2004 YAMAHA TT600RE oil level

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
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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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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CHASFRONT BRAKE
4-15
Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
CAUTION:
WARNING
•Use only designated quality brake fluid.
Otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
•Refill with the same type of brake fluid:
mixing fluids may result in a harmful chem-
ical reaction and lead to poor perform-
ance.
•Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
4. Air bleed:
•Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in CHAPTER 3.
5. Inspect:
•Brake fluid level
Lower than “MIN” mark ➔Fill.
Refer to “BRAKE FLUID INSPECTION”
section in CHAPTER 3.
(a) Minimum level mark “MIN”
6. Install:
•Diaphragm (1)
•Master cylinder cap (2)
•Screw (3) (cap) Screw (master cylinder cap): 1.5 Nm (0.15 mkg)
a
23
1
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FRONT BRAKE
4-20
CHAS
2. Fill:
•Brake fluid reservoir
3. Air bleed:
•Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in CHAPTER 3. Recommended brake fluid:
DOT 4
Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
CAUTION:
WARNING
•Use only designated quality brake fluid.
Otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
•Refill with the same type of brake fluid:
mixing fluids may result in a harmful chem-
ical reaction and lead to poor perform-
ance.
•Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
4. Inspect:
•Brake fluid level
Lower than “MIN” mark ➔Fill.
Refer to “BRAKE FLUID INSPECTION”
section in CHAPTER 3.
(a) Minimum level mark “MIN”
a
WARNING
Check that the brake hose routing is correct.
Refer to “CABLE ROUTING” section.
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CHASFRONT FORK
4-45
OIL CAPACITY (IN EACH FORK LEG): 650 cm3
RECOMMENDED OIL:
Liqui Moly Racing suspension oil SAE 7,5
FRONT FORK OIL LEVEL
STANDARD 180 mm
MINIMUM 190 mm
MAXIMUM 170 mm
From top of inner tube with inner tube fully com-
pressed without spring.
MINIMUM FORK SPRING FREE LENGTH:
530 mm
INNER TUBE BENDING LIMIT:
0.2 mm
1. Park the motorcycle on a level surface.
2. Raise the front wheel by placing a suitable support under the engine.
3. Remove:
•Front wheel
Refer to “FRONT WHEEL REMOVAL”
section.
4. Remove:
•Inner tube protector
•Protector guide
•Gear unit assembly and cable
•Brake caliper and hose
5. Loosen:
•Cap bolt
•Pinch bolt (upper and lower bracket)
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
FRONT FORK REMOVAL
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CHASFRONT FORK
4-47
7. Fill:
•Part of the new oil (with the fork leg in a
vertical position)
Recommended oil: Liqui Moly Racing suspension
oil SAE 7,5
Recommended oil: Liqui Moly Racing suspension
oil SAE 7,5
8. Using the inner tube pump back and forth until a regular drag is felt on the return stroke.
9. With the fork leg in a perfectly upright position, insert the inner tube (1) in the outer tube (2)
completely to the end of the stroke.
10. Finish topping up the oil bringing it to the pre- scribed level from the upper edge measured
with a graduated dipstick or ruler (3).
Oil level:
Standard 180 mm
Minimum 190 mm
Maximum 170 mm
From top of inner tube with inner tube fully
inserted without spring.
12. Screw:
•Cap bolts (5)
(on inner tube, without tighten)
13. Install:
•Fork leg
11. Insert:
•Spring (1) (into the inner tube (2))
•Seat (3)
•Spacer (4)
NOTE:
Usually there is no particular sense in which the
spring is mounted and so it may be inserted from
either end. If there is a hem, however mount it
keeping the hemmed parts towards the top.
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ENGENGINE DISASSEMBLY
5-17
BALANCER SHAFT AND CRANKSHAFT
1. Remove:
•Balancer shaft (1)
2. Remove:
•Crankshaft (1)
NOTE:
•Remove the crankshaft by using the
crankcase separating tool (2).
Crankcase separating tool: P/N. 90890-01135
•Tighten the separating tool bolts, making sure
that the tool body is parallel with the engine
crankcase. If necessary, a screw may be
backed out slightly to level tool body.
OIL STRAINER
NOTE:
It is advisable to replace the oil strainer every time
the engine is disassembled.
1. Remove:
•Oil strainer (1)
•Oil passage cover (2)
•Gasket
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