key YAMAHA TT600RE 2004 Service Manual

EASB0001
NOTICE
This manual was produced by the Belgarda S.p.A. primarily for use by Yamaha dealers and their quali-
fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore,
anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic
understanding of mechanics and the techniques to repair these types of vehicles. Repair and mainte-
nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit
for use.
Belgarda S.p.A. is continually striving to improve all of its models. Modifications and significant changes
in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in
future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE-
TY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death
to
the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE:A NOTE provides key information to make procedures easier or clearer.
CAUTION:
WARNING
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CHASFRONT FORK
4-51
 

3. Insert an Allen key in the bolt (3) at the bottom of the outer tube and the special tool (1) with
the holder (2) on the damper cylinder assem-
bly and unscrew the bolt completely.
Before unscrewing the bolt ensure that the
end of the damper rod holder is correctly
engaged on the damper cylinder assembly.
CAUTION:
4. Remove:
•Damper cylinder assembly (from inner
tube)
5. Clean the inside of the outer tube and the out- side of the damper cylinder assembly with
petrol. T-handle (1):
90890-01326
Front fork damper rod holder (2): 90890-01460
Taking care not to let petrol enter the inside of
the damper cylinder assembly as it would
seriously compromise its functioning.
CAUTION:
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FRONT FORK
4-56
CHAS
OIL LEAKAGE FROM DUST SEAL
If there is a leakage of oil from between the dust
seal (1) and the inner tube (2) replace the oil seal
(refer to “SEAL AND BUSH REPLACEMENT”
section).
ANOMALOUS HYDRAULIC BRAKING
If the fork shows an anomalous hydraulic braking
effect it is necessary to overhaul the damper cylin-
der assembly.
WARNING
Never tamper with the damper cylinder
assembly! This operation should be done by
authorized personnel. Tampering with the
damper cylinder assembly by non authorized
personnel can compromise the safety of the
front fork. The building firm will not assume
any responsibility for any damages resulting
from such action.
2
1
19. Insert:
•Damper cylinder assembly (in the inner
tube)
20. Insert an Allen key in the bolt (3) at the bot- tom of the outer tube and the special tool (1)
with the holder (2) on the damper cylinder
assembly and screw the bolt completely.
During tightening the bolt ensure that the end
of the damper rod holder is correctly engaged
on the damper cylinder assembly.
CAUTION:
21. Fill:
•Fork leg oil
Refer to “OIL REPLACEMENT”section. T-handle (1):
90890-01326
Front fork damper rod holder (2): 90890-01460
Damper cylinder assembly bolt (3):25 Nm (2.5 kgm)
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ENGENGINE DISASSEMBLY
5-11
3. Remove
•Primary drive gear (1)
•Disc (2)
•Balancer drive gear (3)
•Disc (4)
•Key (5)
•Disc washer (6)
•Disc (7)
•Balancer gear (8)
•Straight key (9)
NOTE:
Before loosening the nut (9) (primary drive gear)
and nut (10) (balancer gear), straighten the wash
lock tab.
NOTE:
To loosen nuts (9) and (10), hold the rotor (CA
magneto) firmly in place using special tool (11).
Sheave holder: P/N. 90890-01701
Be careful not to touch jutting edges (12) on
the rotor with the sheave holder.
CAUTION:
4. Remove:
•Push lever (1)
•Spring
•Flat washer
NOTE:
Loosen the screw to remove the push rod.
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ENGENGINE DISASSEMBLY
5-13
AC GENERATOR AND TIMING CHAIN
NOTE:
The AC generator may be inspected with the
engine installed by removing the following parts:
•Crankcase (L)
1. Remove:
•Nut (1)
•Washer (2)
•Rotor (3) (with starter gear)
•Bearing (4)
•Shim adjustment washer (5)
•Key (6)
NOTE:
To loosen the nut (rotor), lock the rotor with the
