2004 YAMAHA TT600RE washer fluid

CHASFRONT BRAKE
4-11
MASTER CYLINDER
Order Job name/Part name Q.ty Remarks Master cylinder removal Remove the parts in order.
Brake fluid Drain.
1 Rear view mirror (right)/ Master cylinder bracket 1/1
2 Brake lever 1
3 Brake switch 1
4 Union bolt 1
5 Plain washer 2 Refer to “MASTER CYLINDER INSTAL-
6 Brake hose 1 LATION” section.
7 Master cylinder 1 Reverse the removal procedure for instal-
lation.
26
4
7
1
9 Nm (0.9 m•kg)
20 Nm (2.0 m•kg)
3
5
New
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FRONT BRAKE
4-14
CHAS
2. Install:
•Circlip (1)
•Master cylinder boot (2)
MASTER CYLINDER INSTALLATION
1. Install:
•Master cylinder (1)
•Master cylinder bracket (2)
Screw (master cylinder bracket): 9 Nm (0.9 mkg)
2. Install:
•Plain washer (1) (new)
•Brake hose (2)
•Union bolt (3)
Union bolt (brake hose): 20 Nm (2.0 mkg)
NOTE:
•When tightening the union bolt be sure to put
the brake hose in the correct position.
•Check that the brake hose has stayed in the
correct position. Adjust if necessary.
WARNING
•Check that the brake hose routing is as
described. Refer to “CABLE ROUTING”
section.
•Always use new plain washers.
3. Fill:
•Brake fluid reservoir
Recommended brake fluid: DOT 4
2
3
1
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FRONT BRAKE
4-16
CHAS
BRAKE CALIPER
Order Job name/Part name Q.ty Remarks Caliper removal Remove the parts in order.
Brake fluid Drain.
1 Union bolt 1
2 Plain washer 2
3 Brake hose 1 Refer to “CALIPER INSTALLATION” sec-
4 Caliper support bolt 2 tion
5 Caliper assembly 1 Reverse the removal procedure for instal-
lation.
20 Nm (2.0 m•kg)
2
5
1
25 Nm (2.5 m•kg)
3
4
New
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CHASFRONT BRAKE
4-19
•Fluid delivery passage (caliper)
Obstruction ➔Clean with compressed air.
CALIPER ASSEMBLY
WARNING
•All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.
•In case of non correct operation of the
brake caliper, replace the brake caliper
assembly. Recommended brake fluid:
DOT 4
2. Install:
•Brake caliper pistons (1)
CALIPER INSTALLATION
1. Install:
•Brake caliper (1)
•Caliper support bolts (2)
Bolt (caliper support): 25 Nm (2.5 mkg)
Union bolt: 20 Nm (2.0 mkg)
WARNING
In case of non correct operation of the brake
caliper, replace the brake caliper assembly.
1. Install:
•Piston seals (1)
•Dust seals (2)
•Brake hose (3)
•Plain washers (4) (new)
•Union bolt (5)
53
2
1
4
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REAR BRAKE
4-32
CHAS
MASTER CYLINDER
Order Job name/Part name Q.ty Remarks Master cylinder removal Remove the parts in order.
Brake fluid Drain.
1 Rear stop switch connector 1
2 Rear stop switch 1
3 Plain washer 2 Refer to “MASTER CYLINDER INSTALLA-
4 Brake hose 1 TION” section.
5 Brake fluid reserve tank 1
6 Brake master cylinder 1
Refer to “BRAKE PEDAL REMOVAL” sec-
7 Brake pedal/spring 1/1 tion.
Reverse the removal procedure for installa-
tion.
New
New
20 Nm (2.0 m•kg)
45 Nm (4.5 m•kg)
10 Nm (1.0 m•kg)
4 Nm (0.4 m•kg)
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REAR BRAKE
4-34
CHAS
MASTER CYLINDER INSTALLATION
1. Install:
•Brake pedal (refer to “BRAKE PEDAL
REMOVAL” section in this Chapter).
NOTE:
Lubricate the pin of the brake pedal with lithium-
base grease.
•Master cylinder
•Brake fluid reserve tank
•Plain washers (1) (new)
•Brake hose (2)
•Stop switch (to mount the brake hose) (3) Brake switch (brake hose): 20 Nm (2.0 mkg)
Master cylinder mounting bolt: 10 Nm (1.0 mkg)
Reserve tank mounting bolt: 4 Nm (0.4 mkg)New
2. Fill:
•Brake fluid reserve tank Recommended brake fluid: DOT 4
Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
CAUTION:
WARNING
•Use only designated quality brake fluid.
Otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
•Refill with the same type of brake fluid:
mixing fluids may result in a harmful chem-
ical reaction and lead to poor perform-
ance.
•Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
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CHASREAR BRAKE
4-35
3. Air bleed:
•Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in Chapter 3.
4. Inspect:
•Brake fluid level
Lower than “MIN” mark (1) ➔Fill.
Refer to “BRAKE FLUID INSPECTION”
section in Chapter 3.
(1) Minimum level mark “MIN”
BRAKE PEDAL REMOVAL
1. Remove:
•Split pin (1) (new)
•Plain washer (2)
•Pin (3)
2. Unscrew:
•Bolt (4)
3. Remove:
•Spring (5)
4. Remove:
•Brake pedal (6) from chassis
NOTE:
Pull the brake pedal from the lower part of the
chassis, causing it to rotate progressively as it
comes away.



5. Adjust:
•Brake pedal height (a)
(below the top of the footrest)
Brake pedal height: 10 mm
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REAR BRAKE
4-36
CHAS
BRAKE CALIPER
Order Job name/Part name Q.ty Remarks Caliper removal Remove the parts in order.
Rear wheel Refer to “REAR WHEEL REMOVAL” sec- tion.
Brake fluid Drain.
Brake hose Remove from clamp.
1 Caliper protector 1
2 Brake caliper 1 Remove from caliper support.
3 Union bolt 1 Refer to “BRAKE CALIPER INSTALLA-
4 Plain washer 2
TION” section.
5 Brake hose 1
6 Brake pad support 1 Reverse the removal procedure for installa-
tion.
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