2004 YAMAHA TT600RE brake fluid

SPECGENERAL SPECIFICATIONS
2-3
Item Standard Limit
Brakes
Front:
Type Single Ø 267 mm disk brake,
2 x 28 mm
Operation Right hand
Fluid DOT 4
Rear:
Type Single Ø 220 mm disk brake,
1 x 34 mm caliper
Operation Right foot
Fluid DOT 4
Suspension
Front Telescopic fork Outside tube
dia. 46 mm
Rear Deltabox Swingarm with
adjustable shock absorber
Spring/shock absorber
Front Coil spring / oil damper
RearCoil spring / gas-oil damper, spring
preload adjustable
Wheel travel
Front 230 mm •••
Rear 230 mm •••
Electrical system
Ignition system Transistorized coil ignition (digital)
Charging system:
Type A.C. magneto
Standard output 14V, 13.5A at 5.000 r/min •••
Battery:
Model GT9B-4
Voltage, capacity 12V, 8Ah •••
Headlight typeQuartz bulb (halogen)
Bulb voltage, wattage x quantity
Headlight 12V 60W / 55W x 1 •••
Tail/brake light 12V 5W / 21W x 1 •••
Turn signal light 12V 10W x 4 •••
Auxiliary light 12V 5W x 1 •••
Meter lighting 12V 3W x 1 •••
Turn signal indicator light 12V 1.2W x 1 •••
Neutral indicator light 12V 1.2W x 1 •••
Auxiliary indicator light 12V 1.2W x 1 •••
High beam indicator light 12V 1.2W x 1 •••
Fuse20A •••
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SPECMAINTENANCE SPECIFICATIONS
2-13
Item Standard Limit
Drive chain
Type/manufacturer 520 135ORSB / Regina Chain
Link quantity 114
Drive chain slack 30.0 - 40.0 mm •••
Front disc brake
Disc outside diameter x thickness 267 x 4 mm •••
Max. deflection ••• 0.15 mm
Brake pad lining thickness-inner 7.5 mm * 3.7 mm
Brake pad lining thickness-outer 7.5 mm * 3.7 mm
Master cylinder inside diameter 13 mm
Caliper cylinder inside diameter 28 mm x 2
Recommended fluid DOT 4
Rear disc brake
Disc outside diameter x thickness 220.0 x 5.0 mm •••
Max. deflection ••• 0.15 mm
Brake pad lining thickness-inner 9.0 mm * 4.5 mm
Brake pad lining thickness-outer 9.0 mm * 4.5 mm
Master cylinder inside diameter 12.7 mm
Caliper cylinder inside diameter 34 mm
Recommended fluid DOT 4
Front brake leverAdjustable
Brake pedal lever
Brake pedal position 10 mm (below the footrest plane) •••
Clutch lever
Clutch lever free play (lever end) 10.0 - 15.0 mm •••
Throttle grip
Throttle cable free play 3.0 - 5.0 mm •••
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SPECCABLE ROUTING
2-28
(1) Tachometer/
odometer cable
(2) Tachometer/
odometer cable
holder
(3) Tachometer/
odometer cable
band
(4) Right tube guard
(5) Spark plug cable
(6) Horn(7) Carburetor suction
pipe
(8) Main wire harness
band
(9) Rear brake switch
wire harness
(10) Rear brake fluid
tank hose
(11) Hose from rear
master cylinder to
caliper(12) Rear brake hose
holders
(13) Pipe
(14) Air breather pipe
(15) Spark plug ignition
coil
(16) Chassis ground
(17) Engine oil
breather pipe
(to air filer case)[A] Insert the
tachometer/
odometer cable into
the band 3 and the
holder 2.



















