2004 YAMAHA TT600RE Service Manual

INSP
ADJ
ENGINE OIL TANK FILTER CLEANING
3-27
7. Reassemble:
•OR gaskets
•Oil tank filter
•Oil delivery hose flange fastening screws
Screw (oil delivery hose flange):
10 Nm (1.0 mkg)
Screw (oil return hose flange):
35 Nm (3.5 mkg)
•Oil return hose
•Oil return hose flange fastening screws
8. Tighten:
•Stay (rear left side cover) fastening
screws
9. Reassemble:
•Engine oil tank
•Rear frame
•Joint air cleaner clamps
•Rear shock absorber
See section “REAR SHOCK ABSORBER”
in Chapter 4.
•Exhaust pipe
•Exhaust muffler
•Rear wire harness
•Rear cowling
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
10. Fill:
•Engine oil
See section “ENGINE OIL REPLACE-
MENT”.
11. Reassemble:
•Engine tank capScrew (seat):
10 Nm (1.0 mkg)
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SUCTION HOSE AND MANIFOLD INSPECTION/
FUEL LINE INSPECTION
3-28
INSP
ADJ
SUCTION HOSE AND MANIFOLD INSPECTION
1. Remove:
•Seat
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING”.
2. Inspect:
•Suction hoses (1)
Cracked/damaged ➔Replace.
Screw (2) (carburetor manifold):
10 Nm (1.0 mkg)
Screw (3) (clamp):
2 Nm (0.2 mkg)
3. Reassemble:
•Fuel tank
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
FUEL LINE INSPECTION
1. Inspect:
•Fuel pipe (1)
Cracked/Damaged ➔Replace. Seat screws:
10 Nm (1.0 mkg)
1
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INSP
ADJCRANCKCASE VENTILATION HOSE INSPECTION/
EXHAUST SYSTEM INSPECTION
3-29
CRANCKCASE VENTILATION HOSE
INSPECTION
1. Inspect:
•Crankcase ventilation hoses (1)
Cracked/Damaged ➔Replace.
EXHAUST SYSTEM INSPECTION
1. Inspect:
•Exhaust pipe (1)
•Muffer (2)
Cracks/Damage ➔Replace.
•Gaskets (3)
Exhaust gas leakage ➔Replace.
Nut (4) (exhaust pipe):
10 Nm (1.0 mkg)
Screw (5) (muffler):
23 Nm (2.3 mkg)
Bolt (6) (flange):
23 Nm (2.3 mkg)
(apply molybdenum disulfide
grease)
Screw (7) (protection):
7 Nm (0.7 mkg)
Use LOCTITE
®.
Nut (8) (muffler):
23 Nm (2.3 mkg)
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ADJUSTING THE FRONT BRAKE
3-30
INSP
ADJ




CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
• Brake lever position
(distance abetween the brake lever and
the handlebar grip)
a. Turn the adjusting dial 1while holding the
lever pushed away from the handlebar grip
NOTE:
Align the setting on the adjusting dial with the
arrow mark 2
WARNING
After adjusting the brake lever position, make
sure the pin on the brake lever holder is firm-
ly inserted in the hole in the adjusting dial.
WARNING
A soft or spongy feeling in the brake lever can
indicate the presence of air in the brake sys-
tem. Before the vehicle is operated, the air
must be removed by bleeding the brake sys-
tem. Air in the brake system will considerably
reduce braking performance and could result
in loss of control and possibly an accident.
Therefore, inspect and, if necessary, bleed the
brake system. After adjusting the brake lever
free play, make sure that there is no brake
drag.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Posizione n. 1 La distanza a a
è la
massima.
Posizione n. 4 La distanza a a
è la
minima.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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1
2
INSP
ADJ
ADJUSTING THE REAR BRAKE
3-31
ADJUSTING THE REAR BRAKE
1. Check:
•Brake pedal position
(distance afrom the top of the rider
footrest to the top of the brake pedal)
Out of specification ➔Adjust.
2. Adjust:
•Brake pedal position
•Tighten lock nut.
After adjusting the brake pedal position, make
sure the brake doesn't oppose resistance.
CAUTION:
•Loosen lock nut (1).
•Turn the adjuster (2) either way to obtain the
correct pedal height.
WARNING
If the brake brake pedal has a soft or slack
feel, this means that there is air in the brake
system. It should be bled away before using
the motorcycle. Air in the system seriously
affects the effectiveness of braking and may
cause loss of control of the motorcycle.
Brake pedal position
(below the top of the rider footrest):
10 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Unscrewing Height (a) diminishes.
Screwing Height (a) increases.
Lock nut:
20 Nm (2.0 mkg)
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CHECKING THE BRAKE FLUID LEVEL
3-32
INSP
ADJ
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
•Place the motorcycle on a suitable stand.
•Make sure that the motorcycle is upright.
2. Check:
•Brake fluid level
Below the minimum level mark a➔Add
the recommended brake fluid to the prop-
er level.
[A] Front brake
[B] Rear brake
WARNING
•Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
•Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
•When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
Brake fluid may damage painted surfaces and
plastic parts. Therefore, always clean up any
spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the reservoir
is horizontal.
CAUTION:
Recommended brake fluid:
DOT4





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INSP
ADJBRAKE PAD WEAR INSPECTION/
BRAKE HOSING INSPECTION
3-33
1. Operate the brake lever or brake pedal.
2. Check:
•Thickness of frictional material
Out of specification ➔Replace.
BRAKE HOSING INSPECTION
1. Inspect:
•Brake hosing
Cracks/Damage ➔Replace.
To replace hosing, see section “FRONT
AND REAR BRAKE” in Chapter 4.
B
B
A
a
Wear limit (a):
Front: 1.0 mm
Rear: 1.0 mm
For brake pad replacement, see section
“BRAKE PAD REPLACEMENT” in
Chapter 4.
[A] Front brake
[B] Rear brake
[A] Front brake
[B] Rear brake
a
A
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BRAKE CIRCUIT BLEEDING
3-34
INSP
ADJ
1
1B
BRAKE CIRCUIT BLEEDING
WARNING
If the brake lever or brake pedal has a soft or
slack feel, this means that there is air in the
brake system. It should be bled away before
using the motorcycle. Air in the system seri-
ously affects the effectiveness of braking and
may cause loss of control of the motorcycle.
In all cases, bleed the brake system if:
•The system has been disassembled.
•A brake hose has been loosened or
removed.
•The brake fluid in the tank is at a very low
level.
•Brake operation is faulty.
Air bleeding procedures:
a. Top up the level of the fluid in the tank to max-
imum.
b. Install the diaphragm. Be careful not to spill
fluid or let it overflow from the tank.
c. Connect the clear plastic hose (1) to the
caliper bleeder screw.
[A] Front
[B] Rear
d. Place the other end of the hose in a container.
e. Slowly pull the brake lever or press the brake
pedal several times.
f. Pull the brake lever right in or press the pedal
right down and hold in position.
g. Loosen the bleeder screw and allow the lever
or pedal to travel slowly towards its limit.
h. Tighten the bleeder screw when the lever or
pedal limit has been reached, then release the
lever or pedal.
Bleeder screw:
14 Nm (1.4 mkg)
i. Repeat operations (e) to (h) until all the air
bubbles have disappeared from the clear
plastic hose (1).
A
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