clutch YAMAHA TT600RE 2004 Owner's Guide

INSPECTION AND REPAIR
5-34
ENG
2. Inspect:
•Clutch gear assy bearing
Damaged ➔Replace.
3. Inspect:
•Groove in clutch boss.
Pitting:
Moderate ➔Burr.
Accentuated ➔ Replace clutch boss.
NOTE:
Pitting of the clutch boss grooves causes irregular
functioning.
4. Measure:
•Thickness of friction plates
Out of specification ➔Replace all plates.
Thickness Wear
limit
Type “A” 2.94 ~ 3.06 mm 2.8 mm
(2 parts)
Type “B” 2.72 ~ 2.88 mm 2.6 mm
(6 parts)
5. Measure:
•Deformation of clutch plates
Out of specification ➔Replace all plates.
Clutch plates deformation: : 0.2 mm
Clutch push rod runout:: 0.2 mm
6. Measure:
•Runout limit of clutch push rod.
Turn clutch push rod on two V blocks.
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ENGINSPECTION AND REPAIR
5-35
7. Measure:
•Free length of clutch compression springs
(a)
Out of specification ➔Replace all springs.
OIL PUMP
1. Measure:
•Clearance between rotors (a)
(Between the internal rotor (1) and the
external rotor (2))
•Side clearance (b)
(Between the external rotor (2) and the
pump stator (3))
Out of specification ➔Replace oil pump.
Free length of clutch compression
spring (a): 42.8 mm
Oil pump clearances:
Clearance between 0.12 mm
rotors (a) : 0.2 mm
Side clearance (b) 0.03 ~ 0.08 mm
: 0.15 mm
2. Inspect:
•Oil pump drive gear (1)
•Oil pump driven gear (2)
Wear/Cracks/Damage ➔Replace.
PRIMARY TRANSMISSION
1. Inspect:
•Primary drive gear teeth (1)
•Primary driven gear teeth (2)
Wear/Damage ➔Replace both gears.
Excess noise during functioning ➔
Replace both gears.
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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
5-70
ENG
CLUTCH
(1) Compression spring
(2) Pressure plate
(3) Push rod
(4) Ball
(5) Friction plate (type A)
(6) Clutch boss spring
(7) Clutch plate
(8) Friction plate (type B) (9) Clutch boss
(10) Thrust plate
(11) Primary driven gear comp.
(12) Push rod
(13) Push lever
(14) Primary drive gear
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ENGENGINE ASSEMBLY AND SETTING
5-71
CLUTCH
1. Install:
•Plain washer
•Spring
•Push lever (1)
Screw (push lever): 12 Nm (1.2 mkg)
2. Install:
•Push rod (1)
•Primary driven gear comp. (2)
•Thrust plate (3)
•Clutch boss (4)
•Lock washer (5)
•Nut (6) (clutch boss)
•Clutch boss spring (7)
•Clutch plate (8)
•Friction plate (9)
•Ball (10)
•Pressure plate (11)
•Compression spring (12)
•Screw (pressure plate) (13)
Nut (clutch boss): 90 Nm (9.0 mkg)
Pressure plate screw: 8 Nm (0.8 mkg)
NOTE:
•To tighten the nut (clutch boss), lock the clutch
drum with the special tool (14).
Clutch holding tool: P/N. 90890-04086
•Bend the lock washer tab along the face of the
nut.
WARNING
Always use a new lock washer.
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ENGINE ASSEMBLY AND SETTING
5-72
ENG
NOTE:
Install the friction and clutch plates to the clutch
boss, beginning and ending with a friction plate.
•The two friction plates (type A) (15) with
the widest internal diameter should be
assembled in second and last place.
•The clutch boss spring (16) should be
placed inside the second friction plate.
CAUTION:
Friction plate
Type “A” Type “B”
Quantity 2 6
Internal 116 mm 113 mm
diameter “D”
NOTE:
Align the mark on the clutch boss (17) with the
arrow (18) on the pressure plate.
3. Adjust:
•Clutch (free play)
See section “CLUTCH ADJUSTMENT” in
CHAPTER 3.
4. Install:
•Straight key
•Gasket
•Crankcase cover (right) (1)
•O-Ring
•Oil filter
•Filter cover (2) (with O-Ring)
See section “Engine oil replacement (with
oil filter change)” in CHAPTER 3.
Bolt (crankcase cover): 10 Nm (1.0 mkg)
16
15
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ENGENGINE ASSEMBLY AND SETTING
5-73
STARTER GEARS
(1) Starter gear
(2) Starter neutral gear 1
(3) Starter neutral gear 2
(4) Starter gear
(5) Starter clutch
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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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ELECTRICAL CIRCUIT DIAGRAM
7-2
ELEC
B Black B/Y Black/Yellow
Br Brown Br/B Brown/Black
Ch Chocolate Br/W Brown/White
Dg Deep green G/B Green/Black
G Green G/R Green/Red
Gy Grey G/W Green/White
L Blue G/Y Green/Yellow
Or Orange L/R Blue/Red
P Pink L/W Blue/White
R Red L/Y Blue/Yellow
Sb Sky-blue R/B Red/Black
W White R/W Red/White
Y Yellow R/Y Red/Yellow
B/R Black/Red W/L White/Blue
B/W Black/White Y/R Yellow/Red
(1) AC generator/Pickup coil
(2) Rectifier/Regulator
(3) Battery
(4) Starter relay
(5) Starting motor
(6) Fuse
(7) Main switch
(8) Right handlebar switch
(9) Engine stop switch
(10) Starter switch
(11) Diode
(12) Clutch switch
(13) Sidestand switch
(14) Neutral switch
(15) Diode
(16) Ignitor unit
COLOUR CODE (17) Ignition coil
(18) Left handlebar switch
(19) Horn switch
(20) Diode
(21) Pass switch
(22) Dimmer switch
(23) Flasher switch
(24) Horn
(25) Flasher relay
(26) Headlight
(27) Flasher light
(28) Relay assy
(29) Front brake switch
(30) Rear brake switch
(31) Tail/stop light
(32) Meter
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