air filter YAMAHA TT600RE 2004 User Guide

INSP
ADJ
3-19
ENGINE OIL REPLACEMENT
 
Engine oil replacement (with oil filter replace-
ment)
1. Warm up the engine for a few minutes.
2. Stop the engine. Place an oil pan under the
engine and remove the oil filler cap.
3. Remove the drain plug (1) and drain the
engine oil.
4. Remove two bolts (2) and O-ring of the oil
hose flange, and drain the oil from oil tank.
5. Remove the air bleed screw (3) attached to
the oil filter cover (4).
6. Wait until the oil has completely drained.
NOTE:
The oil filter cover is secured by three screws (5).
The lower one should be removed so that the fil-
ter cavity will drain.

7. Remove the other filter cover screws and
remove the oil filter cover.
8. Remove the oil filter (6) and O-ring (7).
9. Inspect:
•All gaskets
•O-rings
Damaged ➔Replace.
10. Reassemble:
•(New) filter cartridge
•Filter cover screw
•Oil filter cover bleeder screw
•Engine drain plug
•Oil tank hose
Fastening torques:
Drain plug (engine):
30 Nm (3.0 mkg)
Oil tank hose (flange):
10 Nm (1.0 mkg)
Filter cover screw:
10 Nm (1.0 mkg)
Oil filter cover bleeder screw:
5 Nm (0.5 mkg)
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AIR FILTER CLEANING
3-24
INSP
ADJ



AIR FILTER CLEANING
1. Remove:
•Fast screws (1)
•Air filter box cap (2)
2. Pull out:
•Filtering element (3) from its seat
3. Wash:
•Filtering element (with water and
biodegradable liquid soap)
NOTE:
Rinse properly and dry perfectly by squeezing the
filtering element, without twisting it!
4. Inspect:
•Filtering element
Damaged ➔Replace.
5. Apply:
•SAE 20W50 engine oil or special filter oil
all over filter surface
6. Squeeze out:
•Excess oil
NOTE:
The filtering element should be wet but not drip-
ping.
3
7. Install:
•Filtering element (4) in its case
NOTE:
When installing the filtering element in its case, fol-
low the direction indicated by the arrows, make sure
that the flame-trap net is set forward and that the
cap is properly assembled.
8. Reassemble:
•Air filter box cap
•Fast screws
Make sure the air filter is properly seated in
the air filter case.
The engine should never be run without the
air filter installed. Excessive piston and/or
cylinder wear may result.
CAUTION:
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INSP
ADJAIR FILTER CLEANING/
FUEL FILTER CLEANING
3-25
Periodically check wheter the sleeve on the
bottom of the air filter case is empty. Remove
the plug (5) and clean it if dirt or water accu-
mulate.
CAUTION:
FUEL FILTER CLEANING
1. Turn the fuel cock to "OFF".
2. Disconnect:
•Fuel pipe from cock
3. Place a fuel pan under the fuel tank and turn
the fuel cock to "RES" to drain the fuel.
Do not bring naked flames or possible
sources of sparks near to the fuel tank: FIRE
AND EXPLOSION RISK! Be careful not to spill
fuel from the tank.
Always wipe off spilled fuel immediately with
a dry and clean soft cloth. Fuel may deterio-
rate painted surfaces or plastic.
4. Disassemble:
•The fuel cock from the fuel tank
5. Wash:
•Fuel filter (1) with solvent
6. Inspect:
•Fuel filter (1)
•Gasket (2)
Damaged ➔Replace.
7. Reassemble:
•Fuel cock to tank
•Fuel pipe to cock
NOTE:
When reassembling the cock, be careful not to
tighten the fastening screws unduly, as the gasket
might leave its housing and cause fuel leakage.
CAUTION:







