2004 YAMAHA TT600RE Service Manual

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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ENGINSPECTION AND REPAIR
5-39
CRANKSHAFT
1. Measure:
•Width of crank (A)
Out of specification ➔Replace crankshaft.
Width of crank: 74.95 ~ 75.00 mm
Crankshaft runout:: 0.03 mm
Connecting rod small end clearance:0.8 mm
Connecting rod big end clearance:0.35 ~ 0.65 mm
•Runout (B)
Out of specification ➔Replace crankshaft
and/or crank bearing.
•Connecting rod small end clearance (C)
Out of specification ➔Replace connecting
rod big end bearing, connecting rod pin
and/or connecting rod.
•Side clearance (D)
Out of specification ➔Replace connecting
rod.
Crankshaft assembly procedure:
The passages of crankshaft (1) oil and con-
necting rod pin (2) oil must coincide with a tol-
erance of less than 1.0 mm.
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INSPECTION AND REPAIR
5-40
ENG
BALANCER SHAFT DRIVE AND DRIVEN
GEARS
1. Inspect:
•Drive gear teeth (1)
•Driven gear teeth (2)
Wear/damage ➔Replace both gears.
2. Check:
•Marks (1)
If they are not aligned ➔Align the marks
as shown in the figure.
CRANKCASE
1. Inspect:
•Crankcase
•Bearing housing
Damaged ➔Replace.
BEARING AND OIL SEAL
1. Inspect:
•Bearing
Roughness/Pitting/Damage ➔Replace.
•Oil seal edge
Damage/Wear ➔Replace.
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ENGENGINE ASSEMBLY AND SETTING
5-41
ENGINE ASSEMBLY AND SETTING
VALVES AND ROCKER ARMS
(1) Rocker arm n. 2
(2) Wave washer
(3) Rocker shaft (intake)
(4) Rocker arm n. 1
(5) Valve cotters
(6) Upper valve spring retainer
(7) Oil seal
(8) Inner valve spring
(9) Outer valve spring (10) Valve (intake)
(11) Lower valve spring retainer
(12) Rocker shaft (exhaust)
(13) Rocker arm n. 4
(14) Rocker arm n. 3
(15) Rocker shaft (exhaust)
(16) Valve (exhaust)
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ENGINE ASSEMBLY AND SETTING
5-42
ENG
VALVES
1. Burrs:
•Valve stem tip
(leave the valve stem tip with an oil stone).
2. Lubricate:
•Valve stem and oil seal (apply high quality
molybdenum disulfide oil)
3. Install:
•Oil seal (1)
•Valves (2)
•Lower valve spring retainer (3)
•Inner valve spring (4)
•Outer valve spring (5)
•Upper valve spring retainer (6)
NOTE:
Install the innner and outer springs with the widest
thread upwards.
4. Install:
•Valve cotters (1)
NOTE:
Compress the valve spring with the specific tool
(2) to fit the cotters.
Valve spring compressor: P/N. 90890-04019
(7) Higher pitch
(8) Lower pitch
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ENGENGINE ASSEMBLY AND SETTING
5-43
ROCKER ARMS
1. Lubricate:
•Rocker shaft (apply engine oil)
2. Install:
•Rocker arm
•Rocker shaft
Screws (1) (rocker shaft): 10 Nm (1.0 kgm)
NOTE:
Each rocker arm is numbered.
(1) # 1
(2) # 2
(3) # 3
(4) # 4
3. Install:
•Cap (1)
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ENGINE ASSEMBLY AND SETTING
5-44
ENG
CRANKSHAFT AND BALANCER SHAFT
(1) Connecting rod pin
(2) Crank (left)
(3) Connecting rod
(4) Bearing (5) Bearing
(6) Bearing
(7) Balancer shaft
(8) Bearing
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