2004 YAMAHA TT600RE wheel

REAR WHEEL AND BRAKE DISC
4-28
CHAS
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 rear wheel static balance.
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CHASREAR BRAKE
4-29
REAR BRAKE
BRAKE PAD
Order Job name/Part name Q.ty Remarks Brake pad removal Remove the parts in order.
Rear wheel Refer to “REAR WHEEL REMOVAL”
section.
Brake hose Remove from clamp.
1 Caliper protector 1
2 Pad pin retainer 1
3 Pad pin 1
4 Brake pad 1 Refer to “BRAKE PAD REPLACEMENT”
5 Brake caliper (remove from caliper 2 section.
support)
6 Brake pad support 1 Reverse the removal procedure for instal-
lation.
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REAR BRAKE
4-30
CHAS
Brake components must not be disassem-
bled. 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 components.
•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 pad
support.
•If one of the two pads has to be replaced
because it is worn, replace both.
BRAKE PAD REPLACEMENT
1. Remove:
•Rear wheel (refer to “REAR WHEEL
REMOVAL” section).
•Bolt (caliper protector) (1)
•Brake caliper protector (2)
•Pad pin retainer (3)
•Brake pad pin (4)
Remove the caliper in the illustrated direc-
tion.
2. Remove:
•Brake pads (5)
•Pad support (6)
643
2
1
5
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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.
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FRONT FORK
4-42
CHAS
FRONT FORK
FRONT FORK REMOVAL
Order Job name/Part name Q.ty Remarks Front fork removal Remove the parts in order.
Front wheel Refer to “FRONT WHEEL” section.
1 Inner tube protector 1
2 Brake hose guide 1
3 Protector guide 2
4 Brake caliper assembly 1
5 Cowling (displace) 1
6 Pinch bolt (upper bracket) 4
7 Cap bolt (loosen) 2 Refer to "FRONT FORK INSTALLATION"
section.
8 Pinch bolt (under bracket) (loosen) 4
9 Fork leg 2 Reverse the removal procedure for instal-
lation.
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CHASFRONT FORK
4-45
OIL CAPACITY (IN EACH FORK LEG): 650 cm3
RECOMMENDED OIL:
Liqui Moly Racing suspension oil SAE 7,5
FRONT FORK OIL LEVEL
STANDARD 180 mm
MINIMUM 190 mm
MAXIMUM 170 mm
From top of inner tube with inner tube fully com-
pressed without spring.
MINIMUM FORK SPRING FREE LENGTH:
530 mm
INNER TUBE BENDING LIMIT:
0.2 mm
1. Park the motorcycle on a level surface.
2. Raise the front wheel by placing a suitable support under the engine.
3. Remove:
•Front wheel
Refer to “FRONT WHEEL REMOVAL”
section.
4. Remove:
•Inner tube protector
•Protector guide
•Gear unit assembly and cable
•Brake caliper and hose
5. Loosen:
•Cap bolt
•Pinch bolt (upper and lower bracket)
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
FRONT FORK REMOVAL
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CHASFRONT FORK
4-59
FRONT FORK INSTALLATION
1. Install:
•Front fork (1)
Temporarily tighten the pinch bolts (lower).
2. Tighten:
•Cap bolt
Cap bolt: 20 Nm (2.0 kgm)
NOTE:
Do not tighten the pinch bolt (upper) yet.
3. Adjust:
•Front fork top end (a)
Front fork top end (a)
(Standard): 0 mm
4. Tighten:
•Pinch bolt (upper and lower bracket)
Pinch bolt (upper bracket): 28 Nm (2.8 mkg)
Pinch bolt (under bracket): 23 Nm (2.3 mkg)
NOTE:
Always tighten the lower pinch bolt (to the pre-
scribed torque) and then the upper one (to the
prescribed torque) and then retighten the lower
one (to the prescribed torque).
5. Install:
•Front wheel
•Caliper
•Brake hose
•Tachometer cable
Refer to “FRONT WHEEL” and “FRONT
BRAKE” sections in this CHAPTER.
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CHAS
4-61
STEERING
Order Job name/Part name Q.ty Remarks Steering removal Remove the parts in order.
Park the motorcycle on a level surface.
WARNING
Securely support the motorcycle to pre-
vent it falling over.
Front wheel Refer to “FRONT WHEEL REMOVAL” sec- tion.
Fork legs Refer to “FRONT FORK” section.
1 Cowling/Meter unit 1 Displace.
2 Front fender 1
3 Handle upper holder 2
4 Handle lower holder 1
5 Handlebar 1 Displace.
6 Nut 1
7 Upper bracket 1
8 Special washer 1
TIGHTENING PROCEDURE
• Initial tightening 38 Nm (3.8 mkg)
• Loosen 1 turn
• Final tightening 4 Nm (0.4 mkg)
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