2004 YAMAHA TT600RE Service Manual

CARBURETOR
6-4
CARB
(1) Carburetor assembly
(2) Cover gasket
(3) Gasket, nozzle
(4) Float
(5) Float pin
(6) Float chamber gasket
(7) Screw
(8) Float chamber fastening screw
(9) Spring washer
(10) Collar
(11) Screw
(12) Gasket (13) Throttle valve
spring
(14) Spring washer
(15) Nut
(16) Gasket
(17) Screw
(18) Stop screw
(19) Nut
(20) Screw
(21) Hose
(22) Diaphragm
(23) Cover
(24) Bracket
(25) O-ring
(26) Spring washer (27) Spring
(28) Drain valve
(29) Pipe
(30) Pipe
(31) Screw
(32) Screw
(33) Pipe
(34) Clip
(35) Main jet 1
(36) Main nozzle 1
(37) Throttle valve
(38) Pilot jet
(39) Main jet 2
(40) Main nozzle 2
(41) Pilot screw set (42) Needle valve set
(43) Stop screw set
(44) Throttle screw set
(45) Diaphragm
(46) Needle set 1
(47) Needle set 2
(48) Starter set
(49) Way 3
(50) Hose
(51) Hose
(52) Hose
(53) Clip
(54) Breather pipe
(55) O-ring
(56) Pipe
SPECIFICATIONS
Main jet #150 FIRST #145 SEC.
Starter jet #74
Needle jet 5C5A-3/5 ( FIRST) 5Y18-3/5 (SEC.)
Main nozzle ø 2,6
Pilot jet #50
Pilot air screw 2,75 ± 0,5 revs approx.,
open
Float height 27~29 mm
Fuel level 6~8 mm
Engine idle speed 1.150~1.450 r/min
Throttle valve seat ø 2,5 mm
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CARBCARBURETOR
6-5
SECTION VIEW
(1) Needle jet (primary)
(2) Valve seat
(3) Needle valve
(4) Main nozzle (primary)
(5) Main jet (primary)
(6) Pilot air screw
(7) Needle jet (secondary)
(8) Main nozzle (secondary)
(9) Main jet (secondary)
[A] Primary carburetor
[B] Secondary carburetor Air
Fuel
Mixture
AB
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CARBURETOR DISASSEMBLY
6-6
CARB
CARBURETOR DISASSEMBLY
1. Remove:
•Support plate (1) (front)
•Support plate (2) (rear)
2. Separate:
•Primary carburetor
•Secondary carburetor
Primary carburetor
1. Remove:
•Float chamber (1)
•Float pin (2)
•Float (3)
NOTE:
Remove the float needle in the direction of the
arrow.
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CARBCARBURETOR DISASSEMBLY
6-7
2. Remove:
•Needle valve set/Valve seat (1)
•Main jet/Main nozzle 1 (2)
•Pilot jet (3)
•Pilot screw set (4)
•O-Ring (5)
3. Remove:
•Stop screw (1)
•Starter set (2)
4. Remove:
•Cover (1) (enrichment)
•Spring (2)
•Diaphragm (3)
5. Remove:
•Top cover (1)
•Cover gasket (2)
•Screw (3) (connecter comp.)
6. Remove:
•Throttle lever (1)
•Collar (2)
•Cable holder (3)
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CARBURETOR DISASSEMBLY
6-8
CARB
7. Remove:
•Throttle shaft (1)
•Spring (2)
8. Remove:
•Connecter comp. (1)
•Needle jet (2)
•Throttle valve (3)
Secondary carburetor
1. Remove:
•Drain plug (1)
•Main jet (2)
2. Remove:
•Top cover (1)
•Spring (2)
3. Remove:
•Diaphragm (1)
•Needle jet 2 (2)
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CARBCARBURETOR INSPECTION
6-9
CARBURETOR INSPECTION
1. Inspect:
•Carburetor body
Soiled ➔Clean.
NOTE:
Use petroleum-based solutions to clean. Clean all
passages and jets with compressed air.
2. Inspect:
•Valve seat (1)
•Needle valve set (2)
Wear/Corrosion ➔Replace.
•O-Ring (3)
Damaged ➔Replace.
NOTE:
Always replace the needle valve set and the valve
seat together.
3. Inspect:
•Starter piston (1)
Wear/Damage ➔Replace
•Stop screw (2)
Damaged ➔Replace.
4. Inspect:
•Diaphragm (1) (piston valve)
•Diaphragm (2) (enrichment)
Damaged ➔Replace.
5. Inspect:
•Needle jet (1) (primary)
•Needle jet (2) (secondary)
Curvature/Wear ➔Replace.
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CARBURETOR INSPECTION
6-10
CARB
6. Inspect:
•Throttle valve (1) (primary)
•Diaphragm (2) (secondary)
ear/Damaged ➔Replace.
7. Check:
•Free movement
Hampered ➔Replace.
Fit the throttle valve and diaphragm into
the carburetor body and check that move-
ment is free.
[A] Primary carburetor
[B] Secondary carburetor
8. Inspect:
•Float (1)
Damaged ➔Replace.
9. Inspect:
•Main jet (1) (primary)
•Main jet (2) (secondary)
•Main nozzle (3) (primary)
•Main nozzle (4) (secondary)
•Pilot jet (5)
NOTE:
Clean jets with compressed air.
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CARBCARBURETOR ASSEMBLY
6-11
CARBURETOR ASSEMBLY
Perform “CARBURETOR DISASSEMBLY” opera-
tions in reverse order. Pay attention to the follow-
ing points.
Wash all parts with clean petrol prior to
reassembly.
CAUTION:
Secondary carburetor
1. Install:
•Needle jet (1)
•Diaphragm (2)
•Spring
NOTE:
Draw the diaphragm tab level with the notch on
the secondary carburetor.
2. Install:
•Top cover
Screw (top cover): 2 Nm (0.2 mkg)
Main jet (secondary): 2 Nm (0.2 mkg)
Drain valve: 9 Nm (0.9 mkg)
3. Install:
•Main jet (secondary)
•Drain vavle
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