2004 YAMAHA TT600RE Service Manual

REAR BRAKE
4-38
CHAS
BRAKE CALIPER DISASSEMBLY
1. Remove:
•Brake caliper piston (1)
•Dust seal (3)
•Piston seal (2)
Removal procedure:
•Blow compressed air into the hose joint open-
ing to force out the caliper piston from the
brake caliper body.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
•Remove the piston seal
CALIPER INSPECTION
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Inspect:
•Caliper piston
Scratches/wear/rust ➔Replace caliper
assembly.
•Caliper cylinder
Scratches/wear ➔Replace caliper assem-
bly.
•Caliper
Cracks/damaged ➔Replace.
Recommended programme for the
replacement of brake system components: Brake pads When necessary
Brake hose Every four years
Replace every
Brake fluid 24,000 km or 24
months and
whenever the brake
is disassembled.
WARNING
All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation. Do not use solvents to
prevent sealing elements from becoming mis-
shapen or swollen.
WARNING
•Never try to pry out the caliper piston.
•Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the master cylinder.
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CHASREAR BRAKE
4-39
•Fluid delivery passage (caliper)
Obstruction ➔Clean with compressed air.
BRAKE CALIPER ASSEMBLY
WARNING
•All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.
•In case of non correct operation of the
brake caliper, replace the brake caliper
assembly. Liquido freni raccomandato:
DOT 4
CALIPER INSTALLATION
1. Install:
•Brake caliper (1)
•Caliper support (2)
•Brake hose (3)
•Plain washers (4) (new)
•Union bolt (5)
Union bolt: 20 Nm (2.0 mkg)
WARNING
In case of non correct operation of the brake
caliper, replace the brake caliper assembly.
1. Install:
•Piston seal (1)
•Dust seal (2)
•Caliper piston (3)
•Caliper protector
3
451
2
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REAR BRAKE
4-40
CHAS
2. Fill:
•Brake fluid reserve tank
Check that the brake hose has stayed in cor-
rect position with the pipe-fitting matching the
projection (a) of the caliper.
CAUTION:
WARNING
Check that the brake hose routing is correct.
Refer to “CABLE ROUTING” section.
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.
3. Air bleed:
•Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in CHAPTER 3.
a
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CHASREAR BRAKE
4-41
4. Inspect:
•Brake fluid level
Lower than “MIN” mark (1) ➔Fill.
Refer to “BRAKE FLUID INSPECTION”
section in Chapter 3.
(1) Minimum level mark “MIN”

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FRONT FORK
4-42
CHAS
FRONT FORK
FRONT FORK REMOVAL
Order Job name/Part name Q.ty Remarks Front fork removal Remove the parts in order.
Front wheel Refer to “FRONT WHEEL” section.
1 Inner tube protector 1
2 Brake hose guide 1
3 Protector guide 2
4 Brake caliper assembly 1
5 Cowling (displace) 1
6 Pinch bolt (upper bracket) 4
7 Cap bolt (loosen) 2 Refer to "FRONT FORK INSTALLATION"
section.
8 Pinch bolt (under bracket) (loosen) 4
9 Fork leg 2 Reverse the removal procedure for instal-
lation.
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CHASFRONT FORK
4-43
Order Job name/Part name Q.ty Remarks Front fork disassembly Remove the parts in order.
Refer to “FRONT FORK REMOVAL/INSTAL-
LATION”.
1 Cap bolt 1
2 Seat 1
3 Spacer 1 Refer to “OIL REPLACEMENT” section.
4 Seat 1
5 Fork spring 1
6 Bolt 1
7 O-ring 1
8 Damper adjusting cylinder 1 Refer to “SEAL AND BUSH REPLACE-
9 Taper spindle 1 MENT” section.
10 Dust seal 1 11 Snap ring 1
FRONT FORK DISASSEMBLY
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FRONT FORK
4-44
CHAS
Order Job name/Part name Q.ty Remarks 12 Inner tube 1
13 Inner tube bushing 1
14 Oil seal 1 Refer to “SEAL AND BUSH REPLACE-
15 Washer 1 MENT” section.
16 Outer tube bushing 1
17 Outer tube 1 Reverse the removal procedure for instal-
lation.
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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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