YAMAHA TT600RE 2004 Service Manual

FRONT WHEEL AND BRAKE DISC
4-6
CHAS
FRONT WHEEL INSTALLATION
1. Install:
•Brake disc (1)
2. Install:
•Speedometer gear unit (1) Screw (brake disc):
12 Nm (1.2 mkg)
NOTE:
•Apply LOCTITE®to the threads of brake disc
screw.
•Tighten the screws (brake disc) in stage using
a crisscross pattern.
3. Tighten:
•Front wheel
•Front wheel axle
NOTE:
Make sure that the wheel hub and the speedome-
ter gear unit are installed with the projections
meshed into the slots.
•Pinch bolt Front wheel axle:
59 Nm (5.9 mkg)
NOTE:
Make sure that the slot (a) in the speedometer
gear unit fits under the stopper on the front fork
outer tube.
Pinch bolt: 9 Nm (0.9 mkg)a
WHEEL STATIC BALANCE ADJUSTMENT
1. Remove:
•Balancing weight
2. Set:
•Wheel (on a suitable stand)
3. Find:
•Heavy spot
NOTE:
•After replacing the tire and/or rim, the wheel
static balance should be adjusted.
•Adjust the front wheel static balance with the
brake disc installed.
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CHASFRONT WHEEL AND BRAKE DISC
4-7
4. Adjust:
•Wheel static balance
Adjusting steps:
•Install a balancing weight (1) on the rim exact-
ly opposite to the heavy spot “X”.
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•Turn the wheel so that the heavy spot is 90°
up.
•Check that the heavy spot is at rest there. If
not, try another weight until the wheel is bal-
anced.
NOTE:
Start with the smallest weight.
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5. Check:
•Wheel static balance
Checking steps:
•Turn the wheel so that it comes to each point
as shown.
•Check that the wheel is at rest at each point.
If not, readjust the front wheel static balance.
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Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “X
1” mark on the wheel’s bottom spot.
c. Turn the wheel so that the “X
1” mark is 90° up.
d. Release the wheel and wait for it to rest. Put an “X
2” mark on the wheel’s bottom spot.
e. Repeat the above b., c., and d. several times until all marks come to the same spot.
f. This spot is the wheel’s heavy spot “X”.
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FRONT BRAKE
4-8
CHAS
FRONT BRAKE
BRAKE PAD
Order Job name/Part name Q.ty Remarks Brake pad removal Remove the parts in order.
1 Brake caliper screw 2
2 Brake caliper 1
3 Pad pin retainer 2 Refer to “BRAKE PAD REPLACEMENT”
4 Pad pin 1 section.
5 Brake pad 2
6 Pad spring 2
Reverse the removal procedure for instal-
lation.
25 Nm (2.5 m•kg)
6
3
54
1
2
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CHASFRONT BRAKE
4-9
Brake components must not be disassembled.
The builder declines every responsibility after
brake components disassembly (brake master
cylinder or brake caliper) or in case of use of
non original parts.
DO NOT:
•Remove brake components from the
motorcycle unless is absolutely necessary.
•Use solvents on internal brake compo-
nents.
•Use brake fluid already used for bleeding.
•Allow brake fluid to come into contact with
the eyes as it may cause injury.
•Allow brake fluid to come into contact with
painted or plastic parts as it may damage
them.
•Disconnect any hydraulic connection, other-
wise the whole system must be disassem-
bled, drained, cleaned, then properly filled
and bled after reassembly.
CAUTION:
NOTE:
It is unnecessary to disassemble the brake hose
to replace the pads.
NOTE:
•If you replace the pads, also replace the
springs.
•If one of the two pads has to be replaced
because it is worn, replace both.
BRAKE PAD REPLACEMENT
1. Remove:
•Caliper bracket fastening screws (1)
(deplace the caliper)
2. Remove:
•Pin retainers (2)
•Pad fastening pin (3)
•Brake pads (4)
•Pad springs (5)
•Caliper bracket (6)
Wear limit (a): 3.7 mm
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FRONT BRAKE
4-10
CHAS
3. Lubricate:
•Guide pins (1)
4. Install:
•Pin bracket (2) (on the caliper body (3))
NOTE:
Fit the rubber protections (4) when installing the
caliper body. Lithium-base grease
5. Install:
•Pad springs (1) (new)
•Brake pads (2) (new)
•Pad fastening pin (3)
•Pin retainers (4)
6. Check:
•Level of brake fluid in reservoir.
See section “BRAKE FLUID LEVEL
INSPECTION” in CHAPTER 3.
