2004 YAMAHA TT600RE Service Manual

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
ProCarManuals.com

GEN
INFO
ProCarManuals.com

1-1
GEN
INFO
VEHICLE IDENTIFICATION


GENERAL INFORMATION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is stamped in-
to the frame.
MODEL LABEL
The model label 1is affixed to the frame under
the seat.
This information will be needed to order spare
parts.
ProCarManuals.com

GEN
INFO
IMPORTANT INFORMATION
1-2
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCEDURES
1. Remove all dirt, mud, dust and foreign materi-
al before removal and disassembly.
2. Use proper tools and cleaning equipment.
Refer to the “SPECIAL TOOLS” section.
3. When disassembling the machine, always
keep mated parts together. This includes
gears, cylinders, pistons and other parts that
have been “mated” through normal wear.
Mated parts must always be reused or
replaced as an assembly.
4. During machine disassembly, clean all parts
and place them in trays in the order of disas-
sembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS
1. Replace all gaskets, seals and O-rings when
overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearings dur-
ing reassembly. Apply grease to the oil seal
lips.
ProCarManuals.com

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
ProCarManuals.com

GEN
INFO
CHECKING OF CONNECTIONS
1-4
EB801000
CHECKING OF CONNECTIONS
Check the connectors for stains, rust, moisture,
etc.
1. Disconnect:
•connector
2. Check:
•connector
Moisture →Dry each terminal with an air
blower.
Stains/rust →Connect and disconnect the
terminals several times.
3. Check:
•connector leads
Looseness →Bend up the pin 1and con-
nect the terminals.
4. Connect:
•connector terminals
NOTE:
The two terminals “click” together.
5. Check:
•continuity (using a pocket tester)
NOTE:
•If there is no continuity, clean the terminals.
•When checking the wire harness be sure to
perform steps 1 to 3.
•As a quick remedy, use a contact revitalizer
available at most part stores.
•Check the connector with a pocket tester as
shown.
ProCarManuals.com

1-5
GEN
INFO
SPECIAL TOOLS
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the
appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or impro-
vised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
90890-03113Engine tachometer
This tool is needed for detecting engine rpm.
90890-03141Timing light
This tool is needed for detecting ignition
timing.
90890-03112Pocket tester
These instruments are invaluable for check-
ing the electrical system.
90890-06754Ignition checker
This instrument is necessary for checking
the ignition system components.
Tool name / Usage Illustration
90890-03081Compression gauge
These tools are used to measure the engine
compression.
90890-04082Adapter (compression gauge)
This tool serves to measure the engine com-
pression.
90890-01312Fuel level gauge
This gauge is used to measure the fuel level
in the float chamber.
90890-01304Piston pin clip puller
This tool serves for removing the piston pin
clip.
ProCarManuals.com

1-6
GEN
INFO
SPECIAL TOOLS
Tool No.
90890-01083Rocker arm shaft puller bolt
These tools are used when removing the
rocker arm shafts.
Tool name / Usage Illustration
90890-01084Weight
These tools are used when removing the
rocker arm shafts.
90890-04019Valve spring compressor
These tools are used when removing or
installing the valve and the valve spring.
90890-012257 mm (0.28 in) valve guide puller
This tool is used to remove the valve guides.
90890-040177 mm (0.28 in) valve guide installer
This tool is necessary to install the valve
slides properly.
90890-012277 mm (0.28 in) valve guide reamer
This tool is used to re-ream the new valve
guide.
90890-01311Valve adjusting tool
This tool is necessary for adjusting valve
clearance.
90890-01701Rotor holder
This tool is used for loosing and tightening
the rotor nut.
90890-01362Rotor screw puller
This tool is used to disassemble the magne-
to flywheel rotor.
ProCarManuals.com