2004 YAMAHA TT600RE light

INSP
ADJ
REPLACING THE HEADLIGHT BULBS
3-55



Auxiliary light bulb
1. Remove:
•Cowling screws (1)
2. Remove:
•Cowling (from the meter bracket)
NOTE:
Remove the cowling from the meter bracket by
lowering it to disengage it, and then lifting it up.
3. Remove:
•Headlight (2)
•Auxiliary light socket (3)
NOTE:
Remove the auxiliary light socket (together with
the bulb) without disconnecting the leads.
•Bulb (by pushing it in and turning it coun-
terclockwise)Cowling screws:
10 Nm (1.0 kgm)
7. Install:
•Headlight bulb (new)
•Headlight bulb holder (by turning it clock-
wise (b))
Do not touch the glass part of the headlight
bulb to keep it free from oil, otherwise the
transparency of the glass, the luminosity of
the bulb, and the bulb life will be adversely
affected. Thoroughly clean off any dirt and
fingerprints on the headlight bulb using a
cloth moistened with alcohol or thinner.
8. Install:
•Headlight bulb cover
9. Connect:
•Headlight coupler
10. Install:
•Upper side of the cowling (onto the meter
bracket)
•Headlight (adjust the headlight beam if
necessary)
11. Install:
•Cowling screws
CAUTION:
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REPLACING THE TURN INDICATOR LIGHT BULB
3-56
INSP
ADJ




REPLACING THE TURN INDICATOR LIGHT
BULB
1. Remove:
•Lens screw (1)
•Lens (2)
•Bulb (3)
NOTE:
To remove the bulb press it into place and turn it
counterclockwise.
2. Install:
•New bulb
NOTE:
To install the bulb press it into place and turn it
clockwise.
•Lens
•Lens screw
Do not overtighten the screw, otherwise the
lens may break.
CAUTION: 4. Install:
•Bulb (new) (by pushing it in and turning it
clockwise)
•Bulb holder
•Upper side of the cowling (onto the meter
bracket)
•Headlight (adjust the headlight beam if
necessary)
5. Install:
•Cowling screws
Cowling screws:
10 Nm (1.0 kgm)
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INSP
ADJREPLACING THE TAIL/
BRAKE LIGHT BULB
3-57






REPLACING THE TAIL/BRAKE LIGHT BULB
1. Remove:
•Screws (1) (lens fixing)
•Lens (2)
•Bulb (3)
NOTE:
To remove the bulb press it into place and turn it
counterclockwise (a).
2. Install:
•New bulb
NOTE:
To install the bulb press it into place and turn it
clockwise (b).
•Lens
•Screws (lens fixing)
Do not overtighten the screws, otherwise the
lens may break.
CAUTION:
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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
5-14
ENG
CRANKCASE (R)
1. Remove:
•Crankcase (R)
NOTE:
•Loosen nuts starting from the one with the
highest number.
•Loosen all by 1/4 turn and then remove.
Removal procedure:
•Set the crankcase separating tool (1) in place.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Crankcase separating tool: P/N. 90890-01135
NOTE:
When tightening the support bolts of the separat-
ing tool, be sure to keep the tool body parallel to
the engine crankcase. If necessary, a screw may
be slightly loosened to put the tool body on level.
•Applying pressure, strike the front engine
assembly flange, the drive shafts and the gear
cam plate with a rubber hammer. Then
remove the crankcase.
NOTE:
•If the crankcase fails come out, lever at points
(2), being careful not to damage the
crankcase.
•Turn the gear cam plate as shown in the fig-
ure to prevent it interfering with the crankcase.
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ENGENGINE DISASSEMBLY
5-17
BALANCER SHAFT AND CRANKSHAFT
1. Remove:
•Balancer shaft (1)
2. Remove:
•Crankshaft (1)
NOTE:
•Remove the crankshaft by using the
crankcase separating tool (2).
Crankcase separating tool: P/N. 90890-01135
•Tighten the separating tool bolts, making sure
that the tool body is parallel with the engine
crankcase. If necessary, a screw may be
backed out slightly to level tool body.
OIL STRAINER
NOTE:
It is advisable to replace the oil strainer every time
the engine is disassembled.
1. Remove:
•Oil strainer (1)
•Oil passage cover (2)
•Gasket
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INSPECTION AND REPAIR
5-26
ENG
5. Emery:
•Valve seal surface
•Valve seat
NOTE:
If the valve seat is renewed or the valve and guide
replaced, the valve seat and seal surface must be
lapped.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Lapping steps:
•Apply rough-lapping compound to the valve
seal surface.
Make sure the lapping compound does not
run into the space between the guide and
valve stem.
CAUTION:
•Apply oil to the molybdenum disulfide on the
valve stem.
•Install the valve in the cylinder head.
•Turn the valve until face and surface are not
evenly polished. Then clean away all the lap-
ping compound.
NOTE:
For best results, during lapping, repeatedly apply
(light) pressure to the valve seat, turning the valve
backwards and forwards by hand.
•Apply a fine-lapping compound on the valve
seal surface and repeat the procedures
described above.
NOTE:
Be sure to remove all the lapping compound from
the valve surface after every lapping operation.
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