2004 YAMAHA TT600RE brake

FRONT WHEEL AND BRAKE DISC
4-2
CHAS
Order Job name/Part name Q.ty Remarks Front wheel disassembly Remove the parts in order.
1 Oil seal 1
2 Bearing 1
3 Spacer 1 Refer to “FRONT WHEEL DISASSEMBLY/
4 Oil seal 1 ASSEMBLY” section.
5 Bearing 1
Reverse the removal procedure for instal-
lation.
1
2
3
5
4
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CHASFRONT WHEEL AND BRAKE DISC
4-3
FRONT WHEEL DISASSEMBLY
1. Remove:
•Oil seal
•Bearing (1)
•Spacer
Removal procedure:
•Clean the outside of the hub.
•Remove the dust cover with a flat-headed
screwdriver.
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•Disassemble the bearing (1) with a normal
puller (2).
NOTE:
Place a rag on the outside to avoid damaging the
hub.
FRONT WHEEL INSPECTION
1. Inspect:
•Front wheel axle
(by rolling it on a flat surface)
Bends ➔Replace.
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WARNING
Do not attempt to straighten a bent axle.
2. Inspect:
•Front tire
Wear/damage ➔Replace.
Refer to “TIRE INSPECTION” in CHAP-
TER 3.
•Front wheel
Refer to “WHEEL INSPECTION” in
CHAPTER 3.
3. Inspect:
•Spoke(s)
Bent/Damaged ➔Replace.
Loose spoke(s) ➔ Tighten.
Turn the wheel and hit the spokes gently
with a screwdriver.
NOTE:
A well tightened spoke makes a distinct, sharp
noise: a loose spoke makes a dull, muffled noise.
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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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CHASFRONT WHEEL AND BRAKE DISC
4-5
BRAKE DISC INSPECTION
1. Inspect:
•Brake disc
Wear/Damage ➔Replace.
2. Measure:
•Brake disc deflection (a)
If over envisaged limits ➔Verify wheel
centring.
If the wheel centring is correct, replace the
brake disc.
Misure at 2 mm from disc edge
•Brake disc thickness (b)
If out of specified limits ➔Replace.
Maximum deflection (brake disc):
0.15 mm
Minimum thickness (brake disc):
3.6 mm
IFRONT WHEEL ASSEMBLY
1. Install:
•Spacer
•Bearings
•Oil seal
Assembly procedure:
•Install the new bearing and the dust cover by fol-
lowing the disassembly procedures in reverse
order.
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NOTE:
Use a wrench (1) with an external diameter equal to
that of the bearing and dust cover.
Do not strike the bearing inner race (2) or balls
(3). The contact must only be made with the
outer race (4).
CAUTION:
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FRONT WHEEL AND BRAKE DISC
4-6
CHAS
FRONT WHEEL INSTALLATION
1. Install:
•Brake disc (1)
2. Install:
•Speedometer gear unit (1) Screw (brake disc):
12 Nm (1.2 mkg)
NOTE:
•Apply LOCTITE®to the threads of brake disc
screw.
•Tighten the screws (brake disc) in stage using
a crisscross pattern.
3. Tighten:
•Front wheel
•Front wheel axle
NOTE:
Make sure that the wheel hub and the speedome-
ter gear unit are installed with the projections
meshed into the slots.
•Pinch bolt Front wheel axle:
59 Nm (5.9 mkg)
NOTE:
Make sure that the slot (a) in the speedometer
gear unit fits under the stopper on the front fork
outer tube.
Pinch bolt: 9 Nm (0.9 mkg)a
WHEEL STATIC BALANCE ADJUSTMENT
1. Remove:
•Balancing weight
2. Set:
•Wheel (on a suitable stand)
3. Find:
•Heavy spot
NOTE:
•After replacing the tire and/or rim, the wheel
static balance should be adjusted.
•Adjust the front wheel static balance with the
brake disc installed.
1
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CHASFRONT WHEEL AND BRAKE DISC
4-7
4. Adjust:
•Wheel static balance
Adjusting steps:
•Install a balancing weight (1) on the rim exact-
ly opposite to the heavy spot “X”.
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•Turn the wheel so that the heavy spot is 90°
up.
•Check that the heavy spot is at rest there. If
not, try another weight until the wheel is bal-
anced.
NOTE:
Start with the smallest weight.
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5. Check:
•Wheel static balance
Checking steps:
•Turn the wheel so that it comes to each point
as shown.
•Check that the wheel is at rest at each point.
If not, readjust the front wheel static balance.
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Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “X
1” mark on the wheel’s bottom spot.
c. Turn the wheel so that the “X
1” mark is 90° up.
d. Release the wheel and wait for it to rest. Put an “X
2” mark on the wheel’s bottom spot.
e. Repeat the above b., c., and d. several times until all marks come to the same spot.
f. This spot is the wheel’s heavy spot “X”.
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FRONT BRAKE
4-8
CHAS
FRONT BRAKE
BRAKE PAD
Order Job name/Part name Q.ty Remarks Brake pad removal Remove the parts in order.
1 Brake caliper screw 2
2 Brake caliper 1
3 Pad pin retainer 2 Refer to “BRAKE PAD REPLACEMENT”
4 Pad pin 1 section.
5 Brake pad 2
6 Pad spring 2
Reverse the removal procedure for instal-
lation.
25 Nm (2.5 m•kg)
6
3
54
1
2
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CHASFRONT BRAKE
4-9
Brake components must not be disassembled.
The builder declines every responsibility after
brake components disassembly (brake master
cylinder or brake caliper) or in case of use of
non original parts.
DO NOT:
•Remove brake components from the
motorcycle unless is absolutely necessary.
•Use solvents on internal brake compo-
nents.
•Use brake fluid already used for bleeding.
•Allow brake fluid to come into contact with
the eyes as it may cause injury.
•Allow brake fluid to come into contact with
painted or plastic parts as it may damage
them.
•Disconnect any hydraulic connection, other-
wise the whole system must be disassem-
bled, drained, cleaned, then properly filled
and bled after reassembly.
CAUTION:
NOTE:
It is unnecessary to disassemble the brake hose
to replace the pads.
NOTE:
•If you replace the pads, also replace the
springs.
•If one of the two pads has to be replaced
because it is worn, replace both.
BRAKE PAD REPLACEMENT
1. Remove:
•Caliper bracket fastening screws (1)
(deplace the caliper)
2. Remove:
•Pin retainers (2)
•Pad fastening pin (3)
•Brake pads (4)
•Pad springs (5)
•Caliper bracket (6)
Wear limit (a): 3.7 mm
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