brake YAMAHA TT600RE 2004 Workshop Manual

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.
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•Remove the piston seal.
CALIPER INSPECTION
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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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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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REAR WHEEL AND BRAKE DISC
4-26
CHAS
Lithium-base grease
Check that the brake caliper support has
stayed in the correct position on the rear arm.
CAUTION:
5. Install:
•Rear wheel assembly (in the rear arm)
•Bearing
•Edge of the hub dust cover
Check that the brake disc is driving through
the brake pads.
CAUTION:
Make sure the collars and chain pullers are
positioned correctly.
CAUTION:
6. Install:
•Drive chain (on the driven sprocket)
•Rear wheel axle (left side)
7. Adjust:
•Drive chain slack Drive chain slack: 30 ~ 40 mm
Refer to “DRIVE CHAIN SLACK INSPEC-
TION AND ADJUSTMENT” section in
Chapter 3.
8. Tighten:
•Wheel axle nut
Wheel axle nut: 115 Nm (11.5 mkg)
4. Lubricate:
•Wheel axle
•Bearings
•Edge of hub dust cover
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CHASREAR WHEEL AND BRAKE DISC
4-27
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 rear wheel static balance with the
brake disc installed.
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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4. Adjust:
•Wheel static balance
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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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