steering YAMAHA TT600RE 2004 User Guide

CHAS
4-61
STEERING
Order Job name/Part name Q.ty Remarks Steering removal Remove the parts in order.
Park the motorcycle on a level surface.
WARNING
Securely support the motorcycle to pre-
vent it falling over.
Front wheel Refer to “FRONT WHEEL REMOVAL” sec- tion.
Fork legs Refer to “FRONT FORK” section.
1 Cowling/Meter unit 1 Displace.
2 Front fender 1
3 Handle upper holder 2
4 Handle lower holder 1
5 Handlebar 1 Displace.
6 Nut 1
7 Upper bracket 1
8 Special washer 1
TIGHTENING PROCEDURE
• Initial tightening 38 Nm (3.8 mkg)
• Loosen 1 turn
• Final tightening 4 Nm (0.4 mkg)
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STEERING
4-62
CHAS
Order Job name/Part name Q.ty Remarks 9 Upper ring nut 1 Refer to “STEERING REMOVAL/INSTAL-
10 Lower ring nut 1 LATION” section. 11 Ball race cover 1
12 Lower bracket/Steering axle 1
13 Bearing (upper) 1
14 Bearing (lower) 1 Reverse the removal procedure for instal-
lation.
TIGHTENING PROCEDURE
• Initial tightening 38 Nm (3.8 mkg)
• Loosen 1 turn
• Final tightening 4 Nm (0.4 mkg)
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CHAS
4-63
STEERING
(1) Handle upper holder
(2) Handle lower holder
(3) Spacer
(4) Nut
(5) Plate washer
(6) Upper bracket (7) Brake hose holder
(8) Plate washer
(9) Special washer
(10) Upper ring nut
(11) Lower ring nut
(12) Ball race cover (13) Bearings
(14) Steering lock
(15) Steering axle
(16) Wire guide
TIGHTENING PROCEDURE
• Initial tightening 38 Nm (3.8 mkg)
• Loosen 1 turn
• Final tightening 4 Nm (0.4 mkg)
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CHAS
4-64
STEERING
STEERING REMOVAL
1. Park the motorcycle on a level surface.
2. Raise the front wheel placing a suitable sup- port under the engine.
3. Remove:
•Front wheel
Refer to “FRONT WHEEL-REMOVAL”
section.
•Front fork
Refer to “FRONT FORK-REMOVAL” sec-
tion.
4. Remove:
•Front fender
•Cowling
•Handlebar
•Meter assembly
Ring nut wrench (3):
90890-01348
5. Remove:
•Steering axle nut (1)
Use the ring nut wrench (3).
WARNING
Support the motorcycle securely to prevent it
falling over.
6. Remove:
•Ring nut (upper) (1)
•Use the ring nut wrench (2)
Ring nut wrench (2):
90890-01268
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CHAS
4-65
STEERING
Ring nut wrench (2):
90890-01268
7. Remove:
•Ring nut (lower) (1)
•Use the ring nut wrench (2)
WARNING
Support the steering axle to prevent it falling.
STEERING INSPECTION
1. Wash the bearings in solvent.
2. Inspect:
•Bearing (upper and lower) (1)
Corrosion/Damage ➔Replace races and
bearing.
Install the bearings in the races. Spin the
bearing by hand.
If the bearing rises or fails to run freely in
the race, replace bearing and race.
3. Inspect:
•Steering axle (1)
Bend/Damage ➔Replace.
STEERING INSTALLATION
1. Install:
•Bearing (1)
•Ball race cover (2)
NOTE:
Apply lithium soap-base grease to the bearing
and ball race cover lip.
2. Install:
•Lower bracket (1)
NOTE:
Apply lithium soap-base grease to the bearing.
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4-66
CHASSTEERING
3. Install:
•Ring nut (lower) (1)
Use the ring nut wrench (2).
Ring nut wrench: 90890-01268
NOTE:
Apply the lithium soap-base grease to the steer-
ing axle thread.
Lower ring nut tightening steps:
•Tighten the ring nut (1) using the ring nut
wrench.
Ring nut (lower)
(initial tightening): 38 Nm (3.8 mkg)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
•Loosen the ring nut completely and retighten
it to specification.
WARNING
Do not tighten excessively.
