ESP YAMAHA TT600RE 2004 Service Manual

DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT/
DRIVE CHAIN LUBRICATION
3-36
INSP
ADJ
Rear wheel axle nut:
115 Nm (11.5 mkg)
•Turn each adjusting bolt exactly the same
amount to maintain correct axle alignment.
There are marks on each side of the
swingarm. Use these marks to align the rear
wheel.
DRIVE CHAIN LUBRICATION
The chain consists of many parts which work with
each other. If the chain is not maintained properly,
it will wear out quickly. Therefore, the chain must
be serviced regularly. This service is especially
necessary when riding in dusty areas. This motor-
cycle has a drive chain with small rubber O-Rings
between the chain plates. Steam cleaning, high-
pressure washing and certain solvents can dam-
age these O-Rings. Use only kerosene to clean
the drive chain. Wipe it dry, and thoroughly lubri-
cate it with SAE 80 ~ 90W motor oil or special lu-
bricant for O-Ring chains. Do not use any other lu-
bricants on the drive chain. They may contain sol-
vents that could damage the O-Rings.
Recommended lubricant:
SAE 80W/90 engine oil or
special lubricant for
O-Ring chains.
(1) O-Rings
•Loosen the axle nut (1).
•Loosen the locknuts (2) on each side. To tight-
en the chain, turn the chain adjusting bolts (3)
in direction (a). Loosen the locknuts on each
side. To loosen the chain, turn the chain
adjusting bolts in direction (b) and push the
wheel forward.
•After adjusting, tighten the locknuts (2). Then
tighten the axle nut (1) to the specified torque.
a
b
2
13
➩➩
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REAR SHOCK ABSORBER ADJUSTMENT
3-38
INSP
ADJ
 



