2004 YAMAHA TT600RE check oil

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

FRONT FORK
4-50
CHAS
4. Using a small screwdriver take a small amount of silicon grease and insert it under
the lip paying attention not to scratch it.
Lubricate the dust seal by rotating it in such a
manner that the grease is distributed in the
inner part of the lip.
5. Remount the dust seal inserting it with force into the oil seal seat.
Check that the oil seal housing edge of the
dust seal adheres perfectly to the oil seal
seat.
CAUTION:
SEAL AND BUSH REPLACEMENT
NOTE:
To ensure maximum efficiency to the fork and
therefore a longer duration and greater safety,
every year (unless there are leakages) it is nec-
essary to replace all the seals and slide bushes.
To carry out this operation it is recommended to
use the proper tools.
To remove the fork leg from the steering unit,
the cap bolt, the spring and to drain and refill
the oil, follow the procedures indicated in the
preceding pages scrupulously.
CAUTION:
1. Drain:
•Fork leg oil Refer to “OIL REPLACEMENT”section.
2. Clamp:
•Fork leg in a vice (in a horizontal position)
Protect the outer tube with a clean rag to
avoid damaging.
CAUTION:
ProCarManuals.com

CHASFRONT FORK
4-53
9. With a few sharp blows withdraw the inner tube (2) from the outer tube (3).
NOTE:
The oil seal (4), the washer (5), the outer tube DU
bush (6) and the inner tube DU bush (7) are
installed on the inner tube and must be removed
and replaced with new one.
10. Install:
•Outer tube DU bush (6) (new)
•Inner tube DU bush (7) (new)
Check that the inner tube bush (7) is inserted
correctly in its seat on the end of the inner
tube.
CAUTION:
11. Mount the tool (1) on the inner tube (2) with the side (3) matching the DU outer tube bush (4)
and clamp it keeping the two joints (5) at the
top and bottom (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
4
25
7
6
3
7
6
34
4
3
21
ProCarManuals.com

ENGINE DISASSEMBLY
5-12
ENG
OIL PUMP AND SHIFT LEVER
NOTE:
The oil pump and shift lever may be checked with
the engine installed by removing the following
parts:
•Footrest (R)
•Oil delivery hose screw
•Crankcase (R)
•Clutch
1. Remove:
•Circlip (1)
•Oil pump gear (2)
•Oil pump (3)
•O-rings (4)
2. Remove:
•Circlip (1) (from drive shaft)
•Ring (2)
•Circlip (3)
3. Remove:
•Circlip (1)
•Shift lever (2)
•Spring (3)
•Flat washer (4)
4. Remove:
•Stopper lever (1)
•Ring (2)
•Spring (3)
ProCarManuals.com

INSPECTION AND REPAIR
5-40
ENG
BALANCER SHAFT DRIVE AND DRIVEN
GEARS
1. Inspect:
•Drive gear teeth (1)
•Driven gear teeth (2)
Wear/damage ➔Replace both gears.
2. Check:
•Marks (1)
If they are not aligned ➔Align the marks
as shown in the figure.
CRANKCASE
1. Inspect:
•Crankcase
•Bearing housing
Damaged ➔Replace.
BEARING AND OIL SEAL
1. Inspect:
•Bearing
Roughness/Pitting/Damage ➔Replace.
•Oil seal edge
Damage/Wear ➔Replace.
ProCarManuals.com

ENGINE ASSEMBLY AND SETTING
5-52
ENG
4. Tighten:
•Screws (crankcase) (1) ~ (14)
NOTE:
Tighten the screws beginning with the one with
the lowest number.
Screw (crankcase): 10 Nm (1.0 mkg)
Stopper lever screw (4):
10 Nm (1.0 mkg)
5. Apply:
•4-stroke engine oil
(to the connecting rod pin, the bearing and
the oil passage).
6. Check:
•Gearbox and transmission functioning
Jerky functioning ➔Replace.
SHIFT SHAFT AND OIL PUMP
1. Install
•Spring (1)
•Collar (2)
•Stopper lever (3)
NOTE:
Place the stopper lever and the spring in the cor-
rect position.
2. Install:
•Plate washer (1)
•Spring (2)
•Shift lever (3)
•Circlip (4)
ProCarManuals.com

ENGINE ASSEMBLY AND SETTING
5-60
ENG
5. Offset the piston ring end gaps as illustrated in the figure.
NOTE:
•Check that the marks and numbers stamped
by the manufacturer on the piston rings face
upwards.
•Before installing the cylinder, lubricate the pis-
ton rings liberally with 4-stroke engine oil.
(1) Upper ring
(2) Scraper (lower ring)
(3) Scraper (upper ring)
(4) Lower ring
6. Install:
•Cylinder (1)
NOTE:
•Install the cylinder to the piston with one hand
while one hand while compressing the piston
rings with the other.
•Bind the timing chain with wire and slip it
through the appropriate slot.
Cylinder:
Screw (2): 10 Nm (1.0 mkg)
Cap nut (3): 42 Nm (4.2 mkg)
Nut (4): 42 Nm (4.2 mkg)
ProCarManuals.com

ENGINE REASSEMBLY
5-78
ENG
9. Install:
•Carburetor Screw (clamp): 2 Nm (0.2 mkg)
Screw (seat): 10 Nm (1.0 mkg)
See section “CARBURETOR-INSTALLA-
TION” in CHAPTER 6.
10. Adjust:
•Throttle cable free play
Free play: 3 ~ 5 mm
Engine idle speed:1.150 ~ 1.450 rpm
See section “THROTTLE CABLE FREE
PLAY ADJUSTMENT” in CHAPTER 3.
11. Install:
•Fuel tank
Do not start the engine until it is filled with oil.
CAUTION:
12. Fill with:
•Engine oil Amount of oil (total): 3.0 litres
13. Check:
•Engine idle speed
See section “IDLE SPEED ADJUST-
MENT” in CHAPTER 3.
14. Install:
•Seat
See section “ENGINE OIL REPLACE-
MENT” in CHAPTER 3.
ProCarManuals.com