ad blue YAMAHA TT600RE 2004 Service Manual

INSPECTION AND REPAIR
5-24
ENG
3. Measure:
•Valve seat width (a)
Out of specification ➔Renew valve seat.
Valve seat width (a):
Intake: 1.0 ~ 1.2 mm
: 1.8 mm
Exhaust: 1.0 ~ 1.2 mm : 1.8 mm
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Measurement steps:
•Apply Prussian blue (Dykem) to the valve
seat.
•Install the valve in the cylinder head.
•Press the valve onto the housing through the
guide to leave a clear outline.
•Measure the width of the valve seat. Where
there is contatc between valve and seat the
Prussian blue is wiped away.
•If the valve seat is too narrow, wide or off-cen-
tre, the valve seat must be renewed.
4. Renew:
•Valve seat
Use the special tool (1) to renew the valve
seat with 30°, 45° and 60° mills.
Turning the cutter, maintain uniform pressure
(about 4-5 kg) to avoid leaving marks on the
valve seat.
CAUTION:
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ENGINSPECTION AND REPAIR
5-27
•Apply Prussian blue (Dykem) to the valve seal
surface.
•Install the valve in the cylinder head.
•Press the valve onto the housing through the
guide to leave a clear outline.
•Measure the valve seat width once more. If
the width of the valve is out of specification
alter and relap.

VALVE SPRINGS
1. Measure:
•Free width of valve springs (a)
Out of specification ➔Replace.
Free width of valve springs
(intake and exhaust):
Internal spring External spring 40.1 mm 43.8 mm
Valve spring load:
Internal spring (intake and exhaust) 164.8 ~ 190.2 N
(16.80 ~ 19.39 kgf) at 22.7 mm
External spring (intake) 71.6 ~ 87.3 N
(7.3 ~ 8.9 kgf) at 34.2 mm
External spring (exhaust) 149.1 ~ 182.4 N
(15.2 ~ 18.6 kgf) at 34.2 mm
2. Measure:
•Spring load
Out of specification ➔Replace.
(b) Length of loaded spring
3. Measure:
•Inclination of spring (a)
Out of specification ➔Replace.
Spring inclination limit:
Internal spring External spring 2.5°/1.7 mm 2.5°/1.9 mm
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INSPECTION AND REPAIR
5-28
ENG
CAMSHAFT
1. Inspect:
•Cam eccentrics
Pitting/Scratches/Blue colour ➔Replace
camshaft.
2. Measure:
•Cam eccentrics
Out of specification ➔Replace camshaft.
(a) (b)
Intake: 36.47~36.57 mm 30.06~30.16 mm
Exhaust: 36.62~36.72 mm 30.11~30.21 mm
ROCKER ARMS AND ROCKER SHAFT
1. Inspect:
•Rocker shafts
Blue colour/Grooves ➔Replace shafts
and check lubrication system.
2. Inspect:
•Rocker shaft slot (1)
•Surface in contact with cam eccentric (2)
•Adjuster surface (3)
Pitting/Wear/Scratches/Blue colour ➔
Replace and check lubrication system.
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ENGINSPECTION AND REPAIR
5-33
PISTON PIN
1. Check:
•Piston pin
Blue colour/Grooves ➔Replace and
check lubrication system.
External diameter (pin): 21.991 ~ 22.000 mm
Clearance between piston pin and pin
seat on piston: 0.004 ~ 0.024 mm
: 0.07 mm
2. Measure:
•External diameter (a) of pin
Out of specification ➔Replace.
3. Measure:
•Clearance between piston pin and pin
seat
Out of specification ➔Replace.
Clearance between piston pin and
piston = Diameter of pin seat on piston (b) –
Diameter of pin (a)
CLUTCH
1. Inspect:
•Clutch gear assy teeth
Cracks/Pitting (on edges):
Moderate ➔Burr.
Accentuated ➔Replace clutch gear assy.
NOTE:
Pitting of the gear assy teeth causes irregular
functioning.
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ENGENGINE ASSEMBLY AND SETTING
5-65
AC GENERATOR
(1) Rotor
(2) Pick-up coil
(3) Stator winding PICKUP COIL RESISTANCE:
230 Ω± 20% at 20°C (68°F)
(Blue/Yellow - Green/White)
CHARGING COIL RESISTANCE:
0.65 Ω ± 20% at 20°C (68°F)
(White - White)
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ELECELECTRICAL CIRCUIT DIAGRAM
7-1
467C4B5CAMP403D494A4856 172320-2
GWLY
BB
B
BBLWRB
R
B
B
B
RLBOrRBLYGW
Or
B
LW
MAIN HARNESSB
B
B
Y Y
LBG
LGRBLYGWLWLBOrRB
LW
GY
GY
RBBr
Br187
GB
12V10W
BL12V5WBY G
12V60/55WBGYAA
12V10W
A
GB
BrBBrB
BGBB
GBBGBB
BrB
12V10WB
B
BrL
GB
12V10WB
B
187
BYB
R
B
BrL
WWB
OFF
BrL
W
B
W
BB
B
B BLB
BBrB
G
B
BrB
Br
OFF
B
EXT. CORD
Br
GY
BL
G
Y
GYB
B
L
GB
BrB
LR
LR Sb
B
RW
-
LR
L
BrL
GBSbB
BrB
YBrBrB
YBrGB
B
Ch
DgBrY
BrB
HIGH
TURN
NEU.ILL.
B
BrL
BrL
LBBY
LY LB
LY
GWB
RBOr
205
B
RBL
BrL
Br
PARKOFFON
ON
ON
Sb
L
GB
GY

