YAMAHA TT600RE 2004 Service Manual

ELECELECTRICAL STARTING SYSTEM
7-27
*
*
CORRECT
7. 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)
8. 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.


 






 


INCORRECT
The sidestand switch is defective. Replace.
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9. 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.
 

 


CORRECT
7-28
ELECELECTRICAL STARTING SYSTEM
INCORRECT
The start switch is defective. Replace the right
handlebar switch.
10. Start switch.
•Disconnect the start switch connector
from the harness.
•Connect the pocket tester ( Ωx 1) to the
handlebar switch terminal.
•Check the start switch component for con-
tinuity between “Blue/White (1)” and
“Black/Yellow (2)”.
Refer to “SWITCH CHECK” in Chapter 3.
CORRECT
 
! "



# 



*
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ELEC
7-29
ELECTRICAL STARTING SYSTEM
11. Harness connections.
Check the connections of the entire starter
system.
See the “ELECTRIC CIRCUIT DIAGRAM”.UNCERTAIN CONNECTIONS
Correct.
*
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ELECTRICAL STARTING SYSTEM
7-30
ELEC
STARTER MOTOR
(1) Brushes
(2) Armature
(3) Stator
(4) O-Ring BRUSH LENGHT LIMIT
5 mm (0.20 in)
COMMUTATOR WEAR LIMIT:
27 mm (1.06 in)
MICA UNDERCUT:
0.7 mm (0.027 in)
ARMATURE COIL RESISTANCE:
0.03 ~ 0.04 Ωat 20°C (68°F)
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ELECELECTRICAL STARTING SYSTEM
Removal
1. Remove:
•The starter motor Refer to the “ENGINE REMOVAL” sec-
tion in CHAPTER 5.
Inspection and repair
1. Inspect:
•Manifold Dirty ➔Clean with sandpaper no. 600.
2. Measure:
•Diameter of the commutator Out of specification ➔Replace the motor.
3. Measure:
•The mica undercut (b).
Out of specification ➔Level the undercut
to the correct value using a hacksaw.
Wear limit of commutator (a): 27 mm
Mica undercut (b):0.7 mm
NOTE:
The mica insulation of the commutator must have
an undercut to ensure proper functioning of the
commutator.
Disassembly
1. Remove:
•Circlip (1)
•Drive gear (2)
•Screws (3)
•Rear bracket (4)
•Washers (5)
•Brushes housing (6)
•Brushes (7)
•Front bracket (8)
•Washers (9)
•Armature (10)
•Stator (11)
7-31
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ELECTRICAL STARTING SYSTEM
7-32
ELEC
4. Inspect:
•Armature coils (insulation/continuity). Out of specification ➔Replace the
motor.
5. Measure:
•Brush lenght
Out of specification ➔Replace all brus-
hes at once.
6. Inspect:
•Brush spring strength
Worn out ➔Replace all springs at once.
7. Inspect:
•Bearings (1)
•Oil seal (2)
•O-Rings
•Bush (3)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
How to inspect the excitation coils:
•Connect the pocket tester and check continuity (1) and insulation (2).
•Check the armature resistance:
•If the resistance is not correct, replace
the starter motor.
Armature coil resistance: Continuity check (1):0 Ω at 20°C (68°F)
Insulation check (2): Over 1 M Ωat 20°C (68°F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Brush spring strength:
8.82 N (899 gf)
Brush lenght limit (a): 5.0 mm
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ELECELECTRICAL STARTING SYSTEM
7-33
Assembly
Revert the disassembly procedure.
Pay attention to the following points:
1. Install:
•Brush housing
2. Install:
•Stator (1)
•Front bracket (2)
NOTE:
Align the jutting surface on the brush housing with
the slot (2).
NOTE:
Align the reference marks (3) on the stator with
the corresponding reference marks on the cover
(4).
3. Install:
•Screws (1)
Installation
1. Install:
•Starter motor. Screw (stator):
7 Nm (0.7 kgm)
Screw (starter motor): 10 Nm (1.0 kgm)
NOTE:
Slightly grease the O-Ring (1)
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7-34
ELEC
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ELECCHARGING SYSTEM
7-35
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
CHARGING SYSTEM – CIRCUIT DIAGRAM
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CHARGING SYSTEM
7-36
ELEC
The diagram illustrates the charging 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
$%

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