2004 YAMAHA TT600RE light

ILLUSTRATED SYMBOLS
The following symbols are not relevant to every
vehicle.
Illustrated symbols 1to 8are printed on the top
right of each page and indicate the subject of
each chapter.
1General information
2Specifications
3Periodic inspections and adjustments
4Chassis
5Engine
6Carburetor
7Electrical system
8Troubleshooting
Illustrated symbols 9to yare used to identify
the specifications appearing in the text.
9Can be serviced with engine mounted
0Filling fluid
qLubricant
wSpecial tool
eTorque
rWear limit, clearance
tEngine speed
yElectrical data
Illustrated symbols uto sin the exploded dia-
grams indicate the types of lubricants and lubrica-
tion points.
uApply engine oil
iApply gear oil
oApply molybdenum disulfide oil
pApply wheel bearing grease
aApply lightweight lithium-soap base grease
sApply molybdenum disulfide grease
Illustrated symbols dto fin the exploded dia-
grams indicate the following:
dApply locking agent (LOCTITE
®)
fReplace the part
GEN
INFOSPEC
INSP
ADJCHAS
ENGCARB
ELECTRBL
SHTG
New
12
34
?
56
78
90
qw
er
ty
uoi
psa
df
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GEN
INFO
IMPORTANT INFORMATION
1-3
EB101030
LOCK WASHERS/PLATES AND COTTER PINS
1. Replace all lock washers/plates 1and cotter
pins after removal. Bend lock tabs along the
bolt or nut flats after the bolt or nut has been
tightened to specification.
EB101040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the man-
ufacturer’s marks or numbers are visible.
When installing oil seals, apply a light coating
of lightweight lithium base grease to the seal
lips. Oil bearings liberally when installing, if
appropriate.
1Oil seal
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.
1Bearing
CAUTION:
EB101050
CIRCLIPS
1. Check all circlips carefully before reassembly.
Always replace piston pin clips after one use.
Replace distorted circlips. When installing a
circlip 1, make sure that the sharp-edged
corner 2is positioned opposite the thrust 3
it receives. See sectional view.
4Shaft
OR
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1-5
GEN
INFO
SPECIAL TOOLS
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the
appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or impro-
vised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
90890-03113Engine tachometer
This tool is needed for detecting engine rpm.
90890-03141Timing light
This tool is needed for detecting ignition
timing.
90890-03112Pocket tester
These instruments are invaluable for check-
ing the electrical system.
90890-06754Ignition checker
This instrument is necessary for checking
the ignition system components.
Tool name / Usage Illustration
90890-03081Compression gauge
These tools are used to measure the engine
compression.
90890-04082Adapter (compression gauge)
This tool serves to measure the engine com-
pression.
90890-01312Fuel level gauge
This gauge is used to measure the fuel level
in the float chamber.
90890-01304Piston pin clip puller
This tool serves for removing the piston pin
clip.
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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
2-14
Tightening
Part to be tightened Thread torque
Remarkssize
N·mm·kg
Engine mounting and rear frame:
Engine front/Stay engine M10 x 1.25 64 6.4
Stay engine (engine front)/Frame M10 x 1.25 64 6.4
Engine rear under/Frame M10 x 1.25 68 6.8
Engine top/Stay engine M10 x 1.25 64 6.4
Engine protector/Frame M6 x 1.0 7 0.7
Chain tensioner top/Frame M8 x 1.25 23 2.3
Chain tensioner under/Frame M8 x 1.25 23 2.3
Frame/Rear frame (upper) M8 x 1.25 23 2.3
Frame/Rear frame (under) M8 x 1.25 23 2.3
Rear frame/Air filter assy M6 x 1.0 5 0.5
Front fork and steering:
Handle crown/Inner tube M8 x 1.25 28 2.8
Handle crown/Steering shaft M28 x 1.5 4 0.4 See “NOTE”
Steering shaft/Ring nut M36 x 1.5 115 11.5
Holder handle upper/Crown handle M8 x 1.25 20 2.0
Holder handle under/Crown handle M10 x 1.5 40 4.0
Front fork under bracket/Inner tube M8 x 1.25 23 2.3
Front master cylinder/Cap M4 x 0.7 1.5 0.15
Front master cylinder/Handle M6 x 1.0 9 0.9
Union bolt tightening M10 x 1.0 20 2.0
Front fender/Front fork M6 x 1.0 7 0.7