GY
RBLYBY
LYBY
RUN
LW
B
B
LY
BY
LBrRR
LWRB
GB
R
B
GW
BrBrW
WB
Br
LY
WB
Sb
B
GWLY
(BLUE)B
B
LYB
OFF
BrRB
LWRB
Y
P
G
GB BBrWBrL
BrB
W
WW
GYBr
GY
Y
P
G
GB B
BrWBrL
BrB
Y
N
RL
LOWHIGH
BrW Br
P
PBr
LY
B
GWLY
Or
RB
Br
LW
BY
BY
START
OFF
R
B
GWLY
W
W W
W
W
W
W
RW
W
W
Sb
B
Sb
BBrBB
-
-
B
LR
WRW
B
-
AL
L
GY
LB
Br
WB
RB
MAIN HARNESS
AHEAD LIGHT
B
B
BrB
17
16
11
12
13
14
15
91029
8
5
3
12
6428
20
21
22
19
2325
24
30
31
27
267
32
18
BrW
ELECTRICAL - ELECTRICAL CIRCUIT DIAGRAM
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ELECTRICAL CIRCUIT DIAGRAM
7-2
ELEC
B Black B/Y Black/Yellow
Br Brown Br/B Brown/Black
Ch Chocolate Br/W Brown/White
Dg Deep green G/B Green/Black
G Green G/R Green/Red
Gy Grey G/W Green/White
L Blue G/Y Green/Yellow
Or Orange L/R Blue/Red
P Pink L/W Blue/White
R Red L/Y Blue/Yellow
Sb Sky-blue R/B Red/Black
W White R/W Red/White
Y Yellow R/Y Red/Yellow
B/R Black/Red W/L White/Blue
B/W Black/White Y/R Yellow/Red
(1) AC generator/Pickup coil
(2) Rectifier/Regulator
(3) Battery
(4) Starter relay
(5) Starting motor
(6) Fuse
(7) Main switch
(8) Right handlebar switch
(9) Engine stop switch
(10) Starter switch
(11) Diode
(12) Clutch switch
(13) Sidestand switch
(14) Neutral switch
(15) Diode
(16) Ignitor unit
COLOUR CODE (17) Ignition coil
(18) Left handlebar switch
(19) Horn switch
(20) Diode
(21) Pass switch
(22) Dimmer switch
(23) Flasher switch
(24) Horn
(25) Flasher relay
(26) Headlight
(27) Flasher light
(28) Relay assy
(29) Front brake switch
(30) Rear brake switch
(31) Tail/stop light
(32) Meter
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ELECIGNITION SYSTEM
7-11
467C4B5CAMP403D494A4856 172320-2
GWLY
BB
B
BBLWRB
R
B
B
B
RLBOrRBLYGW
Or
B
LW
MAIN HARNESSB
B
B
Y Y
LBG
LGRBLYGWLWLBOrRB
LW
GY
GY
RBBr
Br187
GB
12V10W
BL12V5WBY G
12V60/55WBGYAA
12V10W
A
GB
BrBBrB
BGBB
GBBGBB
BrB
12V10WB
B
BrL
GB
12V10WB
B
187
BY
B
R
B
BrL
WWB
OFF
BrL
W
B
W
BB
B
B BLB
BBrB
G
B
BrB
Br
OFF
B
EXT. CORD
Br
GY
BL
G
Y
GYB
B
L
GB
BrB
LR
LR Sb
B
RW
-
LR
L
BrL
GBSbB
BrB
YBrBrB
YBrGB
B
Ch
DgBrY
BrB
HIGH
TURN
NEU.ILL.
B
BrL
BrL
LBBY
LY LB
LY
GWB
RBOr
205
B
RBL
BrL
Br
PARKOFFON
ON
ON
Sb
L
GB
GY

