lock YAMAHA TT600RE 2004 Owner's Manual

INSP
ADJ
REPLACING THE HEADLIGHT BULBS
3-55



Auxiliary light bulb
1. Remove:
•Cowling screws (1)
2. Remove:
•Cowling (from the meter bracket)
NOTE:
Remove the cowling from the meter bracket by
lowering it to disengage it, and then lifting it up.
3. Remove:
•Headlight (2)
•Auxiliary light socket (3)
NOTE:
Remove the auxiliary light socket (together with
the bulb) without disconnecting the leads.
•Bulb (by pushing it in and turning it coun-
terclockwise)Cowling screws:
10 Nm (1.0 kgm)
7. Install:
•Headlight bulb (new)
•Headlight bulb holder (by turning it clock-
wise (b))
Do not touch the glass part of the headlight
bulb to keep it free from oil, otherwise the
transparency of the glass, the luminosity of
the bulb, and the bulb life will be adversely
affected. Thoroughly clean off any dirt and
fingerprints on the headlight bulb using a
cloth moistened with alcohol or thinner.
8. Install:
•Headlight bulb cover
9. Connect:
•Headlight coupler
10. Install:
•Upper side of the cowling (onto the meter
bracket)
•Headlight (adjust the headlight beam if
necessary)
11. Install:
•Cowling screws
CAUTION:
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REPLACING THE TURN INDICATOR LIGHT BULB
3-56
INSP
ADJ




REPLACING THE TURN INDICATOR LIGHT
BULB
1. Remove:
•Lens screw (1)
•Lens (2)
•Bulb (3)
NOTE:
To remove the bulb press it into place and turn it
counterclockwise.
2. Install:
•New bulb
NOTE:
To install the bulb press it into place and turn it
clockwise.
•Lens
•Lens screw
Do not overtighten the screw, otherwise the
lens may break.
CAUTION: 4. Install:
•Bulb (new) (by pushing it in and turning it
clockwise)
•Bulb holder
•Upper side of the cowling (onto the meter
bracket)
•Headlight (adjust the headlight beam if
necessary)
5. Install:
•Cowling screws
Cowling screws:
10 Nm (1.0 kgm)
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INSP
ADJREPLACING THE TAIL/
BRAKE LIGHT BULB
3-57






REPLACING THE TAIL/BRAKE LIGHT BULB
1. Remove:
•Screws (1) (lens fixing)
•Lens (2)
•Bulb (3)
NOTE:
To remove the bulb press it into place and turn it
counterclockwise (a).
2. Install:
•New bulb
NOTE:
To install the bulb press it into place and turn it
clockwise (b).
•Lens
•Screws (lens fixing)
Do not overtighten the screws, otherwise the
lens may break.
CAUTION:
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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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CHASFRONT BRAKE
4-15
Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
CAUTION:
WARNING
•Use only designated quality brake fluid.
Otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
•Refill with the same type of brake fluid:
mixing fluids may result in a harmful chem-
ical reaction and lead to poor perform-
ance.
•Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
4. Air bleed:
•Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in CHAPTER 3.
5. Inspect:
•Brake fluid level
Lower than “MIN” mark ➔Fill.
Refer to “BRAKE FLUID INSPECTION”
section in CHAPTER 3.
(a) Minimum level mark “MIN”
6. Install:
•Diaphragm (1)
•Master cylinder cap (2)
•Screw (3) (cap) Screw (master cylinder cap): 1.5 Nm (0.15 mkg)
a
23
1
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FRONT BRAKE
4-20
CHAS
2. Fill:
•Brake fluid reservoir
3. Air bleed:
•Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in CHAPTER 3. Recommended brake fluid:
DOT 4
Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
CAUTION:
WARNING
•Use only designated quality brake fluid.
Otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
•Refill with the same type of brake fluid:
mixing fluids may result in a harmful chem-
ical reaction and lead to poor perform-
ance.
•Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
4. Inspect:
•Brake fluid level
Lower than “MIN” mark ➔Fill.
Refer to “BRAKE FLUID INSPECTION”
section in CHAPTER 3.
(a) Minimum level mark “MIN”
a
WARNING
Check that the brake hose routing is correct.
Refer to “CABLE ROUTING” section.
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REAR BRAKE
4-34
CHAS
MASTER CYLINDER INSTALLATION
1. Install:
•Brake pedal (refer to “BRAKE PEDAL
REMOVAL” section in this Chapter).
NOTE:
Lubricate the pin of the brake pedal with lithium-
base grease.
•Master cylinder
•Brake fluid reserve tank
•Plain washers (1) (new)
•Brake hose (2)
•Stop switch (to mount the brake hose) (3) Brake switch (brake hose): 20 Nm (2.0 mkg)
Master cylinder mounting bolt: 10 Nm (1.0 mkg)
Reserve tank mounting bolt: 4 Nm (0.4 mkg)New
2. Fill:
•Brake fluid reserve tank Recommended brake fluid: DOT 4
Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
CAUTION:
WARNING
•Use only designated quality brake fluid.
Otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
•Refill with the same type of brake fluid:
mixing fluids may result in a harmful chem-
ical reaction and lead to poor perform-
ance.
•Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
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REAR BRAKE
4-40
CHAS
2. Fill:
•Brake fluid reserve tank
Check that the brake hose has stayed in cor-
rect position with the pipe-fitting matching the
projection (a) of the caliper.
CAUTION:
WARNING
Check that the brake hose routing is correct.
Refer to “CABLE ROUTING” section.
Recommended brake fluid: DOT 4
Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
CAUTION:
WARNING
•Use only designated quality brake fluid.
Otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
•Refill with the same type of brake fluid:
mixing fluids may result in a harmful chem-
ical reaction and lead to poor perform-
ance.
•Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
3. Air bleed:
•Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in CHAPTER 3.
a
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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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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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