2004 YAMAHA TT600RE ECU

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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ENGINE OIL TANK FILTER CLEANING
3-26
INSP
ADJ
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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INSP
ADJSTEERING INSPECTION/
TYRE INSPECTION
3-41
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Nut (steering axle):
115 Nm (11.5 mkg)
Screws (front fork bracket):
28 Nm (2.8 mkg)
•Tighten the steering axle nut and the front fork
bracket screws.
•Reassemble the fuel tank.
See section “SEAT, FUEL TANK AND REAR
COWLING”.
NOTE:
Check the steering head for looseness or binding
by turning it all the way in both directions. If it
binds, remove the steering axle assembly and
inspect the steering bearings.
Refer to “STEERING HEAD” in Chapter 6.
TYRE INSPECTION
WARNING
•Tyre pressure must be checked when the
tyres are at ambient temperature. Pressure
must be adjusted according to the total
weight of luggage, driver, passenger and
accessories (fairings, bags, if approved for
this model) and speed of the motorcycle.
•A list of tyres approved for this model fol-
lowing severe testing by Yamaha is provid-
ed. There can be no guarantee of safe road-
holding if a combination of tyres different
from those indicated is used.
•Front and rear tyres must have the same
design and be of the same make.
•The use of valves and valve stems other
than those indicated might cause the loss
of tyre pressure at high speeds. Use only
original or compatible spare parts.
•Replace the valve cap securely to prevent
losses of tyre pressure at high speed.
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TYRE INSPECTION
3-42
INSP
ADJ
1. Check:
•Tyre pressure
Out of specification ➔Adjust.
Tire air pressure
(measured on cold tires)
Load* Front Rear
200 kPa 220 kPa
Up to 90 kg (2.00 kgf/cm
2, (2.20 kgf/cm2,
2.00 bar) 2.20 bar)
210 kPa 240 kPa
90 kg-maximum (2.10 kgf/cm
2, (2.40 kgf/cm2,
2.10 bar) 2.40 bar)
150 kPa 160 kPa
Off-road riding (1.50 kgf/cm
2, (1.60 kgf/cm2,
1.50 bar) 1.60 bar)
High-speed 210 kPa 240 kPa
riding(2.10 kgf/cm
2, (2.40 kgf/cm2
2.10 bar) 2.40 bar)
Maximum load* 180 kg
* Total weight of rider, passenger, cargo and ac-
cessories.
2. Adjust:
•Air pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjustment:
•Remove the valve cap.
Use an air pump or Increase air
compressed air pistol. pressure
Eliminate air by Air pressure
pressing valve tube diminishes
stem
•Install valve caps securely.
3. Inspect:
•Tyre surface
Wear/Damage ➔Replace.
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CHASFRONT WHEEL AND BRAKE DISC
4-1
CHASSIS - FRONT WHEEL AND BRAKE DISC
Order Job name/Part name Q.ty Remarks Front wheel and brake disc Remove the parts in order.
removal
WARNING
Securely support the motorcycle so there
is no danger of it falling over.
1 Speedometer cable 1 Disconnect.
2 Pinch bolt 2 Loosen.
3 Wheel axle 1
4 Front wheel assembly 1 Refer to “FRONT WHEEL INSTALLATION”
5 Collar 1
section.
6 Gear unit assembly 1
7 Brake disc screw 6
8 Brake disc 1
9 Ring 1 Reverse the removal procedure for instal- lation.
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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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CHASFRONT FORK
4-45
OIL CAPACITY (IN EACH FORK LEG): 650 cm3
RECOMMENDED OIL:
Liqui Moly Racing suspension oil SAE 7,5
FRONT FORK OIL LEVEL
STANDARD 180 mm
MINIMUM 190 mm
MAXIMUM 170 mm
From top of inner tube with inner tube fully com-
pressed without spring.
MINIMUM FORK SPRING FREE LENGTH:
530 mm
INNER TUBE BENDING LIMIT:
0.2 mm
1. Park the motorcycle on a level surface.
2. Raise the front wheel by placing a suitable support under the engine.
3. Remove:
•Front wheel
Refer to “FRONT WHEEL REMOVAL”
section.
4. Remove:
•Inner tube protector
•Protector guide
•Gear unit assembly and cable
•Brake caliper and hose
5. Loosen:
•Cap bolt
•Pinch bolt (upper and lower bracket)
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
FRONT FORK REMOVAL
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CHAS
4-61
STEERING
Order Job name/Part name Q.ty Remarks Steering removal Remove the parts in order.
Park the motorcycle on a level surface.
WARNING
Securely support the motorcycle to pre-
vent it falling over.
Front wheel Refer to “FRONT WHEEL REMOVAL” sec- tion.
Fork legs Refer to “FRONT FORK” section.
1 Cowling/Meter unit 1 Displace.
2 Front fender 1
3 Handle upper holder 2
4 Handle lower holder 1
5 Handlebar 1 Displace.
6 Nut 1
7 Upper bracket 1
8 Special washer 1
TIGHTENING PROCEDURE
• Initial tightening 38 Nm (3.8 mkg)
• Loosen 1 turn
• Final tightening 4 Nm (0.4 mkg)
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