engine YAMAHA TT600RE 2004 Repair Manual

ENGENGINE DISASSEMBLY
5-11
3. Remove
•Primary drive gear (1)
•Disc (2)
•Balancer drive gear (3)
•Disc (4)
•Key (5)
•Disc washer (6)
•Disc (7)
•Balancer gear (8)
•Straight key (9)
NOTE:
Before loosening the nut (9) (primary drive gear)
and nut (10) (balancer gear), straighten the wash
lock tab.
NOTE:
To loosen nuts (9) and (10), hold the rotor (CA
magneto) firmly in place using special tool (11).
Sheave holder: P/N. 90890-01701
Be careful not to touch jutting edges (12) on
the rotor with the sheave holder.
CAUTION:
4. Remove:
•Push lever (1)
•Spring
•Flat washer
NOTE:
Loosen the screw to remove the push rod.
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ENGINE DISASSEMBLY
5-12
ENG
OIL PUMP AND SHIFT LEVER
NOTE:
The oil pump and shift lever may be checked with
the engine installed by removing the following
parts:
•Footrest (R)
•Oil delivery hose screw
•Crankcase (R)
•Clutch
1. Remove:
•Circlip (1)
•Oil pump gear (2)
•Oil pump (3)
•O-rings (4)
2. Remove:
•Circlip (1) (from drive shaft)
•Ring (2)
•Circlip (3)
3. Remove:
•Circlip (1)
•Shift lever (2)
•Spring (3)
•Flat washer (4)
4. Remove:
•Stopper lever (1)
•Ring (2)
•Spring (3)
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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 DISASSEMBLY
5-14
ENG
CRANKCASE (R)
1. Remove:
•Crankcase (R)
NOTE:
•Loosen nuts starting from the one with the
highest number.
•Loosen all by 1/4 turn and then remove.
Removal procedure:
•Set the crankcase separating tool (1) in place.
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Crankcase separating tool: P/N. 90890-01135
NOTE:
When tightening the support bolts of the separat-
ing tool, be sure to keep the tool body parallel to
the engine crankcase. If necessary, a screw may
be slightly loosened to put the tool body on level.
•Applying pressure, strike the front engine
assembly flange, the drive shafts and the gear
cam plate with a rubber hammer. Then
remove the crankcase.
NOTE:
•If the crankcase fails come out, lever at points
(2), being careful not to damage the
crankcase.
•Turn the gear cam plate as shown in the fig-
ure to prevent it interfering with the crankcase.
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ENGENGINE DISASSEMBLY
5-15
•Be careful not to damage surfaces in con-
tact with the crankcase.
•Use a soft hammer to hit the engine
crankcase. Only hit the reinforced parts.
Do not hit the surface in contact with the
gasket. Work slowly and carefully. Be care-
ful to perform the separation uniformly. If
one end locks, remove pressure from the
thrust screw, realign and recommence. If it
is impossible to separate the crankcase,
check that all screws and components
have been disassembled. Do not use force.
CAUTION:
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ENGINE DISASSEMBLY
5-16
ENG
GEARBOX AND TRANSMISSION
1. Remove:
•Guide bar (1)
•Shift cam (2)
•Selector fork # 3 (3)
•Selector fork # 2 (4)
•Selector fork # 1 (5)
2. Remove:
•Transmission assembly unit (1)
3. Remove:
•Shift shaft # 1 (1)
•Shift shaft # 2 (2)
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ENGENGINE DISASSEMBLY
5-17
BALANCER SHAFT AND CRANKSHAFT
1. Remove:
•Balancer shaft (1)
2. Remove:
•Crankshaft (1)
NOTE:
•Remove the crankshaft by using the
crankcase separating tool (2).
Crankcase separating tool: P/N. 90890-01135
•Tighten the separating tool bolts, making sure
that the tool body is parallel with the engine
crankcase. If necessary, a screw may be
backed out slightly to level tool body.
OIL STRAINER
NOTE:
It is advisable to replace the oil strainer every time
the engine is disassembled.
1. Remove:
•Oil strainer (1)
•Oil passage cover (2)
•Gasket
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ENGINE DISASSEMBLY
5-18
ENG
ROCKER ARMS
NOTE:
The rocker arms may be examined with the
engine installed by removing the following parts.
•Seat
•Fuel tank
•Cylinder head cover
1. Remove:
•Cap (1)
2. Remove:
•Bolts (1) (rocker shaft)
3. Remove:
•Rocker shaft
•Rocker arms
NOTE:
Remove the rocker shaft using sliding hammer (1)
and weight (2).
Sliding hammer bolt: P/N. 90890-01083
Weight: P/N. 90890-01084
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ENGENGINE DISASSEMBLY
5-19
VALVES
NOTE:
The valves may be inspected with the engine
installed by removing the following parts.
•Seat
•Fuel tank
•Exhaust pipe
•Carburetor
•Cylinder head cover
•Cylinder head
1. Check:
•Valve seal
Leakage from valve seats’ Inspect the
valve surface, the seat and seat width.
See section “VALVE SEAT INSPECTION
AND REPAIR”.
NOTE:
Check the valve seal before assembling the inter-
nal parts of the cylinder head (valves, valve
springs, spring retainer etc).
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Inspection steps:
•Pour clean solvent (1) into the intake and
exhaust ports.
•Check the valve seal. There must be no blow-
bys from the valve seats (2).
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ENGINE DISASSEMBLY
5-20
ENG
2. Remove:
•Cotters (1)
•Top spring retainer (2)
•Internal spring (3)
•External spring (4)
•Lower spring retainer (5)
•Valve (6)
•Valve stem seal (7)
NOTE:
Mark each part and its position so that each may
reassembled as before.
NOTE:
Compress the valve spring using tool (8) to
remove the cotters. Valve spring compressor: P/N. 90890-04019
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