ad blue YAMAHA TT600RE 2004 User Guide

ELECELECTRICAL STARTING SYSTEM
7-21
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
Br187
GB
12V10W
BL12V5WBY G
12V60/55WBGYAA
12V10W
A
GB
BrBBrB
BGBB
GBBGBB
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 Sb
B
RW
-
LR
L
BrL
GBSbB
BrB
YBrBrB
YBrGB
B
Ch
DgBrY
BrB
HIGH
TURN
NEU.ILL.
B
BrL
BrL
LBBY
LY LB
LY
GWB
RBOr
205
B
RBL
BrL
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 B
BrWBrL
BrB
Y
N
RL
LOWHIGH
BrW Br
P
PBr
LY
B
GWLY
Or
RB
Br
LW
BY
BY
START
OFF
R
B
GWLY
W
W W
W
W
W
W
RW
W
W
Sb
B
Sb
BBrBB
-
-
B
LR
WRW
B
-
AL
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
6428
20
21
22
19
2325
24
30
31
27
267
32
18
BrW
ELECTRICAL STARTING SYSTEM - CIRCUIT DIAGRAM
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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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ELECELECTRICAL STARTING SYSTEM
7-27
*
*
CORRECT
7. 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)
8. Neutral switch.
•Disconnect the neutral switch cable (Sky
blue).
•Connect the pocket tester ( Ωx 1) to the
neutral switch cables. Refer to “SWITCH CHECK” in Chapter 3.
Tester terminal (+) ➔Sky blue cable (1)
Tester terminal (–) ➔Earth
CORRECT
INCORRECT
The neutral switch is defective. Replace.


 






 


INCORRECT
The sidestand switch is defective. Replace.
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*
9. Clutch switch.
•Disconnect the clutch switch connector
from the harness.
•Connect the pocket tester ( Ωx 1) to the
clutch switch cable.
•Check the clutch switch component for
continuity between “Black (1)” and “Black
(2)”.
Refer to “SWITCH CHECK” in Chapter 3.
INCORRECT
The clutch switch is defective. Replace.
 

 


CORRECT
7-28
ELECELECTRICAL STARTING SYSTEM
INCORRECT
The start switch is defective. Replace the right
handlebar switch.
10. Start switch.
•Disconnect the start switch connector
from the harness.
•Connect the pocket tester ( Ωx 1) to the
handlebar switch terminal.
•Check the start switch component for con-
tinuity between “Blue/White (1)” and
“Black/Yellow (2)”.
Refer to “SWITCH CHECK” in Chapter 3.
CORRECT
 
! "



# 



*
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ELECCHARGING SYSTEM
7-35
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
Br187
GB
12V10W
BL12V5WBY G
12V60/55WBGYAA
12V10W
A
GB
BrBBrB
BGBB
GBBGBB
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 Sb
B
RW
-
LR
L
BrL
GBSbB
BrB
YBrBrB
YBrGB
B
Ch
DgBrY
BrB
HIGH
TURN
NEU.ILL.
B
BrL
BrL
LBBY
LY LB
LY
GWB
RBOr
205
B
RBL
BrL
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 B
BrWBrL
BrB
Y
N
RL
LOWHIGH
BrW Br
P
PBr
LY
B
GWLY
Or
RB
Br
LW
BY
BY
START
OFF
R
B
GWLY
W
W W
W
W
W
W
RW
W
W
Sb
B
Sb
BBrBB
-
-
B
LR
WRW
B
-
AL
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
6428
20
21
22
19
2325
24
30
31
27
267
32
18
BrW
CHARGING SYSTEM – CIRCUIT DIAGRAM
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ELECLIGHT SYSTEM
7-41
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
Br187
GB
12V10W
BL12V5WBY G
12V60/55WBGYAA
12V10W
A
GB
BrBBrB
BGBB
GBBGBB
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 Sb
B
RW
-
LR
L
BrL
GBSbB
BrB
YBrBrB
YBrGB
B
Ch
DgBrY
BrB
HIGH
TURN
NEU.ILL.
B
BrL
BrL
LBBY
LY LB
LY
GWB
RBOr
205
B
RBL
BrL
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 B
BrWBrL
BrB
Y
N
RL
LOWHIGH
BrW Br
P
PBr
LY
B
GWLY
Or
RB
Br
LW
BY
BY
START
OFF
R
B
GWLY
W
W W
W
W
W
W
RW
W
W
Sb
B
Sb
BBrBB
-
-
B
LR
WRW
B
-
AL
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
6428
20
21
22
19
2325
24
30
31
27
267
32
18
BrW
LIGHT SYSTEM - CIRCUIT DIAGRAM
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LIGHT SYSTEM
7-44
ELEC
3. Main switch.
•Disconnect the main switch connector
from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
switch cables.
Refer to “SWITCH CHECK” in CHAPTER
3.
CORRECT
INCORRECT
The main switch is defective. Replace.










*
4. Dipped/high beam commutator and dim-
mer switch.
•Disconnect the left handlebar switch con-
nector from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
left handlebar switch terminals.
•Check the switch component for conti-
nuity between “Brown (1)” and “Yellow
(2)”, “Brown/Blue (3)” and “Green (4)”,
“Brown/Blue (3)” and “Yellow (2)”.
Refer to “SWITCH CHECK” in CHAPTER
3.
INCORRECT
The dipped/high beam commutator and/or the
dimmer switch are defective. Replace the left
handlebar switch.
$'\f
\f 



 
 



 \f






\f

CORRECT
*
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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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ELECLIGHT SYSTEM
7-47
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
bulbholder connector.
Tester terminal (+) ➔Blue cable (1)
Tester terminal (–) ➔Black cable (2)
•Turn the main switch to ON.
•Check the voltage (12V) on the “Blue”
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)
•Turn the main switch to ON.
•Turn the lights switch to “LO” or “HI”.
•Check the voltage (12V) on the “Green”
and “Yellow” cable at the bulbholder ter-
minals.
The circuit is efficient.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
The circuit is efficient.
2. The instrument light and/or the parking indica- tor light fails to turn on.
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LIGHT SYSTEM
7-48
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. Voltage.
•Connect the pocket tester (DC 20V) to the
bulbholder connector.
Tester terminal (+) ➔Blue terminal (1)
Tester terminal (–) ➔Black terminal (2)
•Turn the main switch to ON.
•Check the voltage (12V) on the “Blue”
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.
3. The parking light fails to turn on.
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