Stay headlight/Handle crown M6 x 1.0 10 1.0
Stay headlight/Bracket meter M6 x 1.0 6 0.6
Headlight/Stay headlight M6 x 1.0 10 1.0
Rear arm and cushion:
Pivot shaft/Frame M14 x 1.5 90 9.0
Arm relay/Frame M10 x 1.25 60 6.0
Arm relay/Rod connecting M10 x 1.25 52 5.2
Arm relay/Shock absorber M10 x 1.25 59 5.9
Rod connecting/Rear arm M12 x 1.25 66 6.6
Shock absorber upper/Frame M12 x 1.25 66 6.6
Seal guard/Rear arm M6 x 1.0 4 0.4
Support chain/Rear arm M6 x 1.0 9 0.9
Chain case/Rear arm M6 x 1.0 9 0.9
Front wheel:
Front wheel shaft/Front fork M16 x 1.5 59 5.9
Axle holder//Front fork M6 x 1.0 9 0.9
Rear wheel:
Rear wheel shaft/Nut M18 x 1.5 115 11.5
Clutch hub/Sprocket M10 x 1.25 48 4.8
Tightening torques
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SPECMAINTENANCE SPECIFICATIONS
2-15
Tightening
Part to be tightened Thread torque
Remarkssize
N·mm·kg
Front brake:
Front hub/Disc brake M6 x 1.0 12 1.2
Front caliper/Front fork M8 x 1.25 25 2.5
Front caliper/Bleeder tightening M10 x 1.0 14 1.4
Union bolt tightening (front) M10 x 1.0 20 2.0
Rear brake:
Rear hub/Disc brake M6 x 1.0 12 1.2
Rear master cylinder/Frame M6 x 1.0 10 1.0
Rear stop switch/Rear master cylinder M10 x 1.0 20 2.0
Rear caliper/Bleeder tightening M10 x 1.0 14 1.4
Protector rear caliper/Rear caliper M6 x 1.0 10 1.0
Union bolt tightening (rear) M10 x 1.0 20 2.0
Rear brake tank reserve/Air cleaner assy M6 x 1.0 5 0.5
Brake pedal/Frame M10 x 1.25 48 4.8
Sidestand/Footrest:
Sidestand mounting bolt/Frame M12 x 1.25 40 4.0
Sidestand mounting bolt/Nut M12 x 1.25 40 4.0
Sidestand switch/Frame M5 x 0.8 8 0.8
Rear footrest/Rear frame M8 x 1.25 30 3.0
Bracket 1 (main footrest)/Frame M10 x 1.25 48 4.8
Bracket 2 (main footrest)/Frame M10 x 1.25 48 4.8
Footrest cover/Footrest M6 x 1.0 10 1.0
Seat, fuel tank and oil tank:
Seat/Frame M6 x 1.0 10 1.0
Bolt (guide seat)/Fuel tank M6 x 1.0 5 0.5
Fuel tank/Rear frame M6 x 1.0 12 1.2
Damper fuel tank (front)/Frame M8 x 1.25 15 1.5
Fuel tank/Fuel cock M6 x 1.0 7 0.7
Oil tank/Sub-oil tank M6 x 1.0 7 0.7
Union bolt (oil hose 2)/Oil tank assy/Engine M12 x 1.25 35 3.5
Oil hose 1/Oil tank/Engine M6 x 1.0 10 1.0
Oil tank/Rear frame M12 x 1.5 20 2.0
Frame, rear fender compl. and lights:
Rear fender compl. (under)/Rear frame M6 x 1.0 2 0.2
Rear fender compl. (upper)/Rear frame M6 x 1.0 7 0.7
Bracket, license/Rear frame M6 x 1.0 10 1.0
Bracket, license/Rear flasher M6 x 1.0 10 1.0
Horn/Frame M6 x 1.0 13 1.3
Regulator/Frame M8 x 1.25 7 0.7
Igniton coil/Frame M5 x 0.8 13 1.3
Battery box/Rear frame M6 x 1.0 7 0.7
Igniter cover/Battery box M4 1 0.1
Main switch/Frame M24 x 1.0 1 0.1
Tail light (lense)/Rear fender compl. M3.5 1 0.1
Starter switch/Red wire M6 x 1.0 7 0.7
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SPECMAINTENANCE SPECIFICATIONS
2-16
Tightening
Part to be tightened Thread torque
Remarkssize
N·mm·kg
Starting motor cord/Starting motor M6 x 1.0 11 1.1
Wire minus lead (-)/Starting motor M6 x 1.0 10 1.0
Front flasher lights/Stay, headlight M6 x 1.0 1.5 0.15
Clutch wire/Engine M6 x 1.0 7 0.7
Assist grip (Standing handle)/Rear frame M8 x 1.25 23 2.3
Speedometer M5 x 0.8 4 0.4
Air filter case 1/Air filter case 2 (L = 13 mm) M3.9 0.5 0.05
Air filter case 1/Air filter case 2 (L = 19 mm) M3.9 1 0.1
Hose clamp/Joint, carburator M4 x 0.7 0.6 0.06
Hose clamp/Air cleaner/Carburator M5 x 0.8 0.8 0.08
Battery (+)/(-) M6 x 1.0 2.5 0.25
NOTE:
1. First tighten the ring nut approximately 38 Nm (3.8 mkg) by using the torque wrench, then loosen the
ring nut one turn.
2. Final tighten the ring nut at the torque of 4 Nm (0.4 mkg).
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SPECMAINTENANCE SPECIFICATIONS
2-18
Item Standard Limit
Horn
Horn type Plane
Quantity 1 pcs
Manufacturer LEONELLI
Max. amperage 1.5 A •••
Flasher relay
Type Semi-transistor •••
Model/manufacturer FB222M/NIPPONDENSO •••
Self cancelling device No •••
Flasher frequency 75 - 95 cycle/min •••
Wattage 10 W
2 + 3.4 W •••
Daylight switch relay
Model/manufacturer ACA12151-1-MATSUSHITA DENKOU
Circuit breaker
Type Fuse
Amperage for fuse 20 A •••
Reserve 20 A •••
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