2004 YAMAHA TT600RE brake

REAR BRAKE
4-34
CHAS
MASTER CYLINDER INSTALLATION
1. Install:
•Brake pedal (refer to “BRAKE PEDAL
REMOVAL” section in this Chapter).
NOTE:
Lubricate the pin of the brake pedal with lithium-
base grease.
•Master cylinder
•Brake fluid reserve tank
•Plain washers (1) (new)
•Brake hose (2)
•Stop switch (to mount the brake hose) (3) Brake switch (brake hose): 20 Nm (2.0 mkg)
Master cylinder mounting bolt: 10 Nm (1.0 mkg)
Reserve tank mounting bolt: 4 Nm (0.4 mkg)New
2. Fill:
•Brake fluid reserve tank 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.
ProCarManuals.com

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

CHASREAR BRAKE
4-37
Order Job name/Part name Q.ty Remarks Caliper disassembly Remove the parts in order.
1 Caliper protector 1
2 Brake pad support 1
3 Brake pad 2 Refer to “BRAKE PAD” section.
4 Pad support 1
5 Caliper piston 1 Refer to “BRAKE CALIPER DISASSEM-
6 Dust seal 1 BLY/ASSEMBLY” section.
7 Piston seal 1
8 Bleed screw 1 Reverse the removal procedure for installa-
tion.
New
14 Nm (1.4 m•kg)
2
10 Nm (1.0 m•kg)
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