YAMAHA TT600RE 2004 Service Manual

ELECIGNITION SYSTEM
7-17
*
CORRECT
8. 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)
CORRECT
INCORRECT
The emergency stop engine switch is defective.
Replace the right handlebar switch.
INCORRECT
The sidestand switch is defective. Replace.
*
9. 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)





 
 



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IGNITION SYSTEM
7-18
ELEC
*
10. 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.
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11. 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.
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*
CORRECT
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ELECIGNITION SYSTEM
7-19
*
12. Pick-up coil resistance.
•Disconnect the generator connector
(Green/White and Blue/Yellow).
•Connect the pocket tester ( Ωx 100) to
pick-up coil cables.
Tester terminal (+) ➔
Blue/Yellow cable (1)
Tester terminal (–) ➔
Green/White cable (2)
•Check that the pick-up coil resistance is as
specified.
Pick-up coil resistance: 230 Ω ±
±
20% at 20°C (68°F)
(Green/White - Blue/Yellow)
COMPLY WITH
SPECIFICATIONS
CORRECT
OUT OF SPECIFICATIONS
The pick-up coil is defective. Replace.
UNCERTAIN CONNECTIONS Correct.13. Wiring connections.
Check the connections of the entire ignition
system. Refer to “ELECTRICAL CIRCUIT
DIAGRAM” section.
The CDI unit is defective. Replace.
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7-20
ELEC
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ELECELECTRICAL STARTING SYSTEM
7-21
467C4B5CAMP403D494A4856 172320-2
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TURN
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MAIN HARNESS
AHEAD LIGHT
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17
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ELECTRICAL STARTING SYSTEM - CIRCUIT DIAGRAM
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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
4
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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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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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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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