clutch YAMAHA TT600RE 2004 User Guide

SPECCABLE ROUTING
2-26

































CABLE ROUTING
(1) Clutch cable
(2) Brake hose holder
(3) Brake hose
(4) Throttle cables
(5) Bands
(6) Lighting wire
harness
(7) Brake and engine
stop switch wire
harness(8) Tachometer/
odometer cable
(9) Complete wire
harness
(10) Socket cover
(11) Engine stop switch
connector
(12) Headlight wire
harness connector
(13) Left turn light
connector(14) Right turn light
connector
(15) Meter wire harness
connector
(16) Main switch wire
harness connector
(17) Clutch switch
(18) Headlight connector
(19) Side/taillight
connector(20) Clutch switch
connector
(21) Brake switch
connector
(22) Clip
[A] Lay the brake hose
throught the holder
on the handle
crown.
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SPECCABLE ROUTING
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(1) Front brake hose
(2) Brake hose holder
(3) Left tube guard
(4) Plastic plate
(5) Throttle cables
(6) Tachometer/
odometer cable
(7) Clutch cable
(8) Clutch cable holder
(9) Throttle cables
holder
(10) Wire harness band(11) Fuel pipe from fuel
cock
(12) Flasher relay
(13) Main relay
(14) Sidestand switch
(15) Diodes (n. 3)
(16) A.C. generator wire
harness (engine)
(17) Engine oil breather
pipe (to engine oil
tank)
(18) Main switch(19) Oil hose (oil tank to
engine)
(20) Oil hose (engine to
oil tank)
(21) C.D.I. unit
(22) Starting motor plus
cable
(23) Starting motor
minus cable
(24) Battery
(25) Starting relay
(26) Fuse (reserve)
(27) Fuse (main)(28) Wire extension
(29) Battery plus cable
[A] Lay the brake hose
behind the left tube
guard and fasten it
down by means of
the plate 4.
[B] Attach throttle
cables 5.
[C] Fasten the fuel pipe
11 to the tank.
[D] Fit the 3 diodes
inside the chassis,
against the coil clip.
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CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENTS
INTRODUCTION..........................................................................................................3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS........................................3-1
SEAT, FUEL TANK AND REAR COWLING................................................................3-3
REMOVAL ............................................................................................................3-3
INSTALLATION ....................................................................................................3-3
ENGINE........................................................................................................................3-4
VALVE CLEARANCE ADJUSTMENT ..................................................................3-4
DRIVE CHAIN ADJUSTMENT ..............................................................................3-7
IDLE SPEED ADJUSTMENT ................................................................................3-7
THROTTLE CABLE FREE PLAY ADJUSTMENT ................................................3-8
SPARK PLUG INSPECTION ................................................................................3-9
IGNITION TIMING CHECK ................................................................................3-11
COMPRESSION INSPECTION ..........................................................................3-12
ENGINE OIL LEVEL CHECK ..............................................................................3-15
ENGINE OIL REPLACEMENT ............................................................................3-17
ENGINE OIL PRESSURE CHECK ....................................................................3-21
CLUTCH ADJUSTMENT ....................................................................................3-21
AIR FILTER CLEANING ......................................................................................3-24
FUEL FILTER CLEANING ..................................................................................3-25
ENGINE OIL TANK FILTER CLEANING ............................................................3-26
SUCTION HOSE AND MANIFOLD INSPECTION..............................................3-28
FUEL LINE INSPECTION ..................................................................................3-28
CRANKCASE VENTILATION HOSE INSPECTION ..........................................3-29
EXHAUST SYSTEM INSPECTION ....................................................................3-29
CHASSIS....................................................................................................................3-30
ADJUSTING THE FRONT BRAKE ....................................................................3-30
ADJUSTING THE REAR BRAKE ......................................................................3-31
CHECKING THE BRAKE FLUID LEVEL ............................................................3-32
BRAKE PAD WEAR INSPECTION ....................................................................3-33
BRAKE HOSING INSPECTION ..........................................................................3-33
BRAKE CIRCUIT BLEEDING ............................................................................3-34
DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT..................................3-35
DRIVE CHAIN LUBRICATION ............................................................................3-36
