YAMAHA TT600RE 2004 Repair Manual

INSP
ADJDRIVE CHAIN ADJUSTMENT
IDLE SPEED ADJUSTMENT
3-7
DRIVE CHAIN ADJUSTMENT
The drive chain does not need to be adjusted.
IDLE SPEED ADJUSTMENT
1. Start the engine and let it heat.
2. Connect:
•The inductive engine speed indicator to
the spark plug cable
Special tool:
P/N. 90890-03113
Engine idle speed:
1,150 ~ 1,450 rpm
3. Check:
•The engine idle speed.
Out of specification ➔Adjust.
4. Adjust:
•Engine idle speed
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Adjustment:
•Turn the throttle stop screw (1) either way to
obtain the idle speed required.
Screwing (a) Increases idle speed
Unscrewing (b) Decreases idle speed
NOTE:
After setting the idle speed, adjust the accelerator
cable free play.
5. Disconnect:
•Inductive engine speed indicator
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THROTTLE CABLE FREE PLAY ADJUSTMENT
3-8
INSP
ADJ
THROTTLE CABLE FREE PLAY
ADJUSTMENT
NOTE:
Before adjusting the throttle cable free play, adjust
the engine idle speed.
1. Remove:
•Seat
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING”.
2. Check:
•Throttle cable free play (a)
Out of specification ➔Adjust.
Throttle cable free play:
3 ~ 5 mm (at the grip flange)
3. Adjust:
•Throttle cable free play
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Adjustment:
•Loosen the throttle cable (2) lock nuts (1).
•Turn the adjuster (3) clockwise or anticlock-
wise to obtain the required free play.
•If after loosening the adjuster by 5 mm, the
free play is still not correct, tighten the
adjuster (4) on the throttle cable (5) once
more.
•Tighten the lock nuts.
(1), (6) Lock nuts
4. Reassemble:
•Fuel tank
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
a
Seat screws:
10 Nm (1,0 mkg)
2
1
3
6
4
5
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INSP
ADJ
SPARK PLUG INSPECTION
3-9
SPARK PLUG INSPECTION
1. Remove:
•Seat
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING”.
2. Disconnect:
•Spark plug cap
3. Remove:
•Spark plug (1)
Before removing the spark plug, use com-
pressed air to blow away any dirt accumulat-
ed in the spark plug wells to prevent it from
falling into the cylinder.
When removing the spark plug, be careful not
to drop foreign objects inside the engine.
4. Inspect:
•Type of spark plug
Incorrect ➔Replace.
CAUTION:
CAUTION:
Standard spark plug:
DPR8EA-9 (N.G.K.) or DPR9EA-9 (N.G.K.)
5. Inspect:
•Electrodes (1)
Wear and tear/damage ➔Replace.
•Insulator (2)
Normal insulator (2) colour is light tan.
6. Clean the spark plug with a suitable tool and a
steel brush.
7. Measure:
•Spark plug electrode gap (a)
Use a wire or thickness gauge.
Out of specification ➔Regap.
Electrode gap:
0.8 ~ 0.9 mm
1
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SPARK PLUG INSPECTION
3-10
INSP
ADJ
8. Lock tighten:
•Spark plug
Before installing the spark plug, clean the
surface and thread.
Spark plug:
18 Nm (1.8 mkg)
Seat screws:
10 Nm (1.0 mkg)
NOTE:
Tighten the spark plug by hand before torquing to
specification.
9. Connect:
•Spark plug cap
10. Install:
•Fuel tank
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
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INSP
ADJ
3-11
IGNITION TIMING CHECK
IGNITION TIMING CHECK
1. Start the engine and let it heat.
2. Connect:
•Inductive rev counter
•Stroboscopic lamp to spark plug cable
Inductive engine speed indicator:
P/N. 90890-03113
Stroboscopic lamp:
P/N. 90890-03141
3. Remove:
•Cap (1)
In certain conditions, the oil might spray out
when the cap is removed. Be careful therefore
when removing the cap.
4. Check:
•Ignition advance
CAUTION:
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Check:
•Heat engine and let it run to the number of
revs required.
Engine idle speed:
1,150 ~ 1,450 rpm
•Check that reference (1) is in the mobile field
of reference (2) on the flywheel.
Incorrect ignition timing ➔ Check the ignition
coil unit.
NOTE:
Ignition timing cannot be adjusted.
