ABS YAMAHA TT600RE 2004 Owner's Manual

REAR SHOCK ABSORBER
4-74
CHAS
SHOCK ABSORBER INSPECTION
1. Inspect:
•Shock absorber
Oil leak/Damaged ➔Replace.
REAR SHOCK ABSORBER ADJUSTMENT
This shock absorber is equipped with a spring pre-
load adjuster.



 

Never attempt to turn an adjusting mecha-
nism beyond the maximum or minimum set-
tings.
CAUTION:
Adjust the spring preload as follows.
1. Loosen the locknut.
2. To increase the spring preload and thereby harden the suspension, turn the adjusting nut
in direction a. To decrease the spring preload
and thereby soften the suspension, turn the
adjusting nut in direction b.
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
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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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SWINGARM
4-80
CHAS
SWINGARM INSTALLATION
Perform “removal” operations in reverse order.
Note the following points.
1. Lubricate:
•Bearings
•Bushes
•Thrust cover (inside)
•Flange
•Swingarm pivot shaft
•Bolt (connecting rod)
•Bolt (relay arm)
•Bolt (shock absorber)
Lithium-base grease
2. Tighten: Nut (relay arm-swingarm): 66 Nm (6.6 mkg)
Nut (relay arm - connecting rod): 52 Nm (5.2 mkg)
Bolt (chain case): 9 Nm (0.9 mkg)
Nut (swingarm pivot shaft): 90 Nm (9.0 mkg)
Bolt (chain support): 4 Nm (0.4 mkg)
Screw (chain case): 4 Nm (0.4 mkg)
Nut (relay arm-frame): 60 Nm (6.0 mkg)
Bolt (rear shock absorber): 59 Nm (5.9 mkg)
3. Install:
•Rear wheel
Refer to “REAR WHEEL INSTALLATION”
section.
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CHASDRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-83

6. Remove:
•Swingarm
•Drive chain
Refer to “REAR SHOCK ABSORBER
REMOVAL” and “SWINGARM REMOVAL”
sections.
DRIVE CHAIN INSPECTION
1. Measure:
•Length of 10 links (drive chain)
Out of specification ➔Replace drive
chain.
Maximum lenght of 10 links (a): 150.2 mm
NOTE:
•Stretch the chain by hand to measure it.
•The length of the 10 links is recorded between
the inside of the link pins (1) and (11) as
shown.
•The length of the 10 links is measured at var-
ious points.
2. Clean:
•Drive chain
Immerge in kerosene and brush thorough-
ly to remove as much dirt as possible.
Remove from kerosene and allow to dry.
This motorcycle is fitted with a chain with
small O-Rings (1) fitted between its plates.
Vapour cleaning, pressurised washing and
certain types of solvents may damage these
seal rings.
To clean the transmission chain use only
kerosene.
CAUTION:
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DEFECTIVE BRAKES/
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK
8-6
TRBL
SHTG
?
PROBABLE CAUSES
•Brake pads worn
•Brake disc worn
•Water in the brake fluid
•Brake fluid leak
•Brake fluid tank defective
•Bleed cap not sealed to calipers
•Union bolt loose
•Brake hose cracked
•Brake disc dirty or greasy
•Brake pads dirty or greasy
•Incorrect brake fluid level
POOR BRAKING
DEFECTIVE BRAKES
PROBABLE CAUSES
•Inner tube deformed, damaged or rusty
•Outer tube damaged or cracked
•Oil seal lip damaged
•Oil seal assembled incorrectly
•Oil level incorrect (excessive)
•Shock-absorber rod stop bolt loose
•O-ring on cap bolt broken
OIL LEAKS
PROBABLE CAUSES
•Inner tube deformed, damaged or rusty
•Outer tube deformed or damaged
•Fork spring damaged
•Piston worn or damaged
•Shock-absorber rod deformed or damaged
•Incorrect oil viscosity
•Incorrect oil level
MALFUNCTIONING
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK
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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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DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS
8-8
TRBL
SHTG
?
PROBABLE CAUSES
•Incorrect bulb
•Excessive absorption of electrical accessories
•Difficulties in charging (charging coil broken
and/or rectifier/regulator defective)
•Uncertain connections
•Wrong negative earthing
•Insufficient contacts (main switch)
•Bulb gone
HEADLIGHT DOES NOT LIGHT
PROBABLE CAUSES
•Light relay/diode defective
•Incorrect bulb
•Rectifier/regulator defective
•Wrong negative earthing
•Main switch defective
•Bulbs gone
FREQUENT BURNING OF BULB PROBABLE CAUSES
•Wrong negative earthing
•Battery flat
•Defective direction indicator switch
•Indicator lamp relay defective
•Harness cut off
•Connector loose
•Bulb gone
DIRECTION INDICATORS FAIL TO TURN ON
PROBABLE CAUSES
•Indicator lamp relay defective
•Insufficient battery capacity
(battery almost flat)
•Bulb (front or rear) burnt out
•Direction indicator switch defective
DIRECTION INDICATORS FAIL TO TURN OFF
DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS
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