2004 YAMAHA TT600RE Service Manual

ENGENGINE ASSEMBLY AND SETTING
5-53
NOTE:
When installing the shift lever, align the mark on
the lever with that on the shift shaft.
3. Install:
•Circlip (1) (to the driving axle)
•Spacer (2)
•Circlip (3)
4. Apply:
•4-stroke engine oil
(oil pipes in crankcase)
To avoid damage to the engine, lubricate the
oil pump pipes in the crankcase liberally with
4-stroke engine oil.
CAUTION:
5. Apply:
•4-stroke engine oil
(oil pump pipes)
6. Apply:
•O-Ring (1)
•Oil pump (2)
•Oil pump gear (3)
•Circlip (4) Screw (5) (oil pump): 10 Nm (1.0 mkg)
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ENGINE ASSEMBLY AND SETTING
5-54
ENG
TIMING CHAIN
1. Install:
•Timing chain (1)
•Chain guide (2)
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ENGENGINE ASSEMBLY AND SETTING
5-55
PISTON AND RINGS
(1) Ring (upper)
(2) Ring (lower)
(3) Scraper
(4) Piston
(5) Piston pin
(6) Circlip PISTON SIZE:
94.915 ~ 94.965 mm
PISTON RING END GAP:
TOP: 0.30 ~ 0.45 mm
2ND: 0.30 ~ 0.45 mm
OIL: 0.20 ~ 0.70 mm
PISTON RING SIDE CLEARANCE:
TOP: 0.04 ~ 0.08 mm
2ND: 0.03 ~ 0.07 mm
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ENGINE ASSEMBLY AND SETTING
5-56
ENG
CYLINDER
(1) Gasket
(2) Cylinder
(3) O-Ring
(4) Gasket
(5) Dowel pin
(6) Dowel pin
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ENGENGINE ASSEMBLY AND SETTING
5-57
CYLINDER HEAD
(1) Cylinder head cover
(2) O-Ring
(3) Tappet cover (intake)
(4) Tappet covers (exhaust)
(5) O-Ring
(6) Cap (7) Cylinder head
(8) Valve guide (intake valve)
(9) Valve guide (exhaust valve)
(10) Spark plug
(11) Dowel pin
10 Nm (1.0 m•kg 7.2 ft•lb)
A
10 Nm (1.0 m•kg 7.2 ft•lb)
10 Nm (1.0 m•kg 7.2 ft•lb)
18 Nm (1.8 m•kg 13 ft•lb)
7 Nm (0.7 m•kg 5.1 ft•lb)
20 Nm (2.0 m•kg 14 ft•lb)
12 Nm (1.2 m•kg 8.7 ft•lb)
10 Nm
(1.0 m
•kg 7.2 ft•lb)
10 Nm
(1.0 m
•kg 7.2 ft•lb)
SEALANT (QUICK GASKET) ®
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ENGINE ASSEMBLY AND SETTING
5-58
ENG
CAMSHAFT AND TIMING CHAIN
(1) Camshaft
(2) Cam chain sprocket
(3) Chain stopper guide
(4) Timing chain
(5) Chain stopper guide
(6) Gasket
(7) Chain tensioner
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ENGENGINE ASSEMBLY AND SETTING
5-59
PISTON, CYLINDER, CYLINDER HEAD AND
CAMSHAFT
1. Apply:
•4-stroke engine oil
(on piston pin).
2. Install:
•Piston (1)
•Pin (2)
•Circlip (3)
NOTE:
•Arrow (4) on the piston must point towards the
front of the engine.
•Before installing the piston pin circlips, cover
the crankcase with a clean cloth to prevent
foreign bodies falling into it.
WARNING
Always use new circlips for the piston pin.
3. Install:
•Dowel pins (1)
•O-Ring (2)
4. Install:
•Gasket (1) (cylinder)
NOTE:
Install the cylinder gasket as shown in the illustra-
tion.
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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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