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INSP
ADJ
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENTS
INTRODUCTION..........................................................................................................3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS........................................3-1
SEAT, FUEL TANK AND REAR COWLING................................................................3-3
REMOVAL ............................................................................................................3-3
INSTALLATION ....................................................................................................3-3
ENGINE........................................................................................................................3-4
VALVE CLEARANCE ADJUSTMENT ..................................................................3-4
DRIVE CHAIN ADJUSTMENT ..............................................................................3-7
IDLE SPEED ADJUSTMENT ................................................................................3-7
THROTTLE CABLE FREE PLAY ADJUSTMENT ................................................3-8
SPARK PLUG INSPECTION ................................................................................3-9
IGNITION TIMING CHECK ................................................................................3-11
COMPRESSION INSPECTION ..........................................................................3-12
ENGINE OIL LEVEL CHECK ..............................................................................3-15
ENGINE OIL REPLACEMENT ............................................................................3-17
ENGINE OIL PRESSURE CHECK ....................................................................3-21
CLUTCH ADJUSTMENT ....................................................................................3-21
AIR FILTER CLEANING ......................................................................................3-24
FUEL FILTER CLEANING ..................................................................................3-25
ENGINE OIL TANK FILTER CLEANING ............................................................3-26
SUCTION HOSE AND MANIFOLD INSPECTION..............................................3-28
FUEL LINE INSPECTION ..................................................................................3-28
CRANKCASE VENTILATION HOSE INSPECTION ..........................................3-29
EXHAUST SYSTEM INSPECTION ....................................................................3-29
CHASSIS....................................................................................................................3-30
ADJUSTING THE FRONT BRAKE ....................................................................3-30
ADJUSTING THE REAR BRAKE ......................................................................3-31
CHECKING THE BRAKE FLUID LEVEL ............................................................3-32
BRAKE PAD WEAR INSPECTION ....................................................................3-33
BRAKE HOSING INSPECTION ..........................................................................3-33
BRAKE CIRCUIT BLEEDING ............................................................................3-34
DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT..................................3-35
DRIVE CHAIN LUBRICATION ............................................................................3-36
FRONT FORK INSPECTION ..............................................................................3-37
ADJUSTING THE FRONT FORK ......................................................................3-37
REAR SHOCK ABSORBER ADJUSTMENT ......................................................3-38
STEERING INSPECTION ..................................................................................3-40
TYRE INSPECTION ............................................................................................3-41
WHEEL INSPECTION ........................................................................................3-44
SPOKE INSPECTION AND TIGHTENING ........................................................3-44
CABLE INSPECTION..........................................................................................3-45
LEVER AND PEDAL LUBRICATION ..................................................................3-45
SIDESTAND LUBRICATION ..............................................................................3-46
REAR SUSPENSION LUBRICATION ................................................................3-46
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INSP
ADJINTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
3-1
PERIODIC INSPECTION AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a
longer service life. The need for costly overhaul work will be greatly reduced. This information applies to
vehicles already in service as well as to new vehicles that are being prepared for sale. All service techni-
cians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
ODOMETER READING (x 1,000 km)
ANNUAL N0. ITEM CHECK OR MAINTENANCE JOB
110 2030 40CHECK
1
*Fuel line• Check fuel hoses for cracks or damage. ✓✓ ✓✓ ✓•
• Check condition.
✓✓
2 Spurk plug• Clean and regap.
• Replace.✓✓
3 * Valves• Check valve clearance.
✓✓ ✓✓
• Adjust.
4Air filter element• Clean.✓✓
• Replace. ✓✓
5 Clutch• Check operation.
✓✓ ✓ ✓✓
• Adjust.
• Check operation, fluid level and vehicle for fluid leakeage.
6 * Front brake•(See NOTE). ✓✓ ✓ ✓✓ ✓•
• Replace brake pads. Whenever worm to the limit
• Check operation, fluid level and vehicle
•for fluid leakage. ✓✓ ✓ ✓✓ ✓
7 * Rear brake•(See NOTE).
• Replace brake pads. Whenever worm to the limit
8 * Brake hoses• Check for cracks or damage.✓✓✓✓ ✓• Replace. (See NOTE). Every 4 years
9 * Wheels• Check runout, spoke tightness and for damage.
✓✓✓ ✓
• Tighten spokes if necessary.
• Check tread depth and for damage.
10 * Tyres• Replace if necessary.
✓✓✓✓ ✓
• Check air pressure.
• Correct if necessary.
11 * Wheel bearings• Check bearing for looseness or damage.✓✓✓✓
12 * Swingarm• Check operation and for excessive play.✓✓✓✓
• Check chain slack.
