lights YAMAHA TT600RE 2004 Service Manual

SPECMAINTENANCE SPECIFICATIONS
2-15
Tightening
Part to be tightened Thread torque
Remarkssize
N·mm·kg
Front brake:
Front hub/Disc brake M6 x 1.0 12 1.2
Front caliper/Front fork M8 x 1.25 25 2.5
Front caliper/Bleeder tightening M10 x 1.0 14 1.4
Union bolt tightening (front) M10 x 1.0 20 2.0
Rear brake:
Rear hub/Disc brake M6 x 1.0 12 1.2
Rear master cylinder/Frame M6 x 1.0 10 1.0
Rear stop switch/Rear master cylinder M10 x 1.0 20 2.0
Rear caliper/Bleeder tightening M10 x 1.0 14 1.4
Protector rear caliper/Rear caliper M6 x 1.0 10 1.0
Union bolt tightening (rear) M10 x 1.0 20 2.0
Rear brake tank reserve/Air cleaner assy M6 x 1.0 5 0.5
Brake pedal/Frame M10 x 1.25 48 4.8
Sidestand/Footrest:
Sidestand mounting bolt/Frame M12 x 1.25 40 4.0
Sidestand mounting bolt/Nut M12 x 1.25 40 4.0
Sidestand switch/Frame M5 x 0.8 8 0.8
Rear footrest/Rear frame M8 x 1.25 30 3.0
Bracket 1 (main footrest)/Frame M10 x 1.25 48 4.8
Bracket 2 (main footrest)/Frame M10 x 1.25 48 4.8
Footrest cover/Footrest M6 x 1.0 10 1.0
Seat, fuel tank and oil tank:
Seat/Frame M6 x 1.0 10 1.0
Bolt (guide seat)/Fuel tank M6 x 1.0 5 0.5
Fuel tank/Rear frame M6 x 1.0 12 1.2
Damper fuel tank (front)/Frame M8 x 1.25 15 1.5
Fuel tank/Fuel cock M6 x 1.0 7 0.7
Oil tank/Sub-oil tank M6 x 1.0 7 0.7
Union bolt (oil hose 2)/Oil tank assy/Engine M12 x 1.25 35 3.5
Oil hose 1/Oil tank/Engine M6 x 1.0 10 1.0
Oil tank/Rear frame M12 x 1.5 20 2.0
Frame, rear fender compl. and lights:
Rear fender compl. (under)/Rear frame M6 x 1.0 2 0.2
Rear fender compl. (upper)/Rear frame M6 x 1.0 7 0.7
Bracket, license/Rear frame M6 x 1.0 10 1.0
Bracket, license/Rear flasher M6 x 1.0 10 1.0
Horn/Frame M6 x 1.0 13 1.3
Regulator/Frame M8 x 1.25 7 0.7
Igniton coil/Frame M5 x 0.8 13 1.3
Battery box/Rear frame M6 x 1.0 7 0.7
Igniter cover/Battery box M4 1 0.1
Main switch/Frame M24 x 1.0 1 0.1
Tail light (lense)/Rear fender compl. M3.5 1 0.1
Starter switch/Red wire M6 x 1.0 7 0.7
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SPECMAINTENANCE SPECIFICATIONS
2-16
Tightening
Part to be tightened Thread torque
Remarkssize
N·mm·kg
Starting motor cord/Starting motor M6 x 1.0 11 1.1
Wire minus lead (-)/Starting motor M6 x 1.0 10 1.0
Front flasher lights/Stay, headlight M6 x 1.0 1.5 0.15
Clutch wire/Engine M6 x 1.0 7 0.7
Assist grip (Standing handle)/Rear frame M8 x 1.25 23 2.3
Speedometer M5 x 0.8 4 0.4
Air filter case 1/Air filter case 2 (L = 13 mm) M3.9 0.5 0.05
Air filter case 1/Air filter case 2 (L = 19 mm) M3.9 1 0.1
Hose clamp/Joint, carburator M4 x 0.7 0.6 0.06
Hose clamp/Air cleaner/Carburator M5 x 0.8 0.8 0.08
Battery (+)/(-) M6 x 1.0 2.5 0.25
NOTE:
1. First tighten the ring nut approximately 38 Nm (3.8 mkg) by using the torque wrench, then loosen the
ring nut one turn.
