YAMAHA TT600RE 2004 Service Manual

ENGENGINE ASSEMBLY AND SETTING
5-47
GEARBOX
(1) Stopper lever
(2) Guide bar
(3) Shift fork #3
(4) Shift fork #1
(5) Shift cam
(6) Guide bar
(7) Shift fork #2
(8) Shift shaft #1
(9) Shift shaft #2
(10) Oil seal
(11) Shift lever
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5-48
ENGENGINE ASSEMBLY AND SETTING
TRANSMISSION AND GEARBOX
1. Install:
•Transmission assembly (1)
2. Install:
•Shift fork #1 (1)
•Shift fork #2 (2)
•Shift fork #3 (3)
•Shift cam (4)
•Guide bar (5)
NOTE:
Each shift fork is identified by the number
stamped on its side. All numbers must face left.
3. Install:
•Shift shaft #1 (1)
•Shift shaft #2 (2)
NOTE:
Align mark (3) on the shift lever shaft with that on
the shift shaft.
4. Check:
•Transmission functioning
Jerky functioning ➔Repair.
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ENGENGINE ASSEMBLY AND SETTING
5-49
ENGINE OIL PUMP AND OIL STRAINER
(1) Oil strainer
(2) Oil pump
(3) Oil pump gear
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ENGINE ASSEMBLY AND SETTING
5-50
ENG
CRANKCASE
(1) Crankcase (R)
(2) Crankcase (L)
(3) Crankcase ventilation hose
(4) Dowel pin
(5) Dowel pin
(6) Dowel pin
(7) Bearing cover plate
(8) Collar
(9) Lock plate
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ENGENGINE ASSEMBLY AND SETTING
5-51
ENGINE OIL STRAINER
1. Install:
•Oil strainer (1)
•Oil passage cover (2)
Screw (oil strainer): 7 Nm (0.7 mkg)
Screw (oil passage cover): 7 Nm (0.7 mkg)
WARNING
Always use a new gasket.
Yamaha bond N° 1215 ®
:
P/N. 90890-85505
2 Install:
•Dowel pin (2)
3. Assemble the left crankcase to the right. Beat gently with a soft hammer.
NOTE:
Turn the shift cam as shown in the figure so that
it does not interfere with the crankcase during
assembly.
CRANKCASE
1. Apply:
•Yamaha bond N° 1215 ®
(1)
(on the crankcase mating surfaces)
Before installing and tightening the fastening
screws, be sure that the transmission is work-
ing properly by hand, turning the shift cam in
both directions.
CAUTION:
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ENGINE ASSEMBLY AND SETTING
5-52
ENG
4. Tighten:
•Screws (crankcase) (1) ~ (14)
NOTE:
Tighten the screws beginning with the one with
the lowest number.
Screw (crankcase): 10 Nm (1.0 mkg)
Stopper lever screw (4):
10 Nm (1.0 mkg)
5. Apply:
•4-stroke engine oil
(to the connecting rod pin, the bearing and
the oil passage).
6. Check:
•Gearbox and transmission functioning
Jerky functioning ➔Replace.
SHIFT SHAFT AND OIL PUMP
1. Install
•Spring (1)
•Collar (2)
•Stopper lever (3)
NOTE:
Place the stopper lever and the spring in the cor-
rect position.
2. Install:
•Plate washer (1)
•Spring (2)
•Shift lever (3)
•Circlip (4)
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ENGENGINE ASSEMBLY AND SETTING
5-53
NOTE:
When installing the shift lever, align the mark on
the lever with that on the shift shaft.
3. Install:
•Circlip (1) (to the driving axle)
•Spacer (2)
•Circlip (3)
4. Apply:
•4-stroke engine oil
(oil pipes in crankcase)
To avoid damage to the engine, lubricate the
oil pump pipes in the crankcase liberally with
4-stroke engine oil.
CAUTION:
5. Apply:
•4-stroke engine oil
(oil pump pipes)
6. Apply:
•O-Ring (1)
•Oil pump (2)
•Oil pump gear (3)
•Circlip (4) Screw (5) (oil pump): 10 Nm (1.0 mkg)
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ENGINE ASSEMBLY AND SETTING
5-54
ENG
TIMING CHAIN
1. Install:
•Timing chain (1)
•Chain guide (2)
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ENGENGINE ASSEMBLY AND SETTING
5-55
PISTON AND RINGS
(1) Ring (upper)
(2) Ring (lower)
(3) Scraper
(4) Piston
(5) Piston pin
(6) Circlip PISTON SIZE:
94.915 ~ 94.965 mm
PISTON RING END GAP:
TOP: 0.30 ~ 0.45 mm
2ND: 0.30 ~ 0.45 mm
OIL: 0.20 ~ 0.70 mm
PISTON RING SIDE CLEARANCE:
TOP: 0.04 ~ 0.08 mm
2ND: 0.03 ~ 0.07 mm
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ENGINE ASSEMBLY AND SETTING
5-56
ENG
CYLINDER
(1) Gasket
(2) Cylinder
(3) O-Ring
(4) Gasket
(5) Dowel pin
(6) Dowel pin
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