2004 YAMAHA TT600RE check engine

STEERING INSPECTION
3-40
INSP
ADJ
STEERING INSPECTION
WARNING
Hold the motorcycle firmly in place to prevent
it falling over.
1. Raise the front wheel and place a support
under the engine.
2. Check:
•Steering bearings
Grasp the bottoms of the front fork legs
and rock back and forward.
Free play ➔Adjust steering bearing.
3. Adjust:
•Steering bearing
Adjustment:
•Remove the fuel tank.
See section “SEAT, FUEL TANK AND REAR
COWLING”.
•Loosen steering axle nut (1) and fork upper
bracket screws (2).
•Tighten the ring nut (3) with the special
wrench.
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1
3
2
2
Ring nut (final tightening):
4 Nm (0.4 mkg)
Ring nut (initial tightening):
38 Nm (3.8 mkg)
Ringnut wrench:
P/N. 90890-01268
P/N. 90890-01348
NOTE:
The torque wrench and the ringnut wrench should
form a right angle.
WARNING
Do not tighten the ring nut excessively.
•Loosen the ring nut one turn.
•Retighten the ring nut using the special
wrench.
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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)
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ENGENGINE DISASSEMBLY
5-15
•Be careful not to damage surfaces in con-
tact with the crankcase.
•Use a soft hammer to hit the engine
crankcase. Only hit the reinforced parts.
Do not hit the surface in contact with the
gasket. Work slowly and carefully. Be care-
ful to perform the separation uniformly. If
one end locks, remove pressure from the
thrust screw, realign and recommence. If it
is impossible to separate the crankcase,
check that all screws and components
have been disassembled. Do not use force.
CAUTION:
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ENGENGINE DISASSEMBLY
5-19
VALVES
NOTE:
The valves may be inspected with the engine
installed by removing the following parts.
•Seat
•Fuel tank
•Exhaust pipe
•Carburetor
•Cylinder head cover
•Cylinder head
1. Check:
•Valve seal
Leakage from valve seats’ Inspect the
valve surface, the seat and seat width.
See section “VALVE SEAT INSPECTION
AND REPAIR”.
NOTE:
Check the valve seal before assembling the inter-
nal parts of the cylinder head (valves, valve
springs, spring retainer etc).
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Inspection steps:
•Pour clean solvent (1) into the intake and
exhaust ports.
•Check the valve seal. There must be no blow-
bys from the valve seats (2).
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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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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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ENGINE ASSEMBLY AND SETTING
5-60
ENG
5. Offset the piston ring end gaps as illustrated in the figure.
NOTE:
•Check that the marks and numbers stamped
by the manufacturer on the piston rings face
upwards.
•Before installing the cylinder, lubricate the pis-
ton rings liberally with 4-stroke engine oil.
(1) Upper ring
(2) Scraper (lower ring)
(3) Scraper (upper ring)
(4) Lower ring
6. Install:
•Cylinder (1)
NOTE:
•Install the cylinder to the piston with one hand
while one hand while compressing the piston
rings with the other.
•Bind the timing chain with wire and slip it
through the appropriate slot.
Cylinder:
Screw (2): 10 Nm (1.0 mkg)
Cap nut (3): 42 Nm (4.2 mkg)
Nut (4): 42 Nm (4.2 mkg)
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ENGINE ASSEMBLY AND SETTING
5-66
ENG
AC GENERATOR
1. Install:
•Woodruff key (1)
•Washer (2)
•Bearing (3)
•Rotor (4)
•Washer (5)
•Nut (6)
NOTE:
When installing the AC generator rotor, check that
the woodruff key fits properly into its seat on the
crankshaft. Apply a thin layer of lithium soap-
based grease on the conical tip of the crankshaft.
2. Tighten:
•Nut (rotor) Nut (rotor): 120 Nm (12.0 mkg)
NOTE:
To tighten the nut, lock the rotor with the special
tool (1).
Sheave holder: P/N. 90890-01701
Be careful not to touch the jutting edges (2) on
the rotor with the sheave holder.
CAUTION:
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