lock YAMAHA TT600RE 2004 Service Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: TT600RE, Model: YAMAHA TT600RE 2004Pages: 382, PDF Size: 6.39 MB
Page 5 of 382
ILLUSTRATED SYMBOLS
The following symbols are not relevant to every
vehicle.
Illustrated symbols 1to 8are printed on the top
right of each page and indicate the subject of
each chapter.
1General information
2Specifications
3Periodic inspections and adjustments
4Chassis
5Engine
6Carburetor
7Electrical system
8Troubleshooting
Illustrated symbols 9to yare used to identify
the specifications appearing in the text.
9Can be serviced with engine mounted
0Filling fluid
qLubricant
wSpecial tool
eTorque
rWear limit, clearance
tEngine speed
yElectrical data
Illustrated symbols uto sin the exploded dia-
grams indicate the types of lubricants and lubrica-
tion points.
uApply engine oil
iApply gear oil
oApply molybdenum disulfide oil
pApply wheel bearing grease
aApply lightweight lithium-soap base grease
sApply molybdenum disulfide grease
Illustrated symbols dto fin the exploded dia-
grams indicate the following:
dApply locking agent (LOCTITE
®)
fReplace the part
GEN
INFOSPEC
INSP
ADJCHAS
ENGCARB
ELECTRBL
SHTG
New
12
34
?
56
78
90
qw
er
ty
uoi
psa
df
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Page 9 of 382
GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION......................................................................................1-1
VEHICLE IDENTIFICATION NUMBER..........................................................................1-1
MODEL LABEL ..............................................................................................................1-1
IMPORTANT INFORMATION..............................................................................................1-2
PREPARATION FOR REMOVAL PROCEDURES ........................................................1-2
REPLACEMENT PARTS ..............................................................................................1-2
GASKETS, OIL SEALS AND O-RINGS ........................................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS ........................................................1-3
BEARINGS AND OIL SEALS ........................................................................................1-3
CIRCLIPS ......................................................................................................................1-3
CHECKING OF CONNECTIONS........................................................................................1-4
SPECIAL TOOLS..................................................................................................................1-5
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Page 13 of 382
GEN
INFO
IMPORTANT INFORMATION
1-3
EB101030
LOCK WASHERS/PLATES AND COTTER PINS
1. Replace all lock washers/plates 1and cotter
pins after removal. Bend lock tabs along the
bolt or nut flats after the bolt or nut has been
tightened to specification.
EB101040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the man-
ufacturer’s marks or numbers are visible.
When installing oil seals, apply a light coating
of lightweight lithium base grease to the seal
lips. Oil bearings liberally when installing, if
appropriate.
1Oil seal
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.
1Bearing
CAUTION:
EB101050
CIRCLIPS
1. Check all circlips carefully before reassembly.
Always replace piston pin clips after one use.
Replace distorted circlips. When installing a
circlip 1, make sure that the sharp-edged
corner 2is positioned opposite the thrust 3
it receives. See sectional view.
4Shaft
OR
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Page 17 of 382
1-7
GEN
INFO
SPECIAL TOOLS
Tool No.Tool name / Usage Illustration
90890-04086All-purpose clutch holder
This tool is used to lock the clutch, when the
clutch boss lock nut is being loosened or
tightened.
90890-01135Crankcase separating tool
This tool is necessary to disassemble the
crankcase.
90890-01274Crankshaft installation hose
This tool is used to install the crankshaft.
90890-01275Crankshaft installation bolt
This tool is used to install the crankshaft.
90890-04059#10 (M14) adapter
This tool is used to install the crankshaft.
90890-04081Crank spacer
This tool is used to install the crankshaft.
90890-85505SEALANT (QUICK GASKET) ®
Yamaha Bond No. 1215 ®
This sealant (adhesive) is used for crankcase
mating surfaces etc.
90890-01268Ringnut wrench
This tool is used to loosen and tighten the
steering ringnut.
90890-01348Ringnut wrench
This tool is used to loosen and tighten the
steering ringnut.
