warning YAMAHA TT600RE 2004 Owner's Manual

CHECKING THE FUSES/
REPLACING THE HEADLIGHT BULBS
3-54
INSP
ADJ
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or using
a fuse with the wrong amperage rating may
cause extensive damage to the electrical sys-
tem, cause the lighting and ignition systems
to malfunction and could possibly cause a fire.
4. Install:
•Pannel
•Seat
REPLACING THE HEADLIGHT BULBS
Low beam/high beam
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)
4. Disconnect:
•Headlight coupler (3)
5. Remove:
•Headlight bulb cover (4)
6. Remove:
•Headlight bulb holder (5) (by turning it
counterclockwise (a))
•Headlight bulb
WARNING
Headlight bulbs get very hot. Therefore, keep
flammable products away from a lit headlight
bulb, and do not touch the bulb until it has
cooled down.








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CHASFRONT WHEEL AND BRAKE DISC
4-1
CHASSIS - FRONT WHEEL AND BRAKE DISC
Order Job name/Part name Q.ty Remarks Front wheel and brake disc Remove the parts in order.
removal
WARNING
Securely support the motorcycle so there
is no danger of it falling over.
1 Speedometer cable 1 Disconnect.
2 Pinch bolt 2 Loosen.
3 Wheel axle 1
4 Front wheel assembly 1 Refer to “FRONT WHEEL INSTALLATION”
5 Collar 1
section.
6 Gear unit assembly 1
7 Brake disc screw 6
8 Brake disc 1
9 Ring 1 Reverse the removal procedure for instal- lation.
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CHASFRONT WHEEL AND BRAKE DISC
4-3
FRONT WHEEL DISASSEMBLY
1. Remove:
•Oil seal
•Bearing (1)
•Spacer
Removal procedure:
•Clean the outside of the hub.
•Remove the dust cover with a flat-headed
screwdriver.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
•Disassemble the bearing (1) with a normal
puller (2).
NOTE:
Place a rag on the outside to avoid damaging the
hub.
FRONT WHEEL INSPECTION
1. Inspect:
•Front wheel axle
(by rolling it on a flat surface)
Bends ➔Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
WARNING
Do not attempt to straighten a bent axle.
2. Inspect:
•Front tire
Wear/damage ➔Replace.
Refer to “TIRE INSPECTION” in CHAP-
TER 3.
•Front wheel
Refer to “WHEEL INSPECTION” in
CHAPTER 3.
3. Inspect:
•Spoke(s)
Bent/Damaged ➔Replace.
Loose spoke(s) ➔ Tighten.
Turn the wheel and hit the spokes gently
with a screwdriver.
NOTE:
A well tightened spoke makes a distinct, sharp
noise: a loose spoke makes a dull, muffled noise.
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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
4-13
MASTER CYLINDER INSPECTION
1. Inspect:
•Master cylinder assembly
Wear/scratches ➔Replace the master
cylinder assembly.
•Master cylinder body
Cracks/damage ➔Replace the master
cylinder assembly.
•Fluid delivery passage
(master cylinder)
Obstruction ➔Clean with a jet of com-
pressed air.
2. Inspect:
•Master cylinder piston unit (1)
Scratches/wear/damage ➔Replace the
master cylinder assembly.
3. Inspect:
•Diaphragm
Wear/damage ➔Replace.
4. Inspect:
•Brake hose
Cracks/wear/damage ➔Replace.
MASTER CYLINDER ASSEMBLY
WARNING
•All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.
Recommended brake fluid: DOT 4
•In case of non correct operation of the
brake master cylinder, replace the master
cylinder assembly.
1. Install:
•Spring (1)
•Master cylinder (2)
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FRONT BRAKE
4-14
CHAS
2. Install:
•Circlip (1)
•Master cylinder boot (2)
MASTER CYLINDER INSTALLATION
1. Install:
•Master cylinder (1)
•Master cylinder bracket (2)
Screw (master cylinder bracket): 9 Nm (0.9 mkg)
2. Install:
•Plain washer (1) (new)
•Brake hose (2)
•Union bolt (3)
Union bolt (brake hose): 20 Nm (2.0 mkg)
NOTE:
•When tightening the union bolt be sure to put
the brake hose in the correct position.
•Check that the brake hose has stayed in the
correct position. Adjust if necessary.
WARNING
•Check that the brake hose routing is as
described. Refer to “CABLE ROUTING”
section.
•Always use new plain washers.
3. Fill:
•Brake fluid reservoir
Recommended brake fluid: DOT 4
2
3
1
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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
4-18
CHAS
BRAKE CALIPER DISASSEMBLY
1. Remove:
•Brake caliper piston
•Dust seal (1)
•Piston seal (2)
Removal procedure:
•Blow compressed air into the hose joint open-
ing to force out the caliper piston from the
brake caliper body.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
•Remove the piston seal.
CALIPER INSPECTION
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Inspect:
•Caliper piston (1)
Scratches/wear/rust ➔Replace caliper
assembly.
•Caliper cylinder (2)
Scratches/wear ➔Replace caliper assem-
bly.
•Caliper (3)
Cracks/damaged ➔Replace the brake
caliper assembly..
Recommended programme for the replace-
ment of brake system components:
Brake pads When necessary
Brake hoses Every four years
Replace every
24,000 km or 24
Brake fluid months and when-
ever the brake is
disassembled.
WARNING
All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation. Do not use solvents to
prevent sealing elements from becoming mis-
shapen or swollen.
WARNING
•Never try to pry out the caliper piston.
•Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the master cylinder.
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CHASFRONT BRAKE
4-19
•Fluid delivery passage (caliper)
Obstruction ➔Clean with compressed air.
CALIPER ASSEMBLY
WARNING
•All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.
•In case of non correct operation of the
brake caliper, replace the brake caliper
assembly. Recommended brake fluid:
DOT 4
2. Install:
•Brake caliper pistons (1)
CALIPER INSTALLATION
1. Install:
•Brake caliper (1)
•Caliper support bolts (2)
Bolt (caliper support): 25 Nm (2.5 mkg)
Union bolt: 20 Nm (2.0 mkg)
WARNING
In case of non correct operation of the brake
caliper, replace the brake caliper assembly.
1. Install:
•Piston seals (1)
•Dust seals (2)
•Brake hose (3)
•Plain washers (4) (new)
•Union bolt (5)
53
2
1
4
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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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