engine YAMAHA TT600RE 2004 Service Manual

ENGENGINE ASSEMBLY AND SETTING
5-71
CLUTCH
1. Install:
•Plain washer
•Spring
•Push lever (1)
Screw (push lever): 12 Nm (1.2 mkg)
2. Install:
•Push rod (1)
•Primary driven gear comp. (2)
•Thrust plate (3)
•Clutch boss (4)
•Lock washer (5)
•Nut (6) (clutch boss)
•Clutch boss spring (7)
•Clutch plate (8)
•Friction plate (9)
•Ball (10)
•Pressure plate (11)
•Compression spring (12)
•Screw (pressure plate) (13)
Nut (clutch boss): 90 Nm (9.0 mkg)
Pressure plate screw: 8 Nm (0.8 mkg)
NOTE:
•To tighten the nut (clutch boss), lock the clutch
drum with the special tool (14).
Clutch holding tool: P/N. 90890-04086
•Bend the lock washer tab along the face of the
nut.
WARNING
Always use a new lock washer.
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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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ENGENGINE ASSEMBLY AND SETTING
5-73
STARTER GEARS
(1) Starter gear
(2) Starter neutral gear 1
(3) Starter neutral gear 2
(4) Starter gear
(5) Starter clutch
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ENGINE ASSEMBLY AND SETTING
5-74
ENG
STARTER NEUTRAL GEAR AND CRANKCASE
COVER (L))
1. Install:
•Stator winding (1)
•Pick-up coil (2)
•Cable clamp (3)
2. Install:
•Bearing (1)
•Intermediate starter gear 2 (2) Screws (stator and coil):
7 Nm (0.7 mkg)
Use LOCTITE ®
Screw (cable clamp): 7 Nm (0.7 mkg)
3. Install:
•Centring pin (1)
•Gasket (2)
•O-Ring (3)
•Crankcase cover (L) (4)
•Plugs
Bolt (crankcase cover): 10 Nm (1.0 mkg)
WARNING
Always use a new gasket.
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ENGENGINE ASSEMBLY AND SETTING
5-75
4. Install:
•Neutral switch cable (1)
5. Install:
•Shaft (1)
•Bearing (2)
•Starter intermediate gear 1 (3)
6. Install:
•Centring pins
•Gasket
•Cover (1) (starter intermediate gear) Screw (cover): 10 Nm (1.0 mkg)
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ENGINE REASSEMBLY
5-76
ENG
ENGINE REASSEMBLY
To reassemble the engine, repeat the procedures
described in the paragraph “ ENGINE REMOVAL”
in this chapter in reverse order. Pay attention to
the following points.
1. Install:
•Sprocket (1)
•Drive chain Nut (sprocket): 110 Nm (11.0 mkg)
Drive chain slack: 30 ~ 40 mm
Screw (sprocket cover):10 Nm (1.0 mkg)
Use LOCTlTE ®
Screw (shift ptidal): 10 Nm (1.0 mkg)
Screw (footrest): 48 Nm (4.8 mkg)
NOTE:
Bend the lock washer tab along the face of the
nut.
WARNING
Always use a new lock washer.
2. Install:
•Cover (sprocket)
•Shift pedal
•Footrest (L)
3. Adjust:
•Drive chain slack
See section “DRIVE CHAIN SLACK
INSPECTION AND ADJUSTMENT” in
CHAPTER
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ENGENGINE REASSEMBLY
5-77
4. Install:
•Oil delivery hose (1) Union bolt: 18 Nm (1.8 mkg)
Screw (tappet cover): 10 Nm (1.0 mkg)
Air bleeder screw (oil filter cover): 5 Nm (0.5 mkg)
Amount of oil: Camshaft0.1 litres
Oil filter housing 0.06 litres
5. Remove:
•Tappet cover (intake)
•Air bleeder screw (oil filter cover)
6. Apply:
•4-stroke engine oil
•(on the top side of the camshaft and in the
oil filter housing).
