lock YAMAHA TT600RE 2004 Owner's Guide

CHASSTEERING
4-67
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Installation steps:
•Install the ring nut (upper) (1).
•Finger tighten the ring nut (upper), then align
the slots of both ring nuts. If not aligned, hold
the lower ring nut and tighten the other until
they are aligned.
•Install the special washer.
NOTE:
Make sure the special washer tabs are in the
slots.
6. Install:
•Upper bracket
•Fork legs (left and right) (1)
NOTE:
Temporarily install the under bracket pinch bolt to
achieve the correct fork position.
Front fork top end (a) (standard): 0 mm
7. Install:
•Plate washer (1)
•Steering axle nut (2)
Use the lock nut wrench (4).
Lock nut wrench (4):
90890-01348
NOTE:
Set the torque wrench to the lock nut wrench so that
they form a right angle.
Steering axle nut: 115 Nm (11.5 mkg)
ProCarManuals.com

CHASREAR SHOCK ABSORBER
4-71
(1) Rear shock absorber
(2) Spring
(3) Spring adjuster ring nut
(4) Lock ring nut
(5) End of stroke buffer
(6) Special spanner
ProCarManuals.com

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
ProCarManuals.com

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:
ProCarManuals.com

DRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-82
CHAS
DRIVE CHAIN, DRIVE SPROCKET AND
REAR WHEEL SPROCKET
NOTE:
Before removing the drive chain, drive sprocket
and rear wheel sprocket, it is necessary to meas-
ure the free play and length of the 10 links in the
chain.
DRIVE CHAIN REMOVAL
1. Park the motorcycle upright on an even sur- face.
2. Remove:
•Shift pedal (1)
•Cover (2) (drive sprocket)
3. Remove:
•Drive sprocket (1)
NOTE:
•Before removing the sprocket nut, straighten
the tab on the lock washer.
•Loosen the nut with the rear brake pulled.
4. Raise the rear wheel placing a suitable sup- port under the engine.
WARNING
Set the motorcycle up securely to prevent it
falling over.
5. Remove:
•Rear wheel
•Rear wheel sprocket
•Hub
•Damper
•Spacer
Refer to “REAR WHEEL REMOVAL” sec-
tion.


ProCarManuals.com

CHASDRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-85
3. Tighten:
•Rear wheel sprocket fastening bolts
Rear wheel sprocket fastening bolts: 48 Nm (4.8 mkg)
Nut (drive sprocket): 110 Nm (11.0 mkg)
Nut (swingarm pivot shaft): 90 Nm (9.0 mkg)
Nut (frame-relay arm): 60 Nm (6.0 mkg)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
DRIVE CHAIN INSTALLATION
Perform “REMOVAL” operations in reverse order.
Pay special attention to the following points.
1. Install:
•Drive chain
•Swingarm
2. Install:
•Rear wheel
Refer to “REAR WHEEL INSTALLATION”
section.
3. Install:
•Drive sprocket
WARNING
Always use a new lock washer.
NOTE:
•Tighten the drive sprocket nut with the rear
brake pulled.
•After tightening the nut, bend the tab on the
lock washer once more over the faces of the
nut.
4. Adjust:
•Drive chain slack
Refer to “DRIVE CHAIN SLACK ADJUST-
MENT” section in CHAPTER 3.
Drive chain slack: 30 ~ 40 mm
ProCarManuals.com

ENGINE DISASSEMBLY
5-10
ENG
2. Remove:
•Compression spring (1)
•Pressure plate (2)
•Ball (3)
•Friction plate (4)
•Clutch plate (5)
•Clutch boss spring (6)
•Clutch boss (7)
•Thrust plate (8)
•Clutch shroud (9)
•Push rod (10)
1. Remove:
•Engine oil delivery hose screw
•Copper washer
•Oil filter cover (1)
•Oil filter
•Seal ring and O-Ring
•Crankcase cover (2) (R)
NOTE:
•Before loosening the nut (11) (clutch shroud),
straighten the washer lock tab.
•To loosen the nut (clutch boss), block the
clutch boss using the special tool (12).
Clutch holding tool: P/N. 90890-04086
ProCarManuals.com

ENGENGINE DISASSEMBLY
5-11
3. Remove
•Primary drive gear (1)
•Disc (2)
•Balancer drive gear (3)
•Disc (4)
•Key (5)
•Disc washer (6)
•Disc (7)
•Balancer gear (8)
•Straight key (9)
NOTE:
Before loosening the nut (9) (primary drive gear)
and nut (10) (balancer gear), straighten the wash
lock tab.
NOTE:
To loosen nuts (9) and (10), hold the rotor (CA
magneto) firmly in place using special tool (11).
Sheave holder: P/N. 90890-01701
Be careful not to touch jutting edges (12) on
the rotor with the sheave holder.
CAUTION:
4. Remove:
•Push lever (1)
•Spring
•Flat washer
NOTE:
Loosen the screw to remove the push rod.
ProCarManuals.com

ENGENGINE DISASSEMBLY
5-13
AC GENERATOR AND TIMING CHAIN
NOTE:
The AC generator may be inspected with the
engine installed by removing the following parts:
•Crankcase (L)
1. Remove:
•Nut (1)
•Washer (2)
•Rotor (3) (with starter gear)
•Bearing (4)
•Shim adjustment washer (5)
•Key (6)
NOTE:
To loosen the nut (rotor), lock the rotor with the
special tool (7).
Sheave holder: P/N. 90890-01701
Flywheel puller:P/N. 90890-01362
Be careful not to touch the jutting edges (8) on
the rotor with the special tool.
CAUTION:
NOTE:
Remove the rotor with the puller (1).
2. Remove:
•Chain guide (1)
•Timing chain (2)
ProCarManuals.com

ENGENGINE DISASSEMBLY
5-15
•Be careful not to damage surfaces in con-
tact with the crankcase.
•Use a soft hammer to hit the engine
crankcase. Only hit the reinforced parts.
Do not hit the surface in contact with the
gasket. Work slowly and carefully. Be care-
ful to perform the separation uniformly. If
one end locks, remove pressure from the
thrust screw, realign and recommence. If it
is impossible to separate the crankcase,
check that all screws and components
have been disassembled. Do not use force.
CAUTION:
ProCarManuals.com