2004 YAMAHA TT600RE lock

REAR SHOCK ABSORBER ADJUSTMENT
3-38
INSP
ADJ
 



REAR SHOCK ABSORBER ADJUSTMENT
WARNING
This shock absorber contains highly pressur-
ized nitrogen gas. For proper handling, read
and understand the following information
before handling the shock absorber. The man-
ufacturer cannot be held responsible for prop-
erty damage or personal injury that may result
from improper handling.
•Do not tamper with or attempt to open the
gas cylinder.
•Do not subject the shock absorber to an
open flame or other high heat sources,
otherwise it may explode due to excessive
gas pressure.
•Do not deform or damage the gas cylinder
in any way, as this will result in poor damp-
ing performance.
This shock absorber assembly is equipped with a
spring preload adjusting nut.
Never attempt to turn an adjusting mecha-
nism beyond the maximum or minimum set-
tings.
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.
CAUTION:
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INSP
ADJ
REAR SHOCK ABSORBER ADJUSTMENT
3-39
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
2. Tighten the locknut to the specified torque.
Always tighten the locknut against the adjust-
ing nut, and then tighten the locknut to the
specified torque.
CAUTION:Locknut:
45 Nm (4.5 m·kgf)
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INSP
ADJ
TYRE INSPECTION
3-43
Minimum track thickness:
(front and rear)
1,6 mm
NOTE:
These limits may be different by regulation from
country to country. If so, conform to the limits
specified by the regulations of your own country.
(1) Track thickness
(2) Side
(3) Wear indicators
WARNING
The use of worn tyres reduces stability and
may cause a loss of control.
It is not advisable to repair a punctured air
tube. If absolutely necessary, repair with the
utmost care and replace the tube as quickly as
possible with another with the same charac-
teristics.
4. Tighten:
•Valve stem lock nut
Lock nut (valve stem)
1.5 Nm (0.15 kgm)
REAR:
Manufacture Size Type
PIRELLI 90/90-21 54R MT70
MICHELIN 90/90-21 54S T63
Manufacture Size Type
PIRELLI 130/80-18 66R MT70
MICHELIN 130/80-18 66S T63
FRONT:
WARNING
After assembling the new tyres, drive slowly
to allow them to adapt well to the rim and yjus
ensure maximum holding.
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CHECKING THE FUSES/
REPLACING THE HEADLIGHT BULBS
3-54
INSP
ADJ
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or using
a fuse with the wrong amperage rating may
cause extensive damage to the electrical sys-
tem, cause the lighting and ignition systems
to malfunction and could possibly cause a fire.
4. Install:
•Pannel
•Seat
REPLACING THE HEADLIGHT BULBS
Low beam/high beam
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)
4. Disconnect:
•Headlight coupler (3)
5. Remove:
•Headlight bulb cover (4)
6. Remove:
•Headlight bulb holder (5) (by turning it
counterclockwise (a))
•Headlight bulb
WARNING
Headlight bulbs get very hot. Therefore, keep
flammable products away from a lit headlight
bulb, and do not touch the bulb until it has
cooled down.








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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 WHEEL AND BRAKE DISC
4-4
CHAS
4. Tighten:
•Loose spokes
5. Measure:
•Front wheel runout
Over the specified limits ➔Replace.
Spoke:
2 Nm (0.2 mkg)
NOTE:
After tightening the spokes, check the centring of
the wheel.
6. Inspect:
•Front wheel bearings
Bearings allow free play in the wheel hub
or the wheel does not turn smoothly ➔
Replace.
•Oil seal
Wear/damage ➔Replace.
Front wheel runout limits:
Radial (1) : 1.0 mm
Lateral (2) : 0.5 mm
WARNING
•After assembling a tyre, drive slowly to
allow it to adapt to the rim. If this precau-
tion is not observed, damage might be
caused to the motorcycle and accidents to
the driver.
•After repairing or changing a tyre, do not
forget to tighten the valve lock nut (1) to
the prescribed torque.
Valve lock nut: 1.5 Nm (0.15 mkg)
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