Liberally apply 4-stroke engine oil in the oil
passage in the crankcase to prevent damage
to the engine.
CAUTION:
7. Install:
•Tappet cover (intake)
•Air bleeder screw (oil filter cover)
8. Adjust:
•Clutch cable free play Free play (at end of lever): 10 ~ 15 mm
See section “CLUTCH ADJUSTMENT” in
CHAPTER 3.
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ENGINE REASSEMBLY
5-78
ENG
9. Install:
•Carburetor Screw (clamp): 2 Nm (0.2 mkg)
Screw (seat): 10 Nm (1.0 mkg)
See section “CARBURETOR-INSTALLA-
TION” in CHAPTER 6.
10. Adjust:
•Throttle cable free play
Free play: 3 ~ 5 mm
Engine idle speed:1.150 ~ 1.450 rpm
See section “THROTTLE CABLE FREE
PLAY ADJUSTMENT” in CHAPTER 3.
11. Install:
•Fuel tank
Do not start the engine until it is filled with oil.
CAUTION:
12. Fill with:
•Engine oil Amount of oil (total): 3.0 litres
13. Check:
•Engine idle speed
See section “IDLE SPEED ADJUST-
MENT” in CHAPTER 3.
14. Install:
•Seat
See section “ENGINE OIL REPLACE-
MENT” in CHAPTER 3.
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CARBURETOR
6-4
CARB
(1) Carburetor assembly
(2) Cover gasket
(3) Gasket, nozzle
(4) Float
(5) Float pin
(6) Float chamber gasket
(7) Screw
(8) Float chamber fastening screw
(9) Spring washer
(10) Collar
(11) Screw
(12) Gasket (13) Throttle valve
spring
(14) Spring washer
(15) Nut
(16) Gasket
(17) Screw
(18) Stop screw
(19) Nut
(20) Screw
(21) Hose
(22) Diaphragm
(23) Cover
(24) Bracket
(25) O-ring
(26) Spring washer (27) Spring
(28) Drain valve
(29) Pipe
(30) Pipe
(31) Screw
(32) Screw
(33) Pipe
(34) Clip
(35) Main jet 1
(36) Main nozzle 1
(37) Throttle valve
(38) Pilot jet
(39) Main jet 2
(40) Main nozzle 2
(41) Pilot screw set (42) Needle valve set
(43) Stop screw set
(44) Throttle screw set
(45) Diaphragm
(46) Needle set 1
(47) Needle set 2
(48) Starter set
(49) Way 3
(50) Hose
(51) Hose
(52) Hose
(53) Clip
(54) Breather pipe
(55) O-ring
(56) Pipe
SPECIFICATIONS
Main jet #150 FIRST #145 SEC.
Starter jet #74
Needle jet 5C5A-3/5 ( FIRST) 5Y18-3/5 (SEC.)
Main nozzle ø 2,6
Pilot jet #50
Pilot air screw 2,75 ± 0,5 revs approx.,
open
Float height 27~29 mm
Fuel level 6~8 mm
Engine idle speed 1.150~1.450 r/min
Throttle valve seat ø 2,5 mm
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CARBURETOR ASSEMBLY
6-16
CARB
FUEL LEVEL ADJUSTMENT (CARBURE-
TOR INSTALLED
1. Place the motorcycle on a level surface.
2. Make sure that the carburetor is in a horizon- tal position by placing a hydraulic jack under
the engine.
Fuel level gauge: P/N. 90890-01312
4. Loosen drain screw (2) and heat the engine.
5. Measure:
•Fuel level (a)
Out of specification ➔Adjust.
Fuel level: 6.0 ~ 8.0 mm
Under the edge of the carburetor
body.
6. Adjust:
•Fuel level
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Fuel level adjustment:
•Remove carburetor assembly.
•Inspect valve seat and needle valve set.
•If either of the two is worn, replace both.
•If both are perfect, adjust float height by bend-
ing the wing tab of the float itself (1).
•Recheck the fuel level.
3. Connect the fuel level gauge (1) to the carbu- rettor nipple.
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