2004 YAMAHA TT600RE low oil pressure

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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INSP
ADJ
3-13
COMPRESSION INSPECTION
Inspection:
•Turn the main switch to "ON".
•With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilized.
WARNING
While operating the starter, disconnect the
spark plug cap to avoid sparks.
•Compare the pressure reading with those in
the table.
Pressure under compression:
Standard
1,100 kPa (11 kg/cm
2, 156 psi)
Minimum
900 kPa (9 kg/cm
2, 128 psi)
Maximum
1.200 kPa (12 kg/cm
2, 171 psi)
8. Check:
•Pressure under compression
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
•If the pressure reading is lower than minimum:
1) Add a few drops of oil to the cylinder through
the hole in the spark plug.
2) Measure the compression again.
3) Compare the new reading with the first, then
proceed according to the indications in the
table.
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INSP
ADJ
3-21
ENGINE OIL PRESSURE CHECK/
CLUTCH ADJUSTMENT







ENGINE OIL PRESSURE CHECK
1. Remove:
•Bleeder screw (1)
2. Start the engine and keep it idling until oil
flows out of the bleed hole.
3. Inspect:
•Conditions of oil at bleeder hole.
Oil leakage ➔Oil pressure good.
No leakage ➔Pressure insufficient.
If the oil does not come out after one minute,
stop the engine immediately to prevent
seizure.
4. Tighten:
•Bleeder screw
CAUTION:
Bleeder screw:
5 Nm (0.5 kgm)
CLUTCH ADJUSTMENT
Cable free play adjustment
1. Check:
•Clutch free play adjustment (a)
Out of specification ➔Adjust.
Free play:
10 ~ 15 mm
2. Adjust:
•Clutch cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjustment:
•Loosen lock nuts (1).
•Turn the adjuster (2) either way to obtain cor-
rect free play.
•Tighten lock nuts after adjustment.

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CHASFRONT FORK
4-49
CLEANING THE DUST SEAL
NOTE:
After using the motorcycle it is necessary to clean
the dust seal carefully in order to maintain the fork
at maximum efficiency.
In fact, if dust infiltrates to the inside of the dust
seal it can compromise the smoothness and
therefore the sensitivity of the fork, and also
cause the premature wear of the underlying oil
seal.
Just a few simple operations then, guided by the
following indications are necessary to maintain
the optimum functioning of the fork with time.
1. With a screwdriver prise the dust seal (1) from the oil seal seat (2) and then withdraw it using
force.
2. Using a low pressure jet of compressed air clean the inside of the dust seal and the oil
seal seat.
3. Insert the edge of a cloth under the lip and keeping the cloth steady, carefully clean the
lip by rotating the dust seal.
1
2
1
2
12
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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
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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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UNSTABLE STEERING
8-7
TRBL
SHTG
?
Handlebar
Steering PROBABLE CAUSES•Assembled crooked or incorrectly
•Handlebar crown assembled incorrectly
•Lower bracket crooked
•Lower steering column installed incorrectly
(threaded ring nuts not tightened correctly)
•Bearing or bearing tracks damaged
Front fork
•Oil level not the same in both tubes
•Spring broken
•Front fork crooked
Tyres
•Tyre pressure incorrect for type of road
•Tyre pressure incorrect
•Tyres worn non-uniformly
Wheels
•Wheels balanced incorrectly
•Wheel deformed
•Bearing loose
•Wheel axle deformed or loose
•Wheels excessively off-centre
Frame
•Deformed
•Head tube damaged
•Ball track installed incorrectly
Rear shock absorber
•Spring yielded
•Spring preloaded
•Oil leak
Rear arm
•Bushes or bearings consumed
•Deformed or damaged
Drive chain
•Chain set incorrectly
UNSTABLE STEERING
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