engine YAMAHA TT600RE 2004 Service Manual

ELECTRICAL CIRCUIT DIAGRAM
7-2
ELEC
B Black B/Y Black/Yellow
Br Brown Br/B Brown/Black
Ch Chocolate Br/W Brown/White
Dg Deep green G/B Green/Black
G Green G/R Green/Red
Gy Grey G/W Green/White
L Blue G/Y Green/Yellow
Or Orange L/R Blue/Red
P Pink L/W Blue/White
R Red L/Y Blue/Yellow
Sb Sky-blue R/B Red/Black
W White R/W Red/White
Y Yellow R/Y Red/Yellow
B/R Black/Red W/L White/Blue
B/W Black/White Y/R Yellow/Red
(1) 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
(10) Starter switch
(11) Diode
(12) Clutch switch
(13) Sidestand switch
(14) Neutral switch
(15) Diode
(16) Ignitor unit
COLOUR CODE (17) Ignition coil
(18) Left handlebar switch
(19) Horn switch
(20) Diode
(21) Pass switch
(22) Dimmer switch
(23) Flasher switch
(24) Horn
(25) Flasher relay
(26) Headlight
(27) Flasher light
(28) Relay assy
(29) Front brake switch
(30) Rear brake switch
(31) Tail/stop light
(32) Meter
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IGNITION SYSTEM
7-12
ELEC
The diagram illustrates the ignition circuit inside the motorcycles electric system. NOTE:
For the colour code and legend, see page 7-2.
(1) AC generator/Pickup coil
(2) Rectifier/Regulator
(3) Battery
(6) Fuse
(7) Main switch
(9) Engine stop switch
(11) Diode (12) Clutch switch
(13) Sidestand switch
(14) Neutral switch
(15) Diode
(16) Ignitor unit
(17) Ignition coil

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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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IGNITION SYSTEM
7-14
ELEC
3. Spark plug.
•Check the conditions of the spark plug.
•Check the type of spark plug used.
•Check the electrodes gap.
Standard spark plug: DPR8EA-9 (NGK), DPR9EA-9
4. Amplitude of the ignition spark.
•Detach the spark plug cap from the spark
plug.
•Connect the dynamic spark tester (1) as
shown in the figure.
(2) Spark plug cover (3) Spark plug
•Turn the main switch ON.
•Check the amplitude of the ignition spark.
•Start the engine and increase the ampli-
tude until the ignition becomes discontin-
uous.
Electrodes gap: DPR8EA-9, DPR9EA-9 (NGK)
0.8 ~ 0.9 mm
YES
OUT OF SPECIFICATION
Correct the electrodes gap or replace the spark
plug.
Spark amplitude if the ignition
system is efficient: 6.0 mm
THE IGNITION SYSTEM IS INEFFICIENT
OR THERE IS NO SPARK
IN COMPLIANCE WITH SPECIFICATIONS
Minimum spark amplitude.
*
*
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ELECIGNITION SYSTEM
7-17
*
CORRECT
8. Emergency stop engine switch.
•Disconnect the emergency stop engine
switch connector (Brown, Green/Yellow
and Red/Black) from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
switch cables. Refer to “SWITCH CHECK” in Chapter 3.
Tester terminal (+) ➔Red/Black (1) cable
Tester terminal (–) ➔Brown cable (2)
CORRECT
INCORRECT
The emergency stop engine switch is defective.
Replace the right handlebar switch.
INCORRECT
The sidestand switch is defective. Replace.
*
9. Sidestand switch.
•Disconnect the sidestand switch connec-
tor (Black and Black) from the wire har-
ness.
•Connect the pocket tester ( Ωx 1) to the
sidestand switch cables. Refer to “SWITCH CHECK” in Chapter 3.
Tester terminal (+) ➔Black cable (1)
Tester terminal (–) ➔Black cable (2)





 
 



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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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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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ELECTRICAL STARTING SYSTEM
7-26
ELEC
5. 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.










6. Emergency stop engine switch.
•Disconnect the emergency stop engine
switch connector (Brown, Green/Yellow
and Red/Black) from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
switch cables. Refer to “SWITCH CHECK” in Chapter 3.
Tester terminal (+) ➔
Red/Black (1) cable
Tester terminal (–) ➔Brown cable (2)
INCORRECT
The emergency stop engine switch is defective.
Replace the right handlebar switch.
*
CORRECT
*




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ELECELECTRICAL STARTING SYSTEM
Removal
1. Remove:
•The starter motor Refer to the “ENGINE REMOVAL” sec-
tion in CHAPTER 5.
Inspection and repair
1. Inspect:
•Manifold Dirty ➔Clean with sandpaper no. 600.
2. Measure:
•Diameter of the commutator Out of specification ➔Replace the motor.
3. Measure:
•The mica undercut (b).
Out of specification ➔Level the undercut
to the correct value using a hacksaw.
Wear limit of commutator (a): 27 mm
Mica undercut (b):0.7 mm
NOTE:
The mica insulation of the commutator must have
an undercut to ensure proper functioning of the
commutator.
Disassembly
1. Remove:
•Circlip (1)
•Drive gear (2)
•Screws (3)
•Rear bracket (4)
•Washers (5)
•Brushes housing (6)
•Brushes (7)
•Front bracket (8)
•Washers (9)
•Armature (10)
•Stator (11)
7-31
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