relay YAMAHA TT600RE 2004 Service Manual

SPECMAINTENANCE SPECIFICATIONS
2-14
Tightening
Part to be tightened Thread torque
Remarkssize
N·mm·kg
Engine mounting and rear frame:
Engine front/Stay engine M10 x 1.25 64 6.4
Stay engine (engine front)/Frame M10 x 1.25 64 6.4
Engine rear under/Frame M10 x 1.25 68 6.8
Engine top/Stay engine M10 x 1.25 64 6.4
Engine protector/Frame M6 x 1.0 7 0.7
Chain tensioner top/Frame M8 x 1.25 23 2.3
Chain tensioner under/Frame M8 x 1.25 23 2.3
Frame/Rear frame (upper) M8 x 1.25 23 2.3
Frame/Rear frame (under) M8 x 1.25 23 2.3
Rear frame/Air filter assy M6 x 1.0 5 0.5
Front fork and steering:
Handle crown/Inner tube M8 x 1.25 28 2.8
Handle crown/Steering shaft M28 x 1.5 4 0.4 See “NOTE”
Steering shaft/Ring nut M36 x 1.5 115 11.5
Holder handle upper/Crown handle M8 x 1.25 20 2.0
Holder handle under/Crown handle M10 x 1.5 40 4.0
Front fork under bracket/Inner tube M8 x 1.25 23 2.3
Front master cylinder/Cap M4 x 0.7 1.5 0.15
Front master cylinder/Handle M6 x 1.0 9 0.9
Union bolt tightening M10 x 1.0 20 2.0
Front fender/Front fork M6 x 1.0 7 0.7
Stay headlight/Handle crown M6 x 1.0 10 1.0
Stay headlight/Bracket meter M6 x 1.0 6 0.6
Headlight/Stay headlight M6 x 1.0 10 1.0
Rear arm and cushion:
Pivot shaft/Frame M14 x 1.5 90 9.0
Arm relay/Frame M10 x 1.25 60 6.0
Arm relay/Rod connecting M10 x 1.25 52 5.2
Arm relay/Shock absorber M10 x 1.25 59 5.9
Rod connecting/Rear arm M12 x 1.25 66 6.6
Shock absorber upper/Frame M12 x 1.25 66 6.6
Seal guard/Rear arm M6 x 1.0 4 0.4
Support chain/Rear arm M6 x 1.0 9 0.9
Chain case/Rear arm M6 x 1.0 9 0.9
Front wheel:
Front wheel shaft/Front fork M16 x 1.5 59 5.9
Axle holder//Front fork M6 x 1.0 9 0.9
Rear wheel:
Rear wheel shaft/Nut M18 x 1.5 115 11.5
Clutch hub/Sprocket M10 x 1.25 48 4.8
Tightening torques
ProCarManuals.com

SPECMAINTENANCE SPECIFICATIONS
2-17
Item Standard Limit
Ignition system
Ignition timing (B.T.D.C.) 12° / 1,300 r/min •••
Advanced timing (B.T.D.C.) 31° / 7,500 r/min •••
Advancer type Electrical type
Transistorized coil ignition
Pickup coil resistance 230 Ω± 20% L/Y-G/W •••
T.C.I. unit model/manufacturer TNDF09 / NIPPON DENSO
Ignition coil
Model/manufacturer JO300 / NIPPON DENSO
Primary coil resistance 4 Ω± 15% •••
Secondary coil resistance 13 kΩ± 20% •••
Spark plug cap
Material Resin
Resistance 10 kΩ•••
Charging system
Type A.C. magneto
Model/manufacturer TLMZ48 / NIPPON DENSO
Standard output 14.0 V 13.5 A 5,000 r/min •••
Stator coil resistance 0.65 Ω± 20% W-W •••
Rectifier/regulator
Regulator type Semi conductor-short circuit
Model/manufacturer SH629A-12/SHINDENGEN
No load regulated voltage 14.5 ± 0.4 V •••
Rectifier capacity 25 A •••
Withstand voltage 240 V •••
Battery
Specific gravity 1.320 •••
Electric starting system
System type Constant mesh
Starter motor:
Model/manufacturer SM-13/MITSUBA
Power output 0.80 kW •••
Armature coil resistance 0.03 - 0.04 Ω•••
Brush overall length 10.0 mm 5 mm
Brush spring force 8.82 N (899 gf) •••
Commutator diameter 28.0 mm 27 mm
Mica undercut (depth) 0.70 mm •••
Starter relay:
Model/manufacturer MS5F-721 / JIDECO
Amperage 180 A •••
Coil resistance 4,4 Ω± 5% •••
ELECTRICAL
ProCarManuals.com

