battery YAMAHA TT600RE 2004 User Guide

INSP
ADJ
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
ProCarManuals.com

CHECKING AND CHARGING THE BATTERY
3-52
INSP
ADJ
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
ProCarManuals.com

CHASREAR SHOCK ABSORBER
4-69
Order Job name/Part name Q.ty Remarks Shock absorber removal Remove the parts in order.
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
Seat Refer to “SEAT, FUEL TANK AND REAR
Fuel tank
Rear cowling COWLING” section in Chapter 3.
Battery leads 2 Disconnect. NOTE:
First, disconnect the negative lead, then the
positive lead.
1 Muffler 1
2 Exhaust pipe assembly 1 Refer to “REAR SHOCK ABSORBER RE-
3 Rear frame 1 MOV AL” section.
4 Brake fluid reserve tank 1 Secure the brake fluid tank to the frame in
5 Air filter case 1 an upright position to avoid air entering the hydraulic system.
ProCarManuals.com

CHASREAR SHOCK ABSORBER
4-73
SHOCK ABSORBER REMOVAL
WARNING
Support the motorcycle securely to prevent it
from falling over.
1. Park the motorcycle on a level surface.
2. Remove:
•Seat
•Rear cowling
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING” in CHAPTER 3.
3. Disconnect:
•Battery leads
8. Remove:
•Upper mounting bolt (1)
•Rear shock absorber
1
NOTE:
First, disconnect the negative lead, then the posi-
tive lead.
4. Remove:
•Exhaust pipe assembly
•Rear frame
•Air filter case
5. Raise the rear wheel placing a suitable sup- port under the engine.
6. Remove:
•Rear wheel
Refer to “REAR WHEEL REMOVAL” sec-
tion.
7. Remove:
•Shock absorber fastening nut (1)
•Lower mounting bolt
ProCarManuals.com

ENGINE REMOVAL
5-2
ENG
Order Job name/Part name Q.ty Remarks Drain the engine oil (refer to “ENGINE OIL
REPLACEMENT” section in CHAPTER
3). Remove the seat, the fuel tank and
the rear cowling (refer to “SEAT, FUEL
TANK AND REAR COWLING” section in
CHAPTER 3).
1 Battery leads connector 1 Disconnect.
2 Muffler 1
3 Exhaust pipe 1
4 Engine protector 1
5 Shift pedal 1
6 Drive sprocket crankcase cover 1
7 Drive sprocket 1 Displace the drive chain.
8 Clutch cable 1 Disconnect.
9 Plug cap 1 Disconnect.
ProCarManuals.com

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
ProCarManuals.com

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
ProCarManuals.com

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

\f

\f\f
\f
\f
\f\f
\f\f
ProCarManuals.com

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
*
ProCarManuals.com

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
\f(

365
12
11141315
4
ProCarManuals.com