2004 YAMAHA TT600RE weight

INSP
ADJSTEERING INSPECTION/
TYRE INSPECTION
3-41
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Nut (steering axle):
115 Nm (11.5 mkg)
Screws (front fork bracket):
28 Nm (2.8 mkg)
•Tighten the steering axle nut and the front fork
bracket screws.
•Reassemble the fuel tank.
See section “SEAT, FUEL TANK AND REAR
COWLING”.
NOTE:
Check the steering head for looseness or binding
by turning it all the way in both directions. If it
binds, remove the steering axle assembly and
inspect the steering bearings.
Refer to “STEERING HEAD” in Chapter 6.
TYRE INSPECTION
WARNING
•Tyre pressure must be checked when the
tyres are at ambient temperature. Pressure
must be adjusted according to the total
weight of luggage, driver, passenger and
accessories (fairings, bags, if approved for
this model) and speed of the motorcycle.
•A list of tyres approved for this model fol-
lowing severe testing by Yamaha is provid-
ed. There can be no guarantee of safe road-
holding if a combination of tyres different
from those indicated is used.
•Front and rear tyres must have the same
design and be of the same make.
•The use of valves and valve stems other
than those indicated might cause the loss
of tyre pressure at high speeds. Use only
original or compatible spare parts.
•Replace the valve cap securely to prevent
losses of tyre pressure at high speed.
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TYRE INSPECTION
3-42
INSP
ADJ
1. Check:
•Tyre pressure
Out of specification ➔Adjust.
Tire air pressure
(measured on cold tires)
Load* Front Rear
200 kPa 220 kPa
Up to 90 kg (2.00 kgf/cm
2, (2.20 kgf/cm2,
2.00 bar) 2.20 bar)
210 kPa 240 kPa
90 kg-maximum (2.10 kgf/cm
2, (2.40 kgf/cm2,
2.10 bar) 2.40 bar)
150 kPa 160 kPa
Off-road riding (1.50 kgf/cm
2, (1.60 kgf/cm2,
1.50 bar) 1.60 bar)
High-speed 210 kPa 240 kPa
riding(2.10 kgf/cm
2, (2.40 kgf/cm2
2.10 bar) 2.40 bar)
Maximum load* 180 kg
* Total weight of rider, passenger, cargo and ac-
cessories.
2. Adjust:
•Air pressure
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Adjustment:
•Remove the valve cap.
Use an air pump or Increase air
compressed air pistol. pressure
Eliminate air by Air pressure
pressing valve tube diminishes
stem
•Install valve caps securely.
3. Inspect:
•Tyre surface
Wear/Damage ➔Replace.
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FRONT WHEEL AND BRAKE DISC
4-6
CHAS
FRONT WHEEL INSTALLATION
1. Install:
•Brake disc (1)
2. Install:
•Speedometer gear unit (1) Screw (brake disc):
12 Nm (1.2 mkg)
NOTE:
•Apply LOCTITE®to the threads of brake disc
screw.
•Tighten the screws (brake disc) in stage using
a crisscross pattern.
3. Tighten:
•Front wheel
•Front wheel axle
NOTE:
Make sure that the wheel hub and the speedome-
ter gear unit are installed with the projections
meshed into the slots.
•Pinch bolt Front wheel axle:
59 Nm (5.9 mkg)
NOTE:
Make sure that the slot (a) in the speedometer
gear unit fits under the stopper on the front fork
outer tube.
Pinch bolt: 9 Nm (0.9 mkg)a
WHEEL STATIC BALANCE ADJUSTMENT
1. Remove:
•Balancing weight
2. Set:
•Wheel (on a suitable stand)
3. Find:
•Heavy spot
NOTE:
•After replacing the tire and/or rim, the wheel
static balance should be adjusted.
•Adjust the front wheel static balance with the
brake disc installed.
1
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CHASFRONT WHEEL AND BRAKE DISC
4-7
4. Adjust:
•Wheel static balance
Adjusting steps:
•Install a balancing weight (1) on the rim exact-
ly opposite to the heavy spot “X”.
