torque YAMAHA TT600RE 2004 User Guide

DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT/
DRIVE CHAIN LUBRICATION
3-36
INSP
ADJ
Rear wheel axle nut:
115 Nm (11.5 mkg)
•Turn each adjusting bolt exactly the same
amount to maintain correct axle alignment.
There are marks on each side of the
swingarm. Use these marks to align the rear
wheel.
DRIVE CHAIN LUBRICATION
The chain consists of many parts which work with
each other. If the chain is not maintained properly,
it will wear out quickly. Therefore, the chain must
be serviced regularly. This service is especially
necessary when riding in dusty areas. This motor-
cycle has a drive chain with small rubber O-Rings
between the chain plates. Steam cleaning, high-
pressure washing and certain solvents can dam-
age these O-Rings. Use only kerosene to clean
the drive chain. Wipe it dry, and thoroughly lubri-
cate it with SAE 80 ~ 90W motor oil or special lu-
bricant for O-Ring chains. Do not use any other lu-
bricants on the drive chain. They may contain sol-
vents that could damage the O-Rings.
Recommended lubricant:
SAE 80W/90 engine oil or
special lubricant for
O-Ring chains.
(1) O-Rings
•Loosen the axle nut (1).
•Loosen the locknuts (2) on each side. To tight-
en the chain, turn the chain adjusting bolts (3)
in direction (a). Loosen the locknuts on each
side. To loosen the chain, turn the chain
adjusting bolts in direction (b) and push the
wheel forward.
•After adjusting, tighten the locknuts (2). Then
tighten the axle nut (1) to the specified torque.
a
b
2
13
➩➩
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INSP
ADJ
REAR SHOCK ABSORBER ADJUSTMENT
3-39
NOTE:
•Use the special wrench included in the
owner's tool kit to make the adjustment.
•The spring preload setting is determined by
measuring distance A, shown in the illustra-
tion. The longer distance A is, the lower the
spring preload; the shorter distance A is, the
higher the spring preload. With each com-
plete turn of the adjusting nut, distance A
changes by 1.5 mm.
Spring preload:
Minimum (soft):
Distance A = 217 mm
Standard:
Distance A = 211 mm
Maximum (hard):
Distance A = 205 mm
2. Tighten the locknut to the specified torque.
Always tighten the locknut against the adjust-
ing nut, and then tighten the locknut to the
specified torque.
CAUTION:Locknut:
45 Nm (4.5 m·kgf)
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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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FRONT WHEEL AND BRAKE DISC
4-4
CHAS
4. Tighten:
•Loose spokes
5. Measure:
•Front wheel runout
Over the specified limits ➔Replace.
Spoke:
2 Nm (0.2 mkg)
NOTE:
After tightening the spokes, check the centring of
the wheel.
6. Inspect:
•Front wheel bearings
Bearings allow free play in the wheel hub
or the wheel does not turn smoothly ➔
Replace.
•Oil seal
Wear/damage ➔Replace.
Front wheel runout limits:
Radial (1) : 1.0 mm
Lateral (2) : 0.5 mm
WARNING
•After assembling a tyre, drive slowly to
allow it to adapt to the rim. If this precau-
tion is not observed, damage might be
caused to the motorcycle and accidents to
the driver.
•After repairing or changing a tyre, do not
forget to tighten the valve lock nut (1) to
the prescribed torque.
Valve lock nut: 1.5 Nm (0.15 mkg)
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FRONT FORK
4-48
CHAS
Cap bolt (on inner tube): 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).
15. Tighten:
•Cap bolt (on inner tube)
14. Tighten:
•Pinch bolt (upper and lower bracket)
Pinch bolt (upper bracket): 28 Nm (2.8 mkg)
Pinch bolt (under bracket): 23 Nm (2.3 mkg)
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CHASFRONT FORK
4-59
FRONT FORK INSTALLATION
1. Install:
•Front fork (1)
Temporarily tighten the pinch bolts (lower).
2. Tighten:
•Cap bolt
Cap bolt: 20 Nm (2.0 kgm)
NOTE:
Do not tighten the pinch bolt (upper) yet.
3. Adjust:
•Front fork top end (a)
Front fork top end (a)
(Standard): 0 mm
4. Tighten:
•Pinch bolt (upper and lower bracket)
Pinch bolt (upper bracket): 28 Nm (2.8 mkg)
Pinch bolt (under bracket): 23 Nm (2.3 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).
5. Install:
•Front wheel
•Caliper
•Brake hose
•Tachometer cable
Refer to “FRONT WHEEL” and “FRONT
BRAKE” sections in this CHAPTER.
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CHASSTEERING
4-67
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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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CHASREAR SHOCK ABSORBER
4-75
2. Tighten the locknut to the specified torque. Locknut: 45 Nm (4.5 m·kgf)
Always tighten the locknut against the adjust-
ing nut, and then tighten the locknut to the
specified torque.
CAUTION:
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CHASSWINGARM
4-77
SWINGARM REMOVAL
NOTE
Check free play and remove swingarm, if neces-
sary, after removing the rear shock absorber.
1 . Remove:
•Swingarm connecting rod bolt (1)
2 . Check:
•Swingarm free play▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Inspection procedure:
•Check the tightening torque of the nut which
fastens the swingarm pivot shaft (1).
Nut (pivot shaft): 90 Nm (9.0 mkg)
Lateral free play
(at end of swing arm):
Limit: 1.0 mm
•Check the lateral free play [A] of the swingarm
moving it laterally.
If the free play seems excessive, verify the
collar, bearings, washer and thrust cover.
•Check the vertical movement [B] of the
swingarm, moving it up and down.
If the movement seems rigid, unsmooth or
jerky, inspect the internal collar, the bearings,
the washer and the thrust cover.
1
1
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