engine oil YAMAHA TT600RE 2004 Workshop Manual

ENGENGINE ASSEMBLY AND SETTING
5-43
ROCKER ARMS
1. Lubricate:
•Rocker shaft (apply engine oil)
2. Install:
•Rocker arm
•Rocker shaft
Screws (1) (rocker shaft): 10 Nm (1.0 kgm)
NOTE:
Each rocker arm is numbered.
(1) # 1
(2) # 2
(3) # 3
(4) # 4
3. Install:
•Cap (1)
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ENGENGINE ASSEMBLY AND SETTING
5-45
CRANKSHAFT AND BALANCER SHAFT
1. Install:
•Crankshaft
Crankshaft installation tool (1):
P/N. Y U-90050
Crankshaft installation tool spacer (2):
P/N. 90890-01274
Crankshaft installation tool bolt (3):
P/N. 90890-01275
Adapter # 10 (Ml 4) (4):
P/N. Y M-90069
P/N. 90890-04059
Crank spacer (5):
P/N. YM-91044
P/N. 90890-04081
Spacer (6):
P/N. 90890-01016
NOTE:
Hold the connecting rod at top dead centre with
one hand and turn the assembly tool nut with the
other.
Work on the assembly tool until the lower part of
the crankshaft enters into contact with the bear-
ings.
To protect the crankshaft from scratches and
facilitate assembly operations, apply grease
to the edges of the oil seals and engine oil to
the bearings.
CAUTION:
2. Install:
•Balancer shaft (1)
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ENGINE ASSEMBLY AND SETTING
5-46
ENG
TRANSMISSION
(1) Sprocket
(2) Oil seal
(3) Bearing
(4) Second wheel gear
(5) Secondary shaft
(6) Fifth wheel gear
(7) Third wheel gear
(8) Fourth wheel gear
(9) First wheel gear (10) Bearing
(11) Bearing
(12) Second sprocket gear
(13) Fifth sprocket gear
(14) Third sprocket gear
(15) Fourth sprocket gear
(16) Main shaft
(17) Bearing
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ENGENGINE ASSEMBLY AND SETTING
5-47
GEARBOX
(1) Stopper lever
(2) Guide bar
(3) Shift fork #3
(4) Shift fork #1
(5) Shift cam
(6) Guide bar
(7) Shift fork #2
(8) Shift shaft #1
(9) Shift shaft #2
(10) Oil seal
(11) Shift lever
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ENGENGINE ASSEMBLY AND SETTING
5-49
ENGINE OIL PUMP AND OIL STRAINER
(1) Oil strainer
(2) Oil pump
(3) Oil pump gear
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ENGENGINE ASSEMBLY AND SETTING
5-51
ENGINE OIL STRAINER
1. Install:
•Oil strainer (1)
•Oil passage cover (2)
Screw (oil strainer): 7 Nm (0.7 mkg)
Screw (oil passage cover): 7 Nm (0.7 mkg)
WARNING
Always use a new gasket.
Yamaha bond N° 1215 ®
:
P/N. 90890-85505
2 Install:
•Dowel pin (2)
3. Assemble the left crankcase to the right. Beat gently with a soft hammer.
NOTE:
Turn the shift cam as shown in the figure so that
it does not interfere with the crankcase during
assembly.
CRANKCASE
1. Apply:
•Yamaha bond N° 1215 ®
(1)
(on the crankcase mating surfaces)
Before installing and tightening the fastening
screws, be sure that the transmission is work-
ing properly by hand, turning the shift cam in
both directions.
CAUTION:
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ENGINE ASSEMBLY AND SETTING
5-52
ENG
4. Tighten:
•Screws (crankcase) (1) ~ (14)
NOTE:
Tighten the screws beginning with the one with
the lowest number.
Screw (crankcase): 10 Nm (1.0 mkg)
Stopper lever screw (4):
10 Nm (1.0 mkg)
5. Apply:
•4-stroke engine oil
(to the connecting rod pin, the bearing and
the oil passage).
6. Check:
•Gearbox and transmission functioning
Jerky functioning ➔Replace.
SHIFT SHAFT AND OIL PUMP
1. Install
•Spring (1)
•Collar (2)
•Stopper lever (3)
NOTE:
Place the stopper lever and the spring in the cor-
rect position.
2. Install:
•Plate washer (1)
•Spring (2)
•Shift lever (3)
•Circlip (4)
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ENGENGINE ASSEMBLY AND SETTING
5-53
NOTE:
When installing the shift lever, align the mark on
the lever with that on the shift shaft.
3. Install:
•Circlip (1) (to the driving axle)
•Spacer (2)
•Circlip (3)
4. Apply:
•4-stroke engine oil
(oil pipes in crankcase)
To avoid damage to the engine, lubricate the
oil pump pipes in the crankcase liberally with
4-stroke engine oil.
CAUTION:
5. Apply:
•4-stroke engine oil
(oil pump pipes)
6. Apply:
•O-Ring (1)
•Oil pump (2)
•Oil pump gear (3)
•Circlip (4) Screw (5) (oil pump): 10 Nm (1.0 mkg)
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ENGENGINE ASSEMBLY AND SETTING
5-55
PISTON AND RINGS
(1) Ring (upper)
(2) Ring (lower)
(3) Scraper
(4) Piston
(5) Piston pin
(6) Circlip PISTON SIZE:
94.915 ~ 94.965 mm
PISTON RING END GAP:
TOP: 0.30 ~ 0.45 mm
2ND: 0.30 ~ 0.45 mm
OIL: 0.20 ~ 0.70 mm
PISTON RING SIDE CLEARANCE:
TOP: 0.04 ~ 0.08 mm
2ND: 0.03 ~ 0.07 mm
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ENGENGINE ASSEMBLY AND SETTING
5-59
PISTON, CYLINDER, CYLINDER HEAD AND
CAMSHAFT
1. Apply:
•4-stroke engine oil
(on piston pin).
2. Install:
•Piston (1)
•Pin (2)
•Circlip (3)
NOTE:
•Arrow (4) on the piston must point towards the
front of the engine.
•Before installing the piston pin circlips, cover
the crankcase with a clean cloth to prevent
foreign bodies falling into it.
WARNING
Always use new circlips for the piston pin.
3. Install:
•Dowel pins (1)
•O-Ring (2)
4. Install:
•Gasket (1) (cylinder)
NOTE:
Install the cylinder gasket as shown in the illustra-
tion.
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