YAMAHA TT600RE 2004 Service Manual

ENGENGINE ASSEMBLY AND SETTING
5-57
CYLINDER HEAD
(1) Cylinder head cover
(2) O-Ring
(3) Tappet cover (intake)
(4) Tappet covers (exhaust)
(5) O-Ring
(6) Cap (7) Cylinder head
(8) Valve guide (intake valve)
(9) Valve guide (exhaust valve)
(10) Spark plug
(11) Dowel pin
10 Nm (1.0 m•kg 7.2 ft•lb)
A
10 Nm (1.0 m•kg 7.2 ft•lb)
10 Nm (1.0 m•kg 7.2 ft•lb)
18 Nm (1.8 m•kg 13 ft•lb)
7 Nm (0.7 m•kg 5.1 ft•lb)
20 Nm (2.0 m•kg 14 ft•lb)
12 Nm (1.2 m•kg 8.7 ft•lb)
10 Nm
(1.0 m
•kg 7.2 ft•lb)
10 Nm
(1.0 m
•kg 7.2 ft•lb)
SEALANT (QUICK GASKET) ®
ProCarManuals.com

ENGINE ASSEMBLY AND SETTING
5-58
ENG
CAMSHAFT AND TIMING CHAIN
(1) Camshaft
(2) Cam chain sprocket
(3) Chain stopper guide
(4) Timing chain
(5) Chain stopper guide
(6) Gasket
(7) Chain tensioner
ProCarManuals.com

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.
ProCarManuals.com

ENGINE ASSEMBLY AND SETTING
5-60
ENG
5. Offset the piston ring end gaps as illustrated in the figure.
NOTE:
•Check that the marks and numbers stamped
by the manufacturer on the piston rings face
upwards.
•Before installing the cylinder, lubricate the pis-
ton rings liberally with 4-stroke engine oil.
(1) Upper ring
(2) Scraper (lower ring)
(3) Scraper (upper ring)
(4) Lower ring
6. Install:
•Cylinder (1)
NOTE:
•Install the cylinder to the piston with one hand
while one hand while compressing the piston
rings with the other.
•Bind the timing chain with wire and slip it
through the appropriate slot.
Cylinder:
Screw (2): 10 Nm (1.0 mkg)
Cap nut (3): 42 Nm (4.2 mkg)
Nut (4): 42 Nm (4.2 mkg)
ProCarManuals.com

ENGENGINE ASSEMBLY AND SETTING
5-61
7. Install:
•Dowel pins (1)
•O-Ring (2)
•Gasket (3) (cylinder head)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Cylinder head:
Screw (l), (2), (3) and (4): 29 Nm (2.9 mkg)
Nut (5) and (6): 22 Nm (2.2 mkg)
Screw (7): 10 Nm (1.0 mkg)
8. Install:
•Cylinder head
NOTE:
Tighten screws beginning with the one with the
lowest number.
9. Install:
•Chain stopper guide
•Camshaft
•Cam chain sprocket
Timing chain installation:
•Install the cam chain on the cylinder head as
illustrated (compression phase timing).
•Run the cam shaft in an anticlockwise direc-
tion until the mark on the crankcase (1) and
the point on the cam chain gearwheel (2) are
aligned.
ProCarManuals.com

ENGINE ASSEMBLY AND SETTING
5-62
ENG
•Install the gear wheel with the timing marks as
shown in the figure and tighten the screws on
the gear wheel by hand.
(3) Upper cylinder head surface
(4) Timing marks
(5) Upper position mark
•When pushing the chain tensioner be sure
that the marks on the cam chain sprocket are
aligned with the top surface of the cylinder
head.
•If the marks are aligned, tighten the cam chain
sprocket bolts.
Bolt (cam chain sprocket): 20 Nm (2.0 mkg)
•If the marks are not aligned, replace the chain
sprocket mating piston and chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
10. Apply:
•Yamaha Bond N° 1215 ®
(1)
(on the mating surfaces)
Sigillante (Quick Gasket) ®
Yamaha bond N° 1215 ®
:
P/N. 90890-85505
11. Install:
•Dowel pins (2)
12. Install:
•Cap
•Cylinder head cover
NOTE:
Cross-tighten the screws repeatedly.
Bolt (cylinder head cover): 10 Nm (1.0 mkg)
ProCarManuals.com

ENGENGINE ASSEMBLY AND SETTING
5-63
13. Install:
•Chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Assembly steps:
•Remove the chain tensioner screw (1), the
washer (2) and the spring (3).
•Release the chain tensioner unidirectional
cam (4) and push the thrust rod (5).
•Install the chain tensioner in the cylinder with
a new gasket.
Screw (chain tensioner body): 10 Nm (1.0 mkg)
Chain tensioner screw: 20 Nm (2.0 mkg)
WARNING
Always use a new gasket.
•Install the spring, the washer and the chain
tensioner.
14. Adjust:
•Valve clearance Valve clearance: Intake0.05 ~ 0.10 mm
Exhaust 0.12 - 0.17 mm
See section “VALVE CLEARANCE
ADJUSTMENT” in CHAPTER 3.
ProCarManuals.com

ENGINE ASSEMBLY AND SETTING
5-64
ENG
15. Install:
•Tappet covers (1) (exhaust)
•Tappet cover (2) (intake)
•Spark plug (3) Tappet cover (exhaust): 12 Nm (1.2 mkg)
Screw (tappet cover-intake): 10 Nm (1.0 mkg)
Spark plug: 18 Nm (1.8 mkg)
NOTE:
The tappet cover (intake) should be assembled
with the arrow (4) pointing upwards.
ProCarManuals.com

ENGENGINE ASSEMBLY AND SETTING
5-65
AC GENERATOR
(1) Rotor
(2) Pick-up coil
(3) Stator winding PICKUP COIL RESISTANCE:
230 Ω± 20% at 20°C (68°F)
(Blue/Yellow - Green/White)
CHARGING COIL RESISTANCE:
0.65 Ω ± 20% at 20°C (68°F)
(White - White)
ProCarManuals.com

ENGINE ASSEMBLY AND SETTING
5-66
ENG
AC GENERATOR
1. Install:
•Woodruff key (1)
•Washer (2)
•Bearing (3)
•Rotor (4)
•Washer (5)
•Nut (6)
NOTE:
When installing the AC generator rotor, check that
the woodruff key fits properly into its seat on the
crankshaft. Apply a thin layer of lithium soap-
based grease on the conical tip of the crankshaft.
2. Tighten:
•Nut (rotor) Nut (rotor): 120 Nm (12.0 mkg)
NOTE:
To tighten the nut, lock the rotor with the special
tool (1).
Sheave holder: P/N. 90890-01701
Be careful not to touch the jutting edges (2) on
the rotor with the sheave holder.
CAUTION:
ProCarManuals.com