2004 YAMAHA TT600RE Service Manual

INSP
ADJ
DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT
3-35

NOTE:
If bleeing proves difficult, it may be necessary to
allow the brake fluid system to stabilise for a few
hours. Repeat the bleeding procedure when the
tiny bubbles in the system have disappeared.
j. Top up fluid to the maximum level.
DRIVE CHAIN SLACK INSPECTION AND
ADJUSTMENT
Inspecting slack:
NOTE:
Before checking and/or adjusting the chain, rotate
the rear wheel through several revolutions and
check the slack several times to find the point on
the wheel where chain slack is highest.
Check and/or adjust chain slack with rear wheel in
this “tight chain” position.
Drive chain slack:
30 ~ 40 mm
NOTE:
To check chain slack, the motorcycle must stand
in an upright position with its two wheels touching
the ground and no one sitting on it. Check slack in
the position shown in the figure.
2. Adjust:
•Drive chain slack
Slack adjustment:
Too little chain slack will overload the engine
and other vital parts. Keep the slack within the
specified limits.
CAUTION: 1. Check:
•Drive chain slack (a)
Out of specification ➔Adjust.
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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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INSP
ADJFRONT FORK INSPECTION/
FRONT FORK ADJUSTMENT
3-37
 


FRONT FORK INSPECTION
WARNING
When inspecting the front fork, hold the
motorcycle firmly to prevent it falling over.
1. Place the motorcycle on a level surface.
2. Check:
•Inner tube
Scratches/Damage ➔Replace.
•Oil seal
Undue oil leakage ➔Replace.
3. With the motorcycle in a level upright position
operate the front brake.
4. Check:
•Proper functioning
Compress and release the front fork sev-
eral times.
Irregular/jerky functioning ➔Repair.
See section “FRONT FORK” in Chapter 4.
ADJUSTING THE FRONT FORK
This front fork is equipped with spring pre-load ad-
justing bolts.
WARNING0
Always adjust both fork legs equally, other-
wise poor handling and loss of stability may
result.
Adjust the spring preload as follows.
To increase the spring preload and thereby hard-
en the suspension, turn the adjusting bolt on each
fork leg in direction a. To decrease the spring
preload and thereby soften the suspension, turn
the adjusting bolt on each fork leg in direction b.
Setting
Minimum (soft) 1-2-3
Standard 4
Maximum (hard) 5-6-7-8-9-10
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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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INSP
ADJ
REAR SHOCK ABSORBER ADJUSTMENT
3-39
NOTE:
•Use the special wrench included in the
owner's tool kit to make the adjustment.
•The spring preload setting is determined by
measuring distance A, shown in the illustra-
tion. The longer distance A is, the lower the
spring preload; the shorter distance A is, the
higher the spring preload. With each com-
plete turn of the adjusting nut, distance A
changes by 1.5 mm.
Spring preload:
Minimum (soft):
Distance A = 217 mm
Standard:
Distance A = 211 mm
Maximum (hard):
Distance A = 205 mm
2. Tighten the locknut to the specified torque.
Always tighten the locknut against the adjust-
ing nut, and then tighten the locknut to the
specified torque.
CAUTION:Locknut:
45 Nm (4.5 m·kgf)
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STEERING INSPECTION
3-40
INSP
ADJ
STEERING INSPECTION
WARNING
Hold the motorcycle firmly in place to prevent
it falling over.
1. Raise the front wheel and place a support
under the engine.
2. Check:
•Steering bearings
Grasp the bottoms of the front fork legs
and rock back and forward.
Free play ➔Adjust steering bearing.
3. Adjust:
•Steering bearing
Adjustment:
•Remove the fuel tank.
See section “SEAT, FUEL TANK AND REAR
COWLING”.
•Loosen steering axle nut (1) and fork upper
bracket screws (2).
•Tighten the ring nut (3) with the special
wrench.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
3
2
2
Ring nut (final tightening):
4 Nm (0.4 mkg)
Ring nut (initial tightening):
38 Nm (3.8 mkg)
Ringnut wrench:
P/N. 90890-01268
P/N. 90890-01348
NOTE:
The torque wrench and the ringnut wrench should
form a right angle.
WARNING
Do not tighten the ring nut excessively.
•Loosen the ring nut one turn.
•Retighten the ring nut using the special
wrench.
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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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