2004 YAMAHA TT600RE oil filter

AIR FILTER CLEANING
3-24
INSP
ADJ



AIR FILTER CLEANING
1. Remove:
•Fast screws (1)
•Air filter box cap (2)
2. Pull out:
•Filtering element (3) from its seat
3. Wash:
•Filtering element (with water and
biodegradable liquid soap)
NOTE:
Rinse properly and dry perfectly by squeezing the
filtering element, without twisting it!
4. Inspect:
•Filtering element
Damaged ➔Replace.
5. Apply:
•SAE 20W50 engine oil or special filter oil
all over filter surface
6. Squeeze out:
•Excess oil
NOTE:
The filtering element should be wet but not drip-
ping.
3
7. Install:
•Filtering element (4) in its case
NOTE:
When installing the filtering element in its case, fol-
low the direction indicated by the arrows, make sure
that the flame-trap net is set forward and that the
cap is properly assembled.
8. Reassemble:
•Air filter box cap
•Fast screws
Make sure the air filter is properly seated in
the air filter case.
The engine should never be run without the
air filter installed. Excessive piston and/or
cylinder wear may result.
CAUTION:
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ENGINE OIL TANK FILTER CLEANING
3-26
INSP
ADJ
ENGINE OIL TANK FILTER CLEANING
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Drain:
•Engine oil
See section “ENGINE OIL REPLACE-
MENT”.
2. Remove:
•Seat
•Rear cowling
See section “SEAT, FUEL TANK AND
REAR COWLING”.
•Rear wire harness
•Exhaust muffler
•Exhaust pipe
•Rear shock absorber
See section “REAR SHOCK ABSORBER”
in Chapter 4.
•Joint air cleaner clamps
•Rear frame
•Engine oil tank
3. Loosen:
•Stay (rear left side cover) fastening
screws
4. Remove:
•Oil tank cap (1)
•Oil return hose (2)
•Oil return hose flange (4) fastening screw
(3)
•Oil delivery hose flange (6) fastening
screws (5)
•Oil tank filter (7)
•OR gaskets (8)
5. Clean:
•Oil tank filter (with solvent)
•Oil tank (with solvent)
NOTE:
After cleaning the inside of the oil tank, remove
the remaining solvent.
6. Inspect:
•OR gaskets
Damaged ➔Replace.
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INSP
ADJ
ENGINE OIL TANK FILTER CLEANING
3-27
7. Reassemble:
•OR gaskets
•Oil tank filter
•Oil delivery hose flange fastening screws
Screw (oil delivery hose flange):
10 Nm (1.0 mkg)
Screw (oil return hose flange):
35 Nm (3.5 mkg)
•Oil return hose
•Oil return hose flange fastening screws
8. Tighten:
•Stay (rear left side cover) fastening
screws
9. Reassemble:
•Engine oil tank
•Rear frame
•Joint air cleaner clamps
•Rear shock absorber
See section “REAR SHOCK ABSORBER”
in Chapter 4.
•Exhaust pipe
•Exhaust muffler
•Rear wire harness
•Rear cowling
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
10. Fill:
•Engine oil
See section “ENGINE OIL REPLACE-
MENT”.
11. Reassemble:
•Engine tank capScrew (seat):
10 Nm (1.0 mkg)
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ENG
ENGINE ASSEMBLY AND SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
VALVES AND ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
CRANKSHAFT AND BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
TRANSMISSION AND GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
ENGINE OIL PUMP AND OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
ENGINE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
SHIFT SHAFT AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
PISTON AND RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
CAMSHAFT AND TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
PISTON, CYLINDER, CYLINDER HEAD AND CAMSHAFT . . . . . . . . . . . . . . . . . . . 5-59
AC GENERATOR.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
OIL FILTER AND OIL HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
BALANCER SHAFT GEAR AND PRIMARY
TRANSMISSION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
STARTER GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
STARTER NEUTRAL GEAR AND CRANKCASE COVER (L) . . . . . . . . . . . . . . . . . 5-74
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
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ENGENGINE REMOVAL
5-3
Order Job name/Part name Q.ty Remarks – Starter leads 2 Disconnect.
– Starter 1 Remove.
10 Connectors of engine wire harness 2 Disconnect. 11 Oil delivery hose 1 Disconnect.
12 Oil return hose 1 Disconnect.
13 Oil breather pipe (to oil tank) – Disconnect.
14 Oil breather pipe (to air filter box) – Disconnect. Reverse the removal procedure for
installation.
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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
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ENGENGINE ASSEMBLY AND SETTING
5-67
OIL FILTER AND OIL HOSES
(1) Oil filter
(2) Filter cover
(3) Oil hose
(4) Oil hose
(5) Oil delivery hose
(6) Oil drain plug
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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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