2004 YAMAHA TT600RE length

DRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-82
CHAS
DRIVE CHAIN, DRIVE SPROCKET AND
REAR WHEEL SPROCKET
NOTE:
Before removing the drive chain, drive sprocket
and rear wheel sprocket, it is necessary to meas-
ure the free play and length of the 10 links in the
chain.
DRIVE CHAIN REMOVAL
1. Park the motorcycle upright on an even sur- face.
2. Remove:
•Shift pedal (1)
•Cover (2) (drive sprocket)
3. Remove:
•Drive sprocket (1)
NOTE:
•Before removing the sprocket nut, straighten
the tab on the lock washer.
•Loosen the nut with the rear brake pulled.
4. Raise the rear wheel placing a suitable sup- port under the engine.
WARNING
Set the motorcycle up securely to prevent it
falling over.
5. Remove:
•Rear wheel
•Rear wheel sprocket
•Hub
•Damper
•Spacer
Refer to “REAR WHEEL REMOVAL” sec-
tion.


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CHASDRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-83

6. Remove:
•Swingarm
•Drive chain
Refer to “REAR SHOCK ABSORBER
REMOVAL” and “SWINGARM REMOVAL”
sections.
DRIVE CHAIN INSPECTION
1. Measure:
•Length of 10 links (drive chain)
Out of specification ➔Replace drive
chain.
Maximum lenght of 10 links (a): 150.2 mm
NOTE:
•Stretch the chain by hand to measure it.
•The length of the 10 links is recorded between
the inside of the link pins (1) and (11) as
shown.
•The length of the 10 links is measured at var-
ious points.
2. Clean:
•Drive chain
Immerge in kerosene and brush thorough-
ly to remove as much dirt as possible.
Remove from kerosene and allow to dry.
This motorcycle is fitted with a chain with
small O-Rings (1) fitted between its plates.
Vapour cleaning, pressurised washing and
certain types of solvents may damage these
seal rings.
To clean the transmission chain use only
kerosene.
CAUTION:
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ENGINSPECTION AND REPAIR
5-27
•Apply Prussian blue (Dykem) to the valve seal
surface.
•Install the valve in the cylinder head.
•Press the valve onto the housing through the
guide to leave a clear outline.
•Measure the valve seat width once more. If
the width of the valve is out of specification
alter and relap.

VALVE SPRINGS
1. Measure:
•Free width of valve springs (a)
Out of specification ➔Replace.
Free width of valve springs
(intake and exhaust):
Internal spring External spring 40.1 mm 43.8 mm
Valve spring load:
Internal spring (intake and exhaust) 164.8 ~ 190.2 N
(16.80 ~ 19.39 kgf) at 22.7 mm
External spring (intake) 71.6 ~ 87.3 N
(7.3 ~ 8.9 kgf) at 34.2 mm
External spring (exhaust) 149.1 ~ 182.4 N
(15.2 ~ 18.6 kgf) at 34.2 mm
2. Measure:
•Spring load
Out of specification ➔Replace.
(b) Length of loaded spring
3. Measure:
•Inclination of spring (a)
Out of specification ➔Replace.
Spring inclination limit:
Internal spring External spring 2.5°/1.7 mm 2.5°/1.9 mm
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ENGINSPECTION AND REPAIR
5-35
7. Measure:
•Free length of clutch compression springs
(a)
Out of specification ➔Replace all springs.
OIL PUMP
1. Measure:
•Clearance between rotors (a)
(Between the internal rotor (1) and the
external rotor (2))
•Side clearance (b)
(Between the external rotor (2) and the
pump stator (3))
Out of specification ➔Replace oil pump.
Free length of clutch compression
spring (a): 42.8 mm
Oil pump clearances:
Clearance between 0.12 mm
rotors (a) : 0.2 mm
Side clearance (b) 0.03 ~ 0.08 mm
: 0.15 mm
2. Inspect:
•Oil pump drive gear (1)
•Oil pump driven gear (2)
Wear/Cracks/Damage ➔Replace.
PRIMARY TRANSMISSION
1. Inspect:
•Primary drive gear teeth (1)
•Primary driven gear teeth (2)
Wear/Damage ➔Replace both gears.
Excess noise during functioning ➔
Replace both gears.
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