13 * Drive chain• Make sure that the rear wheel is properly aligned.Every 500 km and after washing the
• Clean and lubricate.motorcycle or riding in the rain.
14 *Steering • Check bearing play and steering for roughness. ✓✓ ✓ ✓✓bearings
• Lubrificate with lithium-soap-based grease. Every 20,000 km
15 *Chassis • Make sure that all nuts, bolts and screws are properly
✓✓ ✓✓ ✓
fasteners•tightened.
16Sidestand• Check operation.
✓✓ ✓✓ ✓
• Lubricate.
17
*Sidestand
• Check operation and for oil leakage. ✓✓ ✓ ✓✓ ✓
switch
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INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
3-2
INSP
ADJ
ODOMETER READING (x 1,000 km)
ANNUAL N0. ITEM CHECK OR MAINTENANCE JOB
110 2030 40CHECK
18 * Rear brake• Check operation, fluid level and vehicle for fluid leakage. ✓✓✓ ✓
Rear shock
• Check operation and shock absorber for oil leakage.
19
*absorber ✓✓✓ ✓
assemblysull’ammortizzatore.
Rear suspension
• Check operation.
✓✓✓ ✓
20*
relay arm and
connecting arm
• Lubricate with lithium-soap-based grease.
✓✓
pivoting points
• Check starter (choke) operation.
21 * Carburator
• Adjust engine idling speed.✓✓ ✓✓ ✓ ✓
22 Engine oil• Change.
✓✓ ✓✓ ✓ ✓
• Check oil level and oil leakage.
23Engine oil filter
• Replace.✓✓✓
element
24 *Front and rear •
brake switches• Check operation.✓✓ ✓✓ ✓ ✓
Moving parts
25
and cables• Lubricate. ✓✓✓ ✓ ✓
Throttle grip • Check operation and free play.
26 * housing and • Adjust the throttle cable free play if necessary.
✓✓✓ ✓ ✓
cable • Lubricate the throttle grip housing and cable.
27 *Muffler and
• Check the screw clamp for looseness. ✓
exhaust pipe
28 *Lights, signals • Check operation.
✓✓ ✓✓ ✓ ✓
and switches• Adjust headlight beam.
* Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance is per-
formed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake system:
• Check the brake fluid level regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
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CHECKING THE BRAKE FLUID LEVEL
3-32
INSP
ADJ
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
•Place the motorcycle on a suitable stand.
•Make sure that the motorcycle is upright.
2. Check:
•Brake fluid level
Below the minimum level mark a➔Add
the recommended brake fluid to the prop-
er level.
[A] Front brake
[B] Rear brake
WARNING
•Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
•Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
•When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
Brake fluid may damage painted surfaces and
plastic parts. Therefore, always clean up any
spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the reservoir
is horizontal.
CAUTION:
Recommended brake fluid:
DOT4





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BRAKE CIRCUIT BLEEDING
3-34
INSP
ADJ
1
1B
BRAKE CIRCUIT BLEEDING
WARNING
If the brake lever or brake pedal has a soft or
slack feel, this means that there is air in the
brake system. It should be bled away before
using the motorcycle. Air in the system seri-
ously affects the effectiveness of braking and
may cause loss of control of the motorcycle.
In all cases, bleed the brake system if:
•The system has been disassembled.
•A brake hose has been loosened or
removed.
•The brake fluid in the tank is at a very low
level.
•Brake operation is faulty.
Air bleeding procedures:
a. Top up the level of the fluid in the tank to max-
imum.
b. Install the diaphragm. Be careful not to spill
fluid or let it overflow from the tank.
c. Connect the clear plastic hose (1) to the
caliper bleeder screw.
[A] Front
[B] Rear
d. Place the other end of the hose in a container.
e. Slowly pull the brake lever or press the brake
pedal several times.
f. Pull the brake lever right in or press the pedal
right down and hold in position.
g. Loosen the bleeder screw and allow the lever
or pedal to travel slowly towards its limit.
h. Tighten the bleeder screw when the lever or
pedal limit has been reached, then release the
lever or pedal.
Bleeder screw:
14 Nm (1.4 mkg)
i. Repeat operations (e) to (h) until all the air
bubbles have disappeared from the clear
plastic hose (1).
A
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