fuel YAMAHA TT600RE 2004 Owner's Manual

CHASREAR SHOCK ABSORBER
4-69
Order Job name/Part name Q.ty Remarks Shock absorber removal Remove the parts in order.
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
Seat Refer to “SEAT, FUEL TANK AND REAR
Fuel tank
Rear cowling COWLING” section in Chapter 3.
Battery leads 2 Disconnect. NOTE:
First, disconnect the negative lead, then the
positive lead.
1 Muffler 1
2 Exhaust pipe assembly 1 Refer to “REAR SHOCK ABSORBER RE-
3 Rear frame 1 MOV AL” section.
4 Brake fluid reserve tank 1 Secure the brake fluid tank to the frame in
5 Air filter case 1 an upright position to avoid air entering the hydraulic system.
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CHASREAR SHOCK ABSORBER
4-73
SHOCK ABSORBER REMOVAL
WARNING
Support the motorcycle securely to prevent it
from falling over.
1. Park the motorcycle on a level surface.
2. Remove:
•Seat
•Rear cowling
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING” in CHAPTER 3.
3. Disconnect:
•Battery leads
8. Remove:
•Upper mounting bolt (1)
•Rear shock absorber
1
NOTE:
First, disconnect the negative lead, then the posi-
tive lead.
4. Remove:
•Exhaust pipe assembly
•Rear frame
•Air filter case
5. Raise the rear wheel placing a suitable sup- port under the engine.
6. Remove:
•Rear wheel
Refer to “REAR WHEEL REMOVAL” sec-
tion.
7. Remove:
•Shock absorber fastening nut (1)
•Lower mounting bolt
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CHASSWINGARM
4-81
Drive chain slack: 30 ~ 40 mm
Refer to “DRIVE CHAIN SLACK ADJUST-
MENT” in CHAPTER 3.
5. Install:
•Fuel tank
•Rear cowling
•Seat
Bolt (seat): 10 Nm (1.0 mkg)
Refer to “SEAT, FUEL TANK AND REAR
COWLING” section in CHAPTER 3.
4. Adjust:
•Drive chain slack
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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
5-5
ENGINE DISASSEMBLY
CYLINDER HEAD, CYLINDER, CAMSHAFT
AND PISTON
NOTE:
The cylinder head, cylinder, camshaft and piston
can be examined with the engine installed by
removing the following parts.
•Seat
•Fuel tank
•Rear cowling
•Carburetor
•Exhaust pipe
1. Remove:
•Spark plug (1)
•Tappet cover (2) (intake)
•Tappet covers (3) (exhaust)
•Cylinder head cover (4)
•Cap (5)
•Pins (6)
2. Loosen:
•Bolt (1) (chain tensioner)
3. Remove:
•Chain tensioner (2)
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ENGINE DISASSEMBLY
5-18
ENG
ROCKER ARMS
NOTE:
The rocker arms may be examined with the
engine installed by removing the following parts.
•Seat
•Fuel tank
•Cylinder head cover
1. Remove:
•Cap (1)
2. Remove:
•Bolts (1) (rocker shaft)
3. Remove:
•Rocker shaft
•Rocker arms
NOTE:
Remove the rocker shaft using sliding hammer (1)
and weight (2).
Sliding hammer bolt: P/N. 90890-01083
Weight: P/N. 90890-01084
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ENGENGINE DISASSEMBLY
5-19
VALVES
NOTE:
The valves may be inspected with the engine
installed by removing the following parts.
•Seat
•Fuel tank
•Exhaust pipe
•Carburetor
•Cylinder head cover
•Cylinder head
1. Check:
•Valve seal
Leakage from valve seats’ Inspect the
valve surface, the seat and seat width.
See section “VALVE SEAT INSPECTION
AND REPAIR”.
NOTE:
Check the valve seal before assembling the inter-
nal parts of the cylinder head (valves, valve
springs, spring retainer etc).
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▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Inspection steps:
•Pour clean solvent (1) into the intake and
exhaust ports.
•Check the valve seal. There must be no blow-
bys from the valve seats (2).
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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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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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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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