engine YAMAHA TT600RE 2004 Manual PDF

ENGENGINE ASSEMBLY AND SETTING
5-41
ENGINE ASSEMBLY AND SETTING
VALVES AND ROCKER ARMS
(1) Rocker arm n. 2
(2) Wave washer
(3) Rocker shaft (intake)
(4) Rocker arm n. 1
(5) Valve cotters
(6) Upper valve spring retainer
(7) Oil seal
(8) Inner valve spring
(9) Outer valve spring (10) Valve (intake)
(11) Lower valve spring retainer
(12) Rocker shaft (exhaust)
(13) Rocker arm n. 4
(14) Rocker arm n. 3
(15) Rocker shaft (exhaust)
(16) Valve (exhaust)
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ENGINE ASSEMBLY AND SETTING
5-42
ENG
VALVES
1. Burrs:
•Valve stem tip
(leave the valve stem tip with an oil stone).
2. Lubricate:
•Valve stem and oil seal (apply high quality
molybdenum disulfide oil)
3. Install:
•Oil seal (1)
•Valves (2)
•Lower valve spring retainer (3)
•Inner valve spring (4)
•Outer valve spring (5)
•Upper valve spring retainer (6)
NOTE:
Install the innner and outer springs with the widest
thread upwards.
4. Install:
•Valve cotters (1)
NOTE:
Compress the valve spring with the specific tool
(2) to fit the cotters.
Valve spring compressor: P/N. 90890-04019
(7) Higher pitch
(8) Lower pitch
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ENGENGINE ASSEMBLY AND SETTING
5-43
ROCKER ARMS
1. Lubricate:
•Rocker shaft (apply engine oil)
2. Install:
•Rocker arm
•Rocker shaft
Screws (1) (rocker shaft): 10 Nm (1.0 kgm)
NOTE:
Each rocker arm is numbered.
(1) # 1
(2) # 2
(3) # 3
(4) # 4
3. Install:
•Cap (1)
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ENGINE ASSEMBLY AND SETTING
5-44
ENG
CRANKSHAFT AND BALANCER SHAFT
(1) Connecting rod pin
(2) Crank (left)
(3) Connecting rod
(4) Bearing (5) Bearing
(6) Bearing
(7) Balancer shaft
(8) Bearing
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ENGENGINE ASSEMBLY AND SETTING
5-45
CRANKSHAFT AND BALANCER SHAFT
1. Install:
•Crankshaft
Crankshaft installation tool (1):
P/N. Y U-90050
Crankshaft installation tool spacer (2):
P/N. 90890-01274
Crankshaft installation tool bolt (3):
P/N. 90890-01275
Adapter # 10 (Ml 4) (4):
P/N. Y M-90069
P/N. 90890-04059
Crank spacer (5):
P/N. YM-91044
P/N. 90890-04081
Spacer (6):
P/N. 90890-01016
NOTE:
Hold the connecting rod at top dead centre with
one hand and turn the assembly tool nut with the
other.
Work on the assembly tool until the lower part of
the crankshaft enters into contact with the bear-
ings.
To protect the crankshaft from scratches and
facilitate assembly operations, apply grease
to the edges of the oil seals and engine oil to
the bearings.
CAUTION:
2. Install:
•Balancer shaft (1)
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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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ENGENGINE ASSEMBLY AND SETTING
5-47
GEARBOX
(1) Stopper lever
(2) Guide bar
(3) Shift fork #3
(4) Shift fork #1
(5) Shift cam
(6) Guide bar
(7) Shift fork #2
(8) Shift shaft #1
(9) Shift shaft #2
(10) Oil seal
(11) Shift lever
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5-48
ENGENGINE ASSEMBLY AND SETTING
TRANSMISSION AND GEARBOX
1. Install:
•Transmission assembly (1)
2. Install:
•Shift fork #1 (1)
•Shift fork #2 (2)
•Shift fork #3 (3)
•Shift cam (4)
•Guide bar (5)
NOTE:
Each shift fork is identified by the number
stamped on its side. All numbers must face left.
3. Install:
•Shift shaft #1 (1)
•Shift shaft #2 (2)
NOTE:
Align mark (3) on the shift lever shaft with that on
the shift shaft.
4. Check:
•Transmission functioning
Jerky functioning ➔Repair.
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ENGENGINE ASSEMBLY AND SETTING
5-49
ENGINE OIL PUMP AND OIL STRAINER
(1) Oil strainer
(2) Oil pump
(3) Oil pump gear
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ENGINE ASSEMBLY AND SETTING
5-50
ENG
CRANKCASE
(1) Crankcase (R)
(2) Crankcase (L)
(3) Crankcase ventilation hose
(4) Dowel pin
(5) Dowel pin
(6) Dowel pin
(7) Bearing cover plate
(8) Collar
(9) Lock plate
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