YAMAHA TT600RE 2004 Service Manual

ELECSWITCH CHECK
7-7




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NOTE:
Use the thin tester terminals to check continuity,
as the terminals might come into contact with oth-
ers inside the connector.
•Check continuity between “R” and “Br” at
switch positions ON (1), OFF (2) and PARK (3).
There must be continuity (ie the tester must
show “0”) at ON and there must be no continu-
ity (ie the tester must show “ ∞” ) at OFF and
PARK. Something is not working between “R
and Br” if there is no continuity between these
two points at position ON, or if there is some
continuity in one of the other positions OFF or
PARK.
NOTE:
Check switch continuity various times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Continue to check continuity between “R” and “L” and “L” and “Br” in the respective switch
positions in the manner described above.
6. If anything wrong is noted in any of the com- binations, replace the switch component.
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LIGHT INSPECTION
7-8
ELEC
LIGHT INSPECTION (HEADLIGHTS,
TAIL LIGHT AND BRAKE LIGHTS,
DIRECTION INDICATOR LIGHTS,
INSTRUMENT LIGHTS, ETC)
Check the continuity between the bulb terminals to
see that they are undamaged.
BULB TYPES
The bulbs used are classified as shown to the left
according to type of attachment.
(B) is H4 type halogen bulb (12V - 55/60W) and it
is used for headlight.
Avoid touching the glass part of a bulb. Keep it
free from oil; otherwise, the transparency of
the glass, life of the bulb, and luminous flux will
be adversely affected. If oil gets on a bulb,
thoroughly clean it with a cloth moistened with
alcohol or lacquer thinner.
(A) and (C) are used mainly for headlights.
(D) is used mainly for direction indicator lights and
the rear and braking lights.
(E) and (F) are used especially for instrument and
other indication lights.
BULB INSPECTION
1. Remove the bulb.
NOTE:
•Bulbs of type (B) and (C) use special supports
(bulbholders). Remove the bulbholder before
removing the bulb. Most of these bulbholders
may be removed by turning in an anticlockwise
direction.
•Most bulbs of type (A), (D) and (E) may be
removed from their housing by pushing them
and turning them in an anticlockwise direction.
•Bulbs of type (F) may be removed simply by
pulling them out.
CAUTION:
A
F
CB
ED
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ELECLIGHT INSPECTION
7-9
When removing a bulb be careful to hold the
bulbholder or its housing firmly. Never pull the
cable, as it might detach from the terminal
inside the connector.
CAUTION:
WARNING
Keep inflammable products and hands well
away from bulbs when they are on (danger of
burns and fire). Do not touch the bulb before it
is cool.
2. Check the continuity between the bulb termi- nals.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Control procedure:
•Set the tester selector to Ωx 1”.
•Connect the tester terminals to the bulb pins.
Take, for example, a three pin bulb as shown
in the figure. First check continuity between
pins (1) and (2), connecting tester terminal (+)
to pin (1) and terminal (–) to pole (2). Then
check the continuity between poles (1) and
(3), again connecting tester terminal (+) to
pole (1), and terminal (–) to pole (3). If the
tester indicates “ ∞”, even in one case only, the
bulb must be replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. . Check the bulb attachment by installing a test bulb. Furthermore, during inspection of
the bulbs, connect the tester terminals to the
respective socket cables and check continuity
as described.
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7-10
ELEC
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ELECIGNITION SYSTEM
7-11
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
IGNITION SYSTEM -CIRCUIT DIAGRAM
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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
7-15
IN COMPLIANCE
WITH SPECIFICATIONS
5. Spark plug cap resistance.
•Remove the spark plug cap.
•Connect the pocket tester ( Ωx 1k) to the
spark plug cap.
•Check that the spark plug cap has the
specified resistance.
OUT OF SPECIFICATION
The spark plug cap is defective.
Replace.
Resistance of spark plug cap: 10 k Ωat 20°C (68°F)
6. Ignition winding resistance.
•Disconnect the ignition coil cables from
the wire harness.
•Connect the pocket tester ( Ωx 1) to the
ignition coil.
Tester terminal (+) ➔Pole (+)
Tester terminal (–) ➔Pole (–)
•Check that the primary coil has the speci-
fied resistance.
*
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IGNITION SYSTEM
7-16
ELEC
•Connect the pocket tester ( Ωx 1) to the
ignition coil.
Tester terminal (+) ➔Spark plug cable (1)
Tester terminal (–) ➔Pole (+)
•Check that the secondary coil has the
specified resistance
Secondary winding resistance: 13 k Ω ±
±

20% at 20°C (68°F)
(Spark plug cable – Terminal (–))
BOTH RESISTANCE
VALUES ARE CORRECT
OUT OF SPECIFICATION
The ignition coil is defective.
Replace.
*
Primary winding resistance: 4 Ω ±
±
15% at 20°C (68°F)
(Terminal (+) – Terminal (–))
7. 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.





 


  
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