transmission YAMAHA TT600RE 2004 User Guide

ENGINSPECTION AND REPAIR
5-37
6. Inspect:
•Gear teeth
Brown colouring/Pitting/Wear ➔Replace.
•Mating clutches
Rounded edges/Cracks/Missing frag-
ments ➔Replace.
7. Check:
•Proper mating of each gear (with corre-
sponding part)
•Gear movement
Roughness ➔Replace.
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Transmission gear assembly steps:
•Fit the second gear (2) to the propeller shaft
(1) as shown in the figure.
(a) 60.0 mm
•Fit the second sprocket (4) and fifth sprocket
(5) to the main shaft (3).
(b) 90.5 mm
8. Inspect:
•Circlip
Damage/Loosening/Bending ➔Replace.
SHAFT AND STOPPER LEVER
1. Inspect:
•Shift shaft
Bent/Wear/Damage ➔Replace.
2. Inspect:
•Stopper lever (1)
The roller rotates jerkily ➔Replace.
Bent/Damage ➔Replace.
3. Inspect:
•Return spring (2)
Damage/Cracks ➔Replace.
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•Install the starter rim on the gear and hold
the gear firm.
•When turning the gear rim in a clockwise
direction (A), the gear and rim must be
meshed. Otherwise, the gear is faulty and
must be replaced.
•When the gear rim is turned in a anti-
clockwise direction (B), it must turn freely.
Otherwise, the gear is faulty and must be
replaced.
INSPECTION AND REPAIR
5-38
ENG
STARTER TRANSMISSION
1. Check:
•Starter clutch functioning (1).
Turn the clutch in the direction indicated
by the arrow.
Irregular functioning/Damage ➔ Replace
the clutch.
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2. Inspect:
•Starter neutral gear teeth (1)
•Starter neutral gear teeth (2)
•Starter rim teeth (3)
Burrs/Shavings/Roughness/Wear ➔
Replace.
3. Inspect:
•Starter rim (contact surfaces)
Pitting/Wear/Damage ➔ Replace.
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ENGINE ASSEMBLY AND SETTING
5-46
ENG
TRANSMISSION
(1) Sprocket
(2) Oil seal
(3) Bearing
(4) Second wheel gear
(5) Secondary shaft
(6) Fifth wheel gear
(7) Third wheel gear
(8) Fourth wheel gear
(9) First wheel gear (10) Bearing
(11) Bearing
(12) Second sprocket gear
(13) Fifth sprocket gear
(14) Third sprocket gear
(15) Fourth sprocket gear
(16) Main shaft
(17) Bearing
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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
5-51
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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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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ELECELECTRICAL STARTING SYSTEM
7-23
STARTING CIRCUIT OPERATION
The starting circuit on this model consists of the
starter motor, starter relay, and the starting circuit
cut-off relay. If the engine stop switch is on “RUN”
and the main switch is on “ON” (both switches are
closed), the starter motor can operate only if:
The starting circuit cut-off relay prevents the
starter from operating when neither of these con-
ditions have been met. In this instance, the start-
ing circuit cut-off relay is open so current cannot
reach the starter motor.
When at least one of the above conditions have
been met however, the starting circuit cut-off relay
is closed, and the engine can be started by press-
ing the starter switch.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE CLUTCH LEVER IS PULLED IN
1 Battery
2 Main switch
3 Engine stop switch
4 Starter relay
5 Starting circuit cut-off relay
6 Start switch
7 Starter motor
8 Neutral switch
9 Clutch switch
0 Sidestand switch
The transmission is in neutral (the neutral
switch is closed). or if
The clutch lever is pulled to the handlebar (the
clutch switch is closed) and the sidestand is up
(the sidestand switch is closed).
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DIFFICULTIES IN SHIFTING
8-4
TRBL
SHTG
?
Clutch
Engine oil PROBABLE CAUSES•Clutch cable wrongly set
•Wrong position of push lever
•Irregular engagement of push lever and push
rod
•Pressure plate deformed
•Clutch springs not preloaded uniformly
•Reference marks not aligned
•Push rod broken
•Clutch gear assy nut loose or push rod deformed
•Primary driven gear bearing defective
•Driven plates deformed
•Driving plates deformed
•Clutch cable damaged
•Oil level over maximum
•Incorrect gradation (high viscosity)
•Degradation
SHIFTING IMPOSSIBLE
DIFFICULTIES IN SHIFTING
Shift shaft
Shift cam, shift fork PROBABLE CAUSES•Shift shaft deformed
•Groove with impurities or foreign bodies
•Shift fork stuck
•Shift fork guide bar deformed
THE SHIFT PEDAL FAILS TO MOVE
Transmission•Transmission gears struck
•Gears stuck by impurities or foreign bodies
•Wrong transmission assembly
Shift shaft
Shift fork PROBABLE CAUSES•Shift lever set wrongly
•Shift cam
stop lever fails to return freely
•Shift forks worn
Transmission
•Gear clutches worn
DISENGAGING GEARS
Shift cam
•Shaft cam with thrust free play
•Shift cam groove worn
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