2004 YAMAHA TT600RE tow

INSP
ADJ
3-15
ENGINE OIL LEVEL CHECK
ENGINE OIL LEVEL CHECK
Do not put additives into the engine oil. The
latter also lubricates the clutch and additives
might cause it to slide.
WARNING
Never remove the oil tank cap when the
engine is hot. The boiling oil might spill over,
causing burns. Wait for the oil to cool to at
least 60°C (140°F) or thereabouts.
This model is fitted with a dry crankcase lubrica-
tion system. A feed pump delivers oil to the en-
gine; after fully lubricating the latter, the oil is re-
turned to the tank by a scavenge pump. The oil
level must therefore be checked in the oil tank.
1. Start the engine and warm up until the oil tem-
perature rises to approximately 60°C (140°F).
2. Idle the engine for at least 10 seconds while
keeping the motorcycle upright. After stop the
engine and check the oil level through the
level window (3) located on the left side of the
oil tank assy and(or) by oil level gauge.
NOTE:
Be sure the motorcycle is positioned straight up
when checking the oil level. A slight tilt toward the
side can result in false readings.
3. The oil level should be between the maximum
(1) and minimum (2) marks.
CAUTION:
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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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CHASFRONT FORK
4-47
7. Fill:
•Part of the new oil (with the fork leg in a
vertical position)
Recommended oil: Liqui Moly Racing suspension
oil SAE 7,5
Recommended oil: Liqui Moly Racing suspension
oil SAE 7,5
8. Using the inner tube pump back and forth until a regular drag is felt on the return stroke.
9. With the fork leg in a perfectly upright position, insert the inner tube (1) in the outer tube (2)
completely to the end of the stroke.
10. Finish topping up the oil bringing it to the pre- scribed level from the upper edge measured
with a graduated dipstick or ruler (3).
Oil level:
Standard 180 mm
Minimum 190 mm
Maximum 170 mm
From top of inner tube with inner tube fully
inserted without spring.
12. Screw:
•Cap bolts (5)
(on inner tube, without tighten)
13. Install:
•Fork leg
11. Insert:
•Spring (1) (into the inner tube (2))
•Seat (3)
•Spacer (4)
NOTE:
Usually there is no particular sense in which the
spring is mounted and so it may be inserted from
either end. If there is a hem, however mount it
keeping the hemmed parts towards the top.
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CHASFRONT FORK
4-53
9. With a few sharp blows withdraw the inner tube (2) from the outer tube (3).
NOTE:
The oil seal (4), the washer (5), the outer tube DU
bush (6) and the inner tube DU bush (7) are
installed on the inner tube and must be removed
and replaced with new one.
10. Install:
•Outer tube DU bush (6) (new)
•Inner tube DU bush (7) (new)
Check that the inner tube bush (7) is inserted
correctly in its seat on the end of the inner
tube.
CAUTION:
11. Mount the tool (1) on the inner tube (2) with the side (3) matching the DU outer tube bush (4)
and clamp it keeping the two joints (5) at the
top and bottom (never towards the jaws of the
vice) and make it protrude by at least 40 mm
at the sides.
DU bush/oil seal driver (1): 90890-11043
4
25
7
6
3
7
6
34
4
3
21
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FRONT FORK
4-54
CHAS
12. The vice tightened, grip the outer tube and with a few strong blows hit it against the tool
(3) until the DU outer tube bush (4) is correct-
ly positioned in its seat.
13. Remove the fork leg from the vice and remove the tool (1). Insert the new washer (3) and the
new oil seal (4) as shown on the inner tube (2).
NOTE:
Apply lightweight lithium-soap base grease to the
oil seal before installing it.
14. Mount the tool (1) on the inner tube (2) with the side (5) matching the oil seal (4) and clamp it
keeping the two joints (6) at the top and bot-
tom (never towards the jaws of the vice) and
make it protrude by at least 40 mm at the
sides.
DU bush/oil seal driver (1): 90890-11043
54
3
~ 40 mm
124
5
43
21
15. The vice tightened, grip the outer tube and with a few strong blows hit it against the tool
(1). After each blow rotate the outer tube
slightly in order to install the oil seal (4) cor-
rectly and until it is completely inserted in its
seat.
1
2
64
3
~ 40 mm
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ENGENGINE ASSEMBLY AND SETTING
5-59
PISTON, CYLINDER, CYLINDER HEAD AND
CAMSHAFT
1. Apply:
•4-stroke engine oil
(on piston pin).
2. Install:
•Piston (1)
•Pin (2)
•Circlip (3)
NOTE:
•Arrow (4) on the piston must point towards the
front of the engine.
•Before installing the piston pin circlips, cover
the crankcase with a clean cloth to prevent
foreign bodies falling into it.
WARNING
Always use new circlips for the piston pin.
3. Install:
•Dowel pins (1)
•O-Ring (2)
4. Install:
•Gasket (1) (cylinder)
NOTE:
Install the cylinder gasket as shown in the illustra-
tion.
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CARBURETOR REMOVAL
6-2
CARB
Order Job name/Part name Q.ty Remarks 5 Hose clamp 2 Loosen.
NOTE:
Move carburetor manifold clamps towards
the rear side.
6 Carburetor 2 Reverse the removal procedure for installa-
tion.
Adjust throttle cable free play (refer to
THROTTLE CABLE FREE PLAY ADJUST-
MENT” section in CHAPTER 3).
Adjust idle speed (refer to “IDLE SPEED AD-
JUSTMENT” section in CHAPTER 3).
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