YAMAHA TT600RE 2004 Service Manual

ELECLIGHT SYSTEM
7-47
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
bulbholder connector.
Tester terminal (+) ➔Blue cable (1)
Tester terminal (–) ➔Black cable (2)
•Turn the main switch to ON.
•Check the voltage (12V) on the “Blue”
cable of the bulbholder connector.
OUT OF SPECIFICATION
The circuit from the main switch to the bulbhol-
der connector is defective. Repair.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
•Turn the main switch to ON.
•Turn the lights switch to “LO” or “HI”.
•Check the voltage (12V) on the “Green”
and “Yellow” cable at the bulbholder ter-
minals.
The circuit is efficient.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
The circuit is efficient.
2. The instrument light and/or the parking indica- tor light fails to turn on.
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LIGHT SYSTEM
7-48
ELEC
CONTINUITY
DISCONTINUITY Replace the bulb and/or 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
bulbholder connector.
Tester terminal (+) ➔Blue terminal (1)
Tester terminal (–) ➔Black terminal (2)
•Turn the main switch to ON.
•Check the voltage (12V) on the “Blue”
cable of the bulbholder connector.
OUT OF SPECIFICATION
The circuit from the main switch to the bulbhol-
der connector is defective. Repair.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
The circuit is efficient.
3. The parking light fails to turn on.
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ELECLIGHT SYSTEM
7-49
CONTINUITY
DISCONTINUITY Replace the bulb and/or 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
bulbholder connector.
Tester terminal (+) ➔Blue terminal (1)
Tester terminal (–) ➔Black terminal (2)
•Turn the main switch to ON.
•Check the voltage (12V) on the “Blue”
cable of the bulbholder connector.
OUT OF SPECIFICATION
The circuit from the main switch to the bulbhol-
der connector is defective. Repair.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
The circuit is efficient.
4. The rear light fails to turn on.
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7-50
ELEC
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ELECSIGNAL SYSTEM
7-51
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GWLY
BB
B
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B
B
B
RLBOrRBLYGW
Or
B
LW
MAIN HARNESSB
B
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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
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205
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RBL
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Sb
L
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GY

G
Y
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LYBY
RUN
LW
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B
LY
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LWRB
GB
R
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BrBrW
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Br
LY
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Sb
B
GWLY
(BLUE)B
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-
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WRW
B
-
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L
GY
LB
Br
WB
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MAIN HARNESS
AHEAD LIGHT
B
B
BrB
17
16
11
12
13
14
15
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8
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12
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20
21
22
19
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31
27
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BrW
SIGNAL SYSTEM - CIRCUIT DIAGRAM
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SIGNAL SYSTEM
7-52
ELEC
The diagram shows the signal 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
(11) Diode
(14) Neutral switch
(15) Diode
(18) Left handlebar switch
(19) Horn switch (23) Flasher switch
(24) Horn
(25) Flasher relay
(27) Flasher light
(29) Front brake switch
(30) Rear brake switch
(31) Tail/stop light
(32) Meter
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ELECSIGNAL SYSTEM
7-53
DIAGNOSTICS
•THE FLASHER LIGHTS, BRAKE LIGHT AND/OR WARNING LIGHTS FAIL TO TURN ON.
•THE HORN FAILS TO SOUND.
Procedure
Check:
1. Fuse
2. Battery
3. Main switch
4. Harness connections (entire system of con- nections)
NOTE:
•Before starting inspections, remove the following parts:
1. Seat
2. Rear cowling
3. Cowling (headlight)
4. Tail light cover
•To check for operating faults 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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SIGNAL SYSTEM
7-54
ELEC
*
3. Main switch.
•Disconnect the main switch connector
(Blue, Red and Brown) from the wire har-
ness.
•Connect the pocket tester ( Ωx 1) to the
main switch cables. Refer to “SWITCH CHECK” section.
Tester terminal (+) ➔Red cable (1)
Tester terminal (–) ➔Brown cable (2)
Tester terminal (–) ➔Blue cable (3)
CORRECT
DISCONTINUITY
The main switch is defective. Replace.
CORRECT
UNCERTAIN CONNECTIONS Repair.4. Harness connections
•Check the connections of the entire signal
system.
Check the condition of each signal system.
Refer to “ELECTRICAL CIRCUIT DIAGRAM”
section.










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ELECSIGNAL SYSTEM
7-55
SIGNAL SYSTEM CONTROL
1. The horn does not work.
1. Horn switch.
•Disconnect the left handlebar switch con-
nector from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
switch terminals.
•Check the switch component for conti-
nuity between “Pink (1)” and “Black (2)”. Refer to “SWITCH CHECK” section.
CORRECT
DISCONTINUITY
The horn switch is defective. Replace the left
handlebar switch.
2. Voltage.
•Connect the pocket tester (DC 20V) to the
horn cable.
Tester terminal (+) ➔Brown terminal (1)
Tester terminal (–) ➔Earth
•Turn the main switch to ON.
•Check the voltage (12V) on the “Brown”
terminal of the horn.
OUT OF SPECIFICATIONS
The circuit from the main switch to the horn ter-
minal is defective. Repair.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
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*
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SIGNAL SYSTEM
7-56
ELEC
3. Horn.
•Disconnect the “Pink” cable from horn ter-
minal.
•Connect a special cable (1) to the horn
terminal and earth the cable.
•Turn the main switch to ON.
THE HORN DOES
NOT WORK
THE HORN WORKS
The horn is efficient.
4. Voltage.
•Connect the pocket tester (DC 20V) to the
“Pink” terminal of the horn.
Tester terminal (+) ➔Pink cable (1)
Tester terminal (–) ➔Earth
•Turn the main switch to ON.
•Check the voltage (12V) on the “Pink” ter-
minal of the horn.
OUT OF SPECIFICATION
The horn is defective. Repair.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
*
Repair or replace the horn.
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