wheel YAMAHA TT600RE 2004 Workshop Manual

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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SWINGARM
4-80
CHAS
SWINGARM INSTALLATION
Perform “removal” operations in reverse order.
Note the following points.
1. Lubricate:
•Bearings
•Bushes
•Thrust cover (inside)
•Flange
•Swingarm pivot shaft
•Bolt (connecting rod)
•Bolt (relay arm)
•Bolt (shock absorber)
Lithium-base grease
2. Tighten: Nut (relay arm-swingarm): 66 Nm (6.6 mkg)
Nut (relay arm - connecting rod): 52 Nm (5.2 mkg)
Bolt (chain case): 9 Nm (0.9 mkg)
Nut (swingarm pivot shaft): 90 Nm (9.0 mkg)
Bolt (chain support): 4 Nm (0.4 mkg)
Screw (chain case): 4 Nm (0.4 mkg)
Nut (relay arm-frame): 60 Nm (6.0 mkg)
Bolt (rear shock absorber): 59 Nm (5.9 mkg)
3. Install:
•Rear wheel
Refer to “REAR WHEEL INSTALLATION”
section.
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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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CHASDRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-83

6. Remove:
•Swingarm
•Drive chain
Refer to “REAR SHOCK ABSORBER
REMOVAL” and “SWINGARM REMOVAL”
sections.
DRIVE CHAIN INSPECTION
1. Measure:
•Length of 10 links (drive chain)
Out of specification ➔Replace drive
chain.
Maximum lenght of 10 links (a): 150.2 mm
NOTE:
•Stretch the chain by hand to measure it.
•The length of the 10 links is recorded between
the inside of the link pins (1) and (11) as
shown.
•The length of the 10 links is measured at var-
ious points.
2. Clean:
•Drive chain
Immerge in kerosene and brush thorough-
ly to remove as much dirt as possible.
Remove from kerosene and allow to dry.
This motorcycle is fitted with a chain with
small O-Rings (1) fitted between its plates.
Vapour cleaning, pressurised washing and
certain types of solvents may damage these
seal rings.
To clean the transmission chain use only
kerosene.
CAUTION:
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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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CHASDRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-85
3. Tighten:
•Rear wheel sprocket fastening bolts
Rear wheel sprocket fastening bolts: 48 Nm (4.8 mkg)
Nut (drive sprocket): 110 Nm (11.0 mkg)
Nut (swingarm pivot shaft): 90 Nm (9.0 mkg)
Nut (frame-relay arm): 60 Nm (6.0 mkg)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
DRIVE CHAIN INSTALLATION
Perform “REMOVAL” operations in reverse order.
Pay special attention to the following points.
1. Install:
•Drive chain
•Swingarm
2. Install:
•Rear wheel
Refer to “REAR WHEEL INSTALLATION”
section.
3. Install:
•Drive sprocket
WARNING
Always use a new lock washer.
NOTE:
•Tighten the drive sprocket nut with the rear
brake pulled.
•After tightening the nut, bend the tab on the
lock washer once more over the faces of the
nut.
4. Adjust:
•Drive chain slack
Refer to “DRIVE CHAIN SLACK ADJUST-
MENT” section in CHAPTER 3.
Drive chain slack: 30 ~ 40 mm
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DRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-86
CHAS
5. Tighten:
•Rear wheel axle nut
Rear wheel axle nut: 115 Nm (11.5 mkg)
Screws (drive sprocket cover): 10 Nm (1.0 mkg)
Bolt (shift pedal): 10 Nm (1.0 mkg)
Refer to “REAR WHEEL INSTALLATION”
section.
7. Install:
•Cover (drive sprocket)
•Shift pedal
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ENGENGINE DISASSEMBLY
5-13
AC GENERATOR AND TIMING CHAIN
NOTE:
The AC generator may be inspected with the
engine installed by removing the following parts:
•Crankcase (L)
1. Remove:
•Nut (1)
•Washer (2)
•Rotor (3) (with starter gear)
•Bearing (4)
•Shim adjustment washer (5)
•Key (6)
NOTE:
To loosen the nut (rotor), lock the rotor with the
special tool (7).
Sheave holder: P/N. 90890-01701
Flywheel puller:P/N. 90890-01362
Be careful not to touch the jutting edges (8) on
the rotor with the special tool.
CAUTION:
NOTE:
Remove the rotor with the puller (1).
2. Remove:
•Chain guide (1)
•Timing chain (2)
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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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