2004 YAMAHA TT600RE air filter

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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ENGENGINE REMOVAL
5-3
Order Job name/Part name Q.ty Remarks – Starter leads 2 Disconnect.
– Starter 1 Remove.
10 Connectors of engine wire harness 2 Disconnect. 11 Oil delivery hose 1 Disconnect.
12 Oil return hose 1 Disconnect.
13 Oil breather pipe (to oil tank) – Disconnect.
14 Oil breather pipe (to air filter box) – Disconnect. Reverse the removal procedure for
installation.
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ENGENGINE REASSEMBLY
5-77
4. Install:
•Oil delivery hose (1) Union bolt: 18 Nm (1.8 mkg)
Screw (tappet cover): 10 Nm (1.0 mkg)
Air bleeder screw (oil filter cover): 5 Nm (0.5 mkg)
Amount of oil: Camshaft0.1 litres
Oil filter housing 0.06 litres
5. Remove:
•Tappet cover (intake)
•Air bleeder screw (oil filter cover)
6. Apply:
•4-stroke engine oil
•(on the top side of the camshaft and in the
oil filter housing).
Liberally apply 4-stroke engine oil in the oil
passage in the crankcase to prevent damage
to the engine.
CAUTION:
7. Install:
•Tappet cover (intake)
•Air bleeder screw (oil filter cover)
8. Adjust:
•Clutch cable free play Free play (at end of lever): 10 ~ 15 mm
See section “CLUTCH ADJUSTMENT” in
CHAPTER 3.
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FAILURE TO START/
DIFFICULTIES IN STARTING
8-1
TRBL
SHTG
?
TROUBLESHOOTING
NOTE:
The troubleshooting tables that follow do not identify every cause of trouble. They may however prove
helpful as a guide to identifying trouble. To inspect, adjust or replace parts, refer to the appropriate sec-
tion in the manual.
FAILURE TO START/DIFFICULTIES IN STARTING
FUEL SYSTEM
Fuel tank
Fuel cock
Carburetor
Air filter PROBABLE CAUSES
•Empty
•Fuel filter obstructed
•Fuel tank air cap passage obstructed
•Petrol contains water or impurities or is adulterated
•Hose obstructed
•Fuel filter obstructed
•Petrol contains water or impurities or is adulterated
•Pilot jet obstructed
•Pilot air passage obstructed
•Infiltrations of air
•Deformation of float
•Needle valve worn or scratched
•Needle valve seat insufficiently sealed
•Fuel level set wrongly
•Pilot jet set wrongly
•Starter jet obstructed
•Malfunctioning of the starter piston
•Air filter element obstructed
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POOR PERFORMANCE AT IDLE SPEED/
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED
8-3
TRBL
SHTG
?
Carburetor
Electrical system
Valves PROBABLE CAUSES•The starter piston fails to return freely
•Pilot jet obstructed or loose
•Pilot jet obstructed
•Pilot air screw wrongly set
•Idle speed wrongly set
(throttle valve stop screw)
•Throttle cable free play wrongly set
•Carburetor flooded
•Valve clearance wrongly set
Air filter
•Air filter element obstructed
POOR PERFORMANCE AT IDLE SPEED
See “FAILURE TO START/DIFFICULTIES IN STARTING”.
(FUEL SYSTEM, ELECTRICAL SYSTEM, COMPRESSION SYSTEM and Valve clearance)
Carburetor
PROBABLE CAUSES
•Petrol contains water or impurities or is adulterated
•Infiltrations of air
•Deformation of float
•Defective diaphragm
• Needle valve worn or scratched
•Needle valve seat insufficiently sealed
•Needle stop position incorrect
•Fuel level set wrongly
•Main jet obstructed or loose
•Main nozzle obstructed or loose
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED
•Defective battery
•Defective spark plug
•Defective ignition unit
•Defective AC magneto
•Defective ignition coil
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DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS/ OVERHEATING OF ENGINE
8-9
TRBL
SHTG
?
PROBABLE CAUSES
•Indicator lamp relay defective
•Insufficient battery capacity
(battery almost flat)
•Incorrect bulb
•Main switch or direction indicator switch defec-
tive
DELAYED TURNING ON OF INDICATORS
PROBABLE CAUSES
•Battery flat
•Main switch or horn switch defective
•Horn wrongly set
•Defective horn
•Harness cut off
THE HORN FAILS TO WORK
OVERHEATING OF ENGINE
PROBABLE CAUSES
•Incorrect bulb
•Indicator lamp relay defective
EXCESSIVE INDICATOR
INTERMITTENCE FREQUENCY
Ignition system
Fuel feed system PROBABLE CAUSES
•Incorrect electrode gap of spark plug
•Spark plug thermal gradation wrong
•Ignition unit defective
•Incorrect carburetor main jet (incorrect setting)
•Incorrect fuel level
•Air filter element obstructed
Engine compression
•Excess of carbon deposits
Engine oil
•Incorrect oil level
•Incorrect oil viscosity
•Incorrect oil gradation
Brake
•Pads fail to return freely (remains blocked)
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