2004 YAMAHA TT600RE engine

SPECCABLE ROUTING
2-27









































(1) Front brake hose
(2) Brake hose holder
(3) Left tube guard
(4) Plastic plate
(5) Throttle cables
(6) Tachometer/
odometer cable
(7) Clutch cable
(8) Clutch cable holder
(9) Throttle cables
holder
(10) Wire harness band(11) Fuel pipe from fuel
cock
(12) Flasher relay
(13) Main relay
(14) Sidestand switch
(15) Diodes (n. 3)
(16) A.C. generator wire
harness (engine)
(17) Engine oil breather
pipe (to engine oil
tank)
(18) Main switch(19) Oil hose (oil tank to
engine)
(20) Oil hose (engine to
oil tank)
(21) C.D.I. unit
(22) Starting motor plus
cable
(23) Starting motor
minus cable
(24) Battery
(25) Starting relay
(26) Fuse (reserve)
(27) Fuse (main)(28) Wire extension
(29) Battery plus cable
[A] Lay the brake hose
behind the left tube
guard and fasten it
down by means of
the plate 4.
[B] Attach throttle
cables 5.
[C] Fasten the fuel pipe
11 to the tank.
[D] Fit the 3 diodes
inside the chassis,
against the coil clip.
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SPECCABLE ROUTING
2-28
(1) Tachometer/
odometer cable
(2) Tachometer/
odometer cable
holder
(3) Tachometer/
odometer cable
band
(4) Right tube guard
(5) Spark plug cable
(6) Horn(7) Carburetor suction
pipe
(8) Main wire harness
band
(9) Rear brake switch
wire harness
(10) Rear brake fluid
tank hose
(11) Hose from rear
master cylinder to
caliper(12) Rear brake hose
holders
(13) Pipe
(14) Air breather pipe
(15) Spark plug ignition
coil
(16) Chassis ground
(17) Engine oil
breather pipe
(to air filer case)[A] Insert the
tachometer/
odometer cable into
the band 3 and the
holder 2.



















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SPECCABLE ROUTING
2-29
(1) Rectifier
(2) Wire harness bands
(3) Protection
(4) Left turn wire
harness(5) Right turn wire
harness
(6) Tail light wire
harness
(7) Air breather pipe
(carburetor)(8) Wire extension
(9) Starter power
cables
(10) Engine cables and
side stand switch[A] Screw protection 3
after setting wiring
properly.













