stop start YAMAHA TT600RE 2004 User Guide

CARBCARBURETOR ASSEMBLY
6-13
5. Install:
•Cable holder
•Collar
•Throttle lever
NOTE:
Check that the throttle shaft lever (2) and the
adjuster bolt (3) are aligned when tightening the
throttle nut (1).
Screw (cable holder): 3 Nm (0.3 mkg)
Screw (top cover): 2 Nm (0.2 mkg)
Starter piston: 6 Nm (0.6 mkg)
Main nozzle 1: 2 Nm (0.2 mkg)
Screw (valve seat): 2 Nm (0.2 mkg)
6. Install:
•Top cover
7. Install:
•Diaphragm (1) (enrichment)
NOTE:
Make the diaphragm tab coincide with the gravity
enricher notch.
9. Install:
•Pilot screw set (1)
•Pilot jet (2)
•Main nozzle 1 (3)
•Main jet (primary) (4)
•Valve seat (5)
8. Install:
•Starter set
•Stop screw
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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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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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365
12
11141315
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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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LIGHT SYSTEM
7-46
ELEC
LIGHT SYSTEM INSPECTION NOTE:
To proceed to the control of the light system, start the engine and then stop it by the emergency engine
stop switch. In this way the light relay remains excited and it is possible to check the light system.
1. The front headlight and the high beam light fail to turn on.
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
front headlight connectors and the high
beam switch.
Headlight: Tester terminal (+) ➔
Green (2) or Yellow (1) cable
Tester terminal (–) ➔Black cable (3)
High beam light: Tester terminal (+) ➔Yellow cable (4)
Tester terminal (–) ➔Black cable (5)
[A] When the lights switch (commutator) is at
position “HI”.
[B] When the lights switch (commutator) is at position “LO”.
OUT OF SPECIFICATION
The circuit from the main switch to the bulbhol-
der connector is defective. Repair.
A
B
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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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POOR PERFORMANCE AT IDLE SPEED/
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED
8-3
TRBL
SHTG
?
Carburetor
Electrical system
Valves PROBABLE CAUSES•The starter piston fails to return freely
•Pilot jet obstructed or loose
•Pilot jet obstructed
•Pilot air screw wrongly set
•Idle speed wrongly set
(throttle valve stop screw)
•Throttle cable free play wrongly set
•Carburetor flooded
•Valve clearance wrongly set
Air filter
•Air filter element obstructed
POOR PERFORMANCE AT IDLE SPEED
See “FAILURE TO START/DIFFICULTIES IN STARTING”.
(FUEL SYSTEM, ELECTRICAL SYSTEM, COMPRESSION SYSTEM and Valve clearance)
Carburetor
PROBABLE CAUSES
•Petrol contains water or impurities or is adulterated
•Infiltrations of air
•Deformation of float
•Defective diaphragm
• Needle valve worn or scratched
•Needle valve seat insufficiently sealed
•Needle stop position incorrect
•Fuel level set wrongly
•Main jet obstructed or loose
•Main nozzle obstructed or loose
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED
•Defective battery
•Defective spark plug
•Defective ignition unit
•Defective AC magneto
•Defective ignition coil
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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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