clutch YAMAHA TT600RE 2004 Owner's Manual

CLUTCH ADJUSTMENT
3-22
INSP
ADJ
NOTE:
After adjustment, recheck lever free play to make
sure that it works smoothly and progressively.
If it is impossible to obtain the required adjust-
ment or if the clutch does not work properly,
adjust the internal mechanism.
Internal mechanism adjustment
1. Loosen:
•Lock nuts on the lever cable adjuster and
crankcase adjuster
2. Fully tighten:
•Adjusters
3. Drain off:
•Engine oil
See section “ENGINE OIL REPLACE-
MENT”.
4. Remove:
•Footrest (right) (1)
•Engine protector (2)
5. Disconnect:
•Brake pedal return spring (3)
6. Remove:
•Rear master cylinder fastening screws (4)
•Oil delivery hose fastening screw (5)
•Right crankcase cover fastening screws
•Right crankcase cover (6)
7. Loosen:
•Lock nut (1)
8. Push the engine clutch control lever forward
to the stop point.
9. Adjust:
•Free play
With the lever in this position, turn the
adjuster (2) either way until the marks on
the lever (3) and crankcase (4) are
aligned.
10. Tighten:
•Lock nut (1)
Lock nut:
8 Nm (0.8 mkg)
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INSP
ADJ
CLUTCH ADJUSTMENT
3-23
11. Install:
•Right crankcase cover
•Right crankcase cover fastening screws
•Oil delivery hose fastening screw
Screw (crankcase cover):
10 Nm (1.0 mkg)
Oil delivery hose screw:
18 Nm (1.8 mkg)
Screw (rear master cylinder):
10 Nm (1.0 mkg)
Bolt (footrest):
48 Nm (4.8 mkg)
12. Connect:
•Brake pedal return spring
•Rear master cylinder
13. Reassemble:
•Footrest (right)
Free play (at lever tip):
10 ~ 15 mm
See section “Cable free play adjustment”.
•Engine protector
14. Fill:
•Engine oil tank
See section “ENGINE OIL REPLACE-
MENT”.
15. Adjust:
•Clutch cable free play
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INSP
ADJCABLE INSPECTION/
LEVER AND PEDAL LUBRICATION
3-45
CABLE INSPECTION
WARNING
If the cable sheath is damaged, corrosion
might ensue or the cable might not run freely.
To avoid such drawbacks, replaced damaged
cables as quickly as possible.
1. Inspect:
•Cable sheath
Damaged ➔Replace the cable assembly.
2. Check:
•Cable functioning
Does not run freely ➔Replace the cable
assembly.
LEVER AND PEDAL LUBRICATION
1. Lubricate the pivoting parts:
•Clutch lever
•Front brake lever
•Rear brake pedal
•Shift pedal
Recommended lubricant:
SAE 10W30 motor oil
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ENG
CHAPTER 5. ENGINE
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
MUFFLER, EXHAUST PIPE, ENGINE PROTECTOR, DRIVE SPROCKET,
CRANKCASE COVER, DRIVE SPROCKET AND SHIFT PEDAL . . . . . . . . . . . . . . . 5-1
ENGINE MOUNTING BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CYLINDER HEAD, CYLINDER, CAMSHAFT AND PISTON . . . . . . . . . . . . . . . . . . . . 5-5
INTERMEDIATE STARTER GEAR, CRANKCASE COVER (L)
AND GENERATOR STATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
CRANKCASE COVER (R), CLUTCH, PRIMARY DRIVE GEAR
AND BALANCER SHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
OIL PUMP AND SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
AC GENERATOR AND TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
CRANKCASE(R). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
GEARBOX AND TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
BALANCER SHAFT AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
OILSTRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
VALVESEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
ROCKER ARMS AND ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
CAMSHAFT CHAIN AND SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
CAMSHAFT CHAIN GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
PISTONPIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
OILPUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
PRIMARY TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
TRANSMISSION AND GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
SHIFT SHAFT AND STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
STARTER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
BALANCER SHAFT DRIVE
AND DRIVEN GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
BEARING AND OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
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ENG
ENGINE ASSEMBLY AND SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
VALVES AND ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
CRANKSHAFT AND BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
TRANSMISSION AND GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
ENGINE OIL PUMP AND OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
ENGINE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
SHIFT SHAFT AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
PISTON AND RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
CAMSHAFT AND TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
PISTON, CYLINDER, CYLINDER HEAD AND CAMSHAFT . . . . . . . . . . . . . . . . . . . 5-59
AC GENERATOR.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
OIL FILTER AND OIL HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
BALANCER SHAFT GEAR AND PRIMARY
TRANSMISSION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
STARTER GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
STARTER NEUTRAL GEAR AND CRANKCASE COVER (L) . . . . . . . . . . . . . . . . . 5-74
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
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ENGINE REMOVAL
5-2
ENG
Order Job name/Part name Q.ty Remarks Drain the engine oil (refer to “ENGINE OIL
REPLACEMENT” section in CHAPTER
3). Remove the seat, the fuel tank and
the rear cowling (refer to “SEAT, FUEL
TANK AND REAR COWLING” section in
CHAPTER 3).
