warning YAMAHA TT600RE 2004 Workshop Manual

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)
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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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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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INSPECTION AND REPAIR
5-36
ENG
TRANSMISSION AND GEARBOX
1. Inspect:
•Shift fork pin (1)
•Shift fork pawl (2)
Lines/Creases/Wear ➔Replace.
2. Inspect:
•Shift cam groove
•Shift cam pins
Wear/Damage ➔Replace.
3. Check:
•Shift fork movement
Rough functioning ➔Replace shift forks
and/or guide bars.
4. Inspect:
•Guide bar
Turn on a flat surface.
Curvature ➔Replace.
WARNING
Do not attempt to straighten the deformed
guide bar.
5. Measure:
•Transmission shaft eccentricity.
Use the centring tool and micrometer.
Out of specification ➔Replace bent shaft.
Transmission shaft eccentricity: : 0.08 mm
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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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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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ENGENGINE ASSEMBLY AND SETTING
5-63
13. Install:
•Chain tensioner
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Assembly steps:
•Remove the chain tensioner screw (1), the
washer (2) and the spring (3).
•Release the chain tensioner unidirectional
cam (4) and push the thrust rod (5).
•Install the chain tensioner in the cylinder with
a new gasket.
Screw (chain tensioner body): 10 Nm (1.0 mkg)
Chain tensioner screw: 20 Nm (2.0 mkg)
WARNING
Always use a new gasket.
•Install the spring, the washer and the chain
tensioner.
14. Adjust:
•Valve clearance Valve clearance: Intake0.05 ~ 0.10 mm
Exhaust 0.12 - 0.17 mm
See section “VALVE CLEARANCE
ADJUSTMENT” in CHAPTER 3.
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ENGENGINE ASSEMBLY AND SETTING
5-69
BALANCER SHAFT GEAR AND PRIMARY
TRANSMISSION GEAR
1. Install:
•Key (1)
•Balancer shaft gear (2)
•Plate (3)
•Lock washer (4)
•Nut (5) (balancer shaft gear)
•Washer (6)
•Key (7)
•Plate (8)
•Balancer shaft drive gear (9)
•Plate (10)
•Primary drive gear (11)
•Lock washer (12)
•Nut (13) (primary drive gear)
Nut (balancer shaft gear): 60 Nm (6.0 mkg)
Nut (primary drive gear): 120 Nm (12.0 mkg)
NOTE:
When installing the drive gear, align the mark on
it (14) with that of the balancer shaft gear (15).
WARNING
Always use a new lock washer.
NOTE:
To tighten nuts (5) and (13), keep the AC genera-
tor rotor still with the special tool (16).
Sheave holder: P/N. 90890-01701
Be careful not to touch the jutting part (17) of
the rotor with the sheave holder.
2. Bend the lock washer tab along the face of the nut.
CAUTION:
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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
5-74
ENG
STARTER NEUTRAL GEAR AND CRANKCASE
COVER (L))
1. Install:
•Stator winding (1)
•Pick-up coil (2)
•Cable clamp (3)
2. Install:
•Bearing (1)
•Intermediate starter gear 2 (2) Screws (stator and coil):
7 Nm (0.7 mkg)
Use LOCTITE ®
Screw (cable clamp): 7 Nm (0.7 mkg)
3. Install:
•Centring pin (1)
•Gasket (2)
•O-Ring (3)
•Crankcase cover (L) (4)
•Plugs
Bolt (crankcase cover): 10 Nm (1.0 mkg)
WARNING
Always use a new gasket.
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ENGINE REASSEMBLY
5-76
ENG
ENGINE REASSEMBLY
To reassemble the engine, repeat the procedures
described in the paragraph “ ENGINE REMOVAL”
in this chapter in reverse order. Pay attention to
the following points.
1. Install:
•Sprocket (1)
•Drive chain Nut (sprocket): 110 Nm (11.0 mkg)
Drive chain slack: 30 ~ 40 mm
Screw (sprocket cover):10 Nm (1.0 mkg)
Use LOCTlTE ®
Screw (shift ptidal): 10 Nm (1.0 mkg)
Screw (footrest): 48 Nm (4.8 mkg)
NOTE:
Bend the lock washer tab along the face of the
nut.
WARNING
Always use a new lock washer.
2. Install:
•Cover (sprocket)
•Shift pedal
•Footrest (L)
3. Adjust:
•Drive chain slack
See section “DRIVE CHAIN SLACK
INSPECTION AND ADJUSTMENT” in
CHAPTER
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