YAMAHA TT600RE 2004 Service Manual

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CHECKING AND CHARGING THE BATTERY
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
•Wear protective eye gear when handling or
working near batteries.
•Charge batteries in a well-ventilated area.
•Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
•DO NOT SMOKE when charging or han-
dling batteries.
•KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
•Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
First aid in case of bodily contact:
External
•SKIN – Wash with water.
•EYES – Flush with water for 15 minutes
and get immediate medical attention.
Internal
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.
•This is a sealed battery. Never remove the
sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.
•Charging time, charging amperage and
charging voltage for a MF battery are dif-
ferent from those of conventional batter-
ies. The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charg-
ing the battery.
CAUTION:
3-47
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CHECKING AND CHARGING THE BATTERY
3-48
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NOTE:
Since MF batteries are sealed, it is not possible to
check the charge state of the battery by measuring
the specific gravity of the electrolyte. Therefore, the
charge of the battery has to be checked by meas-
uring the voltage at the battery terminals.
1. Remove:
•Seat
•Panel 1
2. Disconnect:
•Battery leads
(from the battery terminals)
First, disconnect the negative lead 1, then the
positive lead 2.
3. Remove:
•Battery
4. Check:
•Battery charge
CAUTION:
a. Connect a pocket tester to the battery termi-
nals.
NOTE:
•The charge state of a MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive terminal is
disconnected).
•No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30 %
5. Charge:
•Battery
(refer to the appropriate charging method
illustration)




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Tester positive ➔Battery positive
lead terminal
Tester negative ➔Battery negative
lead terminal
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Voltmeter
Open-circuit voltage
Relationship between open-circuit
voltage and charging time at 20 °C
Charging time (Hours)
• This varies depending on the temperature, the state of
charge in battery plates and the electrolyte level.13,0
12,5
12,0
11,5
5 6,5 10
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CHECKING AND CHARGING THE BATTERY
3-49
Open-circuit voltage (V)
WARNING
Do not quick charge a battery.
•Never remove the MF battery sealing caps.
•Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
•If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
•When charging a battery, be sure to
remove it from the motorcycle (if charging
has to be done with the battery mounted
on the motorcycle, disconnect the nega-
tive lead from the battery terminal).
•To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the bat-
tery.
•Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
•Make sure that the battery charger lead
clips are in full contact with the battery
terminal and that they are not shorted. A
corroded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
•If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
•As shown in the following illustration, the
open-circuit voltage of a MF battery stabi-
lizes about 30 minutes after charging has
been completed. Therefore, wait 30 min-
utes after charging is completed before
measuring the open-circuit voltage.
CAUTION:
Condition of charge in battery (%)Ambient
temperature
20 °C
Open-circuit voltage (V)
Check the open-circuit
voltage Ambient
temperature 20 °C Charging 14
13
12
11
10
100 75 50 30 2520 00 10 20 30 40 50 60 Time (minutes) 18
17
16
15
14
13
12
11
10
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CHECKING AND CHARGING THE BATTERY
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Charging method using a variable-current (voltage) type charger
ChargerNOTE:Voltage should be measured 30 minutesafter the machine is stopped.
NOTE:
Set the charging voltage at 16 ~ 17 V (if
the setting is lower, charging will be
insufficient. If too high, the battery will be
over-charged.)
AMP
meterMeasure the open-circuit
voltage prior to charging.
Connect a charger and AMP
meter to the battery and start
charging.
Make sure the current is
higher than the standard
charging current written on
the battery.
By turning the charging voltage
adjust dial, set the charging
voltage at 20 ~ 25 V.
Monitor the amperage for 3 ~ 5
minutes to check if the standard
charging current is reached.Adjust the voltage so that
current is at standard charg-
ing level.
Set the timer according to
the charging time suitable for
the open-circuit voltage.
Refer to "Battery condition
checking steps."If the current does
not exceed standard
charging current af-
ter 5 minutes, re-
place the battery.
In case that charging requires more than 5 hours, it is advisable to check
the charging current after a lapse of 5 hours.
If there is any charge in the amperage, readjust the voltage to obtain the
standard charging current.
Measure the battery open-circuit voltage after having left the battery un-
used for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
YES
YESNO
NO
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CHECKING AND CHARGING THE BATTERY
3-51
Charging method using a constant-voltage type charger
Measure the open-circuit
voltage prior to charging.
Connect a charger and AMP
meter to the battery and start
charging.
Make sure the current is
higher than the standard
charging current written on
the battery.
Charge the battery until the battery’s
charging voltage is 15 V.This type of battery charger cannot
charge the MF battery. A variable volt-
NOTE:Voltage should be measured 30 min-utes after the machine is stopped.
Measure the battery open-circuit volt-
age after having left the battery unused
for more than 30 minutes.
12.8 V or more --- Charging is com-
plete.
12.7 V or less --- Recharging is re-
quired.
Under 12.0 V --- Replace the battery.
NOTE:Set the charging time at 20 hours (max-imum).
NO
YES
Charging method using a constant-current type charger
This type of battery charger cannot charge the MF battery.
Charger
AMP meter
Voltmeter
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CHECKING AND CHARGING THE BATTERY
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6. Connect:
•Battery leads
(to the battery terminals)
First, connect the positive lead 2, then the
negative lead 1.
7. Check:
•Battery terminals
Dirt ➔Clean with a wire brush.
Loose connection ➔Connect properly.
8. Lubricate:
•Battery terminals
CAUTION:
9. Install:
•Panel
•Seat