REAR SHOCK ABSORBER ADJUSTMENT
WARNING
This shock absorber contains highly pressur-
ized nitrogen gas. For proper handling, read
and understand the following information
before handling the shock absorber. The man-
ufacturer cannot be held responsible for prop-
erty damage or personal injury that may result
from improper handling.
•Do not tamper with or attempt to open the
gas cylinder.
•Do not subject the shock absorber to an
open flame or other high heat sources,
otherwise it may explode due to excessive
gas pressure.
•Do not deform or damage the gas cylinder
in any way, as this will result in poor damp-
ing performance.
This shock absorber assembly is equipped with a
spring preload adjusting nut.
Never attempt to turn an adjusting mecha-
nism beyond the maximum or minimum set-
tings.
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.
CAUTION:
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CHASFRONT BRAKE
4-9
Brake components must not be disassembled.
The builder declines every responsibility after
brake components disassembly (brake master
cylinder or brake caliper) or in case of use of
non original parts.
DO NOT:
•Remove brake components from the
motorcycle unless is absolutely necessary.
•Use solvents on internal brake compo-
nents.
•Use brake fluid already used for bleeding.
•Allow brake fluid to come into contact with
the eyes as it may cause injury.
•Allow brake fluid to come into contact with
painted or plastic parts as it may damage
them.
•Disconnect any hydraulic connection, other-
wise the whole system must be disassem-
bled, drained, cleaned, then properly filled
and bled after reassembly.
CAUTION:
NOTE:
It is unnecessary to disassemble the brake hose
to replace the pads.
NOTE:
•If you replace the pads, also replace the
springs.
•If one of the two pads has to be replaced
because it is worn, replace both.
BRAKE PAD REPLACEMENT
1. Remove:
•Caliper bracket fastening screws (1)
(deplace the caliper)
2. Remove:
•Pin retainers (2)
•Pad fastening pin (3)
•Brake pads (4)
•Pad springs (5)
•Caliper bracket (6)
Wear limit (a): 3.7 mm
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REAR BRAKE
4-30
CHAS
Brake components must not be disassem-
bled. The builder declines every responsibility
after brake components disassembly (brake
master cylinder or brake caliper) or in case of
use of non original parts.
DO NOT:
•Remove brake components from the
motorcycle unless is absolutely necessary.
•Use solvents on internal brake components.
•Use brake fluid already used for bleeding.
•Allow brake fluid to come into contact with
the eyes as it may cause injury.
•Allow brake fluid to come into contact with
painted or plastic parts as it may damage
them.
•Disconnect any hydraulic connection, other-
wise the whole system must be disassem-
bled, drained, cleaned, then properly filled
and bled after reassembly.
CAUTION:
NOTE:
It is unnecessary to disassemble the brake hose
to replace the pads.
NOTE:
•If you replace the pads, also replace the pad
support.
•If one of the two pads has to be replaced
because it is worn, replace both.
BRAKE PAD REPLACEMENT
1. Remove:
•Rear wheel (refer to “REAR WHEEL
REMOVAL” section).
•Bolt (caliper protector) (1)
•Brake caliper protector (2)
•Pad pin retainer (3)
•Brake pad pin (4)
Remove the caliper in the illustrated direc-
tion.
2. Remove:
•Brake pads (5)
•Pad support (6)
643
2
1
5
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FRONT FORK
4-56
CHAS
OIL LEAKAGE FROM DUST SEAL
If there is a leakage of oil from between the dust
seal (1) and the inner tube (2) replace the oil seal
(refer to “SEAL AND BUSH REPLACEMENT”
section).
ANOMALOUS HYDRAULIC BRAKING
If the fork shows an anomalous hydraulic braking
effect it is necessary to overhaul the damper cylin-
der assembly.
WARNING
Never tamper with the damper cylinder
assembly! This operation should be done by
authorized personnel. Tampering with the
damper cylinder assembly by non authorized
personnel can compromise the safety of the
front fork. The building firm will not assume
any responsibility for any damages resulting
from such action.
2
1
19. Insert:
•Damper cylinder assembly (in the inner
tube)
20. Insert an Allen key in the bolt (3) at the bot- tom of the outer tube and the special tool (1)
with the holder (2) on the damper cylinder
assembly and screw the bolt completely.
During tightening the bolt ensure that the end
of the damper rod holder is correctly engaged
on the damper cylinder assembly.
CAUTION:
21. Fill:
•Fork leg oil
Refer to “OIL REPLACEMENT”section. T-handle (1):
90890-01326
Front fork damper rod holder (2): 90890-01460
Damper cylinder assembly bolt (3):25 Nm (2.5 kgm)
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REAR SHOCK ABSORBER
4-72
CHAS
WARNING
This shock absorber contains high-pressure
nitrogen gas. Read the following information
carefully before handling it. The manufacturer
cannot be held responsible for any damage or
injury that may result from improper handling.
•Never tamper with or attempt to open the
cylinder or the tank.
•Never expose the shock absorber to a
naked flame or other source of heat. This
might cause the pressurised gas to
explode.
•Do not deform or damage the cylinder in
any way. Damage to the cylinder would
impair the damping effect.
•Be careful not to scratch the surface of the
rod: this would cause the oil to leak.
•Before disposing of the shock absorber,
read the section “NOTES ON DISPOSAL”.
NOTE ON DISPOSAL
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Before neutralising the rear shock absorber:
The gas pressure must be discharged before dis-
posing of the shock absorber it is necessary to dis-
charge the gas pressure. To do this, bore a hole of
2~3 mm through the cylinder wall about 15~20
mm from the bottom of the gas chamber.
WARNING
Wear protective goggles to avoid eye injuries
from escaping gas and/or metal chips.
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ELECSWITCH CHECK
7-5

 






