YAMAHA TT600RE 2004 Service Manual

ELECCHARGING SYSTEM
7-37
DIAGNOSTICS THE BATTERY IS NOT BEING CHARGED
Procedure
Inspect:
1. Fuse
2. Battery
3. Charging voltage 4. Stator winding resistance
5. Harness connection (whole connection system)
NOTE:
Before starting inspections, remove the following parts: 1. Seat
2. Rear cowling
•To check for defects use the following special tools.
Inductive rev counter: P/N. 90890-03113
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:
12.8 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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CHARGING SYSTEM
7-38
ELEC
3. Charging voltage
•Connect the inductive rev counter to the
spark plug cable.
•Connect the pocket tester (DC 20V) to the
battery, as shown.
Tester terminal (+) ➔ Battery terminal (+)
Tester terminal (-) ➔Battery terminal (-)
•Start the engine and rev to about 5,000 rpm.
•Check the charging voltage.
Charging voltage:
14.0V at 5,000 rpm
4. Stator coil resistance.
•Disconnect the AC generator connector
from the harness.
•Connect the pocket tester ( Ωx 1) to the sta-
tor coils.
Stator coils (1)
Tester terminal (+) ➔White cable (1)
Tester terminal (-) ➔White cable (2))
*
NOTE:
Use a fully charged battery.
OUT OF SPECIFICATIONS
IN COMPLIANCE WITH
SPECIFICATIONS
Replace the battery.
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ELECCHARGING SYSTEM
7-39
CORRECT
IN COMPLIANCE
WITH SPECIFICATIONS
OUT OF SPECIFICATIONS
Stator winding is defective. Replace.
UNCERTAIN CONNECTIONS Correct.
Stator coils (2)
Tester terminal (+) ➔White cable (1)
Tester terminal (-) ➔White cable (3)
•Check that the winding resistance of the
stator complies with specifications.
Stator coil resistance: White (1) – White (2)
0.65 Ω± 20% at 20°C (68°F)
White (1) – White (3) 0.65 Ω± 20% at 20°C (68°F)


$

5. Wiring connections.
•Check the connections of the entire char-
ging system.
Refer to “ELECTRICAL CIRCUIT DIA-
GRAM” section.
The rectifier/regulator is defective. Replace.
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ELEC
7-40
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ELECLIGHT SYSTEM
7-41
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
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B
L
GB
BrB
LR
LR Sb
B
RW
-
LR
L
BrL
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BrB
YBrBrB
YBrGB
B
Ch
DgBrY
BrB
HIGH
TURN
NEU.ILL.
B
BrL
BrL
LBBY
LY LB
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205
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RBL
BrL
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PARKOFFON
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ON
Sb
L
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G
Y
RBLYBY
LYBY
RUN
LW
B
B
LY
BY
LBrRR
LWRB
GB
R
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GW
BrBrW
WB
Br
LY
WB
Sb
B
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-
-
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WRW
B
-
AL
L
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Br
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MAIN HARNESS
AHEAD LIGHT
B
B
BrB
17
16
11
12
13
14
15
91029
8
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6428
20
21
22
19
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24
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31
27
267
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18
BrW
LIGHT SYSTEM - CIRCUIT DIAGRAM
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LIGHT SYSTEM
7-42
ELEC
The diagram shows the light system circuit inside the electric system of the motorcycle. NOTE:
For the colour codes and complete legend, see page 7-2.
(3) Battery
(6) Fuse
(7) Main switch
(18) Left handlebar switch
(20) Diode
(21) Pass switch
3631
222118
26
28
20
$
&
(22) Dimmer switch
(26) Headlight
(28) Relay assy
(31) Tail/stop light
(32) Meter
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ELECLIGHT SYSTEM
7-43
DIAGNOSTICS THE HIGH BEAM LIGHT, PARKING INDICATOR LIGHT, REAR LIGHT, FRONT PARKING LIGHT AND/OR INSTRUMENT LIGHTS FAIL TO TURN ON.
Procedure
Inspect:
1. Fuse
2. Battery
3. Main switch 4. Dipped/high beam light and dimmer switch
5. Relay assy
6. Harness connections (full system of connec- tions)
NOTE:
•Before starting inspections, remove the following parts:
1. Seat
2. Rear cowling
3. Cowling (headlight)
4. Tail light cover
•To check for defects use the following special tools.
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:
12.8 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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LIGHT SYSTEM
7-44
ELEC
3. Main switch.
•Disconnect the main switch connector
from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
switch cables.
Refer to “SWITCH CHECK” in CHAPTER
3.
CORRECT
INCORRECT
The main switch is defective. Replace.










*
4. Dipped/high beam commutator and dim-
mer switch.
•Disconnect the left handlebar switch con-
nector from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
left handlebar switch terminals.
•Check the switch component for conti-
nuity between “Brown (1)” and “Yellow
(2)”, “Brown/Blue (3)” and “Green (4)”,
“Brown/Blue (3)” and “Yellow (2)”.
Refer to “SWITCH CHECK” in CHAPTER
3.
INCORRECT
The dipped/high beam commutator and/or the
dimmer switch are defective. Replace the left
handlebar switch.
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CORRECT
*
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ELECLIGHT SYSTEM
7-45
*
CORRECT
DEFECTIVE CONNECTIONS Repair.6. Harness connections.
•Check the connections of the entire light
system.
Check the conditions of each circuit for the
entire light system.
See the “ELECTRIC CIRCUIT DIAGRAM”.
5. Starter circuit cut-off relay.
•Connect the pocket tester (DC 20V) and
the battery (12V) to the cut-off relay con-
nector terminal of the starter circuit.
Battery terminal (+) ➔
White/Black terminal (1)
Battery terminal (–) ➔Black terminal (2)
Tester terminal (+) ➔Brown terminal (3)
Tester terminal (–) ➔Earth
DISCONTINUITY
The starter circuit cut-off relay is defective.
Replace.
•Turn the main switch to ON.
•Check the voltage (12V) on the
“Brown/Blue” and “Brown” cable to the
connector terminal of the starter circuit
cut-off relay.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
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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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