5. Install:
•Cap
6. Remove:
•Stroboscopic lamp
•Inductive engine speed indicator


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3-12
INSP
ADJ
COMPRESSION INSPECTION
COMPRESSION INSPECTION
NOTE:
Insufficient compression causes a loss of per-
formance.
WARNING
Set the motorcycle firmly in place to prevent it
falling during the operation.
1. Remove:
•Seat
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING”.
2. Check:
•Valve clearance
Out of specification ➔Adjust.
See section “VALVE CLEARANCE AD-
JUSTMENT”.
3. Install:
•Secondary fuel tank
4. Start engine and let it heat.
•Switch off engine.
5. Disconnect:
•Spark plug cap
6. Remove:
•Spark plug (1)
When removing the spark plug, be careful to
prevent foreign bodies from dropping inside
the engine.
CAUTION:
1
7. Apply:
•Pressure gauge (1)
•Adapter (2)
Pressure gauge:
P/N. 90890-03081
Adapter:
P/N. 90890-04082
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INSP
ADJ
3-13
COMPRESSION INSPECTION
Inspection:
•Turn the main switch to "ON".
•With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilized.
WARNING
While operating the starter, disconnect the
spark plug cap to avoid sparks.
•Compare the pressure reading with those in
the table.
Pressure under compression:
Standard
1,100 kPa (11 kg/cm
2, 156 psi)
Minimum
900 kPa (9 kg/cm
2, 128 psi)
Maximum
1.200 kPa (12 kg/cm
2, 171 psi)
8. Check:
•Pressure under compression
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•If the pressure reading is lower than minimum:
1) Add a few drops of oil to the cylinder through
the hole in the spark plug.
2) Measure the compression again.
3) Compare the new reading with the first, then
proceed according to the indications in the
table.
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3-14
INSP
ADJ
COMPRESSION INSPECTION
9. Remove:
•Secondary fuel tank
•Pressure gauge (with adapter)
10. Reassemble:
•Spark plug
See section “SPARK PLUG INSPEC-
TION”.
Spark plug:
18 Nm (1.8 mkg)
Seat screws:
10 Nm (1.0 mkg)
11. Connect:
•Spark plug cap
12. Reassemble:
•Fuel tank
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.Pressure under compression:
(after adding oil to the cylinder)
Reading Diagnosis
Pressure higherPiston worn or
than beforedamaged.
Pressure same Cylinder head or
as before piston rings, valves,
gaskets may be
faulty.
Pressure above Inspect cylinder
maximum value head, valve sur-
faces, piston rim to
check for carbon
deposits.
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INSP
ADJ
3-15
ENGINE OIL LEVEL CHECK
ENGINE OIL LEVEL CHECK
Do not put additives into the engine oil. The
latter also lubricates the clutch and additives
might cause it to slide.
WARNING
Never remove the oil tank cap when the
engine is hot. The boiling oil might spill over,
causing burns. Wait for the oil to cool to at
least 60°C (140°F) or thereabouts.
This model is fitted with a dry crankcase lubrica-
tion system. A feed pump delivers oil to the en-
gine; after fully lubricating the latter, the oil is re-
turned to the tank by a scavenge pump. The oil
level must therefore be checked in the oil tank.
1. Start the engine and warm up until the oil tem-
perature rises to approximately 60°C (140°F).
2. Idle the engine for at least 10 seconds while
keeping the motorcycle upright. After stop the
engine and check the oil level through the
level window (3) located on the left side of the
oil tank assy and(or) by oil level gauge.
NOTE:
Be sure the motorcycle is positioned straight up
when checking the oil level. A slight tilt toward the
side can result in false readings.
3. The oil level should be between the maximum
(1) and minimum (2) marks.
CAUTION:
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3-16
INSP
ADJ
ENGINE OIL LEVEL CHECK
If the oil level is below minimum ➔Add oil up
to maximum level.
Recommended oil:
SAE20W40SE or SAE10W30SE
Refer to the chart for selection of
the oils suited to the atmospheric
temperature.
API Standard:
API SE, SF, SG or higher grade
•Do not put in any chemical additives or use
oils with a grade of CD (a) or higher.
•Be sure not to use oils labeled “ENERGY
CONSERVING II” (b) or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
•Be sure no foreign material enters the
crankcase.
4. Reassemble the oil tank cap.
Never start the engine when the oil tank is
empty.
CAUTION:
CAUTION:
Oil capacity:
Total:
3.0 litres
Periodic oil change:
2.4 litres
With oil filter change:
2.5 litres
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