engine YAMAHA TT600RE 2004 Workshop Manual

INSP
ADJ
DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT
3-35

NOTE:
If bleeing proves difficult, it may be necessary to
allow the brake fluid system to stabilise for a few
hours. Repeat the bleeding procedure when the
tiny bubbles in the system have disappeared.
j. Top up fluid to the maximum level.
DRIVE CHAIN SLACK INSPECTION AND
ADJUSTMENT
Inspecting slack:
NOTE:
Before checking and/or adjusting the chain, rotate
the rear wheel through several revolutions and
check the slack several times to find the point on
the wheel where chain slack is highest.
Check and/or adjust chain slack with rear wheel in
this “tight chain” position.
Drive chain slack:
30 ~ 40 mm
NOTE:
To check chain slack, the motorcycle must stand
in an upright position with its two wheels touching
the ground and no one sitting on it. Check slack in
the position shown in the figure.
2. Adjust:
•Drive chain slack
Slack adjustment:
Too little chain slack will overload the engine
and other vital parts. Keep the slack within the
specified limits.
CAUTION: 1. Check:
•Drive chain slack (a)
Out of specification ➔Adjust.
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DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT/
DRIVE CHAIN LUBRICATION
3-36
INSP
ADJ
Rear wheel axle nut:
115 Nm (11.5 mkg)
•Turn each adjusting bolt exactly the same
amount to maintain correct axle alignment.
There are marks on each side of the
swingarm. Use these marks to align the rear
wheel.
DRIVE CHAIN LUBRICATION
The chain consists of many parts which work with
each other. If the chain is not maintained properly,
it will wear out quickly. Therefore, the chain must
be serviced regularly. This service is especially
necessary when riding in dusty areas. This motor-
cycle has a drive chain with small rubber O-Rings
between the chain plates. Steam cleaning, high-
pressure washing and certain solvents can dam-
age these O-Rings. Use only kerosene to clean
the drive chain. Wipe it dry, and thoroughly lubri-
cate it with SAE 80 ~ 90W motor oil or special lu-
bricant for O-Ring chains. Do not use any other lu-
bricants on the drive chain. They may contain sol-
vents that could damage the O-Rings.
Recommended lubricant:
SAE 80W/90 engine oil or
special lubricant for
O-Ring chains.
(1) O-Rings
•Loosen the axle nut (1).
•Loosen the locknuts (2) on each side. To tight-
en the chain, turn the chain adjusting bolts (3)
in direction (a). Loosen the locknuts on each
side. To loosen the chain, turn the chain
adjusting bolts in direction (b) and push the
wheel forward.
•After adjusting, tighten the locknuts (2). Then
tighten the axle nut (1) to the specified torque.
a
b
2
13
➩➩
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STEERING INSPECTION
3-40
INSP
ADJ
STEERING INSPECTION
WARNING
Hold the motorcycle firmly in place to prevent
it falling over.
1. Raise the front wheel and place a support
under the engine.
2. Check:
•Steering bearings
Grasp the bottoms of the front fork legs
and rock back and forward.
Free play ➔Adjust steering bearing.
3. Adjust:
•Steering bearing
Adjustment:
•Remove the fuel tank.
See section “SEAT, FUEL TANK AND REAR
COWLING”.
•Loosen steering axle nut (1) and fork upper
bracket screws (2).
•Tighten the ring nut (3) with the special
wrench.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
3
2
2
Ring nut (final tightening):
4 Nm (0.4 mkg)
Ring nut (initial tightening):
38 Nm (3.8 mkg)
Ringnut wrench:
P/N. 90890-01268
P/N. 90890-01348
NOTE:
The torque wrench and the ringnut wrench should
form a right angle.
WARNING
Do not tighten the ring nut excessively.
•Loosen the ring nut one turn.
•Retighten the ring nut using the special
wrench.
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CHASFRONT FORK
4-45
OIL CAPACITY (IN EACH FORK LEG): 650 cm3
RECOMMENDED OIL:
Liqui Moly Racing suspension oil SAE 7,5
FRONT FORK OIL LEVEL
STANDARD 180 mm
MINIMUM 190 mm
MAXIMUM 170 mm
From top of inner tube with inner tube fully com-
pressed without spring.
MINIMUM FORK SPRING FREE LENGTH:
530 mm
INNER TUBE BENDING LIMIT:
0.2 mm
1. Park the motorcycle on a level surface.
2. Raise the front wheel by placing a suitable support under the engine.
3. Remove:
•Front wheel
Refer to “FRONT WHEEL REMOVAL”
section.
4. Remove:
•Inner tube protector
•Protector guide
•Gear unit assembly and cable
•Brake caliper and hose
5. Loosen:
•Cap bolt
•Pinch bolt (upper and lower bracket)
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
FRONT FORK REMOVAL
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CHAS
4-64
STEERING
STEERING REMOVAL
1. Park the motorcycle on a level surface.
2. Raise the front wheel placing a suitable sup- port under the engine.
3. Remove:
•Front wheel
Refer to “FRONT WHEEL-REMOVAL”
section.
•Front fork
Refer to “FRONT FORK-REMOVAL” sec-
tion.
4. Remove:
•Front fender
•Cowling
•Handlebar
•Meter assembly
Ring nut wrench (3):
90890-01348
5. Remove:
•Steering axle nut (1)
Use the ring nut wrench (3).
WARNING
Support the motorcycle securely to prevent it
falling over.
6. Remove:
•Ring nut (upper) (1)
•Use the ring nut wrench (2)
Ring nut wrench (2):
90890-01268
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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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DRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-82
CHAS
DRIVE CHAIN, DRIVE SPROCKET AND
REAR WHEEL SPROCKET
NOTE:
Before removing the drive chain, drive sprocket
and rear wheel sprocket, it is necessary to meas-
ure the free play and length of the 10 links in the
chain.
DRIVE CHAIN REMOVAL
1. Park the motorcycle upright on an even sur- face.
2. Remove:
•Shift pedal (1)
•Cover (2) (drive sprocket)
3. Remove:
•Drive sprocket (1)
NOTE:
•Before removing the sprocket nut, straighten
the tab on the lock washer.
•Loosen the nut with the rear brake pulled.
4. Raise the rear wheel placing a suitable sup- port under the engine.
WARNING
Set the motorcycle up securely to prevent it
falling over.
5. Remove:
•Rear wheel
•Rear wheel sprocket
•Hub
•Damper
•Spacer
Refer to “REAR WHEEL REMOVAL” sec-
tion.


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DRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-84
CHAS
3. Inspect:
•Seal rings (1) (drive chain)
Damaged ➔Replace drive chain.
•Rollers (2)
•Lateral plates (3)
Damage/Wear ➔Replace drive chain.
4. Lubricate:
•Drive chain
Lubricant for drive chain: SAE 80W/90 engine oil or special
lubricant for O-Ring chains.
5. Inspect:
•Drive chain
Rigid ➔Clean and lubricate, replace if
necessary.
6. Inspect:
•Drive sprocket
•Rear wheel sprocket
Wear over 1/4 tooth (1) ➔Replace.
Teeth bent ➔Replace.
(2) Undamaged tooth profile
(3) Roller
(4) Sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
How to replace the rear wheel sprocket:
With wheel removed:
1. Remove:
•Hub (1)
•Sprocket fastening bolts (2)
•Rear wheel sprocket (3)
2. Install:
•New sprocket (3)
•Sprocket fastening bolts (2)
•Hub (1)
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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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