Recommended lubricant
Dielectric grease
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CHECKING THE FUSES
3-53
CHECKING THE FUSES
To avoid a short circuit, always turn the main
switch to "OFF" when checking or replacing a
fuse.
1. Remove:
•Seat
•Panel 1
2. Check:
•Fuse
CAUTION:
a. Connect the pocket tester to the fuse and
check it for continuity.
NOTE:
Set the pocket tester selector to “Ω
1”.
b. If the pocket tester indicates "∞", replace the
fuse.
3. Replace:
•Blown fuse
a. Turn off the ignition.
b. Install a new fuse of the correct amperage rat-
ing.
c. Turn on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check the
electrical circuit.
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Pocket tester
90890-03112
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FusesAmperage
Quantityrating
Main (1) 20 A 1
Reserve (2) 20 A 1



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CHECKING THE FUSES/
REPLACING THE HEADLIGHT BULBS
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WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or using
a fuse with the wrong amperage rating may
cause extensive damage to the electrical sys-
tem, cause the lighting and ignition systems
to malfunction and could possibly cause a fire.
4. Install:
•Pannel
•Seat
REPLACING THE HEADLIGHT BULBS
Low beam/high beam
1. Remove:
•Cowling screws (1)
2. Remove:
•Cowling (from the meter bracket)
NOTE:
Remove the cowling from the meter bracket by
lowering it to disengage it, and then lifting it up.
3. Remove:
•Headlight (2)
4. Disconnect:
•Headlight coupler (3)
5. Remove:
•Headlight bulb cover (4)
6. Remove:
•Headlight bulb holder (5) (by turning it
counterclockwise (a))
•Headlight bulb
WARNING
Headlight bulbs get very hot. Therefore, keep
flammable products away from a lit headlight
bulb, and do not touch the bulb until it has
cooled down.








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REPLACING THE HEADLIGHT BULBS
3-55



Auxiliary light bulb
1. Remove:
•Cowling screws (1)
2. Remove:
•Cowling (from the meter bracket)
NOTE:
Remove the cowling from the meter bracket by
lowering it to disengage it, and then lifting it up.
3. Remove:
•Headlight (2)
•Auxiliary light socket (3)
NOTE:
Remove the auxiliary light socket (together with
the bulb) without disconnecting the leads.
•Bulb (by pushing it in and turning it coun-
terclockwise)Cowling screws:
10 Nm (1.0 kgm)
7. Install:
•Headlight bulb (new)
•Headlight bulb holder (by turning it clock-
wise (b))
Do not touch the glass part of the headlight
bulb to keep it free from oil, otherwise the
transparency of the glass, the luminosity of
the bulb, and the bulb life will be adversely
affected. Thoroughly clean off any dirt and
fingerprints on the headlight bulb using a
cloth moistened with alcohol or thinner.
8. Install:
•Headlight bulb cover
9. Connect:
•Headlight coupler
10. Install:
•Upper side of the cowling (onto the meter
bracket)
•Headlight (adjust the headlight beam if
necessary)
11. Install:
•Cowling screws
CAUTION:
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REPLACING THE TURN INDICATOR LIGHT BULB
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REPLACING THE TURN INDICATOR LIGHT
BULB
1. Remove:
•Lens screw (1)
•Lens (2)
•Bulb (3)
NOTE:
To remove the bulb press it into place and turn it
counterclockwise.
2. Install:
•New bulb
NOTE:
To install the bulb press it into place and turn it
clockwise.
•Lens
•Lens screw
Do not overtighten the screw, otherwise the
lens may break.
CAUTION: 4. Install:
•Bulb (new) (by pushing it in and turning it
clockwise)
•Bulb holder
•Upper side of the cowling (onto the meter
bracket)
•Headlight (adjust the headlight beam if
necessary)
5. Install:
•Cowling screws
Cowling screws:
10 Nm (1.0 kgm)
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