brake YAMAHA TT600RE 2004 User Guide

INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
3-2
INSP
ADJ
ODOMETER READING (x 1,000 km)
ANNUAL N0. ITEM CHECK OR MAINTENANCE JOB
110 2030 40CHECK
18 * Rear brake• Check operation, fluid level and vehicle for fluid leakage. ✓✓✓ ✓
Rear shock
• Check operation and shock absorber for oil leakage.
19
*absorber ✓✓✓ ✓
assemblysull’ammortizzatore.
Rear suspension
• Check operation.
✓✓✓ ✓
20*
relay arm and
connecting arm
• Lubricate with lithium-soap-based grease.
✓✓
pivoting points
• Check starter (choke) operation.
21 * Carburator
• Adjust engine idling speed.✓✓ ✓✓ ✓ ✓
22 Engine oil• Change.
✓✓ ✓✓ ✓ ✓
• Check oil level and oil leakage.
23Engine oil filter
• Replace.✓✓✓
element
24 *Front and rear •
brake switches• Check operation.✓✓ ✓✓ ✓ ✓
Moving parts
25
and cables• Lubricate. ✓✓✓ ✓ ✓
Throttle grip • Check operation and free play.
26 * housing and • Adjust the throttle cable free play if necessary.
✓✓✓ ✓ ✓
cable • Lubricate the throttle grip housing and cable.
27 *Muffler and
• Check the screw clamp for looseness. ✓
exhaust pipe
28 *Lights, signals • Check operation.
✓✓ ✓✓ ✓ ✓
and switches• Adjust headlight beam.
* Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance is per-
formed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake system:
• Check the brake fluid level regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
ProCarManuals.com

CLUTCH ADJUSTMENT
3-22
INSP
ADJ
NOTE:
After adjustment, recheck lever free play to make
sure that it works smoothly and progressively.
If it is impossible to obtain the required adjust-
ment or if the clutch does not work properly,
adjust the internal mechanism.
Internal mechanism adjustment
1. Loosen:
•Lock nuts on the lever cable adjuster and
crankcase adjuster
2. Fully tighten:
•Adjusters
3. Drain off:
•Engine oil
See section “ENGINE OIL REPLACE-
MENT”.
4. Remove:
•Footrest (right) (1)
•Engine protector (2)
5. Disconnect:
•Brake pedal return spring (3)
6. Remove:
•Rear master cylinder fastening screws (4)
•Oil delivery hose fastening screw (5)
•Right crankcase cover fastening screws
•Right crankcase cover (6)
7. Loosen:
•Lock nut (1)
8. Push the engine clutch control lever forward
to the stop point.
9. Adjust:
•Free play
With the lever in this position, turn the
adjuster (2) either way until the marks on
the lever (3) and crankcase (4) are
aligned.
10. Tighten:
•Lock nut (1)
Lock nut:
8 Nm (0.8 mkg)
ProCarManuals.com

INSP
ADJ
CLUTCH ADJUSTMENT
3-23
11. Install:
•Right crankcase cover
•Right crankcase cover fastening screws
•Oil delivery hose fastening screw
Screw (crankcase cover):
10 Nm (1.0 mkg)
Oil delivery hose screw:
18 Nm (1.8 mkg)
Screw (rear master cylinder):
10 Nm (1.0 mkg)
Bolt (footrest):
48 Nm (4.8 mkg)
12. Connect:
•Brake pedal return spring
•Rear master cylinder
13. Reassemble:
•Footrest (right)
Free play (at lever tip):
10 ~ 15 mm
See section “Cable free play adjustment”.
•Engine protector
14. Fill:
•Engine oil tank
See section “ENGINE OIL REPLACE-
MENT”.
15. Adjust:
•Clutch cable free play
ProCarManuals.com

ADJUSTING THE FRONT BRAKE
3-30
INSP
ADJ




CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
• Brake lever position
(distance abetween the brake lever and
the handlebar grip)
a. Turn the adjusting dial 1while holding the
lever pushed away from the handlebar grip
NOTE:
Align the setting on the adjusting dial with the
arrow mark 2
WARNING
After adjusting the brake lever position, make
sure the pin on the brake lever holder is firm-
ly inserted in the hole in the adjusting dial.
WARNING
A soft or spongy feeling in the brake lever can
indicate the presence of air in the brake sys-
tem. Before the vehicle is operated, the air
must be removed by bleeding the brake sys-
tem. Air in the brake system will considerably
reduce braking performance and could result
in loss of control and possibly an accident.
Therefore, inspect and, if necessary, bleed the
brake system. After adjusting the brake lever
free play, make sure that there is no brake
drag.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Posizione n. 1 La distanza a a
è la
massima.
Posizione n. 4 La distanza a a
è la
minima.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ProCarManuals.com

