2004 YAMAHA TT600RE key

ENGINE ASSEMBLY AND SETTING
5-72
ENG
NOTE:
Install the friction and clutch plates to the clutch
boss, beginning and ending with a friction plate.
•The two friction plates (type A) (15) with
the widest internal diameter should be
assembled in second and last place.
•The clutch boss spring (16) should be
placed inside the second friction plate.
CAUTION:
Friction plate
Type “A” Type “B”
Quantity 2 6
Internal 116 mm 113 mm
diameter “D”
NOTE:
Align the mark on the clutch boss (17) with the
arrow (18) on the pressure plate.
3. Adjust:
•Clutch (free play)
See section “CLUTCH ADJUSTMENT” in
CHAPTER 3.
4. Install:
•Straight key
•Gasket
•Crankcase cover (right) (1)
•O-Ring
•Oil filter
•Filter cover (2) (with O-Ring)
See section “Engine oil replacement (with
oil filter change)” in CHAPTER 3.
Bolt (crankcase cover): 10 Nm (1.0 mkg)
16
15
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SWITCH CHECK
7-6
ELEC

 







 


1. Detach the main switch connector from the
harness connector.
When detaching the connector, do not pull by
the cables. This way the cables might discon-
nect from the terminals inside the connector
itself.
2. Check to see if any cables are disconnected from their terminal inside the connector.
Reconnect, if necessary.
NOTE:
If the connector is blocked up with mud or dust,
clean it with a jet of compressed air.
3. Use the connection table to check the combi- nation of colours for continuity (closed circuit).
In this example, continuity is as follows:
“R” and “Br” are continuous when the switch is
at ON.
“L” and “R/B” are continuous when the switch
is at ON.
“R” and “L” are continuous when the switch is
at PARK.
Note that there is no continuity (open circuit)
for any of the combinations of a colour differ-
ent from those mentioned and when the
switch is at OFF.
4. Check the switch component for continuity between “R” and “Br”.
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Control procedure:
•Repeatedly shift the switch key to the various
positions - ON, OFF and PARK.
•Shift the tester selector to “ Ωx1”.
•Connect the tester positive cable (+) to the
terminal of cable “R” of the connector, and the
negative cable (–) to cable terminal “Br”.
CAUTION
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FAILURE TO START/
DIFFICULTIES IN STARTING
8-2
TRBL
SHTG
?
Spark plug
Ignition coil
Ignition unit
Switches and cables PROBABLE CAUSES•Electrodes gap not correct
•Electrodes worn
•Feed cable interrupted
•Wrong thermal grading of spark plug
•Defective spark plug cap
•Primary or secondary winding interrupted
•High voltage cable defective
•Defective coil
•Defective unit
•Defective pick-up coil
•Woodruff key broken
Starter motor
•Starter motor defective
•Starter motor relay defective
•Diodes defectives
•Starter one-way bearing defective
•Main switch defective
•Emergency stop engine switch defective
•Harness with cable interrupted
•Neutral switch defective
•Sidestand switch defective
•Clutch switch defective
•Starter switch defective
ELECTRICAL SYSTEM
Cylinder and cylinder head
Piston and piston rings
Crankcase and valves, crankshaft PROBABLE CAUSES
•Spark plug tightening insufficiently
•Cylinder head or cylinder insufficiently tightened
•Cylinder head gasket broken
•Cylinder gasket broken
•Cylinder worn, damaged or seized
•Piston rings wrongly assembled
•Piston rings worn, yielded or broken
•Piston rings stuck together
•Piston seized or damaged
•Poor crankcase sealing
•Crankshaft oil seal edge damaged
•Poor valve sealing
•Valve and seat with insufficient contact
•Valve timing wrongly
•Valve spring broken
•Crankshaft seized
•Camshaft seized
POOR ENGINE COMPRESSION
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