2004 YAMAHA TT600RE oil pressure

INSP
ADJ
3-21
ENGINE OIL PRESSURE CHECK/
CLUTCH ADJUSTMENT







ENGINE OIL PRESSURE CHECK
1. Remove:
•Bleeder screw (1)
2. Start the engine and keep it idling until oil
flows out of the bleed hole.
3. Inspect:
•Conditions of oil at bleeder hole.
Oil leakage ➔Oil pressure good.
No leakage ➔Pressure insufficient.
If the oil does not come out after one minute,
stop the engine immediately to prevent
seizure.
4. Tighten:
•Bleeder screw
CAUTION:
Bleeder screw:
5 Nm (0.5 kgm)
CLUTCH ADJUSTMENT
Cable free play adjustment
1. Check:
•Clutch free play adjustment (a)
Out of specification ➔Adjust.
Free play:
10 ~ 15 mm
2. Adjust:
•Clutch cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjustment:
•Loosen lock nuts (1).
•Turn the adjuster (2) either way to obtain cor-
rect free play.
•Tighten lock nuts after adjustment.

ProCarManuals.com

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
➩➩
ProCarManuals.com

CHASFRONT FORK
4-49
CLEANING THE DUST SEAL
NOTE:
After using the motorcycle it is necessary to clean
the dust seal carefully in order to maintain the fork
at maximum efficiency.
In fact, if dust infiltrates to the inside of the dust
seal it can compromise the smoothness and
therefore the sensitivity of the fork, and also
cause the premature wear of the underlying oil
seal.
Just a few simple operations then, guided by the
following indications are necessary to maintain
the optimum functioning of the fork with time.
1. With a screwdriver prise the dust seal (1) from the oil seal seat (2) and then withdraw it using
force.
2. Using a low pressure jet of compressed air clean the inside of the dust seal and the oil
seal seat.
3. Insert the edge of a cloth under the lip and keeping the cloth steady, carefully clean the
lip by rotating the dust seal.
1
2
1
2
12
ProCarManuals.com

REAR SHOCK ABSORBER
4-72
CHAS
WARNING
This shock absorber contains high-pressure
nitrogen gas. Read the following information
carefully before handling it. The manufacturer
cannot be held responsible for any damage or
injury that may result from improper handling.
•Never tamper with or attempt to open the
cylinder or the tank.
•Never expose the shock absorber to a
naked flame or other source of heat. This
might cause the pressurised gas to
explode.
•Do not deform or damage the cylinder in
any way. Damage to the cylinder would
impair the damping effect.
•Be careful not to scratch the surface of the
rod: this would cause the oil to leak.
•Before disposing of the shock absorber,
read the section “NOTES ON DISPOSAL”.
NOTE ON DISPOSAL
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Before neutralising the rear shock absorber:
The gas pressure must be discharged before dis-
posing of the shock absorber it is necessary to dis-
charge the gas pressure. To do this, bore a hole of
2~3 mm through the cylinder wall about 15~20
mm from the bottom of the gas chamber.
WARNING
Wear protective goggles to avoid eye injuries
from escaping gas and/or metal chips.
ProCarManuals.com

ENGINE DISASSEMBLY
5-10
ENG
2. Remove:
•Compression spring (1)
•Pressure plate (2)
•Ball (3)
•Friction plate (4)
•Clutch plate (5)
•Clutch boss spring (6)
•Clutch boss (7)
•Thrust plate (8)
•Clutch shroud (9)
•Push rod (10)
1. Remove:
•Engine oil delivery hose screw
•Copper washer
•Oil filter cover (1)
•Oil filter
•Seal ring and O-Ring
•Crankcase cover (2) (R)
NOTE:
•Before loosening the nut (11) (clutch shroud),
straighten the washer lock tab.
•To loosen the nut (clutch boss), block the
clutch boss using the special tool (12).
Clutch holding tool: P/N. 90890-04086
ProCarManuals.com

INSPECTION AND REPAIR
5-26
ENG
5. Emery:
•Valve seal surface
•Valve seat
NOTE:
If the valve seat is renewed or the valve and guide
replaced, the valve seat and seal surface must be
lapped.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Lapping steps:
•Apply rough-lapping compound to the valve
seal surface.
Make sure the lapping compound does not
run into the space between the guide and
valve stem.
CAUTION:
•Apply oil to the molybdenum disulfide on the
valve stem.
•Install the valve in the cylinder head.
•Turn the valve until face and surface are not
evenly polished. Then clean away all the lap-
ping compound.
NOTE:
For best results, during lapping, repeatedly apply
(light) pressure to the valve seat, turning the valve
backwards and forwards by hand.
•Apply a fine-lapping compound on the valve
seal surface and repeat the procedures
described above.
NOTE:
Be sure to remove all the lapping compound from
the valve surface after every lapping operation.
ProCarManuals.com

ENGINE ASSEMBLY AND SETTING
5-72
ENG
NOTE:
Install the friction and clutch plates to the clutch
boss, beginning and ending with a friction plate.
•The two friction plates (type A) (15) with
the widest internal diameter should be
assembled in second and last place.
•The clutch boss spring (16) should be
placed inside the second friction plate.
CAUTION:
Friction plate
Type “A” Type “B”
Quantity 2 6
Internal 116 mm 113 mm
diameter “D”
NOTE:
Align the mark on the clutch boss (17) with the
arrow (18) on the pressure plate.
3. Adjust:
•Clutch (free play)
See section “CLUTCH ADJUSTMENT” in
CHAPTER 3.
4. Install:
•Straight key
•Gasket
•Crankcase cover (right) (1)
•O-Ring
•Oil filter
•Filter cover (2) (with O-Ring)
See section “Engine oil replacement (with
oil filter change)” in CHAPTER 3.
Bolt (crankcase cover): 10 Nm (1.0 mkg)
16
15
ProCarManuals.com

DIFFICULTIES IN SHIFTING
8-4
TRBL
SHTG
?
Clutch
Engine oil PROBABLE CAUSES•Clutch cable wrongly set
•Wrong position of push lever
•Irregular engagement of push lever and push
rod
•Pressure plate deformed
•Clutch springs not preloaded uniformly
•Reference marks not aligned
•Push rod broken
•Clutch gear assy nut loose or push rod deformed
•Primary driven gear bearing defective
•Driven plates deformed
•Driving plates deformed
•Clutch cable damaged
•Oil level over maximum
•Incorrect gradation (high viscosity)
•Degradation
SHIFTING IMPOSSIBLE
DIFFICULTIES IN SHIFTING
Shift shaft
Shift cam, shift fork PROBABLE CAUSES•Shift shaft deformed
•Groove with impurities or foreign bodies
•Shift fork stuck
•Shift fork guide bar deformed
THE SHIFT PEDAL FAILS TO MOVE
Transmission•Transmission gears struck
•Gears stuck by impurities or foreign bodies
•Wrong transmission assembly
Shift shaft
Shift fork PROBABLE CAUSES•Shift lever set wrongly
•Shift cam
stop lever fails to return freely
•Shift forks worn
Transmission
•Gear clutches worn
DISENGAGING GEARS
Shift cam
•Shaft cam with thrust free play
•Shift cam groove worn
ProCarManuals.com