FRONT FORK INSPECTION ..............................................................................3-37
ADJUSTING THE FRONT FORK ......................................................................3-37
REAR SHOCK ABSORBER ADJUSTMENT ......................................................3-38
STEERING INSPECTION ..................................................................................3-40
TYRE INSPECTION ............................................................................................3-41
WHEEL INSPECTION ........................................................................................3-44
SPOKE INSPECTION AND TIGHTENING ........................................................3-44
CABLE INSPECTION..........................................................................................3-45
LEVER AND PEDAL LUBRICATION ..................................................................3-45
SIDESTAND LUBRICATION ..............................................................................3-46
REAR SUSPENSION LUBRICATION ................................................................3-46
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INSP
ADJINTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
3-1
PERIODIC INSPECTION AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a
longer service life. The need for costly overhaul work will be greatly reduced. This information applies to
vehicles already in service as well as to new vehicles that are being prepared for sale. All service techni-
cians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
ODOMETER READING (x 1,000 km)
ANNUAL N0. ITEM CHECK OR MAINTENANCE JOB
110 2030 40CHECK
1
*Fuel line• Check fuel hoses for cracks or damage. ✓✓ ✓✓ ✓•
• Check condition.
✓✓
2 Spurk plug• Clean and regap.
• Replace.✓✓
3 * Valves• Check valve clearance.
✓✓ ✓✓
• Adjust.
4Air filter element• Clean.✓✓
• Replace. ✓✓
5 Clutch• Check operation.
✓✓ ✓ ✓✓
• Adjust.
• Check operation, fluid level and vehicle for fluid leakeage.
6 * Front brake•(See NOTE). ✓✓ ✓ ✓✓ ✓•
• Replace brake pads. Whenever worm to the limit
• Check operation, fluid level and vehicle
•for fluid leakage. ✓✓ ✓ ✓✓ ✓
7 * Rear brake•(See NOTE).
• Replace brake pads. Whenever worm to the limit
8 * Brake hoses• Check for cracks or damage.✓✓✓✓ ✓• Replace. (See NOTE). Every 4 years
9 * Wheels• Check runout, spoke tightness and for damage.
✓✓✓ ✓
• Tighten spokes if necessary.
• Check tread depth and for damage.
10 * Tyres• Replace if necessary.
✓✓✓✓ ✓
• Check air pressure.
• Correct if necessary.
11 * Wheel bearings• Check bearing for looseness or damage.✓✓✓✓
12 * Swingarm• Check operation and for excessive play.✓✓✓✓
• Check chain slack.
13 * Drive chain• Make sure that the rear wheel is properly aligned.Every 500 km and after washing the
• Clean and lubricate.motorcycle or riding in the rain.
14 *Steering • Check bearing play and steering for roughness. ✓✓ ✓ ✓✓bearings
• Lubrificate with lithium-soap-based grease. Every 20,000 km
15 *Chassis • Make sure that all nuts, bolts and screws are properly
✓✓ ✓✓ ✓
fasteners•tightened.
16Sidestand• Check operation.
✓✓ ✓✓ ✓
• Lubricate.
17
*Sidestand
• Check operation and for oil leakage. ✓✓ ✓ ✓✓ ✓
switch
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3-15
ENGINE OIL LEVEL CHECK
ENGINE OIL LEVEL CHECK
Do not put additives into the engine oil. The
latter also lubricates the clutch and additives
might cause it to slide.
WARNING
Never remove the oil tank cap when the
engine is hot. The boiling oil might spill over,
causing burns. Wait for the oil to cool to at
least 60°C (140°F) or thereabouts.
This model is fitted with a dry crankcase lubrica-
tion system. A feed pump delivers oil to the en-
gine; after fully lubricating the latter, the oil is re-
turned to the tank by a scavenge pump. The oil
level must therefore be checked in the oil tank.
1. Start the engine and warm up until the oil tem-
perature rises to approximately 60°C (140°F).
2. Idle the engine for at least 10 seconds while
keeping the motorcycle upright. After stop the
engine and check the oil level through the
level window (3) located on the left side of the
oil tank assy and(or) by oil level gauge.
NOTE:
Be sure the motorcycle is positioned straight up
when checking the oil level. A slight tilt toward the
side can result in false readings.
3. The oil level should be between the maximum
(1) and minimum (2) marks.
CAUTION:
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ENGINE OIL LEVEL CHECK
If the oil level is below minimum ➔Add oil up
to maximum level.
Recommended oil:
SAE20W40SE or SAE10W30SE
Refer to the chart for selection of
the oils suited to the atmospheric
temperature.
API Standard:
API SE, SF, SG or higher grade
•Do not put in any chemical additives or use
oils with a grade of CD (a) or higher.
•Be sure not to use oils labeled “ENERGY
CONSERVING II” (b) or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
•Be sure no foreign material enters the
crankcase.
4. Reassemble the oil tank cap.
Never start the engine when the oil tank is
empty.
CAUTION:
CAUTION:
Oil capacity:
Total:
3.0 litres
Periodic oil change:
2.4 litres
With oil filter change:
2.5 litres
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3-17
ENGINE OIL REPLACEMENT


