YAMAHA TT600RE 2004 Manual PDF

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3-17
ENGINE OIL REPLACEMENT


ENGINE OIL REPLACEMENT
Do not put additives into the engine oil. The
latter also lubricates the clutch and additives
might cause it to slide.
WARNING
Never remove the oil tank cap when the
engine is hot. The boiling oil might spill over,
causing burns. Wait for the oil to cool to at
least 60°C (140°F) or thereabouts.
Engine oil replacement (without replacing filter
oil)
1. Warm up the engine for a few minutes.
2. Stop the engine. Place an oil pan under the
engine and remove the oil filler cap.
3. Remove the drain plug (1) and drain the
engine oil.
4. Remove two bolts (2) and O-ring of the oil
hose flange, and drain the oil from oil tank.
CAUTION:
7. Inspect:
•All gaskets
Damaged ➔Replace.
8. Reassemble:
•Oil filter cover bleeder screw
•Engine oil drain plug
•Oil tank hose and O-ring 5. Remove the air bleed screw (3) attached to
the oil filter cover (4).
6. Wait until the oil has completely drained.
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3-18
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ADJ
ENGINE OIL REPLACEMENT
Fastening torques:
Drain plug (engine):
30 Nm (3.0 mkg)
Oil tank hose (flange):
10 Nm (1.0 mkg)
Oil filter cover air bleeder screw:
5 Nm (0.5 mkg)
9. Fill:
•Oil tank
Recommended oil:
SAE20W40SE or SAE10W30SE
Refer to the chart for selection of
the oils suited to the atmospheric
temperature.
API Standard:
API SE, SF, SG or higher grade
Oil capacity:
Periodic change = 2.4 litres
•Do not put in any chemical additives or
use oils with a grade of CD (a) or higher.
•Be sure not to use oils labeled “ENERGY
CONSERVING II” (b) or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
•Be sure no foreign material enters the
crankcase.
CAUTION:
10. Install:
•Oil tank tap
11. Check:
•Oil level
See section “ENGINE OIL LEVEL
CHECK”.
•Oil pressure
See section “ENGINE OIL PRESSURE
CHECK”.
•Oil leakage
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INSP
ADJ
3-19
ENGINE OIL REPLACEMENT
 
Engine oil replacement (with oil filter replace-
ment)
1. Warm up the engine for a few minutes.
2. Stop the engine. Place an oil pan under the
engine and remove the oil filler cap.
3. Remove the drain plug (1) and drain the
engine oil.
4. Remove two bolts (2) and O-ring of the oil
hose flange, and drain the oil from oil tank.
5. Remove the air bleed screw (3) attached to
the oil filter cover (4).
6. Wait until the oil has completely drained.
NOTE:
The oil filter cover is secured by three screws (5).
The lower one should be removed so that the fil-
ter cavity will drain.

7. Remove the other filter cover screws and
remove the oil filter cover.
8. Remove the oil filter (6) and O-ring (7).
9. Inspect:
•All gaskets
•O-rings
Damaged ➔Replace.
10. Reassemble:
•(New) filter cartridge
•Filter cover screw
•Oil filter cover bleeder screw
•Engine drain plug
•Oil tank hose
Fastening torques:
Drain plug (engine):
30 Nm (3.0 mkg)
Oil tank hose (flange):
10 Nm (1.0 mkg)
Filter cover screw:
10 Nm (1.0 mkg)
Oil filter cover bleeder screw:
5 Nm (0.5 mkg)
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3-20
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ADJ
ENGINE OIL REPLACEMENT
Recommended oil:
SAE20W40SE or SAE10W30SE
Refer to the chart for selection of
the oils suited to the atmospheric
temperature.
API Standard:
API SE, SF, SG or higher grade
Oil capacity:
Total:
3.0 litres
Periodic oil change:
2.4 litres
With oil filter change:
2.5 litres
•Do not put in any chemical additives or use
oils with a grade of CD (a) or higher.
•Be sure not to use oils labeled “ENERGY
CONSERVING II” (b) or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
•Be sure no foreign material enters the
crankcase.
CAUTION:
12. Install:
•Oil tank cap
13. Check:
•Oil level
See section “ENGINE OIL LEVEL
CHECK”.
•Oil pressure
See section “ENGINE OIL PRESSURE
CHECK”.
•Oil leakage 11. Fill:
•Oil tank
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INSP
ADJ
3-21
ENGINE OIL PRESSURE CHECK/
CLUTCH ADJUSTMENT







ENGINE OIL PRESSURE CHECK
1. Remove:
•Bleeder screw (1)
2. Start the engine and keep it idling until oil
flows out of the bleed hole.
3. Inspect:
•Conditions of oil at bleeder hole.
Oil leakage ➔Oil pressure good.
No leakage ➔Pressure insufficient.
If the oil does not come out after one minute,
stop the engine immediately to prevent
seizure.
4. Tighten:
•Bleeder screw
CAUTION:
Bleeder screw:
5 Nm (0.5 kgm)
CLUTCH ADJUSTMENT
Cable free play adjustment
1. Check:
•Clutch free play adjustment (a)
Out of specification ➔Adjust.
Free play:
10 ~ 15 mm
2. Adjust:
•Clutch cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjustment:
•Loosen lock nuts (1).
•Turn the adjuster (2) either way to obtain cor-
rect free play.
•Tighten lock nuts after adjustment.