G
Y
RBLYBY
LYBY
RUN
LW
B
B
LY
BY
LBrRR
LWRB
GB
R
B
GW
BrBrW
WB
Br
LY
WB
Sb
B
GWLY
(BLUE)B
B
LYB
OFF
BrRB
LWRB
Y
P
G
GB BBrWBrL
BrB
W
WW
GYBr
GY
Y
P
G
GB B
BrWBrL
BrB
Y
N
RL
LOWHIGH
BrW Br
P
PBr
LY
B
GWLY
Or
RB
Br
LW
BY
BY
START
OFF
R
B
GWLY
W
W W
W
W
W
W
RW
W
W
Sb
B
Sb
BBrBB
-
-
B
LR
WRW
B
-
AL
L
GY
LB
Br
WB
RB
MAIN HARNESS
AHEAD LIGHT
B
B
BrB
17
16
11
12
13
14
15
91029
8
5
3
12
6428
20
21
22
19
2325
24
30
31
27
267
32
18
BrW
IGNITION SYSTEM -CIRCUIT DIAGRAM
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IGNITION SYSTEM
7-18
ELEC
*
10. Neutral switch.
•Disconnect the neutral switch cable (Sky
blue).
•Connect the pocket tester ( Ωx 1) to the
neutral switch cables. Refer to “SWITCH CHECK” in Chapter 3.
Tester terminal (+) ➔Sky blue cable (1)
Tester terminal (–) ➔Earth
CORRECT
INCORRECT
The neutral switch is defective. Replace.
\f

 !
"#
"#
11. Clutch switch.
•Disconnect the clutch switch connector
from the harness.
•Connect the pocket tester ( Ωx 1) to the
clutch switch cable.
•Check the clutch switch component for
continuity between “Black (1)” and “Black
(2)”.
Refer to “SWITCH CHECK” in Chapter 3.
INCORRECT
The clutch switch is defective. Replace.
!$ %&!'







\f
*
CORRECT
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ELECIGNITION SYSTEM
7-19
*
12. Pick-up coil resistance.
•Disconnect the generator connector
(Green/White and Blue/Yellow).
•Connect the pocket tester ( Ωx 100) to
pick-up coil cables.
Tester terminal (+) ➔
Blue/Yellow cable (1)
Tester terminal (–) ➔
Green/White cable (2)
•Check that the pick-up coil resistance is as
specified.
Pick-up coil resistance: 230 Ω ±
±
20% at 20°C (68°F)
(Green/White - Blue/Yellow)
COMPLY WITH
SPECIFICATIONS
CORRECT
OUT OF SPECIFICATIONS
The pick-up coil is defective. Replace.
UNCERTAIN CONNECTIONS Correct.13. Wiring connections.
Check the connections of the entire ignition
system. Refer to “ELECTRICAL CIRCUIT
DIAGRAM” section.
The CDI unit is defective. Replace.
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