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Page 27 of 382
SPECMAINTENANCE SPECIFICATIONS
2-6
Item Standard Limit
Valve spring
Inner spring:
Free length intake40.10 mm 38.10 mm
exhaust 40.10 mm 38.10 mm
Installed length
(valve closed) intake22.70 mm •••
exhaust 22.70 mm •••
Compressed spring force
(installed)intake164.80 - 190.20 N •••
16.80 - 19.39 kg •••
exhaust 164.80 - 190.20 N •••
16.80 - 19.39 kg •••
Spring tilt intakeintake •••2.5 °/1.7 mm
exhaust ••• 2.5 °/1.7 mm
Winding direction
(top view)intakeClockwise
exhaust Clockwise
Outer spring:
Free length intakeintake43.80 mm 38.10 mm
exhaust 43.80 mm 38.10 mm
Installed length
(valve closed)intake34.20 mm •••
exhaust 34.20 mm •••
Compressed spring force intake71.60 - 87.30 N •••
(installed)7.3 - 8,9 kg •••
exhaust 149.10 - 182.40 N •••
15.2 - 18.6 kg •••
Spring tilt intake •••2.5 °/1.7 mm
exhaust ••• 2.5 °/1.9 mm
Winding direction
(top view)intakeCounterclockwise
exhaust Counterclockwise
Piston
Piston-to-cylinder clearance 0.045 - 0.065 mm 0.15 mm
Diameter D 94.915 - 94.965 mm •••
Height H 5.0 mm •••
Piston pin bore inside diameter 22.004 - 22.015 mm •••
Offset 2.00 mm •••
Offset direction Intake side
Piston pin outside diameter 21.991 - 22.000 mm •••
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Page 31 of 382
SPECMAINTENANCE SPECIFICATIONS
2-10
Tightening
Part torque
Part to be tightened
nameThread size Remarks
Nm mkg
Cylinder head Washer
based bol M8 x 1.25 29 2.9
Cylinder head Stud bolt M10 x 1.25 20 2.0
Cylinder head Hexagon socket
head screw M6 x 1.0 10 1.0
Cylinder head Stud bolt M6 x 1.0 7 0.7
Cylinder head:
Cap (oil check) Union bolt M6 x 1.0 7 0.7
Spark plug – M12 x 1.25 18 1.8
Cylinder head cover Hexagon socket
head screw M6 x 1.0 10 1.0
Tappet cover (intake) Hexagon socket
head screw M6 x 1.0 10 1.0
Tappet cover (exhaust) – M32 x 1.5 12 1.2
Cylinder Crown nut M8 x 1.25 22 2.2
Cylinder Nut M10 x 1.25 42 4.2
Cylinder Hexagon socket
head screw M6 x 1.0 10 1.0
Weight drive gear Hexagon nut M16 x 1.0 60 6.0
Rotor (A.C. magneto) Hexagon nut M14 x 1.5 120 12.0
Lock nut (valve adjusting screw) Hexagon nut M6 x 1.0 14 1.4
Cam chain sprocket Washer based
bolt M7 x 1.0 20 2.0
Cam chain stopper guide Hexagon socket
head screw M6 x 1.0 10 1.0
Cam chain stopper guide Washer based
screw M16 x 1.0 20 2.0
Rocker shaft Hexagon socket
head screw M6 x 1.0 10 1.0
Oil pump Hexagon socket
head screw M6 x 1.0 10 1.0
Oil delivery/retrieval pipe Pan screw M6 x 1.0 7 0.7
Oil draining pipe Washer based
screw M14 x 1.5 30 3.0
Oil filter cover Hexagon socket
head screw M6 x 1.0 10 1.0
Bleed screw (oil filter cover) Hexagon screw M5 x 0.8 5 0.5
Push lever (clutch) Pan screw M8 x 1.0 12 1.2
Push rod (clutch) Hexagon nut M6 x 1.0 8 0.8
Sprocket Hexagon nut M18 x 1.0 115 11.5
Lock washer (oil seal) Hexagon screw M6 x 1.0 10 1.0
Stop lever Bolt M6 x 1.0 10 1.0
Shift cam Hexagon screw M6 x 1.0 10 1.0
Stator Pan head (+)
screw M5 x 0.8 5 0.5
Tightening torques
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Page 33 of 382
SPECMAINTENANCE SPECIFICATIONS
2-12
Item Standard Limit
Steering
Steering bearing type Taper roller bearing
Lock to lock angle (left) 45° •••
Lock to lock angle (right) 45° •••