SPECMAINTENANCE SPECIFICATIONS
2-18
Item Standard Limit
Horn
Horn type Plane
Quantity 1 pcs
Manufacturer LEONELLI
Max. amperage 1.5 A •••
Flasher relay
Type Semi-transistor •••
Model/manufacturer FB222M/NIPPONDENSO •••
Self cancelling device No •••
Flasher frequency 75 - 95 cycle/min •••
Wattage 10 W
2 + 3.4 W •••
Daylight switch relay
Model/manufacturer ACA12151-1-MATSUSHITA DENKOU
Circuit breaker
Type Fuse
Amperage for fuse 20 A •••
Reserve 20 A •••
ProCarManuals.com

SPECCABLE ROUTING
2-27









































(1) Front brake hose
(2) Brake hose holder
(3) Left tube guard
(4) Plastic plate
(5) Throttle cables
(6) Tachometer/
odometer cable
(7) Clutch cable
(8) Clutch cable holder
(9) Throttle cables
holder
(10) Wire harness band(11) Fuel pipe from fuel
cock
(12) Flasher relay
(13) Main relay
(14) Sidestand switch
(15) Diodes (n. 3)
(16) A.C. generator wire
harness (engine)
(17) Engine oil breather
pipe (to engine oil
tank)
(18) Main switch(19) Oil hose (oil tank to
engine)
(20) Oil hose (engine to
oil tank)
(21) C.D.I. unit
(22) Starting motor plus
cable
(23) Starting motor
minus cable
(24) Battery
(25) Starting relay
(26) Fuse (reserve)
(27) Fuse (main)(28) Wire extension
(29) Battery plus cable
[A] Lay the brake hose
behind the left tube
guard and fasten it
down by means of
the plate 4.
[B] Attach throttle
cables 5.
[C] Fasten the fuel pipe
11 to the tank.
[D] Fit the 3 diodes
inside the chassis,
against the coil clip.
ProCarManuals.com

INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
3-2
INSP
ADJ
ODOMETER READING (x 1,000 km)
ANNUAL N0. ITEM CHECK OR MAINTENANCE JOB
110 2030 40CHECK
18 * Rear brake• Check operation, fluid level and vehicle for fluid leakage. ✓✓✓ ✓
Rear shock
• Check operation and shock absorber for oil leakage.
19
*absorber ✓✓✓ ✓
assemblysull’ammortizzatore.
Rear suspension
• Check operation.
✓✓✓ ✓
20*
relay arm and
connecting arm
• Lubricate with lithium-soap-based grease.
✓✓
pivoting points
• Check starter (choke) operation.
21 * Carburator
• Adjust engine idling speed.✓✓ ✓✓ ✓ ✓
22 Engine oil• Change.
✓✓ ✓✓ ✓ ✓
• Check oil level and oil leakage.
23Engine oil filter
• Replace.✓✓✓
element
24 *Front and rear •
brake switches• Check operation.✓✓ ✓✓ ✓ ✓
Moving parts
25
and cables• Lubricate. ✓✓✓ ✓ ✓
Throttle grip • Check operation and free play.
26 * housing and • Adjust the throttle cable free play if necessary.
✓✓✓ ✓ ✓
cable • Lubricate the throttle grip housing and cable.
27 *Muffler and
• Check the screw clamp for looseness. ✓
exhaust pipe
28 *Lights, signals • Check operation.
✓✓ ✓✓ ✓ ✓
and switches• Adjust headlight beam.
* Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance is per-
formed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake system:
• Check the brake fluid level regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
ProCarManuals.com