special tool (7).
Sheave holder: P/N. 90890-01701
Flywheel puller:P/N. 90890-01362
Be careful not to touch the jutting edges (8) on
the rotor with the special tool.
CAUTION:
NOTE:
Remove the rotor with the puller (1).
2. Remove:
•Chain guide (1)
•Timing chain (2)
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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:
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ENGINE ASSEMBLY AND SETTING
5-68
ENG
BALANCER SHAFT GEAR AND PRIMARY TRANSMISSION GEAR
(1) Straight key
(2) Balancer shaft gear
(3) Breather plate
(4) Lock washer
(5) Nut
(6) Plate washer
(7) Straight key
(8) Plate (9) Balancer shaft drive gear
(10) Plate
(11) Primary drive gear
(12) Lock washer
(13) Nut
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ENGENGINE ASSEMBLY AND SETTING
5-69
BALANCER SHAFT GEAR AND PRIMARY
TRANSMISSION GEAR
1. Install:
•Key (1)
•Balancer shaft gear (2)
•Plate (3)
•Lock washer (4)
•Nut (5) (balancer shaft gear)
•Washer (6)
•Key (7)
•Plate (8)
•Balancer shaft drive gear (9)
•Plate (10)
•Primary drive gear (11)
•Lock washer (12)
•Nut (13) (primary drive gear)
Nut (balancer shaft gear): 60 Nm (6.0 mkg)
Nut (primary drive gear): 120 Nm (12.0 mkg)
NOTE:
When installing the drive gear, align the mark on
it (14) with that of the balancer shaft gear (15).
WARNING
Always use a new lock washer.
NOTE:
To tighten nuts (5) and (13), keep the AC genera-
tor rotor still with the special tool (16).
Sheave holder: P/N. 90890-01701
Be careful not to touch the jutting part (17) of
the rotor with the sheave holder.
2. Bend the lock washer tab along the face of the nut.
CAUTION:
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ENGINE ASSEMBLY AND SETTING
5-72
ENG
NOTE:
Install the friction and clutch plates to the clutch
boss, beginning and ending with a friction plate.
•The two friction plates (type A) (15) with
the widest internal diameter should be
assembled in second and last place.
•The clutch boss spring (16) should be
placed inside the second friction plate.
CAUTION:
Friction plate
Type “A” Type “B”
Quantity 2 6
Internal 116 mm 113 mm
diameter “D”
NOTE:
Align the mark on the clutch boss (17) with the
arrow (18) on the pressure plate.
3. Adjust:
•Clutch (free play)
See section “CLUTCH ADJUSTMENT” in
CHAPTER 3.
4. Install:
•Straight key
•Gasket
•Crankcase cover (right) (1)
•O-Ring
•Oil filter
•Filter cover (2) (with O-Ring)
See section “Engine oil replacement (with
oil filter change)” in CHAPTER 3.
Bolt (crankcase cover): 10 Nm (1.0 mkg)
16
15
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SWITCH CHECK
7-6
ELEC

 







 


1. Detach the main switch connector from the
harness connector.
When detaching the connector, do not pull by
the cables. This way the cables might discon-
nect from the terminals inside the connector
itself.
2. Check to see if any cables are disconnected from their terminal inside the connector.
Reconnect, if necessary.
NOTE:
If the connector is blocked up with mud or dust,
clean it with a jet of compressed air.
3. Use the connection table to check the combi- nation of colours for continuity (closed circuit).
In this example, continuity is as follows:
“R” and “Br” are continuous when the switch is
at ON.
“L” and “R/B” are continuous when the switch
is at ON.
“R” and “L” are continuous when the switch is
at PARK.
Note that there is no continuity (open circuit)
for any of the combinations of a colour differ-
ent from those mentioned and when the
switch is at OFF.
4. Check the switch component for continuity between “R” and “Br”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Control procedure:
•Repeatedly shift the switch key to the various
positions - ON, OFF and PARK.
•Shift the tester selector to “ Ωx1”.
•Connect the tester positive cable (+) to the
terminal of cable “R” of the connector, and the
negative cable (–) to cable terminal “Br”.
CAUTION
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