2004 YAMAHA TT600RE oil filter

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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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INSP
ADJINTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
3-1
PERIODIC INSPECTION AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a
longer service life. The need for costly overhaul work will be greatly reduced. This information applies to
vehicles already in service as well as to new vehicles that are being prepared for sale. All service techni-
cians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
ODOMETER READING (x 1,000 km)
ANNUAL N0. ITEM CHECK OR MAINTENANCE JOB
110 2030 40CHECK
1
*Fuel line• Check fuel hoses for cracks or damage. ✓✓ ✓✓ ✓•
• Check condition.
✓✓
2 Spurk plug• Clean and regap.
• Replace.✓✓
3 * Valves• Check valve clearance.
✓✓ ✓✓
• Adjust.
4Air filter element• Clean.✓✓
• Replace. ✓✓
5 Clutch• Check operation.
✓✓ ✓ ✓✓
• Adjust.
• Check operation, fluid level and vehicle for fluid leakeage.
6 * Front brake•(See NOTE). ✓✓ ✓ ✓✓ ✓•
• Replace brake pads. Whenever worm to the limit
• Check operation, fluid level and vehicle
•for fluid leakage. ✓✓ ✓ ✓✓ ✓
7 * Rear brake•(See NOTE).
• Replace brake pads. Whenever worm to the limit
8 * Brake hoses• Check for cracks or damage.✓✓✓✓ ✓• Replace. (See NOTE). Every 4 years
9 * Wheels• Check runout, spoke tightness and for damage.
✓✓✓ ✓
• Tighten spokes if necessary.
• Check tread depth and for damage.
10 * Tyres• Replace if necessary.
✓✓✓✓ ✓
• Check air pressure.
• Correct if necessary.
11 * Wheel bearings• Check bearing for looseness or damage.✓✓✓✓
12 * Swingarm• Check operation and for excessive play.✓✓✓✓
• Check chain slack.
13 * Drive chain• Make sure that the rear wheel is properly aligned.Every 500 km and after washing the
• Clean and lubricate.motorcycle or riding in the rain.
14 *Steering • Check bearing play and steering for roughness. ✓✓ ✓ ✓✓bearings
• Lubrificate with lithium-soap-based grease. Every 20,000 km
15 *Chassis • Make sure that all nuts, bolts and screws are properly
✓✓ ✓✓ ✓
fasteners•tightened.
16Sidestand• Check operation.
✓✓ ✓✓ ✓
• Lubricate.
17
*Sidestand
• Check operation and for oil leakage. ✓✓ ✓ ✓✓ ✓
switch
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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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3-16
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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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3-17
ENGINE OIL REPLACEMENT


ENGINE OIL REPLACEMENT
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.
Engine oil replacement (without replacing filter
oil)
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.
CAUTION:
7. Inspect:
•All gaskets
Damaged ➔Replace.
8. Reassemble:
•Oil filter cover bleeder screw
•Engine oil drain plug
•Oil tank hose and O-ring 5. Remove the air bleed screw (3) attached to
the oil filter cover (4).
6. Wait until the oil has completely drained.
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3-18
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ENGINE OIL REPLACEMENT
Fastening torques:
Drain plug (engine):
30 Nm (3.0 mkg)
Oil tank hose (flange):
10 Nm (1.0 mkg)
Oil filter cover air bleeder screw:
5 Nm (0.5 mkg)
9. Fill:
•Oil tank
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
Oil capacity:
Periodic change = 2.4 litres
•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.
CAUTION:
10. Install:
•Oil tank tap
11. Check:
•Oil level
See section “ENGINE OIL LEVEL
CHECK”.
•Oil pressure
See section “ENGINE OIL PRESSURE
CHECK”.
•Oil leakage
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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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3-20
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ENGINE OIL REPLACEMENT
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
Oil capacity:
Total:
3.0 litres
Periodic oil change:
2.4 litres
With oil filter change:
2.5 litres
•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.
CAUTION:
12. Install:
•Oil tank cap
13. Check:
•Oil level
See section “ENGINE OIL LEVEL
CHECK”.
•Oil pressure
See section “ENGINE OIL PRESSURE
CHECK”.
•Oil leakage 11. Fill:
•Oil tank
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