YAMAHA TT600RE 2004 Service Manual

ELECSIGNAL SYSTEM
7-57
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. The rear stop light fails to turn on.
2. Brake switch.
•Disconnect the brake switch cables and
the connector from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
brake switch terminals.
•Check the switch component for conti-
nuity between “Green/Yellow (1)” and
“Brown (2)”, or “Black (3)” and “Black (4)”. Refer to “SWITCH CHECK” section.
[A] Front brake switch
[B] Rear brake switch
INCORRECT
The brake switch is defective. Replace.
*
ON (Step down)
OFF (Free) BB
BB
G/Y Br
34
2
G/Y RW
1
ON (Pull in) OFF (Free)
G/Y
Br
A
B
Br
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SIGNAL SYSTEM
7-58
ELEC
3. Voltage.
•Connect the pocket tester (DC 20V) to the
bulbholder connector.
Tester terminal (+) ➔Green/Yellow cable (1)
Tester terminal (–) ➔Black terminal (2)
•Turn the main switch to ON.
•The brake lever is pulled or the brake
pedal is pressed.
•Check the voltage (12V) on the
“Green/Yellow” 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.
CONTINUITY
DISCONTINUITY
Replace the bulb and/or bulbholder.
3. The direction indicator light and/or the direc- tion indicator light fail to flash.
1. Bulb and bulbholder.
•Check the continuity of the bulb and bulb-
holder.
Refer to “BULB INSPECTION” section.
2. Direction indicator switch.
•Disconnect the left handlebar switch con-
nector from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
left handlebar switch cables.
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ELECSIGNAL SYSTEM
7-59
•Check the switch component for conti-
nuity between “Brown/White (1)” and
“Brown/Black (2)” and “Brown/White (1)”
and “Green/Black (3)”.
Refer to “SWITCH CHECK” section.
CORRECT
3. Direction indicator lamp relay.
•Connect the pocket tester (DC 20V) to the
indicator lamp relay.
Tester terminal (+) ➔Brown terminal (1)
Tester terminal (–) ➔Earth
•Turn the main switch to ON.
•Check the voltage (12V) on the “Brown”
cable to the indicator lamp relay terminal.
OUT OF SPECIFICATION
The circuit from the main switch to the lamp re-
lay connector is defective. Repair.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
*



 








\f
INCORRECT
The direction indicator switch is defective.
Replace.
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SIGNAL SYSTEM
7-60
ELEC
OUT OF SPECIFICATION The direction indicator lamp relay is defective.
Replace.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
* *
4. Voltage.
•Connect the pocket tester (DC 20V) to the
bulbholder connector.
Tester terminal (+) ➔
Brown/White terminal (1)
Tester terminal (–) ➔Earth
•Turn the main switch to ON.
•Check the voltage (12V) on the “Blue”
cable to the bulbholder connector.
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ELECSIGNAL SYSTEM
7-61
5. Voltage.
•Connect the pocket tester (DC 20V) to the
bulbholder connector.
•Connect the left handlebar switch connec-
tor to the wire harness.
To the left flasher light:
Tester terminal (+) ➔
Green/Black terminal (1)
Tester terminal (–) ➔Earth
To the right flasher light:
Tester terminal (+) ➔
Brown/Black terminal (1)
Tester terminal (–) ➔Earth
•Turn the main switch to ON.
•Turn the direction indicator switch to “L” or
“R”.
•Check the voltage (it flashes at 2-8V) on
the “Green/Black” or “Brown/Black” cable
at the bulbholder connector.
OUT OF SPECIFICATION
The circuit from the direction indicator switch to
the bulbholder is defective. Repair.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
The circuit is efficient.
*
GBBrB
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SIGNAL SYSTEM
7-62
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. Neutral switch.
•Disconnect the neutral switch cable from
the wire harness.
•Connect the pocket tester ( Ωx 1) to the
neutral switch cables.
•Check the switch component for continuity
between “Sky blue (1)” and “earth”.
Refer to “SWITCH CHECK” section.
INCORRECT
The neutral switch is defective. Replace.
CORRECT
4. The “N” neutral light fails to turn on.
3. Voltage.
•Connect the pocket tester (DC 20V) to the
bulbholder connector.
Tester terminal (+) ➔Brown cable (1)
Tester terminal (–) ➔Earth





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ELECSIGNAL SYSTEM
7-63
The circuit is efficient.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
OUT OF SPECIFICATION
The circuit from the main switch to the bulbhol-
der connector is defective. Repair.•Turn the main switch to ON.
•Check the voltage (12V) on the Brown ca-
ble of the bulbholder connector.
4. Neutral switch cable.
•Disconnect the neutral switch connector
from the wire harness and the bulbholder
connector.
•Connect the pocket tester ( Ωx 1) to the
neutral switch cable (on the harness side)
and the bulbholder connector (1).
DISCONTINUITY
The circuit from the bulb to the neutral switch
cable is defective. Repair.
CONTINUITY
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7-64
ELEC
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8
TRBL
SHTG
?
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TRBL
SHTG
?
CHAPTER 8°
TROUBLESHOOTING
FAILURE TO START/DIFFICULTIES IN STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
POOR ENGINE COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
POOR PERFORMANCE AT IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED . . . . . . . . . . . . . . . . . 8-3
DIFFICULTIES IN SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
SHIFTING IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
THE SHIFT PEDAL FAILS TO MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
DISENGAGING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
CLUTCH SLIDES OR FAILS TO RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CLUTCH SLIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CLUTCH FAILS TO RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
DEFECTIVE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
POOR BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
OIL LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
MALFUNCTIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
UNSTABLE STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . 8-8
POOR HEADLIGHT ILLUMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
FREQUENT BURNING OF BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DIRECTION INDICATORS FAIL TO TURN ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DIRECTION INDICATORS FAIL TO TURN OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DELAYED TURNING ON OF INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
EXCESSIVE INDICATOR INTERMITTENCE FREQUENCY . . . . . . . . . . . . . . . . . . . 8-9
THE HORN FAILS TO WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
OVERHEATING OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
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