2004 YAMAHA TT600RE warning

FRONT FORK
4-58
CHAS
WARNING
Do not attempt to straighten a bent inner tube
as this may have dangerous consequences.
4. Inspect :
•Outer tube (1)
Score marks/Wear/Damage ➔Replace.
5. Inspect:
•Cap bolt
•O-ring
Wear/Damage ➔Replace.
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4-60
FRONT FORKCHAS






ADJUSTING THE FRONT FORK
This front fork is equipped with spring pre-load ad-
justing bolts.
WARNING
Always adjust both fork legs equally, other-
wise poor handling and loss of stability may
result.
Adjust the spring preload as follows.
To increase the spring preload and thereby hard-
en the suspension, turn the adjusting bolt on each
fork leg in direction a. To decrease the spring
preload and thereby soften the suspension, turn
the adjusting bolt on each fork leg in direction b.
Setting
Minimum (soft) 1-2-3
Standard 4
Maximum (hard) 5-6-7-8-9-10
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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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CHAS
4-64
STEERING
STEERING REMOVAL
1. Park the motorcycle on a level surface.
2. Raise the front wheel placing a suitable sup- port under the engine.
3. Remove:
•Front wheel
Refer to “FRONT WHEEL-REMOVAL”
section.
•Front fork
Refer to “FRONT FORK-REMOVAL” sec-
tion.
4. Remove:
•Front fender
•Cowling
•Handlebar
•Meter assembly
Ring nut wrench (3):
90890-01348
5. Remove:
•Steering axle nut (1)
Use the ring nut wrench (3).
WARNING
Support the motorcycle securely to prevent it
falling over.
6. Remove:
•Ring nut (upper) (1)
•Use the ring nut wrench (2)
Ring nut wrench (2):
90890-01268
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CHAS
4-65
STEERING
Ring nut wrench (2):
90890-01268
7. Remove:
•Ring nut (lower) (1)
•Use the ring nut wrench (2)
WARNING
Support the steering axle to prevent it falling.
STEERING INSPECTION
1. Wash the bearings in solvent.
2. Inspect:
•Bearing (upper and lower) (1)
Corrosion/Damage ➔Replace races and
bearing.
Install the bearings in the races. Spin the
bearing by hand.
If the bearing rises or fails to run freely in
the race, replace bearing and race.
3. Inspect:
•Steering axle (1)
Bend/Damage ➔Replace.
STEERING INSTALLATION
1. Install:
•Bearing (1)
•Ball race cover (2)
NOTE:
Apply lithium soap-base grease to the bearing
and ball race cover lip.
2. Install:
•Lower bracket (1)
NOTE:
Apply lithium soap-base grease to the bearing.
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4-66
CHASSTEERING
3. Install:
•Ring nut (lower) (1)
Use the ring nut wrench (2).
Ring nut wrench: 90890-01268
NOTE:
Apply the lithium soap-base grease to the steer-
ing axle thread.
Lower ring nut tightening steps:
•Tighten the ring nut (1) using the ring nut
wrench.
Ring nut (lower)
(initial tightening): 38 Nm (3.8 mkg)
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•Loosen the ring nut completely and retighten
it to specification.
WARNING
Do not tighten excessively.
Ring nut (lower)
(final tightening): 4 Nm (0.4 mkg)
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4. Check the steering axle by turning it lock to lock. If there is any binding, remove the steer-
ing axle assembly and inspect the steering
bearings.
5. Install:
•Ring nut (upper) (1)
•Special washer (2)
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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.
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REAR SHOCK ABSORBER
4-72
CHAS
WARNING
This shock absorber contains high-pressure
nitrogen gas. Read the following information
carefully before handling it. The manufacturer
cannot be held responsible for any damage or
injury that may result from improper handling.
•Never tamper with or attempt to open the
cylinder or the tank.
•Never expose the shock absorber to a
naked flame or other source of heat. This
might cause the pressurised gas to
explode.
•Do not deform or damage the cylinder in
any way. Damage to the cylinder would
impair the damping effect.
•Be careful not to scratch the surface of the
rod: this would cause the oil to leak.
•Before disposing of the shock absorber,
read the section “NOTES ON DISPOSAL”.
NOTE ON DISPOSAL
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Before neutralising the rear shock absorber:
The gas pressure must be discharged before dis-
posing of the shock absorber it is necessary to dis-
charge the gas pressure. To do this, bore a hole of
2~3 mm through the cylinder wall about 15~20
mm from the bottom of the gas chamber.
WARNING
Wear protective goggles to avoid eye injuries
from escaping gas and/or metal chips.
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