relay YAMAHA TT600RE 2004 Owner's Manual

SIGNAL SYSTEM
7-52
ELEC
The diagram shows the signal 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
(11) Diode
(14) Neutral switch
(15) Diode
(18) Left handlebar switch
(19) Horn switch (23) Flasher switch
(24) Horn
(25) Flasher relay
(27) Flasher light
(29) Front brake switch
(30) Rear brake switch
(31) Tail/stop light
(32) Meter
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ELECSIGNAL SYSTEM
7-59
•Check the switch component for conti-
nuity between “Brown/White (1)” and
“Brown/Black (2)” and “Brown/White (1)”
and “Green/Black (3)”.
Refer to “SWITCH CHECK” section.
CORRECT
3. Direction indicator lamp relay.
•Connect the pocket tester (DC 20V) to the
indicator lamp relay.
Tester terminal (+) ➔Brown terminal (1)
Tester terminal (–) ➔Earth
•Turn the main switch to ON.
•Check the voltage (12V) on the “Brown”
cable to the indicator lamp relay terminal.
OUT OF SPECIFICATION
The circuit from the main switch to the lamp re-
lay connector is defective. Repair.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
*



 








\f
INCORRECT
The direction indicator switch is defective.
Replace.
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SIGNAL SYSTEM
7-60
ELEC
OUT OF SPECIFICATION The direction indicator lamp relay is defective.
Replace.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
* *
4. Voltage.
•Connect the pocket tester (DC 20V) to the
bulbholder connector.
Tester terminal (+) ➔
Brown/White terminal (1)
Tester terminal (–) ➔Earth
•Turn the main switch to ON.
•Check the voltage (12V) on the “Blue”
cable to the bulbholder connector.
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FAILURE TO START/
DIFFICULTIES IN STARTING
8-2
TRBL
SHTG
?
Spark plug
Ignition coil
Ignition unit
Switches and cables PROBABLE CAUSES•Electrodes gap not correct
•Electrodes worn
•Feed cable interrupted
•Wrong thermal grading of spark plug
•Defective spark plug cap
•Primary or secondary winding interrupted
•High voltage cable defective
•Defective coil
•Defective unit
•Defective pick-up coil
•Woodruff key broken
Starter motor
•Starter motor defective
•Starter motor relay defective
•Diodes defectives
•Starter one-way bearing defective
•Main switch defective
•Emergency stop engine switch defective
•Harness with cable interrupted
•Neutral switch defective
•Sidestand switch defective
•Clutch switch defective
•Starter switch defective
ELECTRICAL SYSTEM
Cylinder and cylinder head
Piston and piston rings
Crankcase and valves, crankshaft PROBABLE CAUSES
•Spark plug tightening insufficiently
•Cylinder head or cylinder insufficiently tightened
•Cylinder head gasket broken
•Cylinder gasket broken
•Cylinder worn, damaged or seized
•Piston rings wrongly assembled
•Piston rings worn, yielded or broken
•Piston rings stuck together
•Piston seized or damaged
•Poor crankcase sealing
•Crankshaft oil seal edge damaged
•Poor valve sealing
•Valve and seat with insufficient contact
•Valve timing wrongly
•Valve spring broken
•Crankshaft seized
•Camshaft seized
POOR ENGINE COMPRESSION
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DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS
8-8
TRBL
SHTG
?
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
?
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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TT600RE WIRING DIAGRAM
467C4B5CAMP403D494A4856 172320-2
GWLY
BB
B
BBLWRB
R
B
B
B
RLBOrRBLYGW
Or
B
LW
MAIN HARNESSB
B
B
Y Y
LBG
LGRBLYGWLWLBOrRB
LW
GY
GY
RBBr
Br
187
GB
12V10W
BL12V5WB
Y G
12V60/55WBGYA
A
12V10W
A
GB
BrBBrB
B
GBB
GBB
GBB
BrB
12V10WB
B
BrL
GB
12V10WB
B
187
BY
B
R
B
BrL
WWB
OFF
BrL
W
B
W
BB
B
B
BLB
BBrB
G
B
BrB
Br
OFF
B
EXT. CORD
Br
GY
BL
G Y
GYB
B
L
GB
BrB
LR
LR SbB
RW
-
LR
L
BrL
GBSbB
BrB
YBrBrB
YBrGB
B
Ch
DgBrY
BrB
HIGH
TURN
NEU.ILL.
B
BrL
BrL
LB
BY
LY
LB
LYGW
B
RBOr
205
B
RBLBrL
Br
PARKOFFON
ON
ON
Sb
L
GB
GY G
Y
RBLYBY
LYBY
RUN
LW
B
B
LY
BY
LBrRR
LWRB
GB
R
B
GW
BrBrW
WB
Br
LY
WB
Sb
B
GWLY
(BLUE)B
B
LYB
OFF
BrRB
LWRB
Y
P
G
GB BBrWBrL
BrB
W
WW
GYBr
GY
Y
P
G
GB BBrWBrL
BrB
Y
N
RL
LOWHIGH
BrW BrWBr
PPBr
LY
B
GWLY
Or
RBBr
LW
BY
BY
START
OFF
R
B
GWLY
W
W
W
W
W
W
WRW
W
W
Sb
B
Sb
B
BrBB
-
-
B
LR
WRW
B
-
A
L
L
GY
LB
Br
WB
RB
MAIN HARNESS
AHEAD LIGHT
B
B
BrB

17
16
11
12
13
14
15
91029
8
5
3
12
64
28
20
21
22
19
2325
24
30
31
27
267
32
18
ELECTRICAL SYSTEM
DIAGRAM1 AC generator/Pickup coil
2 Rectifier/Regulator
3 Battery
4 Starter relay
5 Starting motor
6 Fuse
7 Main switch
8 Right handlebar switch
9 Engine stop switch
0 Starter switch
q Diode
w Clutch switch
e Sidestand switch
r Neutral switch
t Diode
y Ignitor unit
u Ignition coil
i Left handlebar switch
o Horn switch
p Diode
a Pass switch
s Dimmer switch
d Flasher switch
f Horn
g Flasher relay
h Headlight
j Flasher light
k Relay assy
l Front brake switch
; Rear brake switch
z Tail/stop light
x Meter
COLOR CODE
B ...........Black
Br ..........Brown
Ch .........Chocolate
Dg .........Dark green
G...........Green Gy .........Gray
L............Blue
Lg..........Light green
O...........Orange
P ...........Pink R...........Red
Sb .........Sky blue
W..........White
Y ...........Yellow
B/L ........Black/Blue B/W.......Black/White
B/Y........Black/Yellow
Br/B.......Brown/Black
Br/L .......Brown/Blue
Br/W......Brown/White Br/Y.......Brown/Yellow
L/B ........Blue/Black
L/R ........Blue/Red
L/W .......Blue/White
L/Y ........Blue/Yellow R/B........Red/Black
R/G .......Red/Green
R/W.......Red/White
R/Y........Red/Yellow
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