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INSP
ADJ
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENTS
INTRODUCTION..........................................................................................................3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS........................................3-1
SEAT, FUEL TANK AND REAR COWLING................................................................3-3
REMOVAL ............................................................................................................3-3
INSTALLATION ....................................................................................................3-3
ENGINE........................................................................................................................3-4
VALVE CLEARANCE ADJUSTMENT ..................................................................3-4
DRIVE CHAIN ADJUSTMENT ..............................................................................3-7
IDLE SPEED ADJUSTMENT ................................................................................3-7
THROTTLE CABLE FREE PLAY ADJUSTMENT ................................................3-8
SPARK PLUG INSPECTION ................................................................................3-9
IGNITION TIMING CHECK ................................................................................3-11
COMPRESSION INSPECTION ..........................................................................3-12
ENGINE OIL LEVEL CHECK ..............................................................................3-15
ENGINE OIL REPLACEMENT ............................................................................3-17
ENGINE OIL PRESSURE CHECK ....................................................................3-21
CLUTCH ADJUSTMENT ....................................................................................3-21
AIR FILTER CLEANING ......................................................................................3-24
FUEL FILTER CLEANING ..................................................................................3-25
ENGINE OIL TANK FILTER CLEANING ............................................................3-26
SUCTION HOSE AND MANIFOLD INSPECTION..............................................3-28
FUEL LINE INSPECTION ..................................................................................3-28
CRANKCASE VENTILATION HOSE INSPECTION ..........................................3-29
EXHAUST SYSTEM INSPECTION ....................................................................3-29
CHASSIS....................................................................................................................3-30
ADJUSTING THE FRONT BRAKE ....................................................................3-30
ADJUSTING THE REAR BRAKE ......................................................................3-31
CHECKING THE BRAKE FLUID LEVEL ............................................................3-32
BRAKE PAD WEAR INSPECTION ....................................................................3-33
BRAKE HOSING INSPECTION ..........................................................................3-33
BRAKE CIRCUIT BLEEDING ............................................................................3-34
DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT..................................3-35
DRIVE CHAIN LUBRICATION ............................................................................3-36
FRONT FORK INSPECTION ..............................................................................3-37
ADJUSTING THE FRONT FORK ......................................................................3-37
REAR SHOCK ABSORBER ADJUSTMENT ......................................................3-38
STEERING INSPECTION ..................................................................................3-40
TYRE INSPECTION ............................................................................................3-41
WHEEL INSPECTION ........................................................................................3-44
SPOKE INSPECTION AND TIGHTENING ........................................................3-44
CABLE INSPECTION..........................................................................................3-45
LEVER AND PEDAL LUBRICATION ..................................................................3-45
SIDESTAND LUBRICATION ..............................................................................3-46
REAR SUSPENSION LUBRICATION ................................................................3-46
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INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
3-2
INSP
ADJ
ODOMETER READING (x 1,000 km)
ANNUAL N0. ITEM CHECK OR MAINTENANCE JOB
110 2030 40CHECK
18 * Rear brake• Check operation, fluid level and vehicle for fluid leakage. ✓✓✓ ✓
Rear shock
• Check operation and shock absorber for oil leakage.
19
*absorber ✓✓✓ ✓
assemblysull’ammortizzatore.
Rear suspension
• Check operation.
✓✓✓ ✓
20*
relay arm and
connecting arm
• Lubricate with lithium-soap-based grease.
✓✓
pivoting points
• Check starter (choke) operation.
21 * Carburator
• Adjust engine idling speed.✓✓ ✓✓ ✓ ✓
22 Engine oil• Change.
✓✓ ✓✓ ✓ ✓
• Check oil level and oil leakage.
23Engine oil filter
• Replace.✓✓✓
element
24 *Front and rear •
brake switches• Check operation.✓✓ ✓✓ ✓ ✓
Moving parts
25
and cables• Lubricate. ✓✓✓ ✓ ✓
Throttle grip • Check operation and free play.
26 * housing and • Adjust the throttle cable free play if necessary.
✓✓✓ ✓ ✓
cable • Lubricate the throttle grip housing and cable.
27 *Muffler and
• Check the screw clamp for looseness. ✓
exhaust pipe
28 *Lights, signals • Check operation.
✓✓ ✓✓ ✓ ✓
and switches• Adjust headlight beam.
* Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance is per-
formed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake system:
• Check the brake fluid level regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
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VALVE CLEARANCE ADJUSTMENT
3-4
INSP
ADJ
ENGINE
VALVE CLEARANCE ADJUSTMENT
NOTE:
•Valve clearance must be adjusted when the
engine is at ambient temperature.
•Adjust valve clearance with the piston under
compression at top dead centre (T.D.C.).
WARNING
Hold the motorcycle firmly in place to prevent
it falling over during the operation.
1. Remove:
•Seat
•Fuel tank
See the section “ SEAT, FUEL TANK AND
REAR COWLING”.
2. Disconnect:
•Spark plug cap (1)
3. Remove:
•Spark plug
•Tappet cover (2) (intake)
•Tappet covers (3) (exhaust)
When removing the spark plug and tappet
cover, be careful not to drop foreign objects
inside the engine.
4. Remove:
•Cap (1)
•Cap (2)
CAUTION:
5. Turn the crankshaft anticlockwise using a
wrench.
1
2
3
12
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INSP
ADJDRIVE CHAIN ADJUSTMENT
IDLE SPEED ADJUSTMENT
3-7
DRIVE CHAIN ADJUSTMENT
The drive chain does not need to be adjusted.
IDLE SPEED ADJUSTMENT
1. Start the engine and let it heat.
2. Connect:
•The inductive engine speed indicator to
the spark plug cable
Special tool:
P/N. 90890-03113
Engine idle speed:
1,150 ~ 1,450 rpm
3. Check:
•The engine idle speed.
Out of specification ➔Adjust.
4. Adjust:
•Engine idle speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjustment:
•Turn the throttle stop screw (1) either way to
obtain the idle speed required.
Screwing (a) Increases idle speed
Unscrewing (b) Decreases idle speed
NOTE:
After setting the idle speed, adjust the accelerator
cable free play.
5. Disconnect:
•Inductive engine speed indicator
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THROTTLE CABLE FREE PLAY ADJUSTMENT
3-8
INSP
ADJ
THROTTLE CABLE FREE PLAY
ADJUSTMENT
NOTE:
Before adjusting the throttle cable free play, adjust
the engine idle speed.
1. Remove:
•Seat
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING”.
2. Check:
•Throttle cable free play (a)
Out of specification ➔Adjust.
Throttle cable free play:
3 ~ 5 mm (at the grip flange)
3. Adjust:
•Throttle cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjustment:
•Loosen the throttle cable (2) lock nuts (1).
•Turn the adjuster (3) clockwise or anticlock-
wise to obtain the required free play.
•If after loosening the adjuster by 5 mm, the
free play is still not correct, tighten the
adjuster (4) on the throttle cable (5) once
more.
•Tighten the lock nuts.
(1), (6) Lock nuts
4. Reassemble:
•Fuel tank
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
a
Seat screws:
10 Nm (1,0 mkg)
2
1
3
6
4
5
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