low beam YAMAHA TT600RE 2004 Service Manual

CHECKING THE FUSES/
REPLACING THE HEADLIGHT BULBS
3-54
INSP
ADJ
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or using
a fuse with the wrong amperage rating may
cause extensive damage to the electrical sys-
tem, cause the lighting and ignition systems
to malfunction and could possibly cause a fire.
4. Install:
•Pannel
•Seat
REPLACING THE HEADLIGHT BULBS
Low beam/high beam
1. Remove:
•Cowling screws (1)
2. Remove:
•Cowling (from the meter bracket)
NOTE:
Remove the cowling from the meter bracket by
lowering it to disengage it, and then lifting it up.
3. Remove:
•Headlight (2)
4. Disconnect:
•Headlight coupler (3)
5. Remove:
•Headlight bulb cover (4)
6. Remove:
•Headlight bulb holder (5) (by turning it
counterclockwise (a))
•Headlight bulb
WARNING
Headlight bulbs get very hot. Therefore, keep
flammable products away from a lit headlight
bulb, and do not touch the bulb until it has
cooled down.








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INSP
ADJ
REPLACING THE HEADLIGHT BULBS
3-55



Auxiliary light bulb
1. Remove:
•Cowling screws (1)
2. Remove:
•Cowling (from the meter bracket)
NOTE:
Remove the cowling from the meter bracket by
lowering it to disengage it, and then lifting it up.
3. Remove:
•Headlight (2)
•Auxiliary light socket (3)
NOTE:
Remove the auxiliary light socket (together with
the bulb) without disconnecting the leads.
•Bulb (by pushing it in and turning it coun-
terclockwise)Cowling screws:
10 Nm (1.0 kgm)
7. Install:
•Headlight bulb (new)
•Headlight bulb holder (by turning it clock-
wise (b))
Do not touch the glass part of the headlight
bulb to keep it free from oil, otherwise the
transparency of the glass, the luminosity of
the bulb, and the bulb life will be adversely
affected. Thoroughly clean off any dirt and
fingerprints on the headlight bulb using a
cloth moistened with alcohol or thinner.
8. Install:
•Headlight bulb cover
9. Connect:
•Headlight coupler
10. Install:
•Upper side of the cowling (onto the meter
bracket)
•Headlight (adjust the headlight beam if
necessary)
11. Install:
•Cowling screws
CAUTION:
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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
7-44
ELEC
3. Main switch.
•Disconnect the main switch connector
from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
switch cables.
Refer to “SWITCH CHECK” in CHAPTER
3.
CORRECT
INCORRECT
The main switch is defective. Replace.










*
4. Dipped/high beam commutator and dim-
mer switch.
•Disconnect the left handlebar switch con-
nector from the wire harness.
•Connect the pocket tester ( Ωx 1) to the
left handlebar switch terminals.
•Check the switch component for conti-
nuity between “Brown (1)” and “Yellow
(2)”, “Brown/Blue (3)” and “Green (4)”,
“Brown/Blue (3)” and “Yellow (2)”.
Refer to “SWITCH CHECK” in CHAPTER
3.
INCORRECT
The dipped/high beam commutator and/or the
dimmer switch are defective. Replace the left
handlebar switch.
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CORRECT
*
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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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