Yamaha YFM660 01 User Manual
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8 - 20 –+ELECCHARGING SYSTEM EB804010 TROUBLESHOOTING Procedure Check: 1.Fuse 2.Battery 3.Charging voltageIF THE BATTERY IS NOT CHARGED: 4.Charging coil resistance 5.Wiring connections (the entire charging system) OTE: Remove the following part(s) before trouble- shooting: 1)Seat Use the following special tool(s) for trouble- shooting. Pocket tester: P/N. YU-03112, 90890-03112 EB802011 CONTINUITY 1.Fuse Refer to “CHECKING THE SWITCH”. NO CONTINUITY Replace the fuse. EB802012 CORRECT 2.Battery Check the battery condition. Refer to “CHECKING THE BATTERY” in CHAPTER 3. Open-circuit voltage: 12.8 V or more at 20 °C (68 °F) INCORRECT Clean the battery terminals. Recharge or replace the battery. EB804011 3.Charging voltage Connect the tachometer to the spark plug lead. Connect the pocket tester (DC 20V) to the battery. Tester (+) lead → Battery (+) terminal Tester (–) lead → Battery (–) terminal
8 - 21 –+ELECCHARGING SYSTEM OUT OF SPECIFICATION Start the engine and accelerate to about 5,000 r/min. Charging voltage: 14 V at 5,000 r/minMEETS SPECIFICATION The charging circuit is not faulty. EB804012 MEETS SPECIFICATION 4.Charging coil resistance Disconnect the AC magneto coupler from the wire harness. Connect the pocket tester (Ω × 1) to the charging coils. Tester (+) lead → White terminal 1 Tester (–) lead → White terminal 2 Tester (+) lead → White terminal 1 Tester (–) lead → White terminal 3 Tester (+) lead → White terminal 2 Tester (–) lead → White terminal 3 Measure the stator coil resistance. Charging coil resistance: 0.43 ~ 0.65 Ω at 20 °C (68 °F) OUT OF SPECIFICATION Replace the pickup coil/stator assembly. EB804015 CORRECT 5.Wiring connections Check the connections of the entire charg- ing system. Refer to “CIRCUIT DIAGRAM”. Replace the rectifier/regulator.POOR CONNECTION Properly connect the charging system.
8 - 22 –+ELECLIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 3Main switch 4Battery 5Fuse OLights switch RHeadlight STail/brake light
8 - 23 –+ELECLIGHTING SYSTEM EB805010 TROUBLESHOOTING Procedure Check: 1.Fuse 2.Battery 3.Main switchIF THE HEADLIGHT AND/OR TAIL/BRAKE LIGHT FAIL TO COME ON: 4.Lights switch 5.Wiring connections (the entire lighting system) OTE: Remove the following part(s) before trouble- shooting: 1)Seat 2)Front fender Use the following special tool(s) for trouble- shooting. Pocket tester: P/N. YU-03112, 90890-03112 EB802011 CONTINUITY 1.Fuse Refer to “CHECKING THE SWITCH”. NO CONTINUITY Replace the fuse. EB802012 CORRECT 2.Battery Check the battery condition. Refer to “CHECKING THE BATTERY” in CHAPTER 3. Open-circuit voltage: 12.8 V or more at 20 °C (68 °F) * INCORRECT Clean the battery terminals. Recharge or replace the battery.
8 - 24 –+ELECLIGHTING SYSTEM C0NTINUITY CORRECT 3.Main switch Refer to “CHECKING THE SWITCH”. * INCORRECT Replace the main switch. CORRECT 4.Lights switch Refer to “CHECKING THE SWITCH”. INCORRECT Lights switch is faulty, replace the handlebar switch (left). EB805013 CORRECT 5.Wiring connection Check the connections of the entire lighting system. Refer to “WIRING DIAGRAM”. Check the condition of each of the lighting system’s circuits. Refer to “CHECKING THE LIGHTING SYS- TEM”.POOR CONNECTION Properly connect the lighting system.
8 - 25 –+ELECLIGHTING SYSTEM EB805020 CHECKING THE LIGHTING SYSTEM 1.If the headlights fail to come on: CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for continu- ity. NO CONTINUITY Replace the bulb and/or bulb socket. 2.Voltage Connect the pocket tester (DC 20V) to the headlight couplers. Tester (+) lead → Green terminal 1 or Yellow terminal 2 Tester (–) lead → Black terminal 3 È When the lights switch is on “LO”. ÉWhen the lights switch is on “HI”. ÈÉ MEETS SPECIFICATION Turn the main switch to “ON”. Turn the lights switch to “LO” or “HI”. Check the voltage (12 V) of the “Green” and “Yellow” leads on the bulb socket con- nector. This circuit is not faulty. OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty, repair it.
8 - 26 –+ELECLIGHTING SYSTEM EB805021 2.If the tail/brake light fails to come on: CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for continu- ity. NO CONTINUITY Replace the bulb and/or bulb socket. 2.Voltage Connect the pocket tester (20 V) to the bulb socket coupler. Tester (+) lead → Blue terminal 1 Tester (–) lead → Black terminal 2 MEETS SPECIFICATION Turn the main switch to “ON”. Turn the lights switch to “LO” or “HI”. Check the voltage (12 V) of the “Blue” lead on the bulb socket connector. This circuit is not faulty. OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty, repair it.
8 - 27 –+ELECSIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM 3Main switch 4Battery 5Fuse 0CDI unit CSpeed sensor GCoolant temperature warning light HReverse indicator light INeutral indicator light JNeutral switch KReverse switch LDiode MThermo switch 2 PEngine stop switch QStart switch STail/brake light TRear brake switch UFront brake switch
8 - 28 –+ELECSIGNAL SYSTEM EB806010 TROUBLESHOOTING Procedure Check: 1.Fuse 2.Battery 3.Main switch 4.Wiring connections (the entire signal system) IF THE TAIL/BRAKE LIGHT AND/OR INDICATOR LIGHT FAILS TO COME ON: OTE: Remove the following part(s) before trouble- shooting: 1)Seat 2)Front fender 3)Rear fender Use the following special tool(s) for trouble- shooting. Pocket tester: P/N. YU-03112, 90890-03112 EB802011 CONTINUITY 1.Fuse Refer to “CHECKING THE SWITCH”. NO CONTINUITY Replace the fuse. EB802012 CORRECT 2.Battery Check the battery condition. Refer to “CHECKING THE BATTERY” in CHAPTER 3. Open-circuit voltage: 12.8 V or more at 20 °C (68 °F) * INCORRECT Clean the battery terminals. Recharge or replace the battery.
8 - 29 –+ELECSIGNAL SYSTEM C0NTINUITY CORRECT 3.Main switch Refer to “CHECKING THE SWITCH”. * INCORRECT Replace the main switch. EB806011 CORRECT 4.Wiring connections Check the connections of the entire signal system. Refer to “CIRCUIT DIAGRAM”. Check the condition of each of the signal sys- tem’s circuits. Refer to “CHECKING THE SIGNAL SYS- TEM”. POOR CONNECTION Properly connect the signal system.