engine YAMAHA TT600RE 2004 Workshop Manual

ENGENGINE REMOVAL
5-1
ENGINE
ENGINE REMOVAL
MUFFLER, EXHAUST PIPE, ENGINE PROTECTOR, DRIVE SPROCKET CRANKCASE COVER,
DRIVE SPROCKET AND SHIFT PEDAL
Order Job name/Part name Q.ty Remarks
Muffler, exhaust pipe, engine Remove the parts in order.
protector, drive sprocket crankcase
cover, drive sprocket and shift
pedal removal Park the motorcycle in a stable and level
position.
WARNING
Securely support the motorcycle so there
is no danger of it falling over.
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ENGINE REMOVAL
5-2
ENG
Order Job name/Part name Q.ty Remarks Drain the engine oil (refer to “ENGINE OIL
REPLACEMENT” section in CHAPTER
3). Remove the seat, the fuel tank and
the rear cowling (refer to “SEAT, FUEL
TANK AND REAR COWLING” section in
CHAPTER 3).
1 Battery leads connector 1 Disconnect.
2 Muffler 1
3 Exhaust pipe 1
4 Engine protector 1
5 Shift pedal 1
6 Drive sprocket crankcase cover 1
7 Drive sprocket 1 Displace the drive chain.
8 Clutch cable 1 Disconnect.
9 Plug cap 1 Disconnect.
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ENGENGINE REMOVAL
5-3
Order Job name/Part name Q.ty Remarks – Starter leads 2 Disconnect.
– Starter 1 Remove.
10 Connectors of engine wire harness 2 Disconnect. 11 Oil delivery hose 1 Disconnect.
12 Oil return hose 1 Disconnect.
13 Oil breather pipe (to oil tank) – Disconnect.
14 Oil breather pipe (to air filter box) – Disconnect. Reverse the removal procedure for
installation.
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ENGINE REMOVAL
5-4
ENG
Order Job name/Part name Q.ty Remarks
The engine and rear arm are assembled
together on the rear pivot shaft. When
removing the pivot shaft, it is thus
necessary to pay special care with the
rear arm.
1 Stay of oil tank – Remove the mounting screws (to engine).
2 Hose clamp (carburetor) 2 Loosen.
3 Pivot shaft (rear - top) 1
4 Engine mounting bolt 1 (rear - lower)
5 Engine stay (front - lower) 1
6 Engine stay (front - top/right/left) 1
7 Engine assembly 1
CAUTION:
ENGINE MOUNTING BOLT
NOTE:
Remove the engine from the lower side.
Reverse the removal procedure for
installation.
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ENGENGINE DISASSEMBLY
5-5
ENGINE DISASSEMBLY
CYLINDER HEAD, CYLINDER, CAMSHAFT
AND PISTON
NOTE:
The cylinder head, cylinder, camshaft and piston
can be examined with the engine installed by
removing the following parts.
•Seat
•Fuel tank
•Rear cowling
•Carburetor
•Exhaust pipe
1. Remove:
•Spark plug (1)
•Tappet cover (2) (intake)
•Tappet covers (3) (exhaust)
•Cylinder head cover (4)
•Cap (5)
•Pins (6)
2. Loosen:
•Bolt (1) (chain tensioner)
3. Remove:
•Chain tensioner (2)
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ENGINE DISASSEMBLY
5-6
ENG
4. Remove:
•Cam sprocket (1)
•Camshaft (2)
•Caps (left crankcase cover)
NOTE:
Fix a safety wire (3) to the timing chain to prevent
it falling into the crankcase.
5. Remove:
•Chain stopper guide (1)
6. Remove:
•Cylinder head
NOTE:
Loosen all bolts by a 1/4 turn and remove once all
are loosened.
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ENGENGINE DISASSEMBLY
5-7
7. Remove:
•Gasket (1) (cylinder head)
•Pins (2)
•Cylinder (3)
•Gasket (4) (cylinder)
8. Remove:
•Pins (1)
9. Remove:
•Pin ring (1)
NOTE:
Before removing the pin ring, cover the crankcase
with a clean cloth to prevent the ring falling into
the crankcase cavity.
10. Remove:
•Pin (1)
•Piston (2)
NOTE:
Before removing the pin, burr the pin housing
groove. If it is hard to pull out the pin even with the
groove burred, use the pin puller.
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ENGINE DISASSEMBLY
5-8
ENG
Avoid using the hammer to pull the pin out.
CAUTION: Piston pin puller set:
P/N. 90890-01304
3. Remove:
•Neutral gear switch cable (1)
2. Remove:
•Intermediate starter gear (1)
•Bearing (2)
•Distributor shaft (3)
INTERMEDIATE STARTER GEAR, CRANKCASE
COVER (L) AND GENERATOR STATOR
NOTE:
With the engine installed, maintenance of the inter-
mediate starter gear and the crankcase cover (L)
may be performed by removing the following parts.
•Exhaust pipe
•Starter
•Sprocket cover
1. Remove:
•Cover (1) intermediate starter gear
•Centring pins
•Gasket
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ENGENGINE DISASSEMBLY
5-9
4. Remove:
•Crankcase cover gasket (1) (L)
•Centring pins
•Seal ring and O-ring
•Gasket
6. Remove:
•Cable clamp (1)
•Coil (2)
•Stator (3)
CRANKCASE COVER (R), CLUTCH, PRIMARY
DRIVE GEAR AND BALANCER SHAFT GEAR
NOTE:
The clutch, the primary gear and the balance gear
may be inspected with the engine installed by
removing the following parts.
•Footrest (R)
•Oil delivery hose screw
5. Remove:
•Intermediate starter gear (1)
•Bearing (2)
•Distributor shaft (3)
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ENGINE DISASSEMBLY
5-10
ENG
2. Remove:
•Compression spring (1)
•Pressure plate (2)
•Ball (3)
•Friction plate (4)
•Clutch plate (5)
•Clutch boss spring (6)
•Clutch boss (7)
•Thrust plate (8)
•Clutch shroud (9)
•Push rod (10)
1. Remove:
•Engine oil delivery hose screw
•Copper washer
•Oil filter cover (1)
•Oil filter
•Seal ring and O-Ring
•Crankcase cover (2) (R)
NOTE:
•Before loosening the nut (11) (clutch shroud),
straighten the washer lock tab.
•To loosen the nut (clutch boss), block the
clutch boss using the special tool (12).
Clutch holding tool: P/N. 90890-04086
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