SWINGARM
4-76
CHAS
SWINGARM
(1) Upper chain case
(2) Swingarm
(3) Chain support (4) Swingarm guard seal
(5) Connecting rod
(6) Relay arm [A] LATERAL FREE PLAY (END): 1.0 mm
[B] LATERAL FREE PLAY: 0.4 ~ 0.7 mm
ProCarManuals.com

SWINGARMCHAS
4-78 3. Remove:
•Upper chain case (1)
•Chain support (2)
4. Remove:
•Swingarm pivot shaft
•Swingarm
SWINGARM INSPECTION
1. Inspect:
•Swingarm
Deformation/Cracks/Damage ➔Replace.
2. Inspect:
•Connecting rod (1)
•Relay arm (2)
Deformation/Cracks/Damage ➔Replace.
3. Inspect:
•Oil seals
Wear/Damaged ➔Replace.
•Washers
•Thrust cover
Wear/Damaged ➔Replace.
•Bushes
Scratches/Damaged ➔Replace.
•Bearings
Pitting/Damaged ➔Replace.
4. Inspect:
•Chain guard seal
•Chain case and support
Wear/Damage ➔Replace.
1
2
ProCarManuals.com

SWINGARM
4-80
CHAS
SWINGARM INSTALLATION
Perform “removal” operations in reverse order.
Note the following points.
1. Lubricate:
•Bearings
•Bushes
•Thrust cover (inside)
•Flange
•Swingarm pivot shaft
•Bolt (connecting rod)
•Bolt (relay arm)
•Bolt (shock absorber)
Lithium-base grease
2. Tighten: Nut (relay arm-swingarm): 66 Nm (6.6 mkg)
Nut (relay arm - connecting rod): 52 Nm (5.2 mkg)
Bolt (chain case): 9 Nm (0.9 mkg)
Nut (swingarm pivot shaft): 90 Nm (9.0 mkg)
Bolt (chain support): 4 Nm (0.4 mkg)
Screw (chain case): 4 Nm (0.4 mkg)
Nut (relay arm-frame): 60 Nm (6.0 mkg)
Bolt (rear shock absorber): 59 Nm (5.9 mkg)
3. Install:
•Rear wheel
Refer to “REAR WHEEL INSTALLATION”
section.
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

ELECTRICAL CIRCUIT DIAGRAM
7-2
ELEC
B Black B/Y Black/Yellow
Br Brown Br/B Brown/Black
Ch Chocolate Br/W Brown/White
Dg Deep green G/B Green/Black
G Green G/R Green/Red
Gy Grey G/W Green/White
L Blue G/Y Green/Yellow
Or Orange L/R Blue/Red
P Pink L/W Blue/White
R Red L/Y Blue/Yellow
Sb Sky-blue R/B Red/Black
W White R/W Red/White
Y Yellow R/Y Red/Yellow
B/R Black/Red W/L White/Blue
B/W Black/White Y/R Yellow/Red
(1) AC generator/Pickup coil
(2) Rectifier/Regulator
(3) Battery
(4) Starter relay
(5) Starting motor
(6) Fuse
(7) Main switch
(8) Right handlebar switch
(9) Engine stop switch
(10) Starter switch
(11) Diode
(12) Clutch switch
(13) Sidestand switch
(14) Neutral switch
(15) Diode
(16) Ignitor unit
COLOUR CODE (17) Ignition coil
(18) Left handlebar switch
(19) Horn switch
(20) Diode
(21) Pass switch
(22) Dimmer switch
(23) Flasher switch
(24) Horn
(25) Flasher relay
(26) Headlight
(27) Flasher light
(28) Relay assy
(29) Front brake switch
(30) Rear brake switch
(31) Tail/stop light
(32) Meter
ProCarManuals.com