refer to “BULB INSPECTION” section.
2. Direction indicator switch.
•Disconnect the left handlebar switch con-
nector from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
left handlebar switch cables.
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ELECSIGNAL SYSTEM
7-61
5. Voltage.
•Connect the pocket tester (DC 20V) to the
bulbholder connector.
•Connect the left handlebar switch connec-
tor to the wire harness.
To the left flasher light:
Tester terminal (+) ➔
Green/Black terminal (1)
Tester terminal (–) ➔Earth
To the right flasher light:
Tester terminal (+) ➔
Brown/Black terminal (1)
Tester terminal (–) ➔Earth
•Turn the main switch to ON.
•Turn the direction indicator switch to “L” or
“R”.
•Check the voltage (it flashes at 2-8V) on
the “Green/Black” or “Brown/Black” cable
at the bulbholder connector.
OUT OF SPECIFICATION
The circuit from the direction indicator switch to
the bulbholder is defective. Repair.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
The circuit is efficient.
*
GBBrB
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SIGNAL SYSTEM
7-62
ELEC
CONTINUITY
DISCONTINUITY Replace the bulb and/or bulbholder.1. Bulb and bulbholder.
•Check the continuity of the bulb and bulb-
holder.
Refer to “BULB INSPECTION” section.
2. Neutral switch.
•Disconnect the neutral switch cable from
the wire harness.
•Connect the pocket tester ( Ωx 1) to the
neutral switch cables.
•Check the switch component for continuity
between “Sky blue (1)” and “earth”.
Refer to “SWITCH CHECK” section.
INCORRECT
The neutral switch is defective. Replace.
CORRECT
4. The “N” neutral light fails to turn on.
3. Voltage.
•Connect the pocket tester (DC 20V) to the
bulbholder connector.
Tester terminal (+) ➔Brown cable (1)
Tester terminal (–) ➔Earth





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TRBL
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CHAPTER 8°
TROUBLESHOOTING
FAILURE TO START/DIFFICULTIES IN STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
POOR ENGINE COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
POOR PERFORMANCE AT IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED . . . . . . . . . . . . . . . . . 8-3
DIFFICULTIES IN SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
SHIFTING IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
THE SHIFT PEDAL FAILS TO MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
DISENGAGING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
CLUTCH SLIDES OR FAILS TO RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CLUTCH SLIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CLUTCH FAILS TO RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
DEFECTIVE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
POOR BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
OIL LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
MALFUNCTIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
UNSTABLE STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . 8-8
POOR HEADLIGHT ILLUMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
FREQUENT BURNING OF BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DIRECTION INDICATORS FAIL TO TURN ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DIRECTION INDICATORS FAIL TO TURN OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DELAYED TURNING ON OF INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
EXCESSIVE INDICATOR INTERMITTENCE FREQUENCY . . . . . . . . . . . . . . . . . . . 8-9
THE HORN FAILS TO WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
OVERHEATING OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
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DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS
8-8
TRBL
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PROBABLE CAUSES
•Incorrect bulb
•Excessive absorption of electrical accessories
•Difficulties in charging (charging coil broken
and/or rectifier/regulator defective)
•Uncertain connections
•Wrong negative earthing
•Insufficient contacts (main switch)
•Bulb gone
HEADLIGHT DOES NOT LIGHT
PROBABLE CAUSES
•Light relay/diode defective
•Incorrect bulb
•Rectifier/regulator defective
•Wrong negative earthing
•Main switch defective
•Bulbs gone
FREQUENT BURNING OF BULB PROBABLE CAUSES
•Wrong negative earthing
•Battery flat
•Defective direction indicator switch
•Indicator lamp relay defective
•Harness cut off
•Connector loose
•Bulb gone
DIRECTION INDICATORS FAIL TO TURN ON
PROBABLE CAUSES
•Indicator lamp relay defective
•Insufficient battery capacity
(battery almost flat)
•Bulb (front or rear) burnt out
•Direction indicator switch defective
DIRECTION INDICATORS FAIL TO TURN OFF
DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS
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DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS/ OVERHEATING OF ENGINE
8-9
TRBL
SHTG
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PROBABLE CAUSES
•Indicator lamp relay defective
•Insufficient battery capacity
(battery almost flat)
•Incorrect bulb
•Main switch or direction indicator switch defec-
tive
DELAYED TURNING ON OF INDICATORS
PROBABLE CAUSES
•Battery flat
•Main switch or horn switch defective
•Horn wrongly set
•Defective horn
•Harness cut off
THE HORN FAILS TO WORK
OVERHEATING OF ENGINE
PROBABLE CAUSES
•Incorrect bulb
•Indicator lamp relay defective
EXCESSIVE INDICATOR
INTERMITTENCE FREQUENCY
Ignition system
Fuel feed system PROBABLE CAUSES
•Incorrect electrode gap of spark plug
•Spark plug thermal gradation wrong
•Ignition unit defective
•Incorrect carburetor main jet (incorrect setting)
•Incorrect fuel level
•Air filter element obstructed
Engine compression
•Excess of carbon deposits
Engine oil
•Incorrect oil level
•Incorrect oil viscosity
•Incorrect oil gradation
Brake
•Pads fail to return freely (remains blocked)
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