YAMAHA TT600RE 2004 Service Manual

CARBURETOR ASSEMBLY
6-16
CARB
FUEL LEVEL ADJUSTMENT (CARBURE-
TOR INSTALLED
1. Place the motorcycle on a level surface.
2. Make sure that the carburetor is in a horizon- tal position by placing a hydraulic jack under
the engine.
Fuel level gauge: P/N. 90890-01312
4. Loosen drain screw (2) and heat the engine.
5. Measure:
•Fuel level (a)
Out of specification ➔Adjust.
Fuel level: 6.0 ~ 8.0 mm
Under the edge of the carburetor
body.
6. Adjust:
•Fuel level
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Fuel level adjustment:
•Remove carburetor assembly.
•Inspect valve seat and needle valve set.
•If either of the two is worn, replace both.
•If both are perfect, adjust float height by bend-
ing the wing tab of the float itself (1).
•Recheck the fuel level.
3. Connect the fuel level gauge (1) to the carbu- rettor nipple.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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7
ELEC
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ELEC
CHAPTER 7
ELECTRICAL
ELECTRICAL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
COLOUR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
SWITCH CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
MAIN SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
LIGHT INSPECTION (HEADLIGHTS, TAIL LIGHT AND BRAKE LIGHTS,
DIRECTION INDICATOR LIGHTS, INSTRUMENT LIGHTS, ETC) . . . . . . . . . . . . . . . . . 7-8
BULB TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
BULB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
ELECTRICAL STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
STARTING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
LIGHT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
LIGHT SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46
SIGNALLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
SIGNAL SYSTEM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
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ELEC
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ELECELECTRICAL CIRCUIT DIAGRAM
7-1
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
BYB
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

GY
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 - ELECTRICAL CIRCUIT DIAGRAM
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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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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
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ELECTRICAL COMPONENTS
7-4
ELEC
IGNITION COIL: Primary winding resistance: 4 Ω
Ω
± 15% at 20°C (68°F)
Secondary winding resistance: 13 k Ω
Ω
± 20% at 20°C (68°F)(1) Ignition coil
(2) Spark plug cap
(3) Flasher relay
(4) Horn
(5) Clutch switch
(6) Relay assy
(7) Sidestand switch
(8) Neutral switch
(9) Main switch
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ELECSWITCH CHECK
7-5

 






SWITCH CHECK
Check the continuity between the switch terminals
to verify whether connections are correct.
To check the switch, read the following points.
SWITCH CONNECTION
The table shown here contains the connections
between the switch terminals (eg main switch,
handlebar switches, brake switch, light switch etc).
The column on the far left shows the positions of
the main switch and the top line indicates the
colours of the cables connected with the terminals
of the switch itself.
“o––––o” indicates the terminals between which
there is electrical continuity, ie a closed circuit on
the respective switch positions.
For example, in this table:
“R” and “Br” are continuous when the switch is at
ON.
“L” and “R/B” are continuous when the switch is at
ON.
“R” and “L” are continuous when the switch is at
PARK.
Terminals are not continuous when the switch is at
OFF.
MAIN SWITCH INSPECTION
Before inspecting the switch, see the connection
table shown above and check the terminal con-
nections (closed circuit) by the colour combination.
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SWITCH CHECK
7-6
ELEC

 







 


1. Detach the main switch connector from the
harness connector.
When detaching the connector, do not pull by
the cables. This way the cables might discon-
nect from the terminals inside the connector
itself.
2. Check to see if any cables are disconnected from their terminal inside the connector.
Reconnect, if necessary.
NOTE:
If the connector is blocked up with mud or dust,
clean it with a jet of compressed air.
3. Use the connection table to check the combi- nation of colours for continuity (closed circuit).
In this example, continuity is as follows:
“R” and “Br” are continuous when the switch is
at ON.
“L” and “R/B” are continuous when the switch
is at ON.
“R” and “L” are continuous when the switch is
at PARK.
Note that there is no continuity (open circuit)
for any of the combinations of a colour differ-
ent from those mentioned and when the
switch is at OFF.
4. Check the switch component for continuity between “R” and “Br”.
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Control procedure:
•Repeatedly shift the switch key to the various
positions - ON, OFF and PARK.
•Shift the tester selector to “ Ωx1”.
•Connect the tester positive cable (+) to the
terminal of cable “R” of the connector, and the
negative cable (–) to cable terminal “Br”.
CAUTION
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