engine YAMAHA TT600RE 2004 User Guide

SPECMAINTENANCE SPECIFICATIONS
2-14
Tightening
Part to be tightened Thread torque
Remarkssize
N·mm·kg
Engine mounting and rear frame:
Engine front/Stay engine M10 x 1.25 64 6.4
Stay engine (engine front)/Frame M10 x 1.25 64 6.4
Engine rear under/Frame M10 x 1.25 68 6.8
Engine top/Stay engine M10 x 1.25 64 6.4
Engine protector/Frame M6 x 1.0 7 0.7
Chain tensioner top/Frame M8 x 1.25 23 2.3
Chain tensioner under/Frame M8 x 1.25 23 2.3
Frame/Rear frame (upper) M8 x 1.25 23 2.3
Frame/Rear frame (under) M8 x 1.25 23 2.3
Rear frame/Air filter assy M6 x 1.0 5 0.5
Front fork and steering:
Handle crown/Inner tube M8 x 1.25 28 2.8
Handle crown/Steering shaft M28 x 1.5 4 0.4 See “NOTE”
Steering shaft/Ring nut M36 x 1.5 115 11.5
Holder handle upper/Crown handle M8 x 1.25 20 2.0
Holder handle under/Crown handle M10 x 1.5 40 4.0
Front fork under bracket/Inner tube M8 x 1.25 23 2.3
Front master cylinder/Cap M4 x 0.7 1.5 0.15
Front master cylinder/Handle M6 x 1.0 9 0.9
Union bolt tightening M10 x 1.0 20 2.0
Front fender/Front fork M6 x 1.0 7 0.7
Stay headlight/Handle crown M6 x 1.0 10 1.0
Stay headlight/Bracket meter M6 x 1.0 6 0.6
Headlight/Stay headlight M6 x 1.0 10 1.0
Rear arm and cushion:
Pivot shaft/Frame M14 x 1.5 90 9.0
Arm relay/Frame M10 x 1.25 60 6.0
Arm relay/Rod connecting M10 x 1.25 52 5.2
Arm relay/Shock absorber M10 x 1.25 59 5.9
Rod connecting/Rear arm M12 x 1.25 66 6.6
Shock absorber upper/Frame M12 x 1.25 66 6.6
Seal guard/Rear arm M6 x 1.0 4 0.4
Support chain/Rear arm M6 x 1.0 9 0.9
Chain case/Rear arm M6 x 1.0 9 0.9
Front wheel:
Front wheel shaft/Front fork M16 x 1.5 59 5.9
Axle holder//Front fork M6 x 1.0 9 0.9
Rear wheel:
Rear wheel shaft/Nut M18 x 1.5 115 11.5
Clutch hub/Sprocket M10 x 1.25 48 4.8
Tightening torques
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SPECMAINTENANCE SPECIFICATIONS
2-15
Tightening
Part to be tightened Thread torque
Remarkssize
N·mm·kg
Front brake:
Front hub/Disc brake M6 x 1.0 12 1.2
Front caliper/Front fork M8 x 1.25 25 2.5
Front caliper/Bleeder tightening M10 x 1.0 14 1.4
Union bolt tightening (front) M10 x 1.0 20 2.0
Rear brake:
Rear hub/Disc brake M6 x 1.0 12 1.2
Rear master cylinder/Frame M6 x 1.0 10 1.0
Rear stop switch/Rear master cylinder M10 x 1.0 20 2.0
Rear caliper/Bleeder tightening M10 x 1.0 14 1.4
Protector rear caliper/Rear caliper M6 x 1.0 10 1.0
Union bolt tightening (rear) M10 x 1.0 20 2.0
Rear brake tank reserve/Air cleaner assy M6 x 1.0 5 0.5
Brake pedal/Frame M10 x 1.25 48 4.8
Sidestand/Footrest:
Sidestand mounting bolt/Frame M12 x 1.25 40 4.0
Sidestand mounting bolt/Nut M12 x 1.25 40 4.0
Sidestand switch/Frame M5 x 0.8 8 0.8
Rear footrest/Rear frame M8 x 1.25 30 3.0
Bracket 1 (main footrest)/Frame M10 x 1.25 48 4.8
Bracket 2 (main footrest)/Frame M10 x 1.25 48 4.8
Footrest cover/Footrest M6 x 1.0 10 1.0
Seat, fuel tank and oil tank:
Seat/Frame M6 x 1.0 10 1.0
Bolt (guide seat)/Fuel tank M6 x 1.0 5 0.5
Fuel tank/Rear frame M6 x 1.0 12 1.2
Damper fuel tank (front)/Frame M8 x 1.25 15 1.5
Fuel tank/Fuel cock M6 x 1.0 7 0.7
Oil tank/Sub-oil tank M6 x 1.0 7 0.7
Union bolt (oil hose 2)/Oil tank assy/Engine M12 x 1.25 35 3.5
Oil hose 1/Oil tank/Engine M6 x 1.0 10 1.0
Oil tank/Rear frame M12 x 1.5 20 2.0
Frame, rear fender compl. and lights:
Rear fender compl. (under)/Rear frame M6 x 1.0 2 0.2
Rear fender compl. (upper)/Rear frame M6 x 1.0 7 0.7
Bracket, license/Rear frame M6 x 1.0 10 1.0
Bracket, license/Rear flasher M6 x 1.0 10 1.0
Horn/Frame M6 x 1.0 13 1.3
Regulator/Frame M8 x 1.25 7 0.7
Igniton coil/Frame M5 x 0.8 13 1.3