2. Final tighten the ring nut at the torque of 4 Nm (0.4 mkg).
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INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
3-2
INSP
ADJ
ODOMETER READING (x 1,000 km)
ANNUAL N0. ITEM CHECK OR MAINTENANCE JOB
110 2030 40CHECK
18 * Rear brake• Check operation, fluid level and vehicle for fluid leakage. ✓✓✓ ✓
Rear shock
• Check operation and shock absorber for oil leakage.
19
*absorber ✓✓✓ ✓
assemblysull’ammortizzatore.
Rear suspension
• Check operation.
✓✓✓ ✓
20*
relay arm and
connecting arm
• Lubricate with lithium-soap-based grease.
✓✓
pivoting points
• Check starter (choke) operation.
21 * Carburator
• Adjust engine idling speed.✓✓ ✓✓ ✓ ✓
22 Engine oil• Change.
✓✓ ✓✓ ✓ ✓
• Check oil level and oil leakage.
23Engine oil filter
• Replace.✓✓✓
element
24 *Front and rear •
brake switches• Check operation.✓✓ ✓✓ ✓ ✓
Moving parts
25
and cables• Lubricate. ✓✓✓ ✓ ✓
Throttle grip • Check operation and free play.
26 * housing and • Adjust the throttle cable free play if necessary.
✓✓✓ ✓ ✓
cable • Lubricate the throttle grip housing and cable.
27 *Muffler and
• Check the screw clamp for looseness. ✓
exhaust pipe
28 *Lights, signals • Check operation.
✓✓ ✓✓ ✓ ✓
and switches• Adjust headlight beam.
* Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance is per-
formed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake system:
• Check the brake fluid level regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
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ELEC
CHAPTER 7
ELECTRICAL
ELECTRICAL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
COLOUR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
SWITCH CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
MAIN SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
LIGHT INSPECTION (HEADLIGHTS, TAIL LIGHT AND BRAKE LIGHTS,
DIRECTION INDICATOR LIGHTS, INSTRUMENT LIGHTS, ETC) . . . . . . . . . . . . . . . . . 7-8
BULB TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
BULB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
ELECTRICAL STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
STARTING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
LIGHT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
LIGHT SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46
SIGNALLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
SIGNAL SYSTEM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
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LIGHT INSPECTION
7-8
ELEC
LIGHT INSPECTION (HEADLIGHTS,
TAIL LIGHT AND BRAKE LIGHTS,
DIRECTION INDICATOR LIGHTS,
INSTRUMENT LIGHTS, ETC)
Check the continuity between the bulb terminals to
see that they are undamaged.
BULB TYPES
The bulbs used are classified as shown to the left
according to type of attachment.
(B) is H4 type halogen bulb (12V - 55/60W) and it
is used for headlight.
Avoid touching the glass part of a bulb. Keep it
free from oil; otherwise, the transparency of
the glass, life of the bulb, and luminous flux will
be adversely affected. If oil gets on a bulb,
thoroughly clean it with a cloth moistened with
alcohol or lacquer thinner.
(A) and (C) are used mainly for headlights.
(D) is used mainly for direction indicator lights and
the rear and braking lights.
(E) and (F) are used especially for instrument and
other indication lights.
BULB INSPECTION
1. Remove the bulb.
NOTE:
•Bulbs of type (B) and (C) use special supports
(bulbholders). Remove the bulbholder before
removing the bulb. Most of these bulbholders
may be removed by turning in an anticlockwise
direction.
•Most bulbs of type (A), (D) and (E) may be
removed from their housing by pushing them
and turning them in an anticlockwise direction.
•Bulbs of type (F) may be removed simply by
pulling them out.
CAUTION:
A
F
CB
ED
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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
7-46
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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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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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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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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