(a) Lower minimum level “MIN”
7. Check:
•Brake lever operation
Lever soft and spongy ➔Bleed air from
brake circuit.
See section “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 3.
Installation procedure:
•Connect the hose (1) firmly to the caliper
bleeder screw (2). Place the other end of the
hose in an open container.
•Loosen the caliper bleeder screw and push
the pistons into the caliper with your finger.
•Retighten the bleeder screw (2).
Caliper bleeder screw: 14 Nm (1.4 mkg)
Caliper fastening screw: 25 Nm (2.5 kgm)
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•Install the (new) brake pads and (new)
springs.
•Fit the pad fastening pin well into its housing
by hammering with a punch with a suitable
diameter.
•Install the (new) pin retainers.
•Install the caliper and screws.
a
4
1
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CHASFRONT BRAKE
4-11
MASTER CYLINDER
Order Job name/Part name Q.ty Remarks Master cylinder removal Remove the parts in order.
Brake fluid Drain.
1 Rear view mirror (right)/ Master cylinder bracket 1/1
2 Brake lever 1
3 Brake switch 1
4 Union bolt 1
5 Plain washer 2 Refer to “MASTER CYLINDER INSTAL-
6 Brake hose 1 LATION” section.
7 Master cylinder 1 Reverse the removal procedure for instal-
lation.
26
4
7
1
9 Nm (0.9 m•kg)
20 Nm (2.0 m•kg)
3
5
New
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FRONT BRAKE
4-12
CHAS
Order Job name/Part name Q.ty Remarks Master cylinder disassembly Remove the parts in order.
1 Reservoir cap 1
2 Diaphragm 1
3 Master cylinder boot 1 Refer to “MASTER CYLINDER ASSEM-
4 Circlip 1 BLY” section.
5 Master cylinder assembly 1
6 Spring 2 Reverse the disassembly procedure for
assembly.
1.5 Nm (0.15 m•kg)
6
3
5
4
1
2
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CHASFRONT BRAKE
4-13
MASTER CYLINDER INSPECTION
1. Inspect:
•Master cylinder assembly
Wear/scratches ➔Replace the master
cylinder assembly.
•Master cylinder body
Cracks/damage ➔Replace the master
cylinder assembly.
•Fluid delivery passage
(master cylinder)
Obstruction ➔Clean with a jet of com-
pressed air.
2. Inspect:
•Master cylinder piston unit (1)
Scratches/wear/damage ➔Replace the
master cylinder assembly.
3. Inspect:
•Diaphragm
Wear/damage ➔Replace.
4. Inspect:
•Brake hose
Cracks/wear/damage ➔Replace.
MASTER CYLINDER ASSEMBLY
WARNING
•All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.
Recommended brake fluid: DOT 4
•In case of non correct operation of the
brake master cylinder, replace the master
cylinder assembly.
1. Install:
•Spring (1)
•Master cylinder (2)
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FRONT BRAKE
4-14
CHAS
2. Install:
•Circlip (1)
•Master cylinder boot (2)
MASTER CYLINDER INSTALLATION
1. Install:
•Master cylinder (1)
•Master cylinder bracket (2)
Screw (master cylinder bracket): 9 Nm (0.9 mkg)
2. Install:
•Plain washer (1) (new)
•Brake hose (2)
•Union bolt (3)
Union bolt (brake hose): 20 Nm (2.0 mkg)
NOTE:
•When tightening the union bolt be sure to put
the brake hose in the correct position.
•Check that the brake hose has stayed in the
correct position. Adjust if necessary.
WARNING
•Check that the brake hose routing is as
described. Refer to “CABLE ROUTING”
section.
•Always use new plain washers.
3. Fill:
•Brake fluid reservoir
Recommended brake fluid: DOT 4
2
3
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CHASFRONT BRAKE
4-15
Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
CAUTION:
WARNING
•Use only designated quality brake fluid.
Otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
•Refill with the same type of brake fluid:
mixing fluids may result in a harmful chem-
ical reaction and lead to poor perform-
ance.
•Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
4. Air bleed:
•Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in CHAPTER 3.
5. Inspect:
•Brake fluid level
Lower than “MIN” mark ➔Fill.
Refer to “BRAKE FLUID INSPECTION”
section in CHAPTER 3.
(a) Minimum level mark “MIN”
6. Install:
•Diaphragm (1)
•Master cylinder cap (2)
•Screw (3) (cap) Screw (master cylinder cap): 1.5 Nm (0.15 mkg)
a
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