ENGINE OIL REPLACEMENT
Do not put additives into the engine oil. The
latter also lubricates the clutch and additives
might cause it to slide.
WARNING
Never remove the oil tank cap when the
engine is hot. The boiling oil might spill over,
causing burns. Wait for the oil to cool to at
least 60°C (140°F) or thereabouts.
Engine oil replacement (without replacing filter
oil)
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.
CAUTION:
7. Inspect:
•All gaskets
Damaged ➔Replace.
8. Reassemble:
•Oil filter cover bleeder screw
•Engine oil drain plug
•Oil tank hose and O-ring 5. Remove the air bleed screw (3) attached to
the oil filter cover (4).
6. Wait until the oil has completely drained.
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ENGINE OIL REPLACEMENT
Fastening torques:
Drain plug (engine):
30 Nm (3.0 mkg)
Oil tank hose (flange):
10 Nm (1.0 mkg)
Oil filter cover air bleeder screw:
5 Nm (0.5 mkg)
9. Fill:
•Oil tank
Recommended oil:
SAE20W40SE or SAE10W30SE
Refer to the chart for selection of
the oils suited to the atmospheric
temperature.
API Standard:
API SE, SF, SG or higher grade
Oil capacity:
Periodic change = 2.4 litres
•Do not put in any chemical additives or
use oils with a grade of CD (a) or higher.
•Be sure not to use oils labeled “ENERGY
CONSERVING II” (b) or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
•Be sure no foreign material enters the
crankcase.
CAUTION:
10. Install:
•Oil tank tap
11. Check:
•Oil level
See section “ENGINE OIL LEVEL
CHECK”.
•Oil pressure
See section “ENGINE OIL PRESSURE
CHECK”.
•Oil leakage
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3-20
INSP
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ENGINE OIL REPLACEMENT
Recommended oil:
SAE20W40SE or SAE10W30SE
Refer to the chart for selection of
the oils suited to the atmospheric
temperature.
API Standard:
API SE, SF, SG or higher grade
Oil capacity:
Total:
3.0 litres
Periodic oil change:
2.4 litres
With oil filter change:
2.5 litres
•Do not put in any chemical additives or use
oils with a grade of CD (a) or higher.
•Be sure not to use oils labeled “ENERGY
CONSERVING II” (b) or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
•Be sure no foreign material enters the
crankcase.
CAUTION:
12. Install:
•Oil tank cap
13. Check:
•Oil level
See section “ENGINE OIL LEVEL
CHECK”.
•Oil pressure
See section “ENGINE OIL PRESSURE
CHECK”.
•Oil leakage 11. Fill:
•Oil tank
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3-21
ENGINE OIL PRESSURE CHECK/
CLUTCH ADJUSTMENT







ENGINE OIL PRESSURE CHECK
1. Remove:
•Bleeder screw (1)
2. Start the engine and keep it idling until oil
flows out of the bleed hole.
3. Inspect:
•Conditions of oil at bleeder hole.
Oil leakage ➔Oil pressure good.
No leakage ➔Pressure insufficient.
If the oil does not come out after one minute,
stop the engine immediately to prevent
seizure.
4. Tighten:
•Bleeder screw
CAUTION:
Bleeder screw:
5 Nm (0.5 kgm)
CLUTCH ADJUSTMENT
Cable free play adjustment
1. Check:
•Clutch free play adjustment (a)
Out of specification ➔Adjust.
Free play:
10 ~ 15 mm
2. Adjust:
•Clutch cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjustment:
•Loosen lock nuts (1).
•Turn the adjuster (2) either way to obtain cor-
rect free play.
•Tighten lock nuts after adjustment.

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