2004 YAMAHA TT600RE Service Manual

ENGENGINE ASSEMBLY AND SETTING
5-45
CRANKSHAFT AND BALANCER SHAFT
1. Install:
•Crankshaft
Crankshaft installation tool (1):
P/N. Y U-90050
Crankshaft installation tool spacer (2):
P/N. 90890-01274
Crankshaft installation tool bolt (3):
P/N. 90890-01275
Adapter # 10 (Ml 4) (4):
P/N. Y M-90069
P/N. 90890-04059
Crank spacer (5):
P/N. YM-91044
P/N. 90890-04081
Spacer (6):
P/N. 90890-01016
NOTE:
Hold the connecting rod at top dead centre with
one hand and turn the assembly tool nut with the
other.
Work on the assembly tool until the lower part of
the crankshaft enters into contact with the bear-
ings.
To protect the crankshaft from scratches and
facilitate assembly operations, apply grease
to the edges of the oil seals and engine oil to
the bearings.
CAUTION:
2. Install:
•Balancer shaft (1)
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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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ENGENGINE ASSEMBLY AND SETTING
5-47
GEARBOX
(1) Stopper lever
(2) Guide bar
(3) Shift fork #3
(4) Shift fork #1
(5) Shift cam
(6) Guide bar
(7) Shift fork #2
(8) Shift shaft #1
(9) Shift shaft #2
(10) Oil seal
(11) Shift lever
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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
5-49
ENGINE OIL PUMP AND OIL STRAINER
(1) Oil strainer
(2) Oil pump
(3) Oil pump gear
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ENGINE ASSEMBLY AND SETTING
5-50
ENG
CRANKCASE
(1) Crankcase (R)
(2) Crankcase (L)
(3) Crankcase ventilation hose
(4) Dowel pin
(5) Dowel pin
(6) Dowel pin
(7) Bearing cover plate
(8) Collar
(9) Lock plate
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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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