2004 YAMAHA TT600RE brake fluid

CHASREAR BRAKE
4-35
3. Air bleed:
•Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in Chapter 3.
4. Inspect:
•Brake fluid level
Lower than “MIN” mark (1) ➔Fill.
Refer to “BRAKE FLUID INSPECTION”
section in Chapter 3.
(1) Minimum level mark “MIN”
BRAKE PEDAL REMOVAL
1. Remove:
•Split pin (1) (new)
•Plain washer (2)
•Pin (3)
2. Unscrew:
•Bolt (4)
3. Remove:
•Spring (5)
4. Remove:
•Brake pedal (6) from chassis
NOTE:
Pull the brake pedal from the lower part of the
chassis, causing it to rotate progressively as it
comes away.



5. Adjust:
•Brake pedal height (a)
(below the top of the footrest)
Brake pedal height: 10 mm
ProCarManuals.com

REAR BRAKE
4-36
CHAS
BRAKE CALIPER
Order Job name/Part name Q.ty Remarks Caliper removal Remove the parts in order.
Rear wheel Refer to “REAR WHEEL REMOVAL” sec- tion.
Brake fluid Drain.
Brake hose Remove from clamp.
1 Caliper protector 1
2 Brake caliper 1 Remove from caliper support.
3 Union bolt 1 Refer to “BRAKE CALIPER INSTALLA-
4 Plain washer 2
TION” section.
5 Brake hose 1
6 Brake pad support 1 Reverse the removal procedure for installa-
tion.
ProCarManuals.com

REAR BRAKE
4-38
CHAS
BRAKE CALIPER DISASSEMBLY
1. Remove:
•Brake caliper piston (1)
•Dust seal (3)
•Piston seal (2)
Removal procedure:
•Blow compressed air into the hose joint open-
ing to force out the caliper piston from the
brake caliper body.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
•Remove the piston seal
CALIPER INSPECTION
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Inspect:
•Caliper piston
Scratches/wear/rust ➔Replace caliper
assembly.
•Caliper cylinder
Scratches/wear ➔Replace caliper assem-
bly.
•Caliper
Cracks/damaged ➔Replace.
Recommended programme for the
replacement of brake system components: Brake pads When necessary
Brake hose Every four years
Replace every
Brake fluid 24,000 km or 24
months and
whenever the brake
is disassembled.
WARNING
All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation. Do not use solvents to
prevent sealing elements from becoming mis-
shapen or swollen.
WARNING
•Never try to pry out the caliper piston.
•Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the master cylinder.
ProCarManuals.com

CHASREAR BRAKE
4-39
•Fluid delivery passage (caliper)
Obstruction ➔Clean with compressed air.
BRAKE CALIPER ASSEMBLY
WARNING
•All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.
•In case of non correct operation of the
brake caliper, replace the brake caliper
assembly. Liquido freni raccomandato:
DOT 4
CALIPER INSTALLATION
1. Install:
•Brake caliper (1)
•Caliper support (2)
•Brake hose (3)
•Plain washers (4) (new)
•Union bolt (5)
Union bolt: 20 Nm (2.0 mkg)
WARNING
In case of non correct operation of the brake
caliper, replace the brake caliper assembly.
1. Install:
•Piston seal (1)
•Dust seal (2)
•Caliper piston (3)
•Caliper protector
3
451
2
ProCarManuals.com

REAR BRAKE
4-40
CHAS
2. Fill:
•Brake fluid reserve tank
Check that the brake hose has stayed in cor-
rect position with the pipe-fitting matching the
projection (a) of the caliper.
CAUTION:
WARNING
Check that the brake hose routing is correct.
Refer to “CABLE ROUTING” section.
Recommended brake fluid: DOT 4
Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
CAUTION:
WARNING
•Use only designated quality brake fluid.
Otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
•Refill with the same type of brake fluid:
mixing fluids may result in a harmful chem-
ical reaction and lead to poor perform-
ance.
•Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
3. Air bleed:
•Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in CHAPTER 3.
a
ProCarManuals.com

CHASREAR BRAKE
4-41
4. Inspect:
•Brake fluid level
Lower than “MIN” mark (1) ➔Fill.
Refer to “BRAKE FLUID INSPECTION”
section in Chapter 3.
(1) Minimum level mark “MIN”

ProCarManuals.com

CHASREAR SHOCK ABSORBER
4-69
Order Job name/Part name Q.ty Remarks Shock absorber removal Remove the parts in order.
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
Seat Refer to “SEAT, FUEL TANK AND REAR
Fuel tank
Rear cowling COWLING” section in Chapter 3.
Battery leads 2 Disconnect. NOTE:
First, disconnect the negative lead, then the
positive lead.
1 Muffler 1
2 Exhaust pipe assembly 1 Refer to “REAR SHOCK ABSORBER RE-
3 Rear frame 1 MOV AL” section.
4 Brake fluid reserve tank 1 Secure the brake fluid tank to the frame in
5 Air filter case 1 an upright position to avoid air entering the hydraulic system.
ProCarManuals.com

DEFECTIVE BRAKES/
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK
8-6
TRBL
SHTG
?
PROBABLE CAUSES
•Brake pads worn
•Brake disc worn
•Water in the brake fluid
•Brake fluid leak
•Brake fluid tank defective
•Bleed cap not sealed to calipers
•Union bolt loose
•Brake hose cracked
•Brake disc dirty or greasy
•Brake pads dirty or greasy
•Incorrect brake fluid level
POOR BRAKING
DEFECTIVE BRAKES
PROBABLE CAUSES
•Inner tube deformed, damaged or rusty
•Outer tube damaged or cracked
•Oil seal lip damaged
•Oil seal assembled incorrectly
•Oil level incorrect (excessive)
•Shock-absorber rod stop bolt loose
•O-ring on cap bolt broken
OIL LEAKS
PROBABLE CAUSES
•Inner tube deformed, damaged or rusty
•Outer tube deformed or damaged
•Fork spring damaged
•Piston worn or damaged
•Shock-absorber rod deformed or damaged
•Incorrect oil viscosity
•Incorrect oil level
MALFUNCTIONING
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK
ProCarManuals.com