YAMAHA TT600RE 2004 Service Manual
Manufacturer: YAMAHA, Model Year: 2004, Model line: TT600RE, Model: YAMAHA TT600RE 2004Pages: 382, PDF Size: 6.39 MB
Page 111 of 382
INSP
ADJREPLACING THE TAIL/
BRAKE LIGHT BULB
3-57
REPLACING THE TAIL/BRAKE LIGHT BULB
1. Remove:
•Screws (1) (lens fixing)
•Lens (2)
•Bulb (3)
NOTE:
To remove the bulb press it into place and turn it
counterclockwise (a).
2. Install:
•New bulb
NOTE:
To install the bulb press it into place and turn it
clockwise (b).
•Lens
•Screws (lens fixing)
Do not overtighten the screws, otherwise the
lens may break.
CAUTION:
ProCarManuals.com
Page 112 of 382
INSP
ADJ
ProCarManuals.com
Page 113 of 382
4
CHAS
ProCarManuals.com
Page 114 of 382
CHAS
CHAPTER 4. CHASSIS
FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
FRONT WHEEL AND BRAKE DISC REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
FRONT WHEEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
BRAKE DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
FRONT WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
FRONT WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
WHEEL STATIC BALANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
BRAKE PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
MASTER CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
MASTER CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
BRAKE CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
REAR WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
REAR WHEEL AND BRAKE DISC REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
REAR WHEEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
REAR WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
BRAKE DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
REAR WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
REAR WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
WHEEL STATIC BALANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
BRAKE PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
MASTER CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
MASTER CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
BRAKE PEDAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
BRAKE CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
ProCarManuals.com
Page 115 of 382
CHAS
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
FRONT FORK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
FRONT FORK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
FRONT FORK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
CLEANING THE DUST SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
SEAL AND BUSH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
OIL LEAKAGE FROM DUST SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
ANOMALOUS HYDRAULIC BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
FRONT FORK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
FRONT FORK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
STEERING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
NOTE ON DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
SHOCK ABSORBER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
SHOCK ABSORBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
SHOCK ABSORBER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
SWINGARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
SWINGARM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
LATERAL FREE PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
SWINGARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
DRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET . . . . . . . . . . . . . 4-82
DRIVE CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
DRIVE CHAIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
DRIVE CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
ProCarManuals.com
Page 116 of 382
CHASFRONT WHEEL AND BRAKE DISC
4-1
CHASSIS - FRONT WHEEL AND BRAKE DISC
Order Job name/Part name Q.ty Remarks Front wheel and brake disc Remove the parts in order.
removal
WARNING
Securely support the motorcycle so there
is no danger of it falling over.
1 Speedometer cable 1 Disconnect.
2 Pinch bolt 2 Loosen.
3 Wheel axle 1
4 Front wheel assembly 1 Refer to “FRONT WHEEL INSTALLATION”
5 Collar 1
section.
6 Gear unit assembly 1
7 Brake disc screw 6
8 Brake disc 1
9 Ring 1 Reverse the removal procedure for instal- lation.
ProCarManuals.com
Page 117 of 382
FRONT WHEEL AND BRAKE DISC
4-2
CHAS
Order Job name/Part name Q.ty Remarks Front wheel disassembly Remove the parts in order.
1 Oil seal 1
2 Bearing 1
3 Spacer 1 Refer to “FRONT WHEEL DISASSEMBLY/
4 Oil seal 1 ASSEMBLY” section.
5 Bearing 1
Reverse the removal procedure for instal-
lation.
1
2
3
5
4
ProCarManuals.com
Page 118 of 382
CHASFRONT WHEEL AND BRAKE DISC
4-3
FRONT WHEEL DISASSEMBLY
1. Remove:
•Oil seal
•Bearing (1)
•Spacer
Removal procedure:
•Clean the outside of the hub.
•Remove the dust cover with a flat-headed
screwdriver.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
•Disassemble the bearing (1) with a normal
puller (2).
NOTE:
Place a rag on the outside to avoid damaging the
hub.
FRONT WHEEL INSPECTION
1. Inspect:
•Front wheel axle
(by rolling it on a flat surface)
Bends ➔Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
WARNING
Do not attempt to straighten a bent axle.
2. Inspect:
•Front tire
Wear/damage ➔Replace.
Refer to “TIRE INSPECTION” in CHAP-
TER 3.
•Front wheel
Refer to “WHEEL INSPECTION” in
CHAPTER 3.
3. Inspect:
•Spoke(s)
Bent/Damaged ➔Replace.
Loose spoke(s) ➔ Tighten.
Turn the wheel and hit the spokes gently
with a screwdriver.
NOTE:
A well tightened spoke makes a distinct, sharp
noise: a loose spoke makes a dull, muffled noise.
ProCarManuals.com
Page 119 of 382
FRONT WHEEL AND BRAKE DISC
4-4
CHAS
4. Tighten:
•Loose spokes
5. Measure:
•Front wheel runout
Over the specified limits ➔Replace.
Spoke:
2 Nm (0.2 mkg)
NOTE:
After tightening the spokes, check the centring of
the wheel.
6. Inspect:
•Front wheel bearings
Bearings allow free play in the wheel hub
or the wheel does not turn smoothly ➔
Replace.
•Oil seal
Wear/damage ➔Replace.
Front wheel runout limits:
Radial (1) : 1.0 mm
Lateral (2) : 0.5 mm
WARNING
•After assembling a tyre, drive slowly to
allow it to adapt to the rim. If this precau-
tion is not observed, damage might be
caused to the motorcycle and accidents to
the driver.
•After repairing or changing a tyre, do not
forget to tighten the valve lock nut (1) to
the prescribed torque.
Valve lock nut: 1.5 Nm (0.15 mkg)
ProCarManuals.com
Page 120 of 382
CHASFRONT WHEEL AND BRAKE DISC
4-5
BRAKE DISC INSPECTION
1. Inspect:
•Brake disc
Wear/Damage ➔Replace.
2. Measure:
•Brake disc deflection (a)
If over envisaged limits ➔Verify wheel
centring.
If the wheel centring is correct, replace the
brake disc.
Misure at 2 mm from disc edge
•Brake disc thickness (b)
If out of specified limits ➔Replace.
Maximum deflection (brake disc):
0.15 mm
Minimum thickness (brake disc):
3.6 mm
IFRONT WHEEL ASSEMBLY
1. Install:
•Spacer
•Bearings
•Oil seal
Assembly procedure:
•Install the new bearing and the dust cover by fol-
lowing the disassembly procedures in reverse
order.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
Use a wrench (1) with an external diameter equal to
that of the bearing and dust cover.
Do not strike the bearing inner race (2) or balls
(3). The contact must only be made with the
outer race (4).
CAUTION:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ProCarManuals.com