battery YAMAHA TTR90 2003 User Guide

3 - 24
INSP
ADJ
BATTERY INSPECTION AND CHARGING
Charging method using a constant voltage charger

3 - 25
INSP
ADJ
FUSE INSPECTION
6. Install:
Battery
7. Check:
Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
8. Lubricate:
Battery terminal
9. Connect:
Battery lead coupler
(to the battery terminals)
10. Install:
Rear fender
Seat
Recommended lubricant
Lithium soap base grease
FUSE INSPECTION
CAUTION:
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.
1. Remove:
Seat
Rear fender
2. Check:
Continuity
2Reserve fuse
Checking steps:
Remove the fuse 1.
Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω × 1”.
Pocket tester
YU-03112-C/90890-03112
If the pocket tester indicates “∞”, replace
the fuse.
1 2

6 - 1
–+ELEC

12
3
456
7
0
98

A
B
F
EC
D

ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1
Main switch
2
“ENGINE STOP”
switch
3
Thermo switch
4
Ignition coil
5
CDI unit
6
Battery
7
Rectifier/regulator
8
Neutral switch
9
CDI magneto
0
Carburetor heater
A
Starter relay
B
Fuse
C
Start switch
D
Spark plug
E
Starter motor
F
Starting circuit cut-off
relay
COLOR CODE
B ...................... Black
Br .................... Brown
G ..................... Green
O ..................... Orange
R ..................... Red
Sb .................... Sky blue
W ..................... White
Y ...................... Yellow
EC612000
WIRING DIAGRAM
G/WB/RW/LW/RBr G
RW
B/WBr BRB/WBBrR
B/WB BB
BR/WBr B
GG/W
B/W
B/W
BrB/RWWOO
B
BW/LY/RR
W
B
B
R
W/RY/R
OFF RUNB
Y/R
Y
Y
OBO BY/RYB B
Sb
W W
Sb
ON OFF
OFFON
Y
BB
Y/R
Br
Br
B
B
R
RR
R
B
R/WR/W
R/WR/W
R/W
Sb
Sb
RB
R/WB R
Y/RRB W
B/WB
R/W
R/W
R/W
Sb
9
8
1 B5
4
D
2 3
=A
E 6
C
F 7

B/R ................... Black/Red
B/W .................. Black/White
G/W.................. Green/White
R/W .................. Red/White
W/L .................. White/Blue
W/R .................. White/Red
Y/R ................... Yellow/Red

6 - 6
–+ELEC
ELECTRIC STARTING SYSTEM
STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
If the main switch is set to “ON”, the starter
motor can only operate if the following condi-
tion is met:
The transmission is in neutral (the neutral
switch is closed).
The starting circuit cut-off relay prevents the
starter motor from operating when this condi-
tion has not been met. In this instance, the
starting circuit cut-off relay is open so current
cannot reach the starter motor. When the
above condition has been met the starting cir-
cuit cut-off relay is closed and the engine can
be started by pressing the start switch.
WHEN THE TRANSMISSION IS
IN NEUTRAL
1Battery
2Main fuse
3Main switch
4Start switch
5Starting circuit cut-off relay
6Neutral switch
7Starter relay
8Starter motor
12
M
3
7
54
6 8
ELECTRIC STARTING SYSTEM

–+ELEC
6 - 7
INSPECTION STEPS
If the starter motor will not operate, use the following inspection steps.
*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.
*3 marked: Refer to “MAIN SWITCH INSPECTION” section.
NOTE:
Remove the following parts before inspection.
1) Seat
2) Rear fender
3) Fuel tank
Use 12 V battery in this inspection.
Use the following special tools in this inspection.
Pocket tester:
YU-3112-C/90890-03112
*1 Check fuseReplace fuse and
check wire harness.
*2 Check battery Recharge or replace.
Check each coupler and
wire connection.Repair or replace.
*3 Check main switch. Replace.
Check starter motor
operation.Repair or replace.
Check starting circuit
cut-off relay.Replace.
Check starter relay. Replace.
Check neutral switch. Replace.
Check start switch. Replace.
OK
OK
OK
OK
OK
OK
OK
OK
No good
No good
No good
No good
No good
No good
No good
No good
No good
ELECTRIC STARTING SYSTEM

6 - 8
–+ELEC
EC624000
COUPLERS AND LEADS CONNECTION
INSPECTION
1. Check:
Couplers and leads connection
Rust/dust/looseness/short-circuit →
Repair or replace.
STARTER MOTOR OPERATION
1. Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
lead 3.
Not operate → Repair or replace the
starter motor.
WARNING
A wire that is used as a jumper lead must
have at least the same capacity or more
as that of the a battery lead, otherwise the
jumper lead may burn.
This check is likely to produce sparks,
therefore make sure nothing flammable is
in the vicinity.
STARTING CIRCUIT CUT-OFF RELAY
INSPECTION
1. Remove:
Starting circuit cut-off relay
2. Inspect:
Starting circuit cut-off relay conduct
Use 12 V battery.
Battery (+) lead → Red/White lead 1
Battery (–) lead → Sky blue lead 2
Tester (+) lead → Red/White lead 3
Tester (–) lead → Red/White lead 4
R/W
3R/W
4Tester selec-
tor position
Connected
to battery
Ω × 1Not
connected
to battery
2 4
3
1
ELECTRIC STARTING SYSTEM

6 - 9
–+ELEC
STARTER RELAY INSPECTION
1. Remove:
Starter relay
2. Inspect:
Starter relay conduct
Use 12 V battery.
Continuous while not connected to the battery
→ Replace.
Not continuous while connected to the battery
→ Replace.Battery (+) lead →
Starter relay terminal 1
Battery (–) lead →
Starter relay terminal 2
Tester (+) lead →
Starter relay terminal 3
Tester (–) lead →
Starter relay terminal 4
Ter-
minal
3
Ter-
minal
4Tester selec-
tor position
Connected
to battery
Ω × 1Not
connected
to battery
NEUTRAL SWITCH INSPECTION
1. Inspect:
Neutral switch conduct
No continuous while in neutral → Replace.
Continuous while in gear → Replace. Tester (+) lead → Sky blue lead 1
Tester (–) lead → Black lead 2
Sb
1B
2Tester selec-
tor position
NEU-
TRAL
Ω × 1
IN
GEAR
WSb
YB
1
2
ELECTRIC STARTING SYSTEM

–+ELEC
6 - 14
CHARGING SYSTEM
EC680000
CHARGING SYSTEM
EC681001
INSPECTION STEPS
If the battery is not charged, use the following inspection steps.
*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.
*2 marked: Refer to “CHECKING AND CHARGING THE BATTERY” section in the CHAPTER 3.
NOTE:
Remove the following parts before inspection.
1) Seat
2) Rear fender
3) Fuel tank
Use the following special tool in this inspection.
Pocket tester:
YU-3112-C/90890-03112Inductive tachometer:
YU-8036-B
Engine tachometer:
90890-03113
*1 Check fuse.Replace fuse and
check wire harness.
*2 Check battery. Recharge or replace.
Check each coupler and
wire connection.Repair or replace.
Check charging voltage.Charging system is
good.
Check CDI magneto. Lighting coil Replace.
Replace rectifier/regulator.
OK
OK
OK
No good
OK
No good
No good
No good
No good
OK