1 Battery leads connector 1 Disconnect.
2 Muffler 1
3 Exhaust pipe 1
4 Engine protector 1
5 Shift pedal 1
6 Drive sprocket crankcase cover 1
7 Drive sprocket 1 Displace the drive chain.
8 Clutch cable 1 Disconnect.
9 Plug cap 1 Disconnect.
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ENGENGINE DISASSEMBLY
5-9
4. Remove:
•Crankcase cover gasket (1) (L)
•Centring pins
•Seal ring and O-ring
•Gasket
6. Remove:
•Cable clamp (1)
•Coil (2)
•Stator (3)
CRANKCASE COVER (R), CLUTCH, PRIMARY
DRIVE GEAR AND BALANCER SHAFT GEAR
NOTE:
The clutch, the primary gear and the balance gear
may be inspected with the engine installed by
removing the following parts.
•Footrest (R)
•Oil delivery hose screw
5. Remove:
•Intermediate starter gear (1)
•Bearing (2)
•Distributor shaft (3)
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ENGINE DISASSEMBLY
5-10
ENG
2. Remove:
•Compression spring (1)
•Pressure plate (2)
•Ball (3)
•Friction plate (4)
•Clutch plate (5)
•Clutch boss spring (6)
•Clutch boss (7)
•Thrust plate (8)
•Clutch shroud (9)
•Push rod (10)
1. Remove:
•Engine oil delivery hose screw
•Copper washer
•Oil filter cover (1)
•Oil filter
•Seal ring and O-Ring
•Crankcase cover (2) (R)
NOTE:
•Before loosening the nut (11) (clutch shroud),
straighten the washer lock tab.
•To loosen the nut (clutch boss), block the
clutch boss using the special tool (12).
Clutch holding tool: P/N. 90890-04086
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ENGINE DISASSEMBLY
5-12
ENG
OIL PUMP AND SHIFT LEVER
NOTE:
The oil pump and shift lever may be checked with
the engine installed by removing the following
parts:
•Footrest (R)
•Oil delivery hose screw
•Crankcase (R)
•Clutch
1. Remove:
•Circlip (1)
•Oil pump gear (2)
•Oil pump (3)
•O-rings (4)
2. Remove:
•Circlip (1) (from drive shaft)
•Ring (2)
•Circlip (3)
3. Remove:
•Circlip (1)
•Shift lever (2)
•Spring (3)
•Flat washer (4)
4. Remove:
•Stopper lever (1)
•Ring (2)
•Spring (3)
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ENGINSPECTION AND REPAIR
5-33
PISTON PIN
1. Check:
•Piston pin
Blue colour/Grooves ➔Replace and
check lubrication system.
External diameter (pin): 21.991 ~ 22.000 mm
Clearance between piston pin and pin
seat on piston: 0.004 ~ 0.024 mm
: 0.07 mm
2. Measure:
•External diameter (a) of pin
Out of specification ➔Replace.
3. Measure:
•Clearance between piston pin and pin
seat
Out of specification ➔Replace.
Clearance between piston pin and
piston = Diameter of pin seat on piston (b) –
Diameter of pin (a)
CLUTCH
1. Inspect:
•Clutch gear assy teeth
Cracks/Pitting (on edges):
Moderate ➔Burr.
Accentuated ➔Replace clutch gear assy.
NOTE:
Pitting of the gear assy teeth causes irregular
functioning.
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