clutch YAMAHA TT600RE 2004 Workshop Manual

DIFFICULTIES IN SHIFTING
8-4
TRBL
SHTG
?
Clutch
Engine oil PROBABLE CAUSES•Clutch cable wrongly set
•Wrong position of push lever
•Irregular engagement of push lever and push
rod
•Pressure plate deformed
•Clutch springs not preloaded uniformly
•Reference marks not aligned
•Push rod broken
•Clutch gear assy nut loose or push rod deformed
•Primary driven gear bearing defective
•Driven plates deformed
•Driving plates deformed
•Clutch cable damaged
•Oil level over maximum
•Incorrect gradation (high viscosity)
•Degradation
SHIFTING IMPOSSIBLE
DIFFICULTIES IN SHIFTING
Shift shaft
Shift cam, shift fork PROBABLE CAUSES•Shift shaft deformed
•Groove with impurities or foreign bodies
•Shift fork stuck
•Shift fork guide bar deformed
THE SHIFT PEDAL FAILS TO MOVE
Transmission•Transmission gears struck
•Gears stuck by impurities or foreign bodies
•Wrong transmission assembly
Shift shaft
Shift fork PROBABLE CAUSES•Shift lever set wrongly
•Shift cam
stop lever fails to return freely
•Shift forks worn
Transmission
•Gear clutches worn
DISENGAGING GEARS
Shift cam
•Shaft cam with thrust free play
•Shift cam groove worn
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CLUTCH SLIDES OR FAILS TO RELEASE
8-5
TRBL
SHTG
?
Clutch
Engine oil PROBABLE CAUSES•Clutch cable wrongly set
•Clutch springs loose
•Clutch spring yielded
•Friction plates worn
•Clutch plates worn
•Clutch improperly assembled
•Oil level below minimum
•Incorrect gradation (low viscosity)
•Degradation
CLUTCH SLIDES
CLUTCH SLIDES OR FAILS TO RELEASE
Refer to “SHIFTING IMPOSSIBLE” section.
CLUTCH FAILS TO RELEASE
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TT600RE WIRING DIAGRAM
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
Br
187
GB
12V10W
BL12V5WB
Y G
12V60/55WBGYA
A
12V10W
A
GB
BrBBrB
B
GBB
GBB
GBB
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 SbB
RW
-
LR
L
BrL
GBSbB
BrB
YBrBrB
YBrGB
B
Ch
DgBrY
BrB
HIGH
TURN
NEU.ILL.
B
BrL
BrL
LB
BY
LY
LB
LYGW
B
RBOr
205
B
RBLBrL
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 BBrWBrL
BrB
Y
N
RL
LOWHIGH
BrW BrWBr
PPBr
LY
B
GWLY
Or
RBBr
LW
BY
BY
START
OFF
R
B
GWLY
W
W
W
W
W
W
WRW
W
W
Sb
B
Sb
B
BrBB
-
-
B
LR
WRW
B
-
A
L
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
64
28
20
21
22
19
2325
24
30
31
27
267
32
18
ELECTRICAL SYSTEM
DIAGRAM1 AC generator/Pickup coil
2 Rectifier/Regulator
3 Battery
4 Starter relay
5 Starting motor
6 Fuse
7 Main switch
8 Right handlebar switch
9 Engine stop switch
0 Starter switch
q Diode
w Clutch switch
e Sidestand switch
r Neutral switch
t Diode
y Ignitor unit
u Ignition coil
i Left handlebar switch
o Horn switch
p Diode
a Pass switch
s Dimmer switch
d Flasher switch
f Horn
g Flasher relay
h Headlight
j Flasher light
k Relay assy
l Front brake switch
; Rear brake switch
z Tail/stop light
x Meter
COLOR CODE
B ...........Black
Br ..........Brown
Ch .........Chocolate
Dg .........Dark green
G...........Green Gy .........Gray
L............Blue
Lg..........Light green
O...........Orange
P ...........Pink R...........Red
Sb .........Sky blue
W..........White
Y ...........Yellow
B/L ........Black/Blue B/W.......Black/White
B/Y........Black/Yellow
Br/B.......Brown/Black
Br/L .......Brown/Blue
Br/W......Brown/White Br/Y.......Brown/Yellow
L/B ........Blue/Black
L/R ........Blue/Red
L/W .......Blue/White
L/Y ........Blue/Yellow R/B........Red/Black
R/G .......Red/Green
R/W.......Red/White
R/Y........Red/Yellow
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