2004 YAMAHA TT600RE oil viscosity

DIFFICULTIES IN SHIFTING
8-4
TRBL
SHTG
?
Clutch
Engine oil PROBABLE CAUSES•Clutch cable wrongly set
•Wrong position of push lever
•Irregular engagement of push lever and push
rod
•Pressure plate deformed
•Clutch springs not preloaded uniformly
•Reference marks not aligned
•Push rod broken
•Clutch gear assy nut loose or push rod deformed
•Primary driven gear bearing defective
•Driven plates deformed
•Driving plates deformed
•Clutch cable damaged
•Oil level over maximum
•Incorrect gradation (high viscosity)
•Degradation
SHIFTING IMPOSSIBLE
DIFFICULTIES IN SHIFTING
Shift shaft
Shift cam, shift fork PROBABLE CAUSES•Shift shaft deformed
•Groove with impurities or foreign bodies
•Shift fork stuck
•Shift fork guide bar deformed
THE SHIFT PEDAL FAILS TO MOVE
Transmission•Transmission gears struck
•Gears stuck by impurities or foreign bodies
•Wrong transmission assembly
Shift shaft
Shift fork PROBABLE CAUSES•Shift lever set wrongly
•Shift cam
stop lever fails to return freely
•Shift forks worn
Transmission
•Gear clutches worn
DISENGAGING GEARS
Shift cam
•Shaft cam with thrust free play
•Shift cam groove worn
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CLUTCH SLIDES OR FAILS TO RELEASE
8-5
TRBL
SHTG
?
Clutch
Engine oil PROBABLE CAUSES•Clutch cable wrongly set
•Clutch springs loose
•Clutch spring yielded
•Friction plates worn
•Clutch plates worn
•Clutch improperly assembled
•Oil level below minimum
•Incorrect gradation (low viscosity)
•Degradation
CLUTCH SLIDES
CLUTCH SLIDES OR FAILS TO RELEASE
Refer to “SHIFTING IMPOSSIBLE” section.
CLUTCH FAILS TO RELEASE
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DEFECTIVE BRAKES/
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK
8-6
TRBL
SHTG
?
PROBABLE CAUSES
•Brake pads worn
•Brake disc worn
•Water in the brake fluid
•Brake fluid leak
•Brake fluid tank defective
•Bleed cap not sealed to calipers
•Union bolt loose
•Brake hose cracked
•Brake disc dirty or greasy
•Brake pads dirty or greasy
•Incorrect brake fluid level
POOR BRAKING
DEFECTIVE BRAKES
PROBABLE CAUSES
•Inner tube deformed, damaged or rusty
•Outer tube damaged or cracked
•Oil seal lip damaged
•Oil seal assembled incorrectly
•Oil level incorrect (excessive)
•Shock-absorber rod stop bolt loose
•O-ring on cap bolt broken
OIL LEAKS
PROBABLE CAUSES
•Inner tube deformed, damaged or rusty
•Outer tube deformed or damaged
•Fork spring damaged
•Piston worn or damaged
•Shock-absorber rod deformed or damaged
•Incorrect oil viscosity
•Incorrect oil level
MALFUNCTIONING
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK
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DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS/ OVERHEATING OF ENGINE
8-9
TRBL
SHTG
?
PROBABLE CAUSES
•Indicator lamp relay defective
•Insufficient battery capacity
(battery almost flat)
•Incorrect bulb
•Main switch or direction indicator switch defec-
tive
DELAYED TURNING ON OF INDICATORS
PROBABLE CAUSES
•Battery flat
•Main switch or horn switch defective
•Horn wrongly set
•Defective horn
•Harness cut off
THE HORN FAILS TO WORK
OVERHEATING OF ENGINE
PROBABLE CAUSES
•Incorrect bulb
•Indicator lamp relay defective
EXCESSIVE INDICATOR
INTERMITTENCE FREQUENCY
Ignition system
Fuel feed system PROBABLE CAUSES
•Incorrect electrode gap of spark plug
•Spark plug thermal gradation wrong
•Ignition unit defective
•Incorrect carburetor main jet (incorrect setting)
•Incorrect fuel level
•Air filter element obstructed
Engine compression
•Excess of carbon deposits
Engine oil
•Incorrect oil level
•Incorrect oil viscosity
•Incorrect oil gradation
Brake
•Pads fail to return freely (remains blocked)
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