engine YAMAHA TT600RE 2004 Owners Manual

ENGENGINE ASSEMBLY AND SETTING
5-61
7. Install:
•Dowel pins (1)
•O-Ring (2)
•Gasket (3) (cylinder head)
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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.
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ENGINE ASSEMBLY AND SETTING
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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.
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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)
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ENGENGINE ASSEMBLY AND SETTING
5-63
13. Install:
•Chain tensioner
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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.
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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.
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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)
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ENGINE ASSEMBLY AND SETTING
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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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ENGENGINE ASSEMBLY AND SETTING
5-67
OIL FILTER AND OIL HOSES
(1) Oil filter
(2) Filter cover
(3) Oil hose
(4) Oil hose
(5) Oil delivery hose
(6) Oil drain plug
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ENGINE ASSEMBLY AND SETTING
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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
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ENG
CLUTCH
(1) Compression spring
(2) Pressure plate
(3) Push rod
(4) Ball
(5) Friction plate (type A)
(6) Clutch boss spring
(7) Clutch plate
(8) Friction plate (type B) (9) Clutch boss
(10) Thrust plate
(11) Primary driven gear comp.
(12) Push rod
(13) Push lever
(14) Primary drive gear
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