stop start YAMAHA TT600RE 2004 Service Manual

SPECMAINTENANCE SPECIFICATIONS
2-15
Tightening
Part to be tightened Thread torque
Remarkssize
N·mm·kg
Front brake:
Front hub/Disc brake M6 x 1.0 12 1.2
Front caliper/Front fork M8 x 1.25 25 2.5
Front caliper/Bleeder tightening M10 x 1.0 14 1.4
Union bolt tightening (front) M10 x 1.0 20 2.0
Rear brake:
Rear hub/Disc brake M6 x 1.0 12 1.2
Rear master cylinder/Frame M6 x 1.0 10 1.0
Rear stop switch/Rear master cylinder M10 x 1.0 20 2.0
Rear caliper/Bleeder tightening M10 x 1.0 14 1.4
Protector rear caliper/Rear caliper M6 x 1.0 10 1.0
Union bolt tightening (rear) M10 x 1.0 20 2.0
Rear brake tank reserve/Air cleaner assy M6 x 1.0 5 0.5
Brake pedal/Frame M10 x 1.25 48 4.8
Sidestand/Footrest:
Sidestand mounting bolt/Frame M12 x 1.25 40 4.0
Sidestand mounting bolt/Nut M12 x 1.25 40 4.0
Sidestand switch/Frame M5 x 0.8 8 0.8
Rear footrest/Rear frame M8 x 1.25 30 3.0
Bracket 1 (main footrest)/Frame M10 x 1.25 48 4.8
Bracket 2 (main footrest)/Frame M10 x 1.25 48 4.8
Footrest cover/Footrest M6 x 1.0 10 1.0
Seat, fuel tank and oil tank:
Seat/Frame M6 x 1.0 10 1.0
Bolt (guide seat)/Fuel tank M6 x 1.0 5 0.5
Fuel tank/Rear frame M6 x 1.0 12 1.2
Damper fuel tank (front)/Frame M8 x 1.25 15 1.5
Fuel tank/Fuel cock M6 x 1.0 7 0.7
Oil tank/Sub-oil tank M6 x 1.0 7 0.7
Union bolt (oil hose 2)/Oil tank assy/Engine M12 x 1.25 35 3.5
Oil hose 1/Oil tank/Engine M6 x 1.0 10 1.0
Oil tank/Rear frame M12 x 1.5 20 2.0
Frame, rear fender compl. and lights:
Rear fender compl. (under)/Rear frame M6 x 1.0 2 0.2
Rear fender compl. (upper)/Rear frame M6 x 1.0 7 0.7
Bracket, license/Rear frame M6 x 1.0 10 1.0
Bracket, license/Rear flasher M6 x 1.0 10 1.0
Horn/Frame M6 x 1.0 13 1.3
Regulator/Frame M8 x 1.25 7 0.7
Igniton coil/Frame M5 x 0.8 13 1.3
Battery box/Rear frame M6 x 1.0 7 0.7
Igniter cover/Battery box M4 1 0.1
Main switch/Frame M24 x 1.0 1 0.1
Tail light (lense)/Rear fender compl. M3.5 1 0.1
Starter switch/Red wire M6 x 1.0 7 0.7
ProCarManuals.com

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
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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
ProCarManuals.com

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:
ProCarManuals.com

INSP
ADJ
3-21
ENGINE OIL PRESSURE CHECK/
CLUTCH ADJUSTMENT







ENGINE OIL PRESSURE CHECK
1. Remove:
•Bleeder screw (1)
2. Start the engine and keep it idling until oil
flows out of the bleed hole.
3. Inspect:
•Conditions of oil at bleeder hole.
Oil leakage ➔Oil pressure good.
No leakage ➔Pressure insufficient.
If the oil does not come out after one minute,
stop the engine immediately to prevent
seizure.
4. Tighten:
•Bleeder screw
CAUTION:
Bleeder screw:
5 Nm (0.5 kgm)
CLUTCH ADJUSTMENT
Cable free play adjustment
1. Check:
•Clutch free play adjustment (a)
Out of specification ➔Adjust.
Free play:
10 ~ 15 mm
2. Adjust:
•Clutch cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjustment:
•Loosen lock nuts (1).
•Turn the adjuster (2) either way to obtain cor-
rect free play.
•Tighten lock nuts after adjustment.

ProCarManuals.com

CHECKING AND CHARGING THE BATTERY
3-50
INSP
ADJ
Charging method using a variable-current (voltage) type charger
ChargerNOTE:Voltage should be measured 30 minutesafter the machine is stopped.
NOTE:
Set the charging voltage at 16 ~ 17 V (if
the setting is lower, charging will be
insufficient. If too high, the battery will be
over-charged.)
AMP
meterMeasure the open-circuit
voltage prior to charging.
Connect a charger and AMP
meter to the battery and start
charging.
Make sure the current is
higher than the standard
charging current written on
the battery.
By turning the charging voltage
adjust dial, set the charging
voltage at 20 ~ 25 V.
Monitor the amperage for 3 ~ 5
minutes to check if the standard
charging current is reached.Adjust the voltage so that
current is at standard charg-
ing level.
Set the timer according to
the charging time suitable for
the open-circuit voltage.
Refer to "Battery condition
checking steps."If the current does
not exceed standard
charging current af-
ter 5 minutes, re-
place the battery.
In case that charging requires more than 5 hours, it is advisable to check
the charging current after a lapse of 5 hours.
If there is any charge in the amperage, readjust the voltage to obtain the
standard charging current.
Measure the battery open-circuit voltage after having left the battery un-
used for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
YES
YESNO
NO
ProCarManuals.com