SWITCH CHECK
Check the continuity between the switch terminals
to verify whether connections are correct.
To check the switch, read the following points.
SWITCH CONNECTION
The table shown here contains the connections
between the switch terminals (eg main switch,
handlebar switches, brake switch, light switch etc).
The column on the far left shows the positions of
the main switch and the top line indicates the
colours of the cables connected with the terminals
of the switch itself.
“o––––o” indicates the terminals between which
there is electrical continuity, ie a closed circuit on
the respective switch positions.
For example, in this table:
“R” and “Br” are continuous when the switch is at
ON.
“L” and “R/B” are continuous when the switch is at
ON.
“R” and “L” are continuous when the switch is at
PARK.
Terminals are not continuous when the switch is at
OFF.
MAIN SWITCH INSPECTION
Before inspecting the switch, see the connection
table shown above and check the terminal con-
nections (closed circuit) by the colour combination.
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ELECSWITCH CHECK
7-7




\f


NOTE:
Use the thin tester terminals to check continuity,
as the terminals might come into contact with oth-
ers inside the connector.
•Check continuity between “R” and “Br” at
switch positions ON (1), OFF (2) and PARK (3).
There must be continuity (ie the tester must
show “0”) at ON and there must be no continu-
ity (ie the tester must show “ ∞” ) at OFF and
PARK. Something is not working between “R
and Br” if there is no continuity between these
two points at position ON, or if there is some
continuity in one of the other positions OFF or
PARK.
NOTE:
Check switch continuity various times.
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5. Continue to check continuity between “R” and “L” and “L” and “Br” in the respective switch
positions in the manner described above.
6. If anything wrong is noted in any of the com- binations, replace the switch component.
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LIGHT INSPECTION
7-8
ELEC
LIGHT INSPECTION (HEADLIGHTS,
TAIL LIGHT AND BRAKE LIGHTS,
DIRECTION INDICATOR LIGHTS,
INSTRUMENT LIGHTS, ETC)
Check the continuity between the bulb terminals to
see that they are undamaged.
BULB TYPES
The bulbs used are classified as shown to the left
according to type of attachment.
(B) is H4 type halogen bulb (12V - 55/60W) and it
is used for headlight.
Avoid touching the glass part of a bulb. Keep it
free from oil; otherwise, the transparency of
the glass, life of the bulb, and luminous flux will
be adversely affected. If oil gets on a bulb,
thoroughly clean it with a cloth moistened with
alcohol or lacquer thinner.
(A) and (C) are used mainly for headlights.
(D) is used mainly for direction indicator lights and
the rear and braking lights.
(E) and (F) are used especially for instrument and
other indication lights.
BULB INSPECTION
1. Remove the bulb.
NOTE:
•Bulbs of type (B) and (C) use special supports
(bulbholders). Remove the bulbholder before
removing the bulb. Most of these bulbholders
may be removed by turning in an anticlockwise
direction.
•Most bulbs of type (A), (D) and (E) may be
removed from their housing by pushing them
and turning them in an anticlockwise direction.
•Bulbs of type (F) may be removed simply by
pulling them out.
CAUTION:
A
F
CB
ED
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ELECLIGHT INSPECTION
7-9
When removing a bulb be careful to hold the
bulbholder or its housing firmly. Never pull the
cable, as it might detach from the terminal
inside the connector.
CAUTION:
WARNING
Keep inflammable products and hands well
away from bulbs when they are on (danger of
burns and fire). Do not touch the bulb before it
is cool.
2. Check the continuity between the bulb termi- nals.
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Control procedure:
•Set the tester selector to Ωx 1”.
•Connect the tester terminals to the bulb pins.
Take, for example, a three pin bulb as shown
in the figure. First check continuity between
pins (1) and (2), connecting tester terminal (+)
to pin (1) and terminal (–) to pole (2). Then
check the continuity between poles (1) and
(3), again connecting tester terminal (+) to
pole (1), and terminal (–) to pole (3). If the
tester indicates “ ∞”, even in one case only, the
bulb must be replaced.
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3. . Check the bulb attachment by installing a test bulb. Furthermore, during inspection of
the bulbs, connect the tester terminals to the
respective socket cables and check continuity
as described.
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