1
2
INSP
ADJ
ADJUSTING THE REAR BRAKE
3-31
ADJUSTING THE REAR BRAKE
1. Check:
•Brake pedal position
(distance afrom the top of the rider
footrest to the top of the brake pedal)
Out of specification ➔Adjust.
2. Adjust:
•Brake pedal position
•Tighten lock nut.
After adjusting the brake pedal position, make
sure the brake doesn't oppose resistance.
CAUTION:
•Loosen lock nut (1).
•Turn the adjuster (2) either way to obtain the
correct pedal height.
WARNING
If the brake brake pedal has a soft or slack
feel, this means that there is air in the brake
system. It should be bled away before using
the motorcycle. Air in the system seriously
affects the effectiveness of braking and may
cause loss of control of the motorcycle.
Brake pedal position
(below the top of the rider footrest):
10 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Unscrewing Height (a) diminishes.
Screwing Height (a) increases.
Lock nut:
20 Nm (2.0 mkg)
ProCarManuals.com

CHECKING THE BRAKE FLUID LEVEL
3-32
INSP
ADJ
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
•Place the motorcycle on a suitable stand.
•Make sure that the motorcycle is upright.
2. Check:
•Brake fluid level
Below the minimum level mark a➔Add
the recommended brake fluid to the prop-
er level.
[A] Front brake
[B] Rear brake
WARNING
•Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
•Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
•When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
Brake fluid may damage painted surfaces and
plastic parts. Therefore, always clean up any
spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the reservoir
is horizontal.
CAUTION:
Recommended brake fluid:
DOT4





ProCarManuals.com

INSP
ADJBRAKE PAD WEAR INSPECTION/
BRAKE HOSING INSPECTION
3-33
1. Operate the brake lever or brake pedal.
2. Check:
•Thickness of frictional material
Out of specification ➔Replace.
BRAKE HOSING INSPECTION
1. Inspect:
•Brake hosing
Cracks/Damage ➔Replace.
To replace hosing, see section “FRONT
AND REAR BRAKE” in Chapter 4.
B
B
A
a
Wear limit (a):
Front: 1.0 mm
Rear: 1.0 mm
For brake pad replacement, see section
“BRAKE PAD REPLACEMENT” in
Chapter 4.
[A] Front brake
[B] Rear brake
[A] Front brake
[B] Rear brake
a
A
ProCarManuals.com

BRAKE CIRCUIT BLEEDING
3-34
INSP
ADJ
1
1B
BRAKE CIRCUIT BLEEDING
WARNING
If the brake lever or brake pedal has a soft or
slack feel, this means that there is air in the
brake system. It should be bled away before
using the motorcycle. Air in the system seri-
ously affects the effectiveness of braking and
may cause loss of control of the motorcycle.
In all cases, bleed the brake system if:
•The system has been disassembled.
•A brake hose has been loosened or
removed.
•The brake fluid in the tank is at a very low
level.
•Brake operation is faulty.
Air bleeding procedures:
a. Top up the level of the fluid in the tank to max-
imum.
b. Install the diaphragm. Be careful not to spill
fluid or let it overflow from the tank.
c. Connect the clear plastic hose (1) to the
caliper bleeder screw.
[A] Front
[B] Rear
d. Place the other end of the hose in a container.
e. Slowly pull the brake lever or press the brake
pedal several times.
f. Pull the brake lever right in or press the pedal
right down and hold in position.
g. Loosen the bleeder screw and allow the lever
or pedal to travel slowly towards its limit.
h. Tighten the bleeder screw when the lever or
pedal limit has been reached, then release the
lever or pedal.
Bleeder screw:
14 Nm (1.4 mkg)
i. Repeat operations (e) to (h) until all the air
bubbles have disappeared from the clear
plastic hose (1).
A
ProCarManuals.com

INSP
ADJ
DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT
3-35

NOTE:
If bleeing proves difficult, it may be necessary to
allow the brake fluid system to stabilise for a few
hours. Repeat the bleeding procedure when the
tiny bubbles in the system have disappeared.
j. Top up fluid to the maximum level.
DRIVE CHAIN SLACK INSPECTION AND
ADJUSTMENT
Inspecting slack:
NOTE:
Before checking and/or adjusting the chain, rotate
the rear wheel through several revolutions and
check the slack several times to find the point on
the wheel where chain slack is highest.
Check and/or adjust chain slack with rear wheel in
this “tight chain” position.
Drive chain slack:
30 ~ 40 mm
NOTE:
To check chain slack, the motorcycle must stand
in an upright position with its two wheels touching
the ground and no one sitting on it. Check slack in
the position shown in the figure.
2. Adjust:
•Drive chain slack
Slack adjustment:
Too little chain slack will overload the engine
and other vital parts. Keep the slack within the
specified limits.
CAUTION: 1. Check:
•Drive chain slack (a)
Out of specification ➔Adjust.
ProCarManuals.com

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
ProCarManuals.com