drain bolt YAMAHA TT600RE 2004 Service Manual

SPECMAINTENANCE SPECIFICATIONS
2-10
Tightening
Part torque
Part to be tightened
nameThread size Remarks
Nm mkg
Cylinder head Washer
based bol M8 x 1.25 29 2.9
Cylinder head Stud bolt M10 x 1.25 20 2.0
Cylinder head Hexagon socket
head screw M6 x 1.0 10 1.0
Cylinder head Stud bolt M6 x 1.0 7 0.7
Cylinder head:
Cap (oil check) Union bolt M6 x 1.0 7 0.7
Spark plug – M12 x 1.25 18 1.8
Cylinder head cover Hexagon socket
head screw M6 x 1.0 10 1.0
Tappet cover (intake) Hexagon socket
head screw M6 x 1.0 10 1.0
Tappet cover (exhaust) – M32 x 1.5 12 1.2
Cylinder Crown nut M8 x 1.25 22 2.2
Cylinder Nut M10 x 1.25 42 4.2
Cylinder Hexagon socket
head screw M6 x 1.0 10 1.0
Weight drive gear Hexagon nut M16 x 1.0 60 6.0
Rotor (A.C. magneto) Hexagon nut M14 x 1.5 120 12.0
Lock nut (valve adjusting screw) Hexagon nut M6 x 1.0 14 1.4
Cam chain sprocket Washer based
bolt M7 x 1.0 20 2.0
Cam chain stopper guide Hexagon socket
head screw M6 x 1.0 10 1.0
Cam chain stopper guide Washer based
screw M16 x 1.0 20 2.0
Rocker shaft Hexagon socket
head screw M6 x 1.0 10 1.0
Oil pump Hexagon socket
head screw M6 x 1.0 10 1.0
Oil delivery/retrieval pipe Pan screw M6 x 1.0 7 0.7
Oil draining pipe Washer based
screw M14 x 1.5 30 3.0
Oil filter cover Hexagon socket
head screw M6 x 1.0 10 1.0
Bleed screw (oil filter cover) Hexagon screw M5 x 0.8 5 0.5
Push lever (clutch) Pan screw M8 x 1.0 12 1.2
Push rod (clutch) Hexagon nut M6 x 1.0 8 0.8
Sprocket Hexagon nut M18 x 1.0 115 11.5
Lock washer (oil seal) Hexagon screw M6 x 1.0 10 1.0
Stop lever Bolt M6 x 1.0 10 1.0
Shift cam Hexagon screw M6 x 1.0 10 1.0
Stator Pan head (+)
screw M5 x 0.8 5 0.5
Tightening torques
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INSP
ADJ
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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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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CHASFRONT BRAKE
4-11
MASTER CYLINDER
Order Job name/Part name Q.ty Remarks Master cylinder removal Remove the parts in order.
Brake fluid Drain.
1 Rear view mirror (right)/ Master cylinder bracket 1/1
2 Brake lever 1
3 Brake switch 1
4 Union bolt 1
5 Plain washer 2 Refer to “MASTER CYLINDER INSTAL-
6 Brake hose 1 LATION” section.
7 Master cylinder 1 Reverse the removal procedure for instal-
lation.
26
4
7
1
9 Nm (0.9 m•kg)
20 Nm (2.0 m•kg)
3
5
New
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FRONT BRAKE
4-16
CHAS
BRAKE CALIPER
Order Job name/Part name Q.ty Remarks Caliper removal Remove the parts in order.
Brake fluid Drain.
1 Union bolt 1
2 Plain washer 2
3 Brake hose 1 Refer to “CALIPER INSTALLATION” sec-
4 Caliper support bolt 2 tion
5 Caliper assembly 1 Reverse the removal procedure for instal-
lation.
20 Nm (2.0 m•kg)
2
5
1
25 Nm (2.5 m•kg)
3
4
New
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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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REAR BRAKE
4-36
CHAS
BRAKE CALIPER
Order Job name/Part name Q.ty Remarks Caliper removal Remove the parts in order.
Rear wheel Refer to “REAR WHEEL REMOVAL” sec- tion.
Brake fluid Drain.
Brake hose Remove from clamp.
1 Caliper protector 1
2 Brake caliper 1 Remove from caliper support.
3 Union bolt 1 Refer to “BRAKE CALIPER INSTALLA-
4 Plain washer 2
TION” section.
5 Brake hose 1
6 Brake pad support 1 Reverse the removal procedure for installa-
tion.
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FRONT FORK
4-50
CHAS
4. Using a small screwdriver take a small amount of silicon grease and insert it under
the lip paying attention not to scratch it.
Lubricate the dust seal by rotating it in such a
manner that the grease is distributed in the
inner part of the lip.
5. Remount the dust seal inserting it with force into the oil seal seat.
Check that the oil seal housing edge of the
dust seal adheres perfectly to the oil seal
seat.
CAUTION:
SEAL AND BUSH REPLACEMENT
NOTE:
To ensure maximum efficiency to the fork and
therefore a longer duration and greater safety,
every year (unless there are leakages) it is nec-
essary to replace all the seals and slide bushes.
To carry out this operation it is recommended to
use the proper tools.
To remove the fork leg from the steering unit,
the cap bolt, the spring and to drain and refill
the oil, follow the procedures indicated in the
preceding pages scrupulously.
CAUTION:
1. Drain:
•Fork leg oil Refer to “OIL REPLACEMENT”section.
2. Clamp:
•Fork leg in a vice (in a horizontal position)
Protect the outer tube with a clean rag to
avoid damaging.
CAUTION:
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