YAMAHA TT600RE 2004 Service Manual

SWINGARM
4-76
CHAS
SWINGARM
(1) Upper chain case
(2) Swingarm
(3) Chain support (4) Swingarm guard seal
(5) Connecting rod
(6) Relay arm [A] LATERAL FREE PLAY (END): 1.0 mm
[B] LATERAL FREE PLAY: 0.4 ~ 0.7 mm
ProCarManuals.com

CHASSWINGARM
4-77
SWINGARM REMOVAL
NOTE
Check free play and remove swingarm, if neces-
sary, after removing the rear shock absorber.
1 . Remove:
•Swingarm connecting rod bolt (1)
2 . Check:
•Swingarm free play▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Inspection procedure:
•Check the tightening torque of the nut which
fastens the swingarm pivot shaft (1).
Nut (pivot shaft): 90 Nm (9.0 mkg)
Lateral free play
(at end of swing arm):
Limit: 1.0 mm
•Check the lateral free play [A] of the swingarm
moving it laterally.
If the free play seems excessive, verify the
collar, bearings, washer and thrust cover.
•Check the vertical movement [B] of the
swingarm, moving it up and down.
If the movement seems rigid, unsmooth or
jerky, inspect the internal collar, the bearings,
the washer and the thrust cover.
1
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ProCarManuals.com

SWINGARMCHAS
4-78 3. Remove:
•Upper chain case (1)
•Chain support (2)
4. Remove:
•Swingarm pivot shaft
•Swingarm
SWINGARM INSPECTION
1. Inspect:
•Swingarm
Deformation/Cracks/Damage ➔Replace.
2. Inspect:
•Connecting rod (1)
•Relay arm (2)
Deformation/Cracks/Damage ➔Replace.
3. Inspect:
•Oil seals
Wear/Damaged ➔Replace.
•Washers
•Thrust cover
Wear/Damaged ➔Replace.
•Bushes
Scratches/Damaged ➔Replace.
•Bearings
Pitting/Damaged ➔Replace.
4. Inspect:
•Chain guard seal
•Chain case and support
Wear/Damage ➔Replace.
1
2
ProCarManuals.com

CHASSWINGARM
4-79
LATERAL FREE PLAY ADJUSTMENT
1. Measure:
•Length of bushes A1 and A2
Out of specification ➔Replace.
Length of bushes: A1 = 76.70 ~ 76.85 mm
A2 = 74.90 ~ 75.00 mm
Swing arm lateral free play C: 0.4 ~ 0.7 mm
Measurement of adjust shim (1): 0.3 mm
2. Measure:
•Length B1 and B2
3. Calculate:
•Lateral swing arm side play C.
Out of specification ➔Adjust free play with
special shims.
Use the following formula:
C = (A1+A2) – (B1+B2)
4. Adjust:
•Lateral side play using one or more adjust
shims (1)
NOTE:
When only one shim is used, install it on the left
side; when two shims are used, install one on
each side.
ProCarManuals.com

SWINGARM
4-80
CHAS
SWINGARM INSTALLATION
Perform “removal” operations in reverse order.
Note the following points.
1. Lubricate:
•Bearings
•Bushes
•Thrust cover (inside)
•Flange
•Swingarm pivot shaft
•Bolt (connecting rod)
•Bolt (relay arm)
•Bolt (shock absorber)
Lithium-base grease
2. Tighten: Nut (relay arm-swingarm): 66 Nm (6.6 mkg)
Nut (relay arm - connecting rod): 52 Nm (5.2 mkg)
Bolt (chain case): 9 Nm (0.9 mkg)
Nut (swingarm pivot shaft): 90 Nm (9.0 mkg)
Bolt (chain support): 4 Nm (0.4 mkg)
Screw (chain case): 4 Nm (0.4 mkg)
Nut (relay arm-frame): 60 Nm (6.0 mkg)
Bolt (rear shock absorber): 59 Nm (5.9 mkg)
3. Install:
•Rear wheel
Refer to “REAR WHEEL INSTALLATION”
section.
ProCarManuals.com

CHASSWINGARM
4-81
Drive chain slack: 30 ~ 40 mm
Refer to “DRIVE CHAIN SLACK ADJUST-
MENT” in CHAPTER 3.
5. Install:
•Fuel tank
•Rear cowling
•Seat
Bolt (seat): 10 Nm (1.0 mkg)
Refer to “SEAT, FUEL TANK AND REAR
COWLING” section in CHAPTER 3.
4. Adjust:
•Drive chain slack
ProCarManuals.com

DRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-82
CHAS
DRIVE CHAIN, DRIVE SPROCKET AND
REAR WHEEL SPROCKET
NOTE:
Before removing the drive chain, drive sprocket
and rear wheel sprocket, it is necessary to meas-
ure the free play and length of the 10 links in the
chain.
DRIVE CHAIN REMOVAL
1. Park the motorcycle upright on an even sur- face.
2. Remove:
•Shift pedal (1)
•Cover (2) (drive sprocket)
3. Remove:
•Drive sprocket (1)
NOTE:
•Before removing the sprocket nut, straighten
the tab on the lock washer.
•Loosen the nut with the rear brake pulled.
4. Raise the rear wheel placing a suitable sup- port under the engine.
WARNING
Set the motorcycle up securely to prevent it
falling over.
5. Remove:
•Rear wheel
•Rear wheel sprocket
•Hub
•Damper
•Spacer
Refer to “REAR WHEEL REMOVAL” sec-
tion.


ProCarManuals.com

CHASDRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-83

6. Remove:
•Swingarm
•Drive chain
Refer to “REAR SHOCK ABSORBER
REMOVAL” and “SWINGARM REMOVAL”
sections.
DRIVE CHAIN INSPECTION
1. Measure:
•Length of 10 links (drive chain)
Out of specification ➔Replace drive
chain.
Maximum lenght of 10 links (a): 150.2 mm
NOTE:
•Stretch the chain by hand to measure it.
•The length of the 10 links is recorded between
the inside of the link pins (1) and (11) as
shown.
•The length of the 10 links is measured at var-
ious points.
2. Clean:
•Drive chain
Immerge in kerosene and brush thorough-
ly to remove as much dirt as possible.
Remove from kerosene and allow to dry.
This motorcycle is fitted with a chain with
small O-Rings (1) fitted between its plates.
Vapour cleaning, pressurised washing and
certain types of solvents may damage these
seal rings.
To clean the transmission chain use only
kerosene.
CAUTION:
ProCarManuals.com

DRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-84
CHAS
3. Inspect:
•Seal rings (1) (drive chain)
Damaged ➔Replace drive chain.
•Rollers (2)
•Lateral plates (3)
Damage/Wear ➔Replace drive chain.
4. Lubricate:
•Drive chain
Lubricant for drive chain: SAE 80W/90 engine oil or special
lubricant for O-Ring chains.
5. Inspect:
•Drive chain
Rigid ➔Clean and lubricate, replace if
necessary.
6. Inspect:
•Drive sprocket
•Rear wheel sprocket
Wear over 1/4 tooth (1) ➔Replace.
Teeth bent ➔Replace.
(2) Undamaged tooth profile
(3) Roller
(4) Sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
How to replace the rear wheel sprocket:
With wheel removed:
1. Remove:
•Hub (1)
•Sprocket fastening bolts (2)
•Rear wheel sprocket (3)
2. Install:
•New sprocket (3)
•Sprocket fastening bolts (2)
•Hub (1)
ProCarManuals.com

CHASDRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-85
3. Tighten:
•Rear wheel sprocket fastening bolts
Rear wheel sprocket fastening bolts: 48 Nm (4.8 mkg)
Nut (drive sprocket): 110 Nm (11.0 mkg)
Nut (swingarm pivot shaft): 90 Nm (9.0 mkg)
Nut (frame-relay arm): 60 Nm (6.0 mkg)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
DRIVE CHAIN INSTALLATION
Perform “REMOVAL” operations in reverse order.
Pay special attention to the following points.
1. Install:
•Drive chain
•Swingarm
2. Install:
•Rear wheel
Refer to “REAR WHEEL INSTALLATION”
section.
3. Install:
•Drive sprocket
WARNING
Always use a new lock washer.
NOTE:
•Tighten the drive sprocket nut with the rear
brake pulled.
•After tightening the nut, bend the tab on the
lock washer once more over the faces of the
nut.
4. Adjust:
•Drive chain slack
Refer to “DRIVE CHAIN SLACK ADJUST-
MENT” section in CHAPTER 3.
Drive chain slack: 30 ~ 40 mm
ProCarManuals.com