2004 YAMAHA TT600RE engine oil

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.
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SPECCABLE ROUTING
2-28
(1) Tachometer/
odometer cable
(2) Tachometer/
odometer cable
holder
(3) Tachometer/
odometer cable
band
(4) Right tube guard
(5) Spark plug cable
(6) Horn(7) Carburetor suction
pipe
(8) Main wire harness
band
(9) Rear brake switch
wire harness
(10) Rear brake fluid
tank hose
(11) Hose from rear
master cylinder to
caliper(12) Rear brake hose
holders
(13) Pipe
(14) Air breather pipe
(15) Spark plug ignition
coil
(16) Chassis ground
(17) Engine oil
breather pipe
(to air filer case)[A] Insert the
tachometer/
odometer cable into
the band 3 and the
holder 2.



















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CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENTS
INTRODUCTION..........................................................................................................3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS........................................3-1
SEAT, FUEL TANK AND REAR COWLING................................................................3-3
REMOVAL ............................................................................................................3-3
INSTALLATION ....................................................................................................3-3
ENGINE........................................................................................................................3-4
VALVE CLEARANCE ADJUSTMENT ..................................................................3-4
DRIVE CHAIN ADJUSTMENT ..............................................................................3-7
IDLE SPEED ADJUSTMENT ................................................................................3-7
THROTTLE CABLE FREE PLAY ADJUSTMENT ................................................3-8
SPARK PLUG INSPECTION ................................................................................3-9
IGNITION TIMING CHECK ................................................................................3-11
COMPRESSION INSPECTION ..........................................................................3-12
ENGINE OIL LEVEL CHECK ..............................................................................3-15
ENGINE OIL REPLACEMENT ............................................................................3-17
ENGINE OIL PRESSURE CHECK ....................................................................3-21
CLUTCH ADJUSTMENT ....................................................................................3-21
AIR FILTER CLEANING ......................................................................................3-24
FUEL FILTER CLEANING ..................................................................................3-25
ENGINE OIL TANK FILTER CLEANING ............................................................3-26
SUCTION HOSE AND MANIFOLD INSPECTION..............................................3-28
FUEL LINE INSPECTION ..................................................................................3-28
CRANKCASE VENTILATION HOSE INSPECTION ..........................................3-29
EXHAUST SYSTEM INSPECTION ....................................................................3-29
CHASSIS....................................................................................................................3-30
ADJUSTING THE FRONT BRAKE ....................................................................3-30
ADJUSTING THE REAR BRAKE ......................................................................3-31
CHECKING THE BRAKE FLUID LEVEL ............................................................3-32
BRAKE PAD WEAR INSPECTION ....................................................................3-33
BRAKE HOSING INSPECTION ..........................................................................3-33
BRAKE CIRCUIT BLEEDING ............................................................................3-34
DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT..................................3-35
DRIVE CHAIN LUBRICATION ............................................................................3-36
FRONT FORK INSPECTION ..............................................................................3-37
ADJUSTING THE FRONT FORK ......................................................................3-37
REAR SHOCK ABSORBER ADJUSTMENT ......................................................3-38
STEERING INSPECTION ..................................................................................3-40
TYRE INSPECTION ............................................................................................3-41
WHEEL INSPECTION ........................................................................................3-44
SPOKE INSPECTION AND TIGHTENING ........................................................3-44
CABLE INSPECTION..........................................................................................3-45
LEVER AND PEDAL LUBRICATION ..................................................................3-45
SIDESTAND LUBRICATION ..............................................................................3-46
REAR SUSPENSION LUBRICATION ................................................................3-46
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INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
3-2
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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.
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3-11
IGNITION TIMING CHECK
IGNITION TIMING CHECK
1. Start the engine and let it heat.
2. Connect:
•Inductive rev counter
•Stroboscopic lamp to spark plug cable
Inductive engine speed indicator:
P/N. 90890-03113
Stroboscopic lamp:
P/N. 90890-03141
3. Remove:
•Cap (1)
In certain conditions, the oil might spray out
when the cap is removed. Be careful therefore
when removing the cap.
4. Check:
•Ignition advance
CAUTION:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Check:
•Heat engine and let it run to the number of
revs required.
Engine idle speed:
1,150 ~ 1,450 rpm
•Check that reference (1) is in the mobile field
of reference (2) on the flywheel.
Incorrect ignition timing ➔ Check the ignition
coil unit.
NOTE:
Ignition timing cannot be adjusted.
5. Install:
•Cap
6. Remove:
•Stroboscopic lamp
•Inductive engine speed indicator


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3-13
COMPRESSION INSPECTION
Inspection:
•Turn the main switch to "ON".
•With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilized.
WARNING
While operating the starter, disconnect the
spark plug cap to avoid sparks.
•Compare the pressure reading with those in
the table.
Pressure under compression:
Standard
1,100 kPa (11 kg/cm
2, 156 psi)
Minimum
900 kPa (9 kg/cm
2, 128 psi)
Maximum
1.200 kPa (12 kg/cm
2, 171 psi)
8. Check:
•Pressure under compression
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
•If the pressure reading is lower than minimum:
1) Add a few drops of oil to the cylinder through
the hole in the spark plug.
2) Measure the compression again.
3) Compare the new reading with the first, then
proceed according to the indications in the
table.
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3-15
ENGINE OIL LEVEL CHECK
ENGINE OIL LEVEL CHECK
Do not put additives into the engine oil. The
latter also lubricates the clutch and additives
might cause it to slide.
WARNING
Never remove the oil tank cap when the
engine is hot. The boiling oil might spill over,
causing burns. Wait for the oil to cool to at
least 60°C (140°F) or thereabouts.
This model is fitted with a dry crankcase lubrica-
tion system. A feed pump delivers oil to the en-
gine; after fully lubricating the latter, the oil is re-
turned to the tank by a scavenge pump. The oil
level must therefore be checked in the oil tank.
1. Start the engine and warm up until the oil tem-
perature rises to approximately 60°C (140°F).
2. Idle the engine for at least 10 seconds while
keeping the motorcycle upright. After stop the
engine and check the oil level through the
level window (3) located on the left side of the
oil tank assy and(or) by oil level gauge.
NOTE:
Be sure the motorcycle is positioned straight up
when checking the oil level. A slight tilt toward the
side can result in false readings.
3. The oil level should be between the maximum
(1) and minimum (2) marks.
CAUTION:
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3-16
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ENGINE OIL LEVEL CHECK
If the oil level is below minimum ➔Add oil up
to maximum level.
Recommended oil:
SAE20W40SE or SAE10W30SE
Refer to the chart for selection of
the oils suited to the atmospheric
temperature.
API Standard:
API SE, SF, SG or higher grade
•Do not put in any chemical additives or use
oils with a grade of CD (a) or higher.
•Be sure not to use oils labeled “ENERGY
CONSERVING II” (b) or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
•Be sure no foreign material enters the
crankcase.
4. Reassemble the oil tank cap.
Never start the engine when the oil tank is
empty.
CAUTION:
CAUTION:
Oil capacity:
Total:
3.0 litres
Periodic oil change:
2.4 litres
With oil filter change:
2.5 litres
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