YAMAHA TT600RE 2004 Owners Manual

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
INSP
ADJ
 



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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INSP
ADJ
REAR SHOCK ABSORBER ADJUSTMENT
3-39
NOTE:
•Use the special wrench included in the
owner's tool kit to make the adjustment.
•The spring preload setting is determined by
measuring distance A, shown in the illustra-
tion. The longer distance A is, the lower the
spring preload; the shorter distance A is, the
higher the spring preload. With each com-
plete turn of the adjusting nut, distance A
changes by 1.5 mm.
Spring preload:
Minimum (soft):
Distance A = 217 mm
Standard:
Distance A = 211 mm
Maximum (hard):
Distance A = 205 mm
2. Tighten the locknut to the specified torque.
Always tighten the locknut against the adjust-
ing nut, and then tighten the locknut to the
specified torque.
CAUTION:Locknut:
45 Nm (4.5 m·kgf)
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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
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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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TYRE INSPECTION
3-42
INSP
ADJ
1. Check:
•Tyre pressure
Out of specification ➔Adjust.
Tire air pressure
(measured on cold tires)
Load* Front Rear
200 kPa 220 kPa
Up to 90 kg (2.00 kgf/cm
2, (2.20 kgf/cm2,
2.00 bar) 2.20 bar)
210 kPa 240 kPa
90 kg-maximum (2.10 kgf/cm
2, (2.40 kgf/cm2,
2.10 bar) 2.40 bar)
150 kPa 160 kPa
Off-road riding (1.50 kgf/cm
2, (1.60 kgf/cm2,
1.50 bar) 1.60 bar)
High-speed 210 kPa 240 kPa
riding(2.10 kgf/cm
2, (2.40 kgf/cm2
2.10 bar) 2.40 bar)
Maximum load* 180 kg
* Total weight of rider, passenger, cargo and ac-
cessories.
2. Adjust:
•Air pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjustment:
•Remove the valve cap.
Use an air pump or Increase air
compressed air pistol. pressure
Eliminate air by Air pressure
pressing valve tube diminishes
stem
•Install valve caps securely.
3. Inspect:
•Tyre surface
Wear/Damage ➔Replace.
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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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SIDESTAND LUBRICATION/
REAR SUSPENSION LUBRICATION
3-46
INSP
ADJ
SIDESTAND LUBRICATION
Lubricate the sidestand pivoting and mating parts.
Check to see that the sidestand moves up and
down smoothly.
Recommended lubricant:
SAE 10W30 motor oil

REAR SUSPENSION LUBRICATION
Lubricate the pivoting parts.
Recommended lubricant:
Molybdenum disulfide grease
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