wheel YAMAHA TT600RE 2004 Owner's Manual

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.
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•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.
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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 WHEEL AND BRAKE DISC
4-5
BRAKE DISC INSPECTION
1. Inspect:
•Brake disc
Wear/Damage ➔Replace.
2. Measure:
•Brake disc deflection (a)
If over envisaged limits ➔Verify wheel
centring.
If the wheel centring is correct, replace the
brake disc.
Misure at 2 mm from disc edge
•Brake disc thickness (b)
If out of specified limits ➔Replace.
Maximum deflection (brake disc):
0.15 mm
Minimum thickness (brake disc):
3.6 mm
IFRONT WHEEL ASSEMBLY
1. Install:
•Spacer
•Bearings
•Oil seal
Assembly procedure:
•Install the new bearing and the dust cover by fol-
lowing the disassembly procedures in reverse
order.
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NOTE:
Use a wrench (1) with an external diameter equal to
that of the bearing and dust cover.
Do not strike the bearing inner race (2) or balls
(3). The contact must only be made with the
outer race (4).
CAUTION:
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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
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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”.
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•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.
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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.
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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”.
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CHASREAR WHEEL AND BRAKE DISC
4-21
REAR WHEEL AND BRAKE DISC
Order Job name/Part name Q.ty Remarks Rear wheel and brake disc removal Remove the parts in order.
WARNING
Securely support the motorcycle so there
is no danger of it falling over.
1 Axle nut 1
2 Wheel axle 1
3 Drive chain -
4 Collar 2
5 Rear wheel assembly 1
6 Brake disc 1
Push the wheel forward and remove the
chain.
Refer to “REAR WHEEL INSTALLATION”
section.
Reverse the removal procedure for
installation.
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REAR WHEEL AND BRAKE DISC
4-22
CHAS
Order Job name/Part name Q.ty Remarks Rear wheel disassembly Remove the parts in order.
1 Driven sprocket 1
2 Hub 1
3 Damper 4
4 Spacer 1 Refer to “REAR WHEEL DISASSEMBLY/AS-
5 Oil seal 1 SEMBLY” section.
6 Bearing 1
7 Bearing 1
8 Hub dust cover 1
9 Oil seal 1
10 Bearing 1 Reverse the removal procedure for installa-
11 Bearing spacer 1 tion.
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CHASREAR WHEEL AND BRAKE DISC
4-23
REAR WHEEL DISASSEMBLY
1. Remove:
•Hub and driven sprocket
•Dampers
•Hub spacer
•Oil seal
•Hub bearing
•Wheel bearing
•Wheel spacer
•Wheel bearing
•Dust cover
•Oil seal
•Wheel bearing
•Wheel spacer
Removal procedure:
•Clean the outside of the hub.
•Remove the dust cover with a flat-headed screw
driver.

NOTE:
Place a rag on the outside to avoid damaging the
hub.

WARNING
Do not attempt to straighten a bent axle.
•Disassemble the bearing (1) with a normal
puller (2).
REAR WHEEL INSPECTION
1. Inspect:
•Rear wheel axle
(by rolling it on a flat surface)
Bends ➔Replace.
2. Inspect:
•Rear tire
Refer to “TIRE INSPECTION” in CHAP-
TER 3.
•Rear 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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REAR WHEEL AND BRAKE DISC
4-24
CHAS
4. Tighten:
•Loose spokes
5. Measure:
•Rear 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:
•Rear wheel bearings
Bearings allow free play in the wheel hub
or the wheel does not turn smoothly ➔
Replace.
•Hub dust cover
Wear/damage ➔Replace.
•Oil seal
Wear/damage ➔Replace.
Rear wheel runout limits:
Radial (1) : 1.0 mm
Lateral (2) : 0.5 mm
BRAKE DISC INSPECTION
1. Inspect:
•Brake disc
Wear/Damage ➔Replace.
2. Measure:
•Brake disc deflection (a)
If over envisaged limits ➔Verify wheel
centring.
If the wheel centring is correct, replace the
brake disc.
Misure at 2 mm from disc edge
•Brake disc thickness (b)
If out of specified limits ➔Replace.
Maximum deflection
(brake disc):
0.15 mm
Minimum thickness (brake disc):
4.5 mm
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CHASREAR WHEEL AND BRAKE DISC
4-25
REAR WHEEL ASSEMBLY
1. Install:
•Wheel spacer
•Wheel bearing
•Oil seal
•Dust cover
•Wheel bearing
•Wheel spacer
•Wheel bearing
•Hub bearing
•Oil seal
•Hub spacer
•Dampers
•Hub and driven sprocket
Assembly procedure:
•Install the new bearing, the dust cover and the oil
seal by following the disassembly procedures in
reverse order.
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REAR WHEEL INSTALLATION
1. Install:
•Brake disc (1)
NOTE:
Use a wrench (1) with an external diameter equal to
that of the bearing, dust cover and oil seal.
Do not strike the bearing inner race (2) or balls
(3). The contact must only be made with the
outer race (4).
CAUTION:
2. Install:
•Hub spacer (1)
•Driven sprocket (2)
•Hub and driven sprocket 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.
Screw (driven sprocket): 48 Nm (4.8 mkg)
3. Install:
•Collar
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