2004 YAMAHA TT600RE Service Manual

INSP
ADJ
TYRE INSPECTION
3-43
Minimum track thickness:
(front and rear)
1,6 mm
NOTE:
These limits may be different by regulation from
country to country. If so, conform to the limits
specified by the regulations of your own country.
(1) Track thickness
(2) Side
(3) Wear indicators
WARNING
The use of worn tyres reduces stability and
may cause a loss of control.
It is not advisable to repair a punctured air
tube. If absolutely necessary, repair with the
utmost care and replace the tube as quickly as
possible with another with the same charac-
teristics.
4. Tighten:
•Valve stem lock nut
Lock nut (valve stem)
1.5 Nm (0.15 kgm)
REAR:
Manufacture Size Type
PIRELLI 90/90-21 54R MT70
MICHELIN 90/90-21 54S T63
Manufacture Size Type
PIRELLI 130/80-18 66R MT70
MICHELIN 130/80-18 66S T63
FRONT:
WARNING
After assembling the new tyres, drive slowly
to allow them to adapt well to the rim and yjus
ensure maximum holding.
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WHEEL INSPECTION/
SPOKE INSPECTION AND TIGHTENING
3-44
INSP
ADJ
WHEEL INSPECTION
1. Inspect:
•Wheels
Damage/Deformation ➔Replace.
NOTE:
Always balance the wheel after the replacement
or reassembly of a tyre or rim.
WARNING
Never try to repair a rim in any way.
Bearing inspection
Check the front and rear wheel bearings periodi-
cally to make sure that they do not have free play
in the hub and that the wheel turns smoothly with-
out sticking. Wheel bearings must always be
checked in accordance with the maintenance
table.
SPOKE INSPECTION AND TIGHTENING
1. Inspect:
•Spokes (1)
Curvature/Damaged ➔Replace.
Loose spoke ➔Tighten.
2. Tighten:
•Spoke (s)
NOTE:
Tighten the spokes before and after the break-in
period.
Spoke:
3 Nm (0.3 mkg)
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INSP
ADJCABLE INSPECTION/
LEVER AND PEDAL LUBRICATION
3-45
CABLE INSPECTION
WARNING
If the cable sheath is damaged, corrosion
might ensue or the cable might not run freely.
To avoid such drawbacks, replaced damaged
cables as quickly as possible.
1. Inspect:
•Cable sheath
Damaged ➔Replace the cable assembly.
2. Check:
•Cable functioning
Does not run freely ➔Replace the cable
assembly.
LEVER AND PEDAL LUBRICATION
1. Lubricate the pivoting parts:
•Clutch lever
•Front brake lever
•Rear brake pedal
•Shift pedal
Recommended lubricant:
SAE 10W30 motor oil
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SIDESTAND LUBRICATION/
REAR SUSPENSION LUBRICATION
3-46
INSP
ADJ
SIDESTAND LUBRICATION
Lubricate the sidestand pivoting and mating parts.
Check to see that the sidestand moves up and
down smoothly.
Recommended lubricant:
SAE 10W30 motor oil

REAR SUSPENSION LUBRICATION
Lubricate the pivoting parts.
Recommended lubricant:
Molybdenum disulfide grease
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INSP
ADJ
CHECKING AND CHARGING THE BATTERY
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
•Wear protective eye gear when handling or
working near batteries.
•Charge batteries in a well-ventilated area.
•Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
•DO NOT SMOKE when charging or han-
dling batteries.
•KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
•Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
First aid in case of bodily contact:
External
•SKIN – Wash with water.
•EYES – Flush with water for 15 minutes
and get immediate medical attention.
Internal
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.
•This is a sealed battery. Never remove the
sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.
•Charging time, charging amperage and
charging voltage for a MF battery are dif-
ferent from those of conventional batter-
ies. The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charg-
ing the battery.
CAUTION:
3-47
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CHECKING AND CHARGING THE BATTERY
3-48
INSP
ADJ
NOTE:
Since MF batteries are sealed, it is not possible to
check the charge state of the battery by measuring
the specific gravity of the electrolyte. Therefore, the
charge of the battery has to be checked by meas-
uring the voltage at the battery terminals.
1. Remove:
•Seat
•Panel 1
2. Disconnect:
•Battery leads
(from the battery terminals)
First, disconnect the negative lead 1, then the
positive lead 2.
3. Remove:
•Battery
4. Check:
•Battery charge
CAUTION:
a. Connect a pocket tester to the battery termi-
nals.
NOTE:
•The charge state of a MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive terminal is
disconnected).
•No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30 %
5. Charge:
•Battery
(refer to the appropriate charging method
illustration)




▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Tester positive ➔Battery positive
lead terminal
Tester negative ➔Battery negative
lead terminal
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Voltmeter
Open-circuit voltage
Relationship between open-circuit
voltage and charging time at 20 °C
Charging time (Hours)
• This varies depending on the temperature, the state of
charge in battery plates and the electrolyte level.13,0
12,5
12,0
11,5
5 6,5 10
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INSP
ADJ
CHECKING AND CHARGING THE BATTERY
3-49
Open-circuit voltage (V)
WARNING
Do not quick charge a battery.
•Never remove the MF battery sealing caps.
•Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
•If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
•When charging a battery, be sure to
remove it from the motorcycle (if charging
has to be done with the battery mounted
on the motorcycle, disconnect the nega-
tive lead from the battery terminal).
•To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the bat-
tery.
•Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
•Make sure that the battery charger lead
clips are in full contact with the battery
terminal and that they are not shorted. A
corroded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
•If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
•As shown in the following illustration, the
open-circuit voltage of a MF battery stabi-
lizes about 30 minutes after charging has
been completed. Therefore, wait 30 min-
utes after charging is completed before
measuring the open-circuit voltage.
CAUTION:
Condition of charge in battery (%)Ambient
temperature
20 °C
Open-circuit voltage (V)
Check the open-circuit
voltage Ambient
temperature 20 °C Charging 14
13
12
11
10
100 75 50 30 2520 00 10 20 30 40 50 60 Time (minutes) 18
17
16
15
14
13
12
11
10
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CHECKING AND CHARGING THE BATTERY
3-50
INSP
ADJ
Charging method using a variable-current (voltage) type charger
ChargerNOTE:Voltage should be measured 30 minutesafter the machine is stopped.
NOTE:
Set the charging voltage at 16 ~ 17 V (if
the setting is lower, charging will be
insufficient. If too high, the battery will be
over-charged.)
AMP
meterMeasure the open-circuit
voltage prior to charging.
Connect a charger and AMP
meter to the battery and start
charging.
Make sure the current is
higher than the standard
charging current written on
the battery.
By turning the charging voltage
adjust dial, set the charging
voltage at 20 ~ 25 V.
Monitor the amperage for 3 ~ 5
minutes to check if the standard
charging current is reached.Adjust the voltage so that
current is at standard charg-
ing level.
Set the timer according to
the charging time suitable for
the open-circuit voltage.
Refer to "Battery condition
checking steps."If the current does
not exceed standard
charging current af-
ter 5 minutes, re-
place the battery.
In case that charging requires more than 5 hours, it is advisable to check
the charging current after a lapse of 5 hours.
If there is any charge in the amperage, readjust the voltage to obtain the
standard charging current.
Measure the battery open-circuit voltage after having left the battery un-
used for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
YES
YESNO
NO
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