2004 YAMAHA TT600RE transmission

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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INSPECTION AND REPAIR
5-36
ENG
TRANSMISSION AND GEARBOX
1. Inspect:
•Shift fork pin (1)
•Shift fork pawl (2)
Lines/Creases/Wear ➔Replace.
2. Inspect:
•Shift cam groove
•Shift cam pins
Wear/Damage ➔Replace.
3. Check:
•Shift fork movement
Rough functioning ➔Replace shift forks
and/or guide bars.
4. Inspect:
•Guide bar
Turn on a flat surface.
Curvature ➔Replace.
WARNING
Do not attempt to straighten the deformed
guide bar.
5. Measure:
•Transmission shaft eccentricity.
Use the centring tool and micrometer.
Out of specification ➔Replace bent shaft.
Transmission shaft eccentricity: : 0.08 mm
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ENGINSPECTION AND REPAIR
5-37
6. Inspect:
•Gear teeth
Brown colouring/Pitting/Wear ➔Replace.
•Mating clutches
Rounded edges/Cracks/Missing frag-
ments ➔Replace.
7. Check:
•Proper mating of each gear (with corre-
sponding part)
•Gear movement
Roughness ➔Replace.
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Transmission gear assembly steps:
•Fit the second gear (2) to the propeller shaft
(1) as shown in the figure.
(a) 60.0 mm
•Fit the second sprocket (4) and fifth sprocket
(5) to the main shaft (3).
(b) 90.5 mm
8. Inspect:
•Circlip
Damage/Loosening/Bending ➔Replace.
SHAFT AND STOPPER LEVER
1. Inspect:
•Shift shaft
Bent/Wear/Damage ➔Replace.
2. Inspect:
•Stopper lever (1)
The roller rotates jerkily ➔Replace.
Bent/Damage ➔Replace.
3. Inspect:
•Return spring (2)
Damage/Cracks ➔Replace.
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•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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ENGINE ASSEMBLY AND SETTING
5-46
ENG
TRANSMISSION
(1) Sprocket
(2) Oil seal
(3) Bearing
(4) Second wheel gear
(5) Secondary shaft
(6) Fifth wheel gear
(7) Third wheel gear
(8) Fourth wheel gear
(9) First wheel gear (10) Bearing
(11) Bearing
(12) Second sprocket gear
(13) Fifth sprocket gear
(14) Third sprocket gear
(15) Fourth sprocket gear
(16) Main shaft
(17) Bearing
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5-48
ENGENGINE ASSEMBLY AND SETTING
TRANSMISSION AND GEARBOX
1. Install:
•Transmission assembly (1)
2. Install:
•Shift fork #1 (1)
•Shift fork #2 (2)
•Shift fork #3 (3)
•Shift cam (4)
•Guide bar (5)
NOTE:
Each shift fork is identified by the number
stamped on its side. All numbers must face left.
3. Install:
•Shift shaft #1 (1)
•Shift shaft #2 (2)
NOTE:
Align mark (3) on the shift lever shaft with that on
the shift shaft.
4. Check:
•Transmission functioning
Jerky functioning ➔Repair.
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ENGENGINE ASSEMBLY AND SETTING
5-51
ENGINE OIL STRAINER
1. Install:
•Oil strainer (1)
•Oil passage cover (2)
Screw (oil strainer): 7 Nm (0.7 mkg)
Screw (oil passage cover): 7 Nm (0.7 mkg)
WARNING
Always use a new gasket.
Yamaha bond N° 1215 ®
:
P/N. 90890-85505
2 Install:
•Dowel pin (2)
3. Assemble the left crankcase to the right. Beat gently with a soft hammer.
NOTE:
Turn the shift cam as shown in the figure so that
it does not interfere with the crankcase during
assembly.
CRANKCASE
1. Apply:
•Yamaha bond N° 1215 ®
(1)
(on the crankcase mating surfaces)
Before installing and tightening the fastening
screws, be sure that the transmission is work-
ing properly by hand, turning the shift cam in
both directions.
CAUTION:
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ENGINE ASSEMBLY AND SETTING
5-52
ENG
4. Tighten:
•Screws (crankcase) (1) ~ (14)
NOTE:
Tighten the screws beginning with the one with
the lowest number.
Screw (crankcase): 10 Nm (1.0 mkg)
Stopper lever screw (4):
10 Nm (1.0 mkg)
5. Apply:
•4-stroke engine oil
(to the connecting rod pin, the bearing and
the oil passage).
6. Check:
•Gearbox and transmission functioning
Jerky functioning ➔Replace.
SHIFT SHAFT AND OIL PUMP
1. Install
•Spring (1)
•Collar (2)
•Stopper lever (3)
NOTE:
Place the stopper lever and the spring in the cor-
rect position.
2. Install:
•Plate washer (1)
•Spring (2)
•Shift lever (3)
•Circlip (4)
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