2004 YAMAHA TT600RE Service Manual

REAR SHOCK ABSORBER
4-70
CHAS
Order Job name/Part name Q.ty Remarks 6 Lower bolt 1
7 Upper bolt 1 Reverse the removal procedure for instal-
lation.
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CHASREAR SHOCK ABSORBER
4-71
(1) Rear shock absorber
(2) Spring
(3) Spring adjuster ring nut
(4) Lock ring nut
(5) End of stroke buffer
(6) Special spanner
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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
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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.
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CHASREAR SHOCK ABSORBER
4-73
SHOCK ABSORBER REMOVAL
WARNING
Support the motorcycle securely to prevent it
from falling over.
1. Park the motorcycle on a level surface.
2. Remove:
•Seat
•Rear cowling
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING” in CHAPTER 3.
3. Disconnect:
•Battery leads
8. Remove:
•Upper mounting bolt (1)
•Rear shock absorber
1
NOTE:
First, disconnect the negative lead, then the posi-
tive lead.
4. Remove:
•Exhaust pipe assembly
•Rear frame
•Air filter case
5. Raise the rear wheel placing a suitable sup- port under the engine.
6. Remove:
•Rear wheel
Refer to “REAR WHEEL REMOVAL” sec-
tion.
7. Remove:
•Shock absorber fastening nut (1)
•Lower mounting bolt
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REAR SHOCK ABSORBER
4-74
CHAS
SHOCK ABSORBER INSPECTION
1. Inspect:
•Shock absorber
Oil leak/Damaged ➔Replace.
REAR SHOCK ABSORBER ADJUSTMENT
This shock absorber is equipped with a spring pre-
load adjuster.



 

Never attempt to turn an adjusting mecha-
nism beyond the maximum or minimum set-
tings.
CAUTION:
Adjust the spring preload as follows.
1. Loosen the locknut.
2. To increase the spring preload and thereby harden the suspension, turn the adjusting nut
in direction a. To decrease the spring preload
and thereby soften the suspension, turn the
adjusting nut in direction b.
NOTE:
•Use the special wrench included in the
owner's tool kit to make the adjustment.
•The spring preload setting is determined by
measuring distance A, shown in the illustra-
tion. The longer distance A is, the lower the
spring preload; the shorter distance A is, the
higher the spring preload. With each com-
plete turn of the adjusting nut, distance A
changes by 1.5 mm.
Spring preload: Minimum (soft):Distance A = 217 mm
Standard: Distance A = 211 mm
Maximum (hard): Distance A = 205 mm
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CHASREAR SHOCK ABSORBER
4-75
2. Tighten the locknut to the specified torque. Locknut: 45 Nm (4.5 m·kgf)
Always tighten the locknut against the adjust-
ing nut, and then tighten the locknut to the
specified torque.
CAUTION:
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SWINGARM
4-76
CHAS
SWINGARM
(1) Upper chain case
(2) Swingarm
(3) Chain support (4) Swingarm guard seal
(5) Connecting rod
(6) Relay arm [A] LATERAL FREE PLAY (END): 1.0 mm
[B] LATERAL FREE PLAY: 0.4 ~ 0.7 mm
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CHASSWINGARM
4-77
SWINGARM REMOVAL
NOTE
Check free play and remove swingarm, if neces-
sary, after removing the rear shock absorber.
1 . Remove:
•Swingarm connecting rod bolt (1)
2 . Check:
•Swingarm free play▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Inspection procedure:
•Check the tightening torque of the nut which
fastens the swingarm pivot shaft (1).
Nut (pivot shaft): 90 Nm (9.0 mkg)
Lateral free play
(at end of swing arm):
Limit: 1.0 mm
•Check the lateral free play [A] of the swingarm
moving it laterally.
If the free play seems excessive, verify the
collar, bearings, washer and thrust cover.
•Check the vertical movement [B] of the
swingarm, moving it up and down.
If the movement seems rigid, unsmooth or
jerky, inspect the internal collar, the bearings,
the washer and the thrust cover.
1
1
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