battery YAMAHA TTR90 2004 User Guide

3 - 25
INSP
ADJ
BATTERY INSPECTION AND CHARGING (TT-R90E)
Charging method using a variable voltage charger
Measure the open-circuit
voltage prior to charging.
Connect a charger and
ammeter to the battery
and start charging.
Is the amperage higher
than the standard charg-
ing amperage written on
the battery?NO
YES Charger
Ammeter
Adjust the voltage to obtain
the standard charging
amperage.
Set the timer to the charging
time determined by the open-
circuit voltage.
Refer to “BATTERY INSPEC-
TION AND CHARGING”.
Adjust the charging voltage to
20 ~ 25 V.
Monitor the amperage for 3 ~
5 minutes. Is the standard
charging amperage
exceeded?
NO YES
If the amperage does not
exceed the standard charg-
ing amperage after 5 min-
utes, replace the battery.
If the required charging time exceeds 5 hours, it is advisable to check
the charging amperage after 5 hours. If there is any change in the
amperage, readjust the voltage to obtain the standard charging
amperage.
Leave the battery unused for more than 30 minutes before measuring
its open-circuit voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
Leave the battery unused for more
than 30 minutes before measuring its
open-circuit voltage.
Set the charging voltage to 16 ~ 17 V.
(If the charging voltage is lower, charg-
ing will be insufficient, if it is higher, the
battery will be over-charged.)NOTE:
NOTE:

3 - 26
INSP
ADJ
BATTERY INSPECTION AND CHARGING (TT-R90E)
Charging method using a constant voltage charger
Measure the open-circuit
voltage prior to charging.
Connect a charger and
ammeter to the battery
and start charging.
NO
YESIs the amperage higher
than the standard
charging amperage writ-
ten on the battery?
Charge the battery until the charging
voltage reaches 15 V.
Leave the battery unused for more than
30 minutes before measuring its open-
circuit voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.This type of battery charger cannot
charge an MF battery. A variable
voltage charger is recommended.Leave the battery unused for more
than 30 minutes before measuring its
open-circuit voltage.
Set the charging time to a maximum of 20 hours.
Constant amperage chargers are not
suitable for charging MF batteries.
Charger
Ammeter
Voltmeter
NOTE:
CAUTION:
NOTE:

3 - 27
INSP
ADJ
FUSE INSPECTION (TT-R90E)
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 (TT-R90E)
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 - 2
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12
3
456
7
0
98

A
B
F
EC
D

ELECTRICAL COMPONENTS AND WIRING DIAGRAM
TT-R90E
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
BBY/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 - 7
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ELECTRIC STARTING SYSTEM
(TT-R90E)
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 (TT-R90E)

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6 - 8 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 (TT-R90E)

6 - 9
–+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 (TT-R90E)

6 - 10
–+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 (TT-R90E)

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6 - 15
CHARGING SYSTEM (TT-R90E)
EC680000
CHARGING SYSTEM (TT-R90E)
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