relay YAMAHA TT600RE 2004 User Guide

ELECELECTRICAL COMPONENTS
7-3
ELECTRICAL COMPONENTS
(1) Main wire harness
(2) Diodes
(3) Extension wire harness
(4) Rectifier/Regulator
(5) CDI ignition unit
(6) Battery (12V – 8Ah)
(7) Starter relay
(8) Fuse (20A) BATTERY: CAPACITY 12V – 8Ah
SPECIFIC GRAVITY: 1.320
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ELECTRICAL COMPONENTS
7-4
ELEC
IGNITION COIL: Primary winding resistance: 4 Ω
Ω
± 15% at 20°C (68°F)
Secondary winding resistance: 13 k Ω
Ω
± 20% at 20°C (68°F)(1) Ignition coil
(2) Spark plug cap
(3) Flasher relay
(4) Horn
(5) Clutch switch
(6) Relay assy
(7) Sidestand switch
(8) Neutral switch
(9) Main switch
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ELECTRICAL STARTING SYSTEM
7-22
ELEC
The diagram illustrates the electrical starting system-circuit inside the motorcycles electric system. NOTE:
For the colour code and legend, see page 7-2.
(3) Battery
(4) Starter relay
(5) Starting motor
(6) Fuse
(7) Main switch
(9) Engine stop switch (10) Starter switch
(11) Diode
(12) Clutch switch
(13) Sidestand switch
(14) Neutral switch
(15) Diode
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365
12
11141315
4
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ELECELECTRICAL STARTING SYSTEM
7-23
STARTING CIRCUIT OPERATION
The starting circuit on this model consists of the
starter motor, starter relay, and the starting circuit
cut-off relay. If the engine stop switch is on “RUN”
and the main switch is on “ON” (both switches are
closed), the starter motor can operate only if:
The starting circuit cut-off relay prevents the
starter from operating when neither of these con-
ditions have been met. In this instance, the start-
ing circuit cut-off relay is open so current cannot
reach the starter motor.
When at least one of the above conditions have
been met however, the starting circuit cut-off relay
is closed, and the engine can be started by press-
ing the starter switch.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE CLUTCH LEVER IS PULLED IN
1 Battery
2 Main switch
3 Engine stop switch
4 Starter relay
5 Starting circuit cut-off relay
6 Start switch
7 Starter motor
8 Neutral switch
9 Clutch switch
0 Sidestand switch
The transmission is in neutral (the neutral
switch is closed). or if
The clutch lever is pulled to the handlebar (the
clutch switch is closed) and the sidestand is up
(the sidestand switch is closed).
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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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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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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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LIGHT SYSTEM
7-46
ELEC
LIGHT SYSTEM INSPECTION NOTE:
To proceed to the control of the light system, start the engine and then stop it by the emergency engine
stop switch. In this way the light relay remains excited and it is possible to check the light system.
1. The front headlight and the high beam light fail to turn on.
CONTINUITY
DISCONTINUITY
Replace the bulb and/or the bulbholder.1. Bulb and bulbholder.
•Check the continuity of the bulb and bulb-
holder.
Refer to “BULB INSPECTION” section.
2. Voltage.
•Connect the pocket tester (DC 20V) to the
front headlight connectors and the high
beam switch.
Headlight: Tester terminal (+) ➔
Green (2) or Yellow (1) cable
Tester terminal (–) ➔Black cable (3)
High beam light: Tester terminal (+) ➔Yellow cable (4)
Tester terminal (–) ➔Black cable (5)
[A] When the lights switch (commutator) is at
position “HI”.
[B] When the lights switch (commutator) is at position “LO”.
OUT OF SPECIFICATION
The circuit from the main switch to the bulbhol-
der connector is defective. Repair.
A
B
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