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ENGINE OIL TANK FILTER CLEANING
3-26
INSP
ADJ
ENGINE OIL TANK FILTER CLEANING
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Drain:
•Engine oil
See section “ENGINE OIL REPLACE-
MENT”.
2. Remove:
•Seat
•Rear cowling
See section “SEAT, FUEL TANK AND
REAR COWLING”.
•Rear wire harness
•Exhaust muffler
•Exhaust pipe
•Rear shock absorber
See section “REAR SHOCK ABSORBER”
in Chapter 4.
•Joint air cleaner clamps
•Rear frame
•Engine oil tank
3. Loosen:
•Stay (rear left side cover) fastening
screws
4. Remove:
•Oil tank cap (1)
•Oil return hose (2)
•Oil return hose flange (4) fastening screw
(3)
•Oil delivery hose flange (6) fastening
screws (5)
•Oil tank filter (7)
•OR gaskets (8)
5. Clean:
•Oil tank filter (with solvent)
•Oil tank (with solvent)
NOTE:
After cleaning the inside of the oil tank, remove
the remaining solvent.
6. Inspect:
•OR gaskets
Damaged ➔Replace.
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INSP
ADJ
ENGINE OIL TANK FILTER CLEANING
3-27
7. Reassemble:
•OR gaskets
•Oil tank filter
•Oil delivery hose flange fastening screws
Screw (oil delivery hose flange):
10 Nm (1.0 mkg)
Screw (oil return hose flange):
35 Nm (3.5 mkg)
•Oil return hose
•Oil return hose flange fastening screws
8. Tighten:
•Stay (rear left side cover) fastening
screws
9. Reassemble:
•Engine oil tank
•Rear frame
•Joint air cleaner clamps
•Rear shock absorber
See section “REAR SHOCK ABSORBER”
in Chapter 4.
•Exhaust pipe
•Exhaust muffler
•Rear wire harness
•Rear cowling
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
10. Fill:
•Engine oil
See section “ENGINE OIL REPLACE-
MENT”.
11. Reassemble:
•Engine tank capScrew (seat):
10 Nm (1.0 mkg)
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CHASREAR SHOCK ABSORBER
4-69
Order Job name/Part name Q.ty Remarks Shock absorber removal Remove the parts in order.
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
Seat Refer to “SEAT, FUEL TANK AND REAR
Fuel tank
Rear cowling COWLING” section in Chapter 3.
Battery leads 2 Disconnect. NOTE:
First, disconnect the negative lead, then the
positive lead.
1 Muffler 1
2 Exhaust pipe assembly 1 Refer to “REAR SHOCK ABSORBER RE-
3 Rear frame 1 MOV AL” section.
4 Brake fluid reserve tank 1 Secure the brake fluid tank to the frame in
5 Air filter case 1 an upright position to avoid air entering the hydraulic system.
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CHASREAR SHOCK ABSORBER
4-73
SHOCK ABSORBER REMOVAL
WARNING
Support the motorcycle securely to prevent it
from falling over.
1. Park the motorcycle on a level surface.
2. Remove:
•Seat
•Rear cowling
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING” in CHAPTER 3.
3. Disconnect:
•Battery leads
8. Remove:
•Upper mounting bolt (1)
•Rear shock absorber
1
NOTE:
First, disconnect the negative lead, then the posi-
tive lead.
4. Remove:
•Exhaust pipe assembly
•Rear frame
•Air filter case
5. Raise the rear wheel placing a suitable sup- port under the engine.
6. Remove:
•Rear wheel
Refer to “REAR WHEEL REMOVAL” sec-
tion.
7. Remove:
•Shock absorber fastening nut (1)
•Lower mounting bolt
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ENGENGINE REMOVAL
5-3
Order Job name/Part name Q.ty Remarks – Starter leads 2 Disconnect.
– Starter 1 Remove.
10 Connectors of engine wire harness 2 Disconnect. 11 Oil delivery hose 1 Disconnect.
12 Oil return hose 1 Disconnect.
13 Oil breather pipe (to oil tank) – Disconnect.
14 Oil breather pipe (to air filter box) – Disconnect. Reverse the removal procedure for
installation.
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ENGENGINE REASSEMBLY
5-77
4. Install:
•Oil delivery hose (1) Union bolt: 18 Nm (1.8 mkg)
Screw (tappet cover): 10 Nm (1.0 mkg)
Air bleeder screw (oil filter cover): 5 Nm (0.5 mkg)
Amount of oil: Camshaft0.1 litres
Oil filter housing 0.06 litres
5. Remove:
•Tappet cover (intake)
•Air bleeder screw (oil filter cover)
6. Apply:
•4-stroke engine oil
•(on the top side of the camshaft and in the
oil filter housing).
Liberally apply 4-stroke engine oil in the oil
passage in the crankcase to prevent damage
to the engine.
CAUTION:
7. Install:
•Tappet cover (intake)
•Air bleeder screw (oil filter cover)
8. Adjust:
•Clutch cable free play Free play (at end of lever): 10 ~ 15 mm
See section “CLUTCH ADJUSTMENT” in
CHAPTER 3.
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FAILURE TO START/
DIFFICULTIES IN STARTING
8-1
TRBL
SHTG
?
TROUBLESHOOTING
NOTE:
The troubleshooting tables that follow do not identify every cause of trouble. They may however prove
helpful as a guide to identifying trouble. To inspect, adjust or replace parts, refer to the appropriate sec-
tion in the manual.
FAILURE TO START/DIFFICULTIES IN STARTING
FUEL SYSTEM
Fuel tank
Fuel cock
Carburetor
Air filter PROBABLE CAUSES
•Empty
•Fuel filter obstructed
•Fuel tank air cap passage obstructed
•Petrol contains water or impurities or is adulterated
•Hose obstructed
•Fuel filter obstructed
•Petrol contains water or impurities or is adulterated
•Pilot jet obstructed
•Pilot air passage obstructed
•Infiltrations of air
•Deformation of float
•Needle valve worn or scratched
•Needle valve seat insufficiently sealed
•Fuel level set wrongly
•Pilot jet set wrongly
•Starter jet obstructed
•Malfunctioning of the starter piston
•Air filter element obstructed
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