YAMAHA TT600RE 2004 Service Manual

CARBURETOR DISASSEMBLY
6-6
CARB
CARBURETOR DISASSEMBLY
1. Remove:
•Support plate (1) (front)
•Support plate (2) (rear)
2. Separate:
•Primary carburetor
•Secondary carburetor
Primary carburetor
1. Remove:
•Float chamber (1)
•Float pin (2)
•Float (3)
NOTE:
Remove the float needle in the direction of the
arrow.
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CARBCARBURETOR DISASSEMBLY
6-7
2. Remove:
•Needle valve set/Valve seat (1)
•Main jet/Main nozzle 1 (2)
•Pilot jet (3)
•Pilot screw set (4)
•O-Ring (5)
3. Remove:
•Stop screw (1)
•Starter set (2)
4. Remove:
•Cover (1) (enrichment)
•Spring (2)
•Diaphragm (3)
5. Remove:
•Top cover (1)
•Cover gasket (2)
•Screw (3) (connecter comp.)
6. Remove:
•Throttle lever (1)
•Collar (2)
•Cable holder (3)
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CARBURETOR DISASSEMBLY
6-8
CARB
7. Remove:
•Throttle shaft (1)
•Spring (2)
8. Remove:
•Connecter comp. (1)
•Needle jet (2)
•Throttle valve (3)
Secondary carburetor
1. Remove:
•Drain plug (1)
•Main jet (2)
2. Remove:
•Top cover (1)
•Spring (2)
3. Remove:
•Diaphragm (1)
•Needle jet 2 (2)
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CARBCARBURETOR INSPECTION
6-9
CARBURETOR INSPECTION
1. Inspect:
•Carburetor body
Soiled ➔Clean.
NOTE:
Use petroleum-based solutions to clean. Clean all
passages and jets with compressed air.
2. Inspect:
•Valve seat (1)
•Needle valve set (2)
Wear/Corrosion ➔Replace.
•O-Ring (3)
Damaged ➔Replace.
NOTE:
Always replace the needle valve set and the valve
seat together.
3. Inspect:
•Starter piston (1)
Wear/Damage ➔Replace
•Stop screw (2)
Damaged ➔Replace.
4. Inspect:
•Diaphragm (1) (piston valve)
•Diaphragm (2) (enrichment)
Damaged ➔Replace.
5. Inspect:
•Needle jet (1) (primary)
•Needle jet (2) (secondary)
Curvature/Wear ➔Replace.
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CARBURETOR INSPECTION
6-10
CARB
6. Inspect:
•Throttle valve (1) (primary)
•Diaphragm (2) (secondary)
ear/Damaged ➔Replace.
7. Check:
•Free movement
Hampered ➔Replace.
Fit the throttle valve and diaphragm into
the carburetor body and check that move-
ment is free.
[A] Primary carburetor
[B] Secondary carburetor
8. Inspect:
•Float (1)
Damaged ➔Replace.
9. Inspect:
•Main jet (1) (primary)
•Main jet (2) (secondary)
•Main nozzle (3) (primary)
•Main nozzle (4) (secondary)
•Pilot jet (5)
NOTE:
Clean jets with compressed air.
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CARBCARBURETOR ASSEMBLY
6-11
CARBURETOR ASSEMBLY
Perform “CARBURETOR DISASSEMBLY” opera-
tions in reverse order. Pay attention to the follow-
ing points.
Wash all parts with clean petrol prior to
reassembly.
CAUTION:
Secondary carburetor
1. Install:
•Needle jet (1)
•Diaphragm (2)
•Spring
NOTE:
Draw the diaphragm tab level with the notch on
the secondary carburetor.
2. Install:
•Top cover
Screw (top cover): 2 Nm (0.2 mkg)
Main jet (secondary): 2 Nm (0.2 mkg)
Drain valve: 9 Nm (0.9 mkg)
3. Install:
•Main jet (secondary)
•Drain vavle
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CARBURETOR ASSEMBLY
6-12
CARB
Primary carburetor
1. Install:
•Needle jet (1)
•Connecter comp. (2)
NOTE:
Check that the connecter comp. (1) is in the posi-
tion shown in the figure.
2. Install:
•Throttle valve
3. Install:
•Spring
•Throttle shaft
NOTE:
Assemble the spring as shown in the illustration.
4. Install:
•Screw (connecter comp.)
NOTE:
Turn the throttle shaft clockwise (1/2 turn) to pre-
load the spring and then, holding it in position,
assemble the screw (connecter comp.).
Screw (connecter camp.): 2 Nm (0.2 mkg)
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CARBCARBURETOR ASSEMBLY
6-13
5. Install:
•Cable holder
•Collar
•Throttle lever
NOTE:
Check that the throttle shaft lever (2) and the
adjuster bolt (3) are aligned when tightening the
throttle nut (1).
Screw (cable holder): 3 Nm (0.3 mkg)
Screw (top cover): 2 Nm (0.2 mkg)
Starter piston: 6 Nm (0.6 mkg)
Main nozzle 1: 2 Nm (0.2 mkg)
Screw (valve seat): 2 Nm (0.2 mkg)
6. Install:
•Top cover
7. Install:
•Diaphragm (1) (enrichment)
NOTE:
Make the diaphragm tab coincide with the gravity
enricher notch.
9. Install:
•Pilot screw set (1)
•Pilot jet (2)
•Main nozzle 1 (3)
•Main jet (primary) (4)
•Valve seat (5)
8. Install:
•Starter set
•Stop screw
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CARBURETOR ASSEMBLY
6-14
CARB
10. Install:
•Float pin (1)
NOTE:
Assemble the float pin in the opposite direction to
the arrow.
11. Measure:
•Float height (a)
Out of specification ➔Adjust.
Float height: 27.0 - 29.0 mm
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Measurement and adjustment:
•Hold the carburetor upside down.
•Measure the distance from the joint plane of
the float chamber (without the gasket) and the
top of the float.
NOTE:
The float arm must rest on the neeedle valve
without being pressed.
•If the float height is out of tolerance, check the
valve seat and the needle valve.
•If either is worn, replace both.
•If both are perfect, adjust the float height by
bending the wing tab of the float itself (1).
•Recheck the float height.
12. Install:
•Float chamber
Screw (float chamber): 2 Nm (0.2 mkg)
13. Adjust:
•Pilot air screw (1)
Adjustment:
•Turn the screw until it is slightly locked.
•Unscrew by 3 and 1/2 turns.
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CARBCARBURETOR ASSEMBLY
6-15
14. Install:
•Primary carburetor
•Secondary carburetor
15. Install:
•Support plate (front) (1)
•Support plate (rear) (2) Screw (support plate): 3.5 Nm (0.35 mkg)
16. Adjust:
•Synchronisation of secondary carburetor
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Adjustment:
•Move the primary throttle valve (1) to a height
of 7.0 mm as shown in the figure.
•Tighten or loosen the synchronisation screw
(1) until the secondary throttle valve (2) starts
to open.
•Check that the secondary throttle valve is
open horizontally (a)=(b) when the primary
throttle valve is completely open
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