2004 YAMAHA TT600RE Service Manual

ENGENGINE DISASSEMBLY
5-5
ENGINE DISASSEMBLY
CYLINDER HEAD, CYLINDER, CAMSHAFT
AND PISTON
NOTE:
The cylinder head, cylinder, camshaft and piston
can be examined with the engine installed by
removing the following parts.
•Seat
•Fuel tank
•Rear cowling
•Carburetor
•Exhaust pipe
1. Remove:
•Spark plug (1)
•Tappet cover (2) (intake)
•Tappet covers (3) (exhaust)
•Cylinder head cover (4)
•Cap (5)
•Pins (6)
2. Loosen:
•Bolt (1) (chain tensioner)
3. Remove:
•Chain tensioner (2)
ProCarManuals.com

ENGINE DISASSEMBLY
5-6
ENG
4. Remove:
•Cam sprocket (1)
•Camshaft (2)
•Caps (left crankcase cover)
NOTE:
Fix a safety wire (3) to the timing chain to prevent
it falling into the crankcase.
5. Remove:
•Chain stopper guide (1)
6. Remove:
•Cylinder head
NOTE:
Loosen all bolts by a 1/4 turn and remove once all
are loosened.
ProCarManuals.com

ENGENGINE DISASSEMBLY
5-7
7. Remove:
•Gasket (1) (cylinder head)
•Pins (2)
•Cylinder (3)
•Gasket (4) (cylinder)
8. Remove:
•Pins (1)
9. Remove:
•Pin ring (1)
NOTE:
Before removing the pin ring, cover the crankcase
with a clean cloth to prevent the ring falling into
the crankcase cavity.
10. Remove:
•Pin (1)
•Piston (2)
NOTE:
Before removing the pin, burr the pin housing
groove. If it is hard to pull out the pin even with the
groove burred, use the pin puller.
ProCarManuals.com

ENGINE DISASSEMBLY
5-8
ENG
Avoid using the hammer to pull the pin out.
CAUTION: Piston pin puller set:
P/N. 90890-01304
3. Remove:
•Neutral gear switch cable (1)
2. Remove:
•Intermediate starter gear (1)
•Bearing (2)
•Distributor shaft (3)
INTERMEDIATE STARTER GEAR, CRANKCASE
COVER (L) AND GENERATOR STATOR
NOTE:
With the engine installed, maintenance of the inter-
mediate starter gear and the crankcase cover (L)
may be performed by removing the following parts.
•Exhaust pipe
•Starter
•Sprocket cover
1. Remove:
•Cover (1) intermediate starter gear
•Centring pins
•Gasket
ProCarManuals.com

ENGENGINE DISASSEMBLY
5-9
4. Remove:
•Crankcase cover gasket (1) (L)
•Centring pins
•Seal ring and O-ring
•Gasket
6. Remove:
•Cable clamp (1)
•Coil (2)
•Stator (3)
CRANKCASE COVER (R), CLUTCH, PRIMARY
DRIVE GEAR AND BALANCER SHAFT GEAR
NOTE:
The clutch, the primary gear and the balance gear
may be inspected with the engine installed by
removing the following parts.
•Footrest (R)
•Oil delivery hose screw
5. Remove:
•Intermediate starter gear (1)
•Bearing (2)
•Distributor shaft (3)
ProCarManuals.com

ENGINE DISASSEMBLY
5-10
ENG
2. Remove:
•Compression spring (1)
•Pressure plate (2)
•Ball (3)
•Friction plate (4)
•Clutch plate (5)
•Clutch boss spring (6)
•Clutch boss (7)
•Thrust plate (8)
•Clutch shroud (9)
•Push rod (10)
1. Remove:
•Engine oil delivery hose screw
•Copper washer
•Oil filter cover (1)
•Oil filter
•Seal ring and O-Ring
•Crankcase cover (2) (R)
NOTE:
•Before loosening the nut (11) (clutch shroud),
straighten the washer lock tab.
•To loosen the nut (clutch boss), block the
clutch boss using the special tool (12).
Clutch holding tool: P/N. 90890-04086
ProCarManuals.com

ENGENGINE DISASSEMBLY
5-11
3. Remove
•Primary drive gear (1)
•Disc (2)
•Balancer drive gear (3)
•Disc (4)
•Key (5)
•Disc washer (6)
•Disc (7)
•Balancer gear (8)
•Straight key (9)
NOTE:
Before loosening the nut (9) (primary drive gear)
and nut (10) (balancer gear), straighten the wash
lock tab.
NOTE:
To loosen nuts (9) and (10), hold the rotor (CA
magneto) firmly in place using special tool (11).
Sheave holder: P/N. 90890-01701
Be careful not to touch jutting edges (12) on
the rotor with the sheave holder.
CAUTION:
4. Remove:
•Push lever (1)
•Spring
•Flat washer
NOTE:
Loosen the screw to remove the push rod.
ProCarManuals.com

ENGINE DISASSEMBLY
5-12
ENG
OIL PUMP AND SHIFT LEVER
NOTE:
The oil pump and shift lever may be checked with
the engine installed by removing the following
parts:
•Footrest (R)
•Oil delivery hose screw
•Crankcase (R)
•Clutch
1. Remove:
•Circlip (1)
•Oil pump gear (2)
•Oil pump (3)
•O-rings (4)
2. Remove:
•Circlip (1) (from drive shaft)
•Ring (2)
•Circlip (3)
3. Remove:
•Circlip (1)
•Shift lever (2)
•Spring (3)
•Flat washer (4)
4. Remove:
•Stopper lever (1)
•Ring (2)
•Spring (3)
ProCarManuals.com