2004 YAMAHA TT600RE Service Manual

ENGENGINE ASSEMBLY AND SETTING
5-69
BALANCER SHAFT GEAR AND PRIMARY
TRANSMISSION GEAR
1. Install:
•Key (1)
•Balancer shaft gear (2)
•Plate (3)
•Lock washer (4)
•Nut (5) (balancer shaft gear)
•Washer (6)
•Key (7)
•Plate (8)
•Balancer shaft drive gear (9)
•Plate (10)
•Primary drive gear (11)
•Lock washer (12)
•Nut (13) (primary drive gear)
Nut (balancer shaft gear): 60 Nm (6.0 mkg)
Nut (primary drive gear): 120 Nm (12.0 mkg)
NOTE:
When installing the drive gear, align the mark on
it (14) with that of the balancer shaft gear (15).
WARNING
Always use a new lock washer.
NOTE:
To tighten nuts (5) and (13), keep the AC genera-
tor rotor still with the special tool (16).
Sheave holder: P/N. 90890-01701
Be careful not to touch the jutting part (17) of
the rotor with the sheave holder.
2. Bend the lock washer tab along the face of the nut.
CAUTION:
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ENGINE ASSEMBLY AND SETTING
5-70
ENG
CLUTCH
(1) Compression spring
(2) Pressure plate
(3) Push rod
(4) Ball
(5) Friction plate (type A)
(6) Clutch boss spring
(7) Clutch plate
(8) Friction plate (type B) (9) Clutch boss
(10) Thrust plate
(11) Primary driven gear comp.
(12) Push rod
(13) Push lever
(14) Primary drive gear
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ENGENGINE ASSEMBLY AND SETTING
5-71
CLUTCH
1. Install:
•Plain washer
•Spring
•Push lever (1)
Screw (push lever): 12 Nm (1.2 mkg)
2. Install:
•Push rod (1)
•Primary driven gear comp. (2)
•Thrust plate (3)
•Clutch boss (4)
•Lock washer (5)
•Nut (6) (clutch boss)
•Clutch boss spring (7)
•Clutch plate (8)
•Friction plate (9)
•Ball (10)
•Pressure plate (11)
•Compression spring (12)
•Screw (pressure plate) (13)
Nut (clutch boss): 90 Nm (9.0 mkg)
Pressure plate screw: 8 Nm (0.8 mkg)
NOTE:
•To tighten the nut (clutch boss), lock the clutch
drum with the special tool (14).
Clutch holding tool: P/N. 90890-04086
•Bend the lock washer tab along the face of the
nut.
WARNING
Always use a new lock washer.
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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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ENGENGINE ASSEMBLY AND SETTING
5-73
STARTER GEARS
(1) Starter gear
(2) Starter neutral gear 1
(3) Starter neutral gear 2
(4) Starter gear
(5) Starter clutch
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ENGINE ASSEMBLY AND SETTING
5-74
ENG
STARTER NEUTRAL GEAR AND CRANKCASE
COVER (L))
1. Install:
•Stator winding (1)
•Pick-up coil (2)
•Cable clamp (3)
2. Install:
•Bearing (1)
•Intermediate starter gear 2 (2) Screws (stator and coil):
7 Nm (0.7 mkg)
Use LOCTITE ®
Screw (cable clamp): 7 Nm (0.7 mkg)
3. Install:
•Centring pin (1)
•Gasket (2)
•O-Ring (3)
•Crankcase cover (L) (4)
•Plugs
Bolt (crankcase cover): 10 Nm (1.0 mkg)
WARNING
Always use a new gasket.
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ENGENGINE ASSEMBLY AND SETTING
5-75
4. Install:
•Neutral switch cable (1)
5. Install:
•Shaft (1)
•Bearing (2)
•Starter intermediate gear 1 (3)
6. Install:
•Centring pins
•Gasket
•Cover (1) (starter intermediate gear) Screw (cover): 10 Nm (1.0 mkg)
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ENGINE REASSEMBLY
5-76
ENG
ENGINE REASSEMBLY
To reassemble the engine, repeat the procedures
described in the paragraph “ ENGINE REMOVAL”
in this chapter in reverse order. Pay attention to
the following points.
1. Install:
•Sprocket (1)
•Drive chain Nut (sprocket): 110 Nm (11.0 mkg)
Drive chain slack: 30 ~ 40 mm
Screw (sprocket cover):10 Nm (1.0 mkg)
Use LOCTlTE ®
Screw (shift ptidal): 10 Nm (1.0 mkg)
Screw (footrest): 48 Nm (4.8 mkg)
NOTE:
Bend the lock washer tab along the face of the
nut.
WARNING
Always use a new lock washer.
2. Install:
•Cover (sprocket)
•Shift pedal
•Footrest (L)
3. Adjust:
•Drive chain slack
See section “DRIVE CHAIN SLACK
INSPECTION AND ADJUSTMENT” in
CHAPTER
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