fuel YAMAHA TT600RE 2004 User Guide

INSP
ADJ
SPARK PLUG INSPECTION
3-9
SPARK PLUG INSPECTION
1. Remove:
•Seat
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING”.
2. Disconnect:
•Spark plug cap
3. Remove:
•Spark plug (1)
Before removing the spark plug, use com-
pressed air to blow away any dirt accumulat-
ed in the spark plug wells to prevent it from
falling into the cylinder.
When removing the spark plug, be careful not
to drop foreign objects inside the engine.
4. Inspect:
•Type of spark plug
Incorrect ➔Replace.
CAUTION:
CAUTION:
Standard spark plug:
DPR8EA-9 (N.G.K.) or DPR9EA-9 (N.G.K.)
5. Inspect:
•Electrodes (1)
Wear and tear/damage ➔Replace.
•Insulator (2)
Normal insulator (2) colour is light tan.
6. Clean the spark plug with a suitable tool and a
steel brush.
7. Measure:
•Spark plug electrode gap (a)
Use a wire or thickness gauge.
Out of specification ➔Regap.
Electrode gap:
0.8 ~ 0.9 mm
1
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SPARK PLUG INSPECTION
3-10
INSP
ADJ
8. Lock tighten:
•Spark plug
Before installing the spark plug, clean the
surface and thread.
Spark plug:
18 Nm (1.8 mkg)
Seat screws:
10 Nm (1.0 mkg)
NOTE:
Tighten the spark plug by hand before torquing to
specification.
9. Connect:
•Spark plug cap
10. Install:
•Fuel tank
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
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3-12
INSP
ADJ
COMPRESSION INSPECTION
COMPRESSION INSPECTION
NOTE:
Insufficient compression causes a loss of per-
formance.
WARNING
Set the motorcycle firmly in place to prevent it
falling during the operation.
1. Remove:
•Seat
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING”.
2. Check:
•Valve clearance
Out of specification ➔Adjust.
See section “VALVE CLEARANCE AD-
JUSTMENT”.
3. Install:
•Secondary fuel tank
4. Start engine and let it heat.
•Switch off engine.
5. Disconnect:
•Spark plug cap
6. Remove:
•Spark plug (1)
When removing the spark plug, be careful to
prevent foreign bodies from dropping inside
the engine.
CAUTION:
1
7. Apply:
•Pressure gauge (1)
•Adapter (2)
Pressure gauge:
P/N. 90890-03081
Adapter:
P/N. 90890-04082
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3-14
INSP
ADJ
COMPRESSION INSPECTION
9. Remove:
•Secondary fuel tank
•Pressure gauge (with adapter)
10. Reassemble:
•Spark plug
See section “SPARK PLUG INSPEC-
TION”.
Spark plug:
18 Nm (1.8 mkg)
Seat screws:
10 Nm (1.0 mkg)
11. Connect:
•Spark plug cap
12. Reassemble:
•Fuel tank
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.Pressure under compression:
(after adding oil to the cylinder)
Reading Diagnosis
Pressure higherPiston worn or
than beforedamaged.
Pressure same Cylinder head or
as before piston rings, valves,
gaskets may be
faulty.
Pressure above Inspect cylinder
maximum value head, valve sur-
faces, piston rim to
check for carbon
deposits.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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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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SUCTION HOSE AND MANIFOLD INSPECTION/
FUEL LINE INSPECTION
3-28
INSP
ADJ
SUCTION HOSE AND MANIFOLD INSPECTION
1. Remove:
•Seat
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING”.
2. Inspect:
•Suction hoses (1)
Cracked/damaged ➔Replace.
Screw (2) (carburetor manifold):
10 Nm (1.0 mkg)
Screw (3) (clamp):
2 Nm (0.2 mkg)
3. Reassemble:
•Fuel tank
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
FUEL LINE INSPECTION
1. Inspect:
•Fuel pipe (1)
Cracked/Damaged ➔Replace. Seat screws:
10 Nm (1.0 mkg)
1
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STEERING INSPECTION
3-40
INSP
ADJ
STEERING INSPECTION
WARNING
Hold the motorcycle firmly in place to prevent
it falling over.
1. Raise the front wheel and place a support
under the engine.
2. Check:
•Steering bearings
Grasp the bottoms of the front fork legs
and rock back and forward.
Free play ➔Adjust steering bearing.
3. Adjust:
•Steering bearing
Adjustment:
•Remove the fuel tank.
See section “SEAT, FUEL TANK AND REAR
COWLING”.
•Loosen steering axle nut (1) and fork upper
bracket screws (2).
•Tighten the ring nut (3) with the special
wrench.
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1
3
2
2
Ring nut (final tightening):
4 Nm (0.4 mkg)
Ring nut (initial tightening):
38 Nm (3.8 mkg)
Ringnut wrench:
P/N. 90890-01268
P/N. 90890-01348
NOTE:
The torque wrench and the ringnut wrench should
form a right angle.
WARNING
Do not tighten the ring nut excessively.
•Loosen the ring nut one turn.
•Retighten the ring nut using the special
wrench.
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INSP
ADJSTEERING INSPECTION/
TYRE INSPECTION
3-41
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Nut (steering axle):
115 Nm (11.5 mkg)
Screws (front fork bracket):
28 Nm (2.8 mkg)
•Tighten the steering axle nut and the front fork
bracket screws.
•Reassemble the fuel tank.
See section “SEAT, FUEL TANK AND REAR
COWLING”.
NOTE:
Check the steering head for looseness or binding
by turning it all the way in both directions. If it
binds, remove the steering axle assembly and
inspect the steering bearings.
Refer to “STEERING HEAD” in Chapter 6.
TYRE INSPECTION
WARNING
•Tyre pressure must be checked when the
tyres are at ambient temperature. Pressure
must be adjusted according to the total
weight of luggage, driver, passenger and
accessories (fairings, bags, if approved for
this model) and speed of the motorcycle.
•A list of tyres approved for this model fol-
lowing severe testing by Yamaha is provid-
ed. There can be no guarantee of safe road-
holding if a combination of tyres different
from those indicated is used.
•Front and rear tyres must have the same
design and be of the same make.
•The use of valves and valve stems other
than those indicated might cause the loss
of tyre pressure at high speeds. Use only
original or compatible spare parts.
•Replace the valve cap securely to prevent
losses of tyre pressure at high speed.
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