2004 YAMAHA TT600RE clock

•Install the starter rim on the gear and hold
the gear firm.
•When turning the gear rim in a clockwise
direction (A), the gear and rim must be
meshed. Otherwise, the gear is faulty and
must be replaced.
•When the gear rim is turned in a anti-
clockwise direction (B), it must turn freely.
Otherwise, the gear is faulty and must be
replaced.
INSPECTION AND REPAIR
5-38
ENG
STARTER TRANSMISSION
1. Check:
•Starter clutch functioning (1).
Turn the clutch in the direction indicated
by the arrow.
Irregular functioning/Damage ➔ Replace
the clutch.
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2. Inspect:
•Starter neutral gear teeth (1)
•Starter neutral gear teeth (2)
•Starter rim teeth (3)
Burrs/Shavings/Roughness/Wear ➔
Replace.
3. Inspect:
•Starter rim (contact surfaces)
Pitting/Wear/Damage ➔ Replace.
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ENGENGINE ASSEMBLY AND SETTING
5-61
7. Install:
•Dowel pins (1)
•O-Ring (2)
•Gasket (3) (cylinder head)
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Cylinder head:
Screw (l), (2), (3) and (4): 29 Nm (2.9 mkg)
Nut (5) and (6): 22 Nm (2.2 mkg)
Screw (7): 10 Nm (1.0 mkg)
8. Install:
•Cylinder head
NOTE:
Tighten screws beginning with the one with the
lowest number.
9. Install:
•Chain stopper guide
•Camshaft
•Cam chain sprocket
Timing chain installation:
•Install the cam chain on the cylinder head as
illustrated (compression phase timing).
•Run the cam shaft in an anticlockwise direc-
tion until the mark on the crankcase (1) and
the point on the cam chain gearwheel (2) are
aligned.
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CARBURETOR ASSEMBLY
6-12
CARB
Primary carburetor
1. Install:
•Needle jet (1)
•Connecter comp. (2)
NOTE:
Check that the connecter comp. (1) is in the posi-
tion shown in the figure.
2. Install:
•Throttle valve
3. Install:
•Spring
•Throttle shaft
NOTE:
Assemble the spring as shown in the illustration.
4. Install:
•Screw (connecter comp.)
NOTE:
Turn the throttle shaft clockwise (1/2 turn) to pre-
load the spring and then, holding it in position,
assemble the screw (connecter comp.).
Screw (connecter camp.): 2 Nm (0.2 mkg)
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LIGHT INSPECTION
7-8
ELEC
LIGHT INSPECTION (HEADLIGHTS,
TAIL LIGHT AND BRAKE LIGHTS,
DIRECTION INDICATOR LIGHTS,
INSTRUMENT LIGHTS, ETC)
Check the continuity between the bulb terminals to
see that they are undamaged.
BULB TYPES
The bulbs used are classified as shown to the left
according to type of attachment.
(B) is H4 type halogen bulb (12V - 55/60W) and it
is used for headlight.
Avoid touching the glass part of a bulb. Keep it
free from oil; otherwise, the transparency of
the glass, life of the bulb, and luminous flux will
be adversely affected. If oil gets on a bulb,
thoroughly clean it with a cloth moistened with
alcohol or lacquer thinner.
(A) and (C) are used mainly for headlights.
(D) is used mainly for direction indicator lights and
the rear and braking lights.
(E) and (F) are used especially for instrument and
other indication lights.
BULB INSPECTION
1. Remove the bulb.
NOTE:
•Bulbs of type (B) and (C) use special supports
(bulbholders). Remove the bulbholder before
removing the bulb. Most of these bulbholders
may be removed by turning in an anticlockwise
direction.
•Most bulbs of type (A), (D) and (E) may be
removed from their housing by pushing them
and turning them in an anticlockwise direction.
•Bulbs of type (F) may be removed simply by
pulling them out.
CAUTION:
A
F
CB
ED
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