weight YAMAHA TT600RE 2004 User Guide

FRONT WHEEL AND BRAKE DISC
4-6
CHAS
FRONT WHEEL INSTALLATION
1. Install:
•Brake disc (1)
2. Install:
•Speedometer gear unit (1) Screw (brake disc):
12 Nm (1.2 mkg)
NOTE:
•Apply LOCTITE®to the threads of brake disc
screw.
•Tighten the screws (brake disc) in stage using
a crisscross pattern.
3. Tighten:
•Front wheel
•Front wheel axle
NOTE:
Make sure that the wheel hub and the speedome-
ter gear unit are installed with the projections
meshed into the slots.
•Pinch bolt Front wheel axle:
59 Nm (5.9 mkg)
NOTE:
Make sure that the slot (a) in the speedometer
gear unit fits under the stopper on the front fork
outer tube.
Pinch bolt: 9 Nm (0.9 mkg)a
WHEEL STATIC BALANCE ADJUSTMENT
1. Remove:
•Balancing weight
2. Set:
•Wheel (on a suitable stand)
3. Find:
•Heavy spot
NOTE:
•After replacing the tire and/or rim, the wheel
static balance should be adjusted.
•Adjust the front wheel static balance with the
brake disc installed.
1
ProCarManuals.com

CHASFRONT WHEEL AND BRAKE DISC
4-7
4. Adjust:
•Wheel static balance
Adjusting steps:
•Install a balancing weight (1) on the rim exact-
ly opposite to the heavy spot “X”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
•Turn the wheel so that the heavy spot is 90°
up.
•Check that the heavy spot is at rest there. If
not, try another weight until the wheel is bal-
anced.
NOTE:
Start with the smallest weight.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Check:
•Wheel static balance
Checking steps:
•Turn the wheel so that it comes to each point
as shown.
•Check that the wheel is at rest at each point.
If not, readjust the front wheel static balance.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “X
1” mark on the wheel’s bottom spot.
c. Turn the wheel so that the “X
1” mark is 90° up.
d. Release the wheel and wait for it to rest. Put an “X
2” mark on the wheel’s bottom spot.
e. Repeat the above b., c., and d. several times until all marks come to the same spot.
f. This spot is the wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ProCarManuals.com

CHASREAR WHEEL AND BRAKE DISC
4-27
WHEEL STATIC BALANCE ADJUSTMENT 1. Remove:
•Balancing weight
2. Set:
•Wheel (on a suitable stand)
3. Find:
•Heavy spot
NOTE:
•After replacing the tire and/or rim, the wheel
static balance should be adjusted.
•Adjust the rear wheel static balance with the
brake disc installed.
Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “X
1” mark on the wheel’s bottom spot.
c. Turn the wheel so that the “X
1” mark is 90° up.
d. Release the wheel and wait for it to rest. Put an “X
2” mark on the wheel’s bottom spot.
e. Repeat the above b., c., and d. several times until all marks come to the same spot.
f. This spot is the wheel’s heavy spot “X”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4. Adjust:
•Wheel static balance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjusting steps:
•Install a balancing weight (1) on the rim exact-
ly opposite to the heavy spot “X”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
•Turn the wheel so that the heavy spot is 90°
up.
•Check that the heavy spot is at rest there. If
not, try another weight until the wheel is bal-
anced.
NOTE:
Start with the smallest weight.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ProCarManuals.com

FRONT FORK
4-54
CHAS
12. The vice tightened, grip the outer tube and with a few strong blows hit it against the tool
(3) until the DU outer tube bush (4) is correct-
ly positioned in its seat.
13. Remove the fork leg from the vice and remove the tool (1). Insert the new washer (3) and the
new oil seal (4) as shown on the inner tube (2).
NOTE:
Apply lightweight lithium-soap base grease to the
oil seal before installing it.
14. Mount the tool (1) on the inner tube (2) with the side (5) matching the oil seal (4) and clamp it
keeping the two joints (6) at the top and bot-
tom (never towards the jaws of the vice) and
make it protrude by at least 40 mm at the
sides.
DU bush/oil seal driver (1): 90890-11043
54
3
~ 40 mm
124
5
43
21
15. The vice tightened, grip the outer tube and with a few strong blows hit it against the tool
(1). After each blow rotate the outer tube
slightly in order to install the oil seal (4) cor-
rectly and until it is completely inserted in its
seat.
1
2
64
3
~ 40 mm
ProCarManuals.com

CHASFRONT FORK
4-55
16. Tightly clamp the fork leg horizontally fasten- ing it by caliper attachment on the outer tube.
17. Install:
•Snap ring (1)
Check that the snap ring is correctly seated.
CAUTION:
18. Install:
•Dust seal (1) (new)
NOTE:
Apply lightweight lithium-soap base grease to the
dust seal before installing it.
NOTE:
Taking care to insert completely the dust seal (1)
with force in the outer tube (2).
1
1
 

2
1
ProCarManuals.com

ENGINE DISASSEMBLY
5-18
ENG
ROCKER ARMS
NOTE:
The rocker arms may be examined with the
engine installed by removing the following parts.
•Seat
•Fuel tank
•Cylinder head cover
1. Remove:
•Cap (1)
2. Remove:
•Bolts (1) (rocker shaft)
3. Remove:
•Rocker shaft
•Rocker arms
NOTE:
Remove the rocker shaft using sliding hammer (1)
and weight (2).
Sliding hammer bolt: P/N. 90890-01083
Weight: P/N. 90890-01084
ProCarManuals.com