Battery box/Rear frame M6 x 1.0 7 0.7
Igniter cover/Battery box M4 1 0.1
Main switch/Frame M24 x 1.0 1 0.1
Tail light (lense)/Rear fender compl. M3.5 1 0.1
Starter switch/Red wire M6 x 1.0 7 0.7
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SPECMAINTENANCE SPECIFICATIONS
2-16
Tightening
Part to be tightened Thread torque
Remarkssize
N·mm·kg
Starting motor cord/Starting motor M6 x 1.0 11 1.1
Wire minus lead (-)/Starting motor M6 x 1.0 10 1.0
Front flasher lights/Stay, headlight M6 x 1.0 1.5 0.15
Clutch wire/Engine M6 x 1.0 7 0.7
Assist grip (Standing handle)/Rear frame M8 x 1.25 23 2.3
Speedometer M5 x 0.8 4 0.4
Air filter case 1/Air filter case 2 (L = 13 mm) M3.9 0.5 0.05
Air filter case 1/Air filter case 2 (L = 19 mm) M3.9 1 0.1
Hose clamp/Joint, carburator M4 x 0.7 0.6 0.06
Hose clamp/Air cleaner/Carburator M5 x 0.8 0.8 0.08
Battery (+)/(-) M6 x 1.0 2.5 0.25
NOTE:
1. First tighten the ring nut approximately 38 Nm (3.8 mkg) by using the torque wrench, then loosen the
ring nut one turn.
2. Final tighten the ring nut at the torque of 4 Nm (0.4 mkg).
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2-20
SPECLUBRlCATlON POINTS AND LUBRICANT TYPE
LUBRlCATlON POINTS AND LUBRICANT TYPES
ENGINE
Lubrication points (part name) Lubricant type
Oil seal edges (completely)
Bearing retainer
Rod pins
Rod (big end)
Piston and piston rings
Hub (weight drive sprocket)
Piston pin
Valve stim and guide
Oil seal (valve stim end)
Rocker shaft and rocker arm
Cam and bearing (camshaft)
Rotor and rotor housing (oil pump)
Push rod (clutch)
Primary driven gear and main shaft
Sliding gear (transmission)
Idle gear (transmission)
Shift forks and bar
Shift cam and bearing (gearshift cam)
Shift shaft
Rod housing coupled surfaces Bonding agent (rapid seal adhesive)®
Yamaha bond No. 1215®
Coupled surfaces (cylinder head and cylinder head cover) Bonding agent (rapid seal adhesive)®
Yamaha bond No. 1215®
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2-22
SPECLUBRICATION LAYOUT
LUBRICATION LAYOUT
(1) Oil tank
(2) Oil pump
(3) Oil filter (oil tank)
(4) Oil strainer (engine)
(5) Oil vapour retrieval hose
(6) Oil blow-by retrieval hose[A] DELIVERY
[B] RETRIEVAL
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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
2-27









































(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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SPECCABLE ROUTING
2-28
(1) Tachometer/
odometer cable
(2) Tachometer/
odometer cable
holder
(3) Tachometer/
odometer cable
band
(4) Right tube guard
(5) Spark plug cable
(6) Horn(7) Carburetor suction
pipe
(8) Main wire harness
band
(9) Rear brake switch
wire harness
(10) Rear brake fluid
tank hose
(11) Hose from rear
master cylinder to
caliper(12) Rear brake hose
holders
(13) Pipe
(14) Air breather pipe
(15) Spark plug ignition
coil
(16) Chassis ground
(17) Engine oil
breather pipe
(to air filer case)[A] Insert the
tachometer/
odometer cable into
the band 3 and the
holder 2.



















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SPECCABLE ROUTING
2-29
(1) Rectifier
(2) Wire harness bands
(3) Protection
(4) Left turn wire
harness(5) Right turn wire
harness
(6) Tail light wire
harness
(7) Air breather pipe
(carburetor)(8) Wire extension
(9) Starter power
cables
(10) Engine cables and
side stand switch[A] Screw protection 3
after setting wiring
properly.













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INSP
ADJ
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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