warning YAMAHA TT600RE 2004 User Guide

BRAKE CIRCUIT BLEEDING
3-34
INSP
ADJ
1
1B
BRAKE CIRCUIT BLEEDING
WARNING
If the brake lever or brake pedal has a soft or
slack feel, this means that there is air in the
brake system. It should be bled away before
using the motorcycle. Air in the system seri-
ously affects the effectiveness of braking and
may cause loss of control of the motorcycle.
In all cases, bleed the brake system if:
•The system has been disassembled.
•A brake hose has been loosened or
removed.
•The brake fluid in the tank is at a very low
level.
•Brake operation is faulty.
Air bleeding procedures:
a. Top up the level of the fluid in the tank to max-
imum.
b. Install the diaphragm. Be careful not to spill
fluid or let it overflow from the tank.
c. Connect the clear plastic hose (1) to the
caliper bleeder screw.
[A] Front
[B] Rear
d. Place the other end of the hose in a container.
e. Slowly pull the brake lever or press the brake
pedal several times.
f. Pull the brake lever right in or press the pedal
right down and hold in position.
g. Loosen the bleeder screw and allow the lever
or pedal to travel slowly towards its limit.
h. Tighten the bleeder screw when the lever or
pedal limit has been reached, then release the
lever or pedal.
Bleeder screw:
14 Nm (1.4 mkg)
i. Repeat operations (e) to (h) until all the air
bubbles have disappeared from the clear
plastic hose (1).
A
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INSP
ADJFRONT FORK INSPECTION/
FRONT FORK ADJUSTMENT
3-37
 


FRONT FORK INSPECTION
WARNING
When inspecting the front fork, hold the
motorcycle firmly to prevent it falling over.
1. Place the motorcycle on a level surface.
2. Check:
•Inner tube
Scratches/Damage ➔Replace.
•Oil seal
Undue oil leakage ➔Replace.
3. With the motorcycle in a level upright position
operate the front brake.
4. Check:
•Proper functioning
Compress and release the front fork sev-
eral times.
Irregular/jerky functioning ➔Repair.
See section “FRONT FORK” in Chapter 4.
ADJUSTING THE FRONT FORK
This front fork is equipped with spring pre-load ad-
justing bolts.
WARNING0
Always adjust both fork legs equally, other-
wise poor handling and loss of stability may
result.
Adjust the spring preload as follows.
To increase the spring preload and thereby hard-
en the suspension, turn the adjusting bolt on each
fork leg in direction a. To decrease the spring
preload and thereby soften the suspension, turn
the adjusting bolt on each fork leg in direction b.
Setting
Minimum (soft) 1-2-3
Standard 4
Maximum (hard) 5-6-7-8-9-10
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REAR SHOCK ABSORBER ADJUSTMENT
3-38
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REAR SHOCK ABSORBER ADJUSTMENT
WARNING
This shock absorber contains highly pressur-
ized nitrogen gas. For proper handling, read
and understand the following information
before handling the shock absorber. The man-
ufacturer cannot be held responsible for prop-
erty damage or personal injury that may result
from improper handling.
•Do not tamper with or attempt to open the
gas cylinder.
•Do not subject the shock absorber to an
open flame or other high heat sources,
otherwise it may explode due to excessive
gas pressure.
•Do not deform or damage the gas cylinder
in any way, as this will result in poor damp-
ing performance.
This shock absorber assembly is equipped with a
spring preload adjusting nut.
Never attempt to turn an adjusting mecha-
nism beyond the maximum or minimum set-
tings.
Adjust the spring preload as follows.
1. Loosen the locknut.
2. To increase the spring preload and thereby
harden the suspension, turn the adjusting nut
in direction a. To decrease the spring preload
and thereby soften the suspension, turn the
adjusting nut in direction b.
CAUTION:
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STEERING INSPECTION
3-40
INSP
ADJ
STEERING INSPECTION
WARNING
Hold the motorcycle firmly in place to prevent
it falling over.
1. Raise the front wheel and place a support
under the engine.
2. Check:
•Steering bearings
Grasp the bottoms of the front fork legs
and rock back and forward.
Free play ➔Adjust steering bearing.
3. Adjust:
•Steering bearing
Adjustment:
•Remove the fuel tank.
See section “SEAT, FUEL TANK AND REAR
COWLING”.
•Loosen steering axle nut (1) and fork upper
bracket screws (2).
•Tighten the ring nut (3) with the special
wrench.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
3
2
2
Ring nut (final tightening):
4 Nm (0.4 mkg)
Ring nut (initial tightening):
38 Nm (3.8 mkg)
Ringnut wrench:
P/N. 90890-01268
P/N. 90890-01348
NOTE:
The torque wrench and the ringnut wrench should
form a right angle.
WARNING
Do not tighten the ring nut excessively.
•Loosen the ring nut one turn.
•Retighten the ring nut using the special
wrench.
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INSP
ADJSTEERING INSPECTION/
TYRE INSPECTION
3-41
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Nut (steering axle):
115 Nm (11.5 mkg)
Screws (front fork bracket):
28 Nm (2.8 mkg)
•Tighten the steering axle nut and the front fork
bracket screws.
•Reassemble the fuel tank.
See section “SEAT, FUEL TANK AND REAR
COWLING”.
