YAMAHA TT600RE 2004 Service Manual

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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6
CARB
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CARB
CHAPTER 6
CARBURETOR
CARBURETOR REMOVAL ................................................................................................ 6-1
TECHNICAL SPECIFICATIONS/TIGHTENING TORQUES/EXPLODED VIEW .............. 6-3
SECTION VIEW .......................................................................................................... 6-5
CARBURETOR DISASSEMBLY ........................................................................................ 6-6
CARBURETOR INSPECTION .......................................................................................... 6-9
CARBURETOR ASSEMBLY .............................................................................................. 6-11
FUEL LEVEL ADJUSTMENT (CARBURETOR INSTALLED) .......................................... 6-16
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CARB
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CARBCARBURETOR REMOVAL
6-1
CARBURETOR
CARBURETOR REMOVAL
Order Job name/Part name Q.ty Remarks Carburetor removal Remove the parts in order.
Seat Refer to “SEAT, FUEL TANK AND REAR
COWLING" section in CHAPTER 3.
Fuel pipe NOTE:
Fuel tank Be sure the cap is properly tightened and the fuel cock is in the “OFF” position before
removing the fuel tank.
1 Lock nut 4 Loosen.
2 Throttle cable adjuster 2 Screw.
3 Throttle cable 2
4 Hose clamp 2 Loosen.
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CARBURETOR REMOVAL
6-2
CARB
Order Job name/Part name Q.ty Remarks 5 Hose clamp 2 Loosen.
NOTE:
Move carburetor manifold clamps towards
the rear side.
6 Carburetor 2 Reverse the removal procedure for installa-
tion.
Adjust throttle cable free play (refer to
THROTTLE CABLE FREE PLAY ADJUST-
MENT” section in CHAPTER 3).
Adjust idle speed (refer to “IDLE SPEED AD-
JUSTMENT” section in CHAPTER 3).
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CARBCARBURETOR
6-3
TYPE: Y30PV-2ATK
MANUFACTURER: TEIKEI
3,5 Nm (0.35 m .
kg, 2.5 ft .
lb)
6 Nm (0.6 m .
kg, 4.3 ft .
lb)
8 Nm (0.8 m .
kg, 5.9 ft .
lb)
2 Nm (0.2 m .
kg, 1.4 ft .
lb)
2 Nm (0.2 m .
kg,
1.4 ft .
lb)
9 Nm (0.9 m .
kg, 6.3 ft .
lb)
2 Nm
(0.2 m .
kg,
1.4 ft .
lb)
2 Nm (0.2 m .
kg, 1.4 ft .
lb)
3 Nm (0.3
m .
kg, 2.1 ft .
lb)
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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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CARBCARBURETOR
6-5
SECTION VIEW
(1) Needle jet (primary)
(2) Valve seat
(3) Needle valve
(4) Main nozzle (primary)
(5) Main jet (primary)
(6) Pilot air screw
(7) Needle jet (secondary)
(8) Main nozzle (secondary)
(9) Main jet (secondary)
[A] Primary carburetor
[B] Secondary carburetor Air
Fuel
Mixture
AB
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