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CLUTCH ADJUSTMENT
3-22
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NOTE:
After adjustment, recheck lever free play to make
sure that it works smoothly and progressively.
If it is impossible to obtain the required adjust-
ment or if the clutch does not work properly,
adjust the internal mechanism.
Internal mechanism adjustment
1. Loosen:
•Lock nuts on the lever cable adjuster and
crankcase adjuster
2. Fully tighten:
•Adjusters
3. Drain off:
•Engine oil
See section “ENGINE OIL REPLACE-
MENT”.
4. Remove:
•Footrest (right) (1)
•Engine protector (2)
5. Disconnect:
•Brake pedal return spring (3)
6. Remove:
•Rear master cylinder fastening screws (4)
•Oil delivery hose fastening screw (5)
•Right crankcase cover fastening screws
•Right crankcase cover (6)
7. Loosen:
•Lock nut (1)
8. Push the engine clutch control lever forward
to the stop point.
9. Adjust:
•Free play
With the lever in this position, turn the
adjuster (2) either way until the marks on
the lever (3) and crankcase (4) are
aligned.
10. Tighten:
•Lock nut (1)
Lock nut:
8 Nm (0.8 mkg)
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INSP
ADJ
CLUTCH ADJUSTMENT
3-23
11. Install:
•Right crankcase cover
•Right crankcase cover fastening screws
•Oil delivery hose fastening screw
Screw (crankcase cover):
10 Nm (1.0 mkg)
Oil delivery hose screw:
18 Nm (1.8 mkg)
Screw (rear master cylinder):
10 Nm (1.0 mkg)
Bolt (footrest):
48 Nm (4.8 mkg)
12. Connect:
•Brake pedal return spring
•Rear master cylinder
13. Reassemble:
•Footrest (right)
Free play (at lever tip):
10 ~ 15 mm
See section “Cable free play adjustment”.
•Engine protector
14. Fill:
•Engine oil tank
See section “ENGINE OIL REPLACE-
MENT”.
15. Adjust:
•Clutch cable free play
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AIR FILTER CLEANING
3-24
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AIR FILTER CLEANING
1. Remove:
•Fast screws (1)
•Air filter box cap (2)
2. Pull out:
•Filtering element (3) from its seat
3. Wash:
•Filtering element (with water and
biodegradable liquid soap)
NOTE:
Rinse properly and dry perfectly by squeezing the
filtering element, without twisting it!
4. Inspect:
•Filtering element
Damaged ➔Replace.
5. Apply:
•SAE 20W50 engine oil or special filter oil
all over filter surface
6. Squeeze out:
•Excess oil
NOTE:
The filtering element should be wet but not drip-
ping.
3
7. Install:
•Filtering element (4) in its case
NOTE:
When installing the filtering element in its case, fol-
low the direction indicated by the arrows, make sure
that the flame-trap net is set forward and that the
cap is properly assembled.
8. Reassemble:
•Air filter box cap
•Fast screws
Make sure the air filter is properly seated in
the air filter case.
The engine should never be run without the
air filter installed. Excessive piston and/or
cylinder wear may result.
CAUTION:
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INSP
ADJAIR FILTER CLEANING/
FUEL FILTER CLEANING
3-25
Periodically check wheter the sleeve on the
bottom of the air filter case is empty. Remove
the plug (5) and clean it if dirt or water accu-
mulate.
CAUTION:
FUEL FILTER CLEANING
1. Turn the fuel cock to "OFF".
2. Disconnect:
•Fuel pipe from cock
3. Place a fuel pan under the fuel tank and turn
the fuel cock to "RES" to drain the fuel.
Do not bring naked flames or possible
sources of sparks near to the fuel tank: FIRE
AND EXPLOSION RISK! Be careful not to spill
fuel from the tank.
Always wipe off spilled fuel immediately with
a dry and clean soft cloth. Fuel may deterio-
rate painted surfaces or plastic.
4. Disassemble:
•The fuel cock from the fuel tank
5. Wash:
•Fuel filter (1) with solvent
6. Inspect:
•Fuel filter (1)
•Gasket (2)
Damaged ➔Replace.
7. Reassemble:
•Fuel cock to tank
•Fuel pipe to cock
NOTE:
When reassembling the cock, be careful not to
tighten the fastening screws unduly, as the gasket
might leave its housing and cause fuel leakage.
CAUTION:







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ENGINE OIL TANK FILTER CLEANING
3-26
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ENGINE OIL TANK FILTER CLEANING
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Drain:
•Engine oil
See section “ENGINE OIL REPLACE-
MENT”.
2. Remove:
•Seat
•Rear cowling
See section “SEAT, FUEL TANK AND
REAR COWLING”.
•Rear wire harness
•Exhaust muffler
•Exhaust pipe
•Rear shock absorber
See section “REAR SHOCK ABSORBER”
in Chapter 4.
•Joint air cleaner clamps
•Rear frame
•Engine oil tank
3. Loosen:
•Stay (rear left side cover) fastening
screws
4. Remove:
•Oil tank cap (1)
•Oil return hose (2)
•Oil return hose flange (4) fastening screw
(3)
•Oil delivery hose flange (6) fastening
screws (5)
•Oil tank filter (7)
•OR gaskets (8)
5. Clean:
•Oil tank filter (with solvent)
•Oil tank (with solvent)
NOTE:
After cleaning the inside of the oil tank, remove
the remaining solvent.
6. Inspect:
•OR gaskets
Damaged ➔Replace.
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