NOTE:
Check the steering head for looseness or binding
by turning it all the way in both directions. If it
binds, remove the steering axle assembly and
inspect the steering bearings.
Refer to “STEERING HEAD” in Chapter 6.
TYRE INSPECTION
WARNING
•Tyre pressure must be checked when the
tyres are at ambient temperature. Pressure
must be adjusted according to the total
weight of luggage, driver, passenger and
accessories (fairings, bags, if approved for
this model) and speed of the motorcycle.
•A list of tyres approved for this model fol-
lowing severe testing by Yamaha is provid-
ed. There can be no guarantee of safe road-
holding if a combination of tyres different
from those indicated is used.
•Front and rear tyres must have the same
design and be of the same make.
•The use of valves and valve stems other
than those indicated might cause the loss
of tyre pressure at high speeds. Use only
original or compatible spare parts.
•Replace the valve cap securely to prevent
losses of tyre pressure at high speed.
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INSP
ADJ
TYRE INSPECTION
3-43
Minimum track thickness:
(front and rear)
1,6 mm
NOTE:
These limits may be different by regulation from
country to country. If so, conform to the limits
specified by the regulations of your own country.
(1) Track thickness
(2) Side
(3) Wear indicators
WARNING
The use of worn tyres reduces stability and
may cause a loss of control.
It is not advisable to repair a punctured air
tube. If absolutely necessary, repair with the
utmost care and replace the tube as quickly as
possible with another with the same charac-
teristics.
4. Tighten:
•Valve stem lock nut
Lock nut (valve stem)
1.5 Nm (0.15 kgm)
REAR:
Manufacture Size Type
PIRELLI 90/90-21 54R MT70
MICHELIN 90/90-21 54S T63
Manufacture Size Type
PIRELLI 130/80-18 66R MT70
MICHELIN 130/80-18 66S T63
FRONT:
WARNING
After assembling the new tyres, drive slowly
to allow them to adapt well to the rim and yjus
ensure maximum holding.
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WHEEL INSPECTION/
SPOKE INSPECTION AND TIGHTENING
3-44
INSP
ADJ
WHEEL INSPECTION
1. Inspect:
•Wheels
Damage/Deformation ➔Replace.
NOTE:
Always balance the wheel after the replacement
or reassembly of a tyre or rim.
WARNING
Never try to repair a rim in any way.
Bearing inspection
Check the front and rear wheel bearings periodi-
cally to make sure that they do not have free play
in the hub and that the wheel turns smoothly with-
out sticking. Wheel bearings must always be
checked in accordance with the maintenance
table.
SPOKE INSPECTION AND TIGHTENING
1. Inspect:
•Spokes (1)
Curvature/Damaged ➔Replace.
Loose spoke ➔Tighten.
2. Tighten:
•Spoke (s)
NOTE:
Tighten the spokes before and after the break-in
period.
Spoke:
3 Nm (0.3 mkg)
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INSP
ADJCABLE INSPECTION/
LEVER AND PEDAL LUBRICATION
3-45
CABLE INSPECTION
WARNING
If the cable sheath is damaged, corrosion
might ensue or the cable might not run freely.
To avoid such drawbacks, replaced damaged
cables as quickly as possible.
1. Inspect:
•Cable sheath
Damaged ➔Replace the cable assembly.
2. Check:
•Cable functioning
Does not run freely ➔Replace the cable
assembly.
LEVER AND PEDAL LUBRICATION
1. Lubricate the pivoting parts:
•Clutch lever
•Front brake lever
•Rear brake pedal
•Shift pedal
Recommended lubricant:
SAE 10W30 motor oil
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INSP
ADJ
CHECKING AND CHARGING THE BATTERY
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
•Wear protective eye gear when handling or
working near batteries.
•Charge batteries in a well-ventilated area.
•Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
•DO NOT SMOKE when charging or han-
dling batteries.
•KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
•Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
First aid in case of bodily contact:
External
•SKIN – Wash with water.
•EYES – Flush with water for 15 minutes
and get immediate medical attention.
Internal
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.
•This is a sealed battery. Never remove the
sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.
•Charging time, charging amperage and
charging voltage for a MF battery are dif-
ferent from those of conventional batter-
ies. The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charg-
ing the battery.
CAUTION:
3-47
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INSP
ADJ
CHECKING AND CHARGING THE BATTERY
3-49
Open-circuit voltage (V)
WARNING
Do not quick charge a battery.
•Never remove the MF battery sealing caps.
•Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
•If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
•When charging a battery, be sure to
remove it from the motorcycle (if charging
has to be done with the battery mounted
on the motorcycle, disconnect the nega-
tive lead from the battery terminal).
•To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the bat-
tery.
•Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
•Make sure that the battery charger lead
clips are in full contact with the battery
terminal and that they are not shorted. A
corroded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
•If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
•As shown in the following illustration, the
open-circuit voltage of a MF battery stabi-
lizes about 30 minutes after charging has
been completed. Therefore, wait 30 min-
utes after charging is completed before
measuring the open-circuit voltage.
CAUTION:
Condition of charge in battery (%)Ambient
temperature
20 °C
Open-circuit voltage (V)
Check the open-circuit
voltage Ambient
temperature 20 °C Charging 14
13
12
11
10
100 75 50 30 2520 00 10 20 30 40 50 60 Time (minutes) 18
17
16
15
14
13
12
11
10
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