YAMAHA TT600RE 2004 Service Manual

REAR WHEEL AND BRAKE DISC
4-26
CHAS
Lithium-base grease
Check that the brake caliper support has
stayed in the correct position on the rear arm.
CAUTION:
5. Install:
•Rear wheel assembly (in the rear arm)
•Bearing
•Edge of the hub dust cover
Check that the brake disc is driving through
the brake pads.
CAUTION:
Make sure the collars and chain pullers are
positioned correctly.
CAUTION:
6. Install:
•Drive chain (on the driven sprocket)
•Rear wheel axle (left side)
7. Adjust:
•Drive chain slack Drive chain slack: 30 ~ 40 mm
Refer to “DRIVE CHAIN SLACK INSPEC-
TION AND ADJUSTMENT” section in
Chapter 3.
8. Tighten:
•Wheel axle nut
Wheel axle nut: 115 Nm (11.5 mkg)
4. Lubricate:
•Wheel axle
•Bearings
•Edge of hub dust cover
ProCarManuals.com

CHASREAR WHEEL AND BRAKE DISC
4-27
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 rear wheel static balance with the
brake disc installed.
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”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4. Adjust:
•Wheel static balance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjusting steps:
•Install a balancing weight (1) on the rim exact-
ly opposite to the heavy spot “X”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
•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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ProCarManuals.com

REAR WHEEL AND BRAKE DISC
4-28
CHAS
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 rear wheel static balance.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ProCarManuals.com

CHASREAR BRAKE
4-29
REAR BRAKE
BRAKE PAD
Order Job name/Part name Q.ty Remarks Brake pad removal Remove the parts in order.
Rear wheel Refer to “REAR WHEEL REMOVAL”
section.
Brake hose Remove from clamp.
1 Caliper protector 1
2 Pad pin retainer 1
3 Pad pin 1
4 Brake pad 1 Refer to “BRAKE PAD REPLACEMENT”
5 Brake caliper (remove from caliper 2 section.
support)
6 Brake pad support 1 Reverse the removal procedure for instal-
lation.
ProCarManuals.com

REAR BRAKE
4-30
CHAS
Brake components must not be disassem-
bled. 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 components.
•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 pad
support.
•If one of the two pads has to be replaced
because it is worn, replace both.
BRAKE PAD REPLACEMENT
1. Remove:
•Rear wheel (refer to “REAR WHEEL
REMOVAL” section).
•Bolt (caliper protector) (1)
•Brake caliper protector (2)
•Pad pin retainer (3)
•Brake pad pin (4)
Remove the caliper in the illustrated direc-
tion.
2. Remove:
•Brake pads (5)
•Pad support (6)
643
2
1
5
ProCarManuals.com

CHASREAR BRAKE
4-31



4. Check:
•Brake fluid level
Refer to “BRAKE FLUID INSPECTION”
section in Chapter 3.
(a) Minimum level mark “MIN”
(b) Maximum level mark “MAX”
5. Check:
•Brake pedal operation
Pedal soft and spongy ➔Bleed air from
brake circuit.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in Chapter 3. Caliper bleeder screw:
14 Nm (1.4 mkg)
Caliper protector bolt: 10 Nm (1.0 mkg)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
•Install the (new) brake pads and (new) pad
support.
•Install the caliper (3) and the pad pin (4).
•Install the (new) pin retainer (5)
•Install the caliper protector (6).
3. Install:
•Brake pads
•Pad support
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 piston into the caliper with your finger.
•Retighten the bleeder screw (2).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3
45
62
ProCarManuals.com

REAR BRAKE
4-32
CHAS
MASTER CYLINDER
Order Job name/Part name Q.ty Remarks Master cylinder removal Remove the parts in order.
Brake fluid Drain.
1 Rear stop switch connector 1
2 Rear stop switch 1
3 Plain washer 2 Refer to “MASTER CYLINDER INSTALLA-
4 Brake hose 1 TION” section.
5 Brake fluid reserve tank 1
6 Brake master cylinder 1
Refer to “BRAKE PEDAL REMOVAL” sec-
7 Brake pedal/spring 1/1 tion.
Reverse the removal procedure for installa-
tion.
New
New
20 Nm (2.0 m•kg)
45 Nm (4.5 m•kg)
10 Nm (1.0 m•kg)
4 Nm (0.4 m•kg)
ProCarManuals.com

CHASREAR BRAKE
4-33
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
Scratches/wear/damage ➔Replace the
master cylinder assembly.
3. Inspect:
•Diaphragm (1)
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
•Master cylinder piston unit
ProCarManuals.com

REAR BRAKE
4-34
CHAS
MASTER CYLINDER INSTALLATION
1. Install:
•Brake pedal (refer to “BRAKE PEDAL
REMOVAL” section in this Chapter).
NOTE:
Lubricate the pin of the brake pedal with lithium-
base grease.
•Master cylinder
•Brake fluid reserve tank
•Plain washers (1) (new)
•Brake hose (2)
•Stop switch (to mount the brake hose) (3) Brake switch (brake hose): 20 Nm (2.0 mkg)
Master cylinder mounting bolt: 10 Nm (1.0 mkg)
Reserve tank mounting bolt: 4 Nm (0.4 mkg)New
2. Fill:
•Brake fluid reserve tank Recommended brake fluid: DOT 4
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.
ProCarManuals.com

CHASREAR BRAKE
4-35
3. Air bleed:
•Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in Chapter 3.
4. Inspect:
•Brake fluid level
Lower than “MIN” mark (1) ➔Fill.
Refer to “BRAKE FLUID INSPECTION”
section in Chapter 3.
(1) Minimum level mark “MIN”
BRAKE PEDAL REMOVAL
1. Remove:
•Split pin (1) (new)
•Plain washer (2)
•Pin (3)
2. Unscrew:
•Bolt (4)
3. Remove:
•Spring (5)
4. Remove:
•Brake pedal (6) from chassis
NOTE:
Pull the brake pedal from the lower part of the
chassis, causing it to rotate progressively as it
comes away.



5. Adjust:
•Brake pedal height (a)
(below the top of the footrest)
Brake pedal height: 10 mm
ProCarManuals.com