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•Turn the wheel so that the heavy spot is 90°
up.
•Check that the heavy spot is at rest there. If
not, try another weight until the wheel is bal-
anced.
NOTE:
Start with the smallest weight.
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5. Check:
•Wheel static balance
Checking steps:
•Turn the wheel so that it comes to each point
as shown.
•Check that the wheel is at rest at each point.
If not, readjust the front wheel static balance.
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Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “X
1” mark on the wheel’s bottom spot.
c. Turn the wheel so that the “X
1” mark is 90° up.
d. Release the wheel and wait for it to rest. Put an “X
2” mark on the wheel’s bottom spot.
e. Repeat the above b., c., and d. several times until all marks come to the same spot.
f. This spot is the wheel’s heavy spot “X”.
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CHASREAR WHEEL AND BRAKE DISC
4-27
WHEEL STATIC BALANCE ADJUSTMENT 1. Remove:
•Balancing weight
2. Set:
•Wheel (on a suitable stand)
3. Find:
•Heavy spot
NOTE:
•After replacing the tire and/or rim, the wheel
static balance should be adjusted.
•Adjust the rear wheel static balance with the
brake disc installed.
Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “X
1” mark on the wheel’s bottom spot.
c. Turn the wheel so that the “X
1” mark is 90° up.
d. Release the wheel and wait for it to rest. Put an “X
2” mark on the wheel’s bottom spot.
e. Repeat the above b., c., and d. several times until all marks come to the same spot.
f. This spot is the wheel’s heavy spot “X”.
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4. Adjust:
•Wheel static balance
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Adjusting steps:
•Install a balancing weight (1) on the rim exact-
ly opposite to the heavy spot “X”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
•Turn the wheel so that the heavy spot is 90°
up.
•Check that the heavy spot is at rest there. If
not, try another weight until the wheel is bal-
anced.
NOTE:
Start with the smallest weight.
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FRONT FORK
4-54
CHAS
12. The vice tightened, grip the outer tube and with a few strong blows hit it against the tool
(3) until the DU outer tube bush (4) is correct-
ly positioned in its seat.
13. Remove the fork leg from the vice and remove the tool (1). Insert the new washer (3) and the
new oil seal (4) as shown on the inner tube (2).
NOTE:
Apply lightweight lithium-soap base grease to the
oil seal before installing it.
14. Mount the tool (1) on the inner tube (2) with the side (5) matching the oil seal (4) and clamp it
keeping the two joints (6) at the top and bot-
tom (never towards the jaws of the vice) and
make it protrude by at least 40 mm at the
sides.
DU bush/oil seal driver (1): 90890-11043
54
3
~ 40 mm
124
5
43
21
15. The vice tightened, grip the outer tube and with a few strong blows hit it against the tool
(1). After each blow rotate the outer tube
slightly in order to install the oil seal (4) cor-
rectly and until it is completely inserted in its
seat.
1
2
64
3
~ 40 mm
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CHASFRONT FORK
4-55
16. Tightly clamp the fork leg horizontally fasten- ing it by caliper attachment on the outer tube.
17. Install:
•Snap ring (1)
Check that the snap ring is correctly seated.
CAUTION:
18. Install:
•Dust seal (1) (new)
NOTE:
Apply lightweight lithium-soap base grease to the
dust seal before installing it.
NOTE:
Taking care to insert completely the dust seal (1)
with force in the outer tube (2).
1
1
 

2
1
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ENGINE DISASSEMBLY
5-18
ENG
ROCKER ARMS
NOTE:
The rocker arms may be examined with the
engine installed by removing the following parts.
•Seat
•Fuel tank
•Cylinder head cover
1. Remove:
•Cap (1)
2. Remove:
•Bolts (1) (rocker shaft)
3. Remove:
•Rocker shaft
•Rocker arms
NOTE:
Remove the rocker shaft using sliding hammer (1)
and weight (2).
Sliding hammer bolt: P/N. 90890-01083
Weight: P/N. 90890-01084
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