Front suspension
Front fork travel 277 - 283 mm •••
Fork spring free length 530 mm •••
Spring rate (K1) 7.0 N/mm (0.71 kgf/mm) •••
Spring stroke (K1) 330 mm •••
Spring rate (K2) 11.2 N/mm (1.14 kgf/mm) •••
Optional spring available No
Recommended oil Liqui Moly Racing suspension oil SAE 7,5
Quantity 650 cc •••
Level 180 mm •••
< min - max > 170-190 mm (from upper edge of inner •••
tube, fully compressed without spring)
Rear suspension
Rear shock absorber assembly travel 83 mm
Spring free length 224 mm •••
Installed length 211 mm ± 1.5 mm
Spring rate (K) 80 N/mm (8.1 kgf/mm) •••
Optional spring available No
Swingarm
Free play limit (at the end of
the swingarm)-radial ••• 1.0 mm
Free play limit (at the end of
the swingarm)-axial 0.4 - 0.7 mm •••
Front wheel
Wheel type Spoke wheel
Rim size 21 x 1.85
Rim material Aluminium
Max. radial wheel runout 1.0 mm •••
Max. lateral wheel runout 0.5 mm •••
Rear wheel
Wheel type Spoke wheel
Rim size 18 x MT2.50
Rim material Aluminium
Max. radial wheel runout 1.0 mm •••
Max. lateral wheel runout 0.5 mm •••
CHASSIS
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Page 58 of 382
VALVE CLEARANCE ADJUSTMENT
3-4
INSP
ADJ
ENGINE
VALVE CLEARANCE ADJUSTMENT
NOTE:
•Valve clearance must be adjusted when the
engine is at ambient temperature.
•Adjust valve clearance with the piston under
compression at top dead centre (T.D.C.).
WARNING
Hold the motorcycle firmly in place to prevent
it falling over during the operation.
1. Remove:
•Seat
•Fuel tank
See the section “ SEAT, FUEL TANK AND
REAR COWLING”.
2. Disconnect:
•Spark plug cap (1)
3. Remove:
•Spark plug
•Tappet cover (2) (intake)
•Tappet covers (3) (exhaust)
When removing the spark plug and tappet
cover, be careful not to drop foreign objects
inside the engine.
4. Remove:
•Cap (1)
•Cap (2)
CAUTION:
5. Turn the crankshaft anticlockwise using a
wrench.
1
2
3
12
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Page 59 of 382
INSP
ADJ
VALVE CLEARANCE ADJUSTMENT
3-5
6. Align:
•Reference mark “T” on the flywheel (1)
with the fixed reference mark on the
crankcase (2).
NOTE:
Check that the piston is under compression at top
dead centre (T.D.C.).
(3) Ignition timing reference mark
7. Check:
•Valve clearance
Out of specification ➔Adjust.
Valve clearance (cold):
Intake:
0.05 ~ 0.10 mm
Exhaust:
0.12 ~ 0.17 mm
8. Adjust:
•Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Adjustment:
•Loosen the lock nut (1).
•Fit a thickness gauge (2) between the rocker
arm and the valve stem.
•Turn the adjuster (1) clockwise or anticlock-
wise using the special tool (2) to obtain the
required clearance.
Special tool:
P/N. 90890-01311
•Holding the adjuster firmly in place, lock tight-
en lock nut.
Lock nut:
14 Nm (1.4 mkg)
•Measure valve clearance.
If the clearance is incorrect, repeat the previ-
ous stages to achieve the required value.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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Page 62 of 382
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
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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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