Ring nut (lower)
(final tightening): 4 Nm (0.4 mkg)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check the steering axle by turning it lock to lock. If there is any binding, remove the steer-
ing axle assembly and inspect the steering
bearings.
5. Install:
•Ring nut (upper) (1)
•Special washer (2)
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CHASSTEERING
4-67
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Installation steps:
•Install the ring nut (upper) (1).
•Finger tighten the ring nut (upper), then align
the slots of both ring nuts. If not aligned, hold
the lower ring nut and tighten the other until
they are aligned.
•Install the special washer.
NOTE:
Make sure the special washer tabs are in the
slots.
6. Install:
•Upper bracket
•Fork legs (left and right) (1)
NOTE:
Temporarily install the under bracket pinch bolt to
achieve the correct fork position.
Front fork top end (a) (standard): 0 mm
7. Install:
•Plate washer (1)
•Steering axle nut (2)
Use the lock nut wrench (4).
Lock nut wrench (4):
90890-01348
NOTE:
Set the torque wrench to the lock nut wrench so that
they form a right angle.
Steering axle nut: 115 Nm (11.5 mkg)
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STEERING
4-68
CHAS
8. After tightening the nut, check the steering for smooth movement. If it is not smooth, adjust
by progressively loosening the (lower) ring
nut.
9. Tighten:
•Pinch bolts (upper and lower bracket)
Pinch bolt (upper bracket): 28 Nm (2.8 mkg)
Pinch bolt (under bracket): 23 Nm (2.3 mkg)
Fitting nut (handle lower holder): 40 Nm (4.0 mkg)
Flange bolt (handlebar holder): 20 Nm (2.0 mkg)
NOTE:
Always tighten the lower pinch bolt (to the pre-
scribed torque) and then the upper one (to the
prescribed torque) and then retighten the lower
one (to the prescribed torque).
Tighten the pinch bolt to specified torque. If
torqued too much, it may cause malfunction-
ing of the front fork.
10. Install:
•Handlebar holder
•Handlebar
•Handlebar upper holder
CAUTION:
First tighten the front bolt on the handlebar
holder, then tighten the rear bolt.
CAUTION:
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TRBL
SHTG
?
CHAPTER 8°
TROUBLESHOOTING
FAILURE TO START/DIFFICULTIES IN STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
POOR ENGINE COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
POOR PERFORMANCE AT IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED . . . . . . . . . . . . . . . . . 8-3
DIFFICULTIES IN SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
SHIFTING IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
THE SHIFT PEDAL FAILS TO MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
DISENGAGING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
CLUTCH SLIDES OR FAILS TO RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CLUTCH SLIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CLUTCH FAILS TO RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
DEFECTIVE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
POOR BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
OIL LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
MALFUNCTIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
UNSTABLE STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . 8-8
POOR HEADLIGHT ILLUMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
FREQUENT BURNING OF BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DIRECTION INDICATORS FAIL TO TURN ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DIRECTION INDICATORS FAIL TO TURN OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DELAYED TURNING ON OF INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
EXCESSIVE INDICATOR INTERMITTENCE FREQUENCY . . . . . . . . . . . . . . . . . . . 8-9
THE HORN FAILS TO WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
OVERHEATING OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
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UNSTABLE STEERING
8-7
TRBL
SHTG
?
Handlebar
Steering PROBABLE CAUSES•Assembled crooked or incorrectly
•Handlebar crown assembled incorrectly
•Lower bracket crooked
•Lower steering column installed incorrectly
(threaded ring nuts not tightened correctly)
•Bearing or bearing tracks damaged
Front fork
•Oil level not the same in both tubes
•Spring broken
•Front fork crooked
Tyres
•Tyre pressure incorrect for type of road
•Tyre pressure incorrect
•Tyres worn non-uniformly
Wheels
•Wheels balanced incorrectly
•Wheel deformed
•Bearing loose
•Wheel axle deformed or loose
•Wheels excessively off-centre
Frame
•Deformed
•Head tube damaged
•Ball track installed incorrectly
Rear shock absorber
•Spring yielded
•Spring preloaded
•Oil leak
Rear arm
•Bushes or bearings consumed
•Deformed or damaged
Drive chain
•Chain set incorrectly
UNSTABLE STEERING
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