clutch YAMAHA TT600RE 2004 Workshop Manual

ELECTRICAL COMPONENTS
7-4
ELEC
IGNITION COIL: Primary winding resistance: 4 Ω
Ω
± 15% at 20°C (68°F)
Secondary winding resistance: 13 k Ω
Ω
± 20% at 20°C (68°F)(1) Ignition coil
(2) Spark plug cap
(3) Flasher relay
(4) Horn
(5) Clutch switch
(6) Relay assy
(7) Sidestand switch
(8) Neutral switch
(9) Main switch
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IGNITION SYSTEM
7-12
ELEC
The diagram illustrates the ignition 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
(7) Main switch
(9) Engine stop switch
(11) Diode (12) Clutch switch
(13) Sidestand switch
(14) Neutral switch
(15) Diode
(16) Ignitor unit
(17) Ignition coil

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ELECIGNITION SYSTEM
7-13
DIAGNOSTICS IF THE IGNITION SYSTEM WERE TO STOP WORKING (NO OR INTERMITTENT SPARK)
Procedure
Check:
1. Fuse
2. Battery
3. Spark plug
4. Amplitude of ignition spark
5. Spark plug cap resistance
6. Ignition winding resistance 7. Main switch
8. Engine stop switch
9. Sidestand switch
10. Neutral switch
11. Clutch switch
12. Pick-up coil resistance
13. Wiring connections (whole connection sys- tem)
NOTE:
Before making the inspections mentioned, remove the following parts:
1. Seat
2. Rear cowling 3. Fuel tank
4. Cowling (headlight)
•To check functioning defects use the following special tools.
Dinamic spark tester: P/N. 90890-06754
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:
2.8 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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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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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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12
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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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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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TRBL
SHTG
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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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FAILURE TO START/
DIFFICULTIES IN STARTING
8-2
TRBL
SHTG
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Spark plug
Ignition coil
Ignition unit
Switches and cables PROBABLE CAUSES•Electrodes gap not correct
•Electrodes worn
•Feed cable interrupted
•Wrong thermal grading of spark plug
•Defective spark plug cap
•Primary or secondary winding interrupted
•High voltage cable defective
•Defective coil
•Defective unit
•Defective pick-up coil
•Woodruff key broken
Starter motor
•Starter motor defective
•Starter motor relay defective
•Diodes defectives
•Starter one-way bearing defective
•Main switch defective
•Emergency stop engine switch defective
•Harness with cable interrupted
•Neutral switch defective
•Sidestand switch defective
•Clutch switch defective
•Starter switch defective
ELECTRICAL SYSTEM
Cylinder and cylinder head
Piston and piston rings
Crankcase and valves, crankshaft PROBABLE CAUSES
•Spark plug tightening insufficiently
•Cylinder head or cylinder insufficiently tightened
•Cylinder head gasket broken
•Cylinder gasket broken
•Cylinder worn, damaged or seized
•Piston rings wrongly assembled
•Piston rings worn, yielded or broken
•Piston rings stuck together
•Piston seized or damaged
•Poor crankcase sealing
•Crankshaft oil seal edge damaged
•Poor valve sealing
•Valve and seat with insufficient contact
•Valve timing wrongly
•Valve spring broken
•Crankshaft seized
•Camshaft seized
POOR ENGINE COMPRESSION
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