INSP
ADJ
CHECKING AND CHARGING THE BATTERY
3-51
Charging method using a constant-voltage type charger
Measure the open-circuit
voltage prior to charging.
Connect a charger and AMP
meter to the battery and start
charging.
Make sure the current is
higher than the standard
charging current written on
the battery.
Charge the battery until the battery’s
charging voltage is 15 V.This type of battery charger cannot
charge the MF battery. A variable volt-
NOTE:Voltage should be measured 30 min-utes after the machine is stopped.
Measure the battery open-circuit volt-
age after having left the battery unused
for more than 30 minutes.
12.8 V or more --- Charging is com-
plete.
12.7 V or less --- Recharging is re-
quired.
Under 12.0 V --- Replace the battery.
NOTE:Set the charging time at 20 hours (max-imum).
NO
YES
Charging method using a constant-current type charger
This type of battery charger cannot charge the MF battery.
Charger
AMP meter
Voltmeter
ProCarManuals.com

ENG
CHAPTER 5. ENGINE
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
MUFFLER, EXHAUST PIPE, ENGINE PROTECTOR, DRIVE SPROCKET,
CRANKCASE COVER, DRIVE SPROCKET AND SHIFT PEDAL . . . . . . . . . . . . . . . 5-1
ENGINE MOUNTING BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CYLINDER HEAD, CYLINDER, CAMSHAFT AND PISTON . . . . . . . . . . . . . . . . . . . . 5-5
INTERMEDIATE STARTER GEAR, CRANKCASE COVER (L)
AND GENERATOR STATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
CRANKCASE COVER (R), CLUTCH, PRIMARY DRIVE GEAR
AND BALANCER SHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
OIL PUMP AND SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
AC GENERATOR AND TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
CRANKCASE(R). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
GEARBOX AND TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
BALANCER SHAFT AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
OILSTRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
VALVESEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
ROCKER ARMS AND ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
CAMSHAFT CHAIN AND SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
CAMSHAFT CHAIN GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
PISTONPIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
OILPUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
PRIMARY TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
TRANSMISSION AND GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
SHIFT SHAFT AND STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
STARTER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
BALANCER SHAFT DRIVE
AND DRIVEN GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
BEARING AND OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
ProCarManuals.com

CARBURETOR
6-4
CARB
(1) Carburetor assembly
(2) Cover gasket
(3) Gasket, nozzle
(4) Float
(5) Float pin
(6) Float chamber gasket
(7) Screw
(8) Float chamber fastening screw
(9) Spring washer
(10) Collar
(11) Screw
(12) Gasket (13) Throttle valve
spring
(14) Spring washer
(15) Nut
(16) Gasket
(17) Screw
(18) Stop screw
(19) Nut
(20) Screw
(21) Hose
(22) Diaphragm
(23) Cover
(24) Bracket
(25) O-ring
(26) Spring washer (27) Spring
(28) Drain valve
(29) Pipe
(30) Pipe
(31) Screw
(32) Screw
(33) Pipe
(34) Clip
(35) Main jet 1
(36) Main nozzle 1
(37) Throttle valve
(38) Pilot jet
(39) Main jet 2
(40) Main nozzle 2
(41) Pilot screw set (42) Needle valve set
(43) Stop screw set
(44) Throttle screw set
(45) Diaphragm
(46) Needle set 1
(47) Needle set 2
(48) Starter set
(49) Way 3
(50) Hose
(51) Hose
(52) Hose
(53) Clip
(54) Breather pipe
(55) O-ring
(56) Pipe
SPECIFICATIONS
Main jet #150 FIRST #145 SEC.
Starter jet #74
Needle jet 5C5A-3/5 ( FIRST) 5Y18-3/5 (SEC.)
Main nozzle ø 2,6
Pilot jet #50
Pilot air screw 2,75 ± 0,5 revs approx.,
open
Float height 27~29 mm
Fuel level 6~8 mm
Engine idle speed 1.150~1.450 r/min
Throttle valve seat ø 2,5 mm
ProCarManuals.com

CARBCARBURETOR DISASSEMBLY
6-7
2. Remove:
•Needle valve set/Valve seat (1)
•Main jet/Main nozzle 1 (2)
•Pilot jet (3)
•Pilot screw set (4)
•O-Ring (5)
3. Remove:
•Stop screw (1)
•Starter set (2)
4. Remove:
•Cover (1) (enrichment)
•Spring (2)
•Diaphragm (3)
5. Remove:
•Top cover (1)
•Cover gasket (2)
•Screw (3) (connecter comp.)
6. Remove:
•Throttle lever (1)
•Collar (2)
•Cable holder (3)
ProCarManuals.com

CARBCARBURETOR INSPECTION
6-9
CARBURETOR INSPECTION
1. Inspect:
•Carburetor body
Soiled ➔Clean.
NOTE:
Use petroleum-based solutions to clean. Clean all
passages and jets with compressed air.
2. Inspect:
•Valve seat (1)
•Needle valve set (2)
Wear/Corrosion ➔Replace.
•O-Ring (3)
Damaged ➔Replace.
NOTE:
Always replace the needle valve set and the valve
seat together.
3. Inspect:
•Starter piston (1)
Wear/Damage ➔Replace
•Stop screw (2)
Damaged ➔Replace.
4. Inspect:
•Diaphragm (1) (piston valve)
•Diaphragm (2) (enrichment)
Damaged ➔Replace.
5. Inspect:
•Needle jet (1) (primary)
•Needle jet (2) (secondary)
Curvature/Wear ➔Replace.
ProCarManuals.com