2004 YAMAHA TT600RE clutch

ENG
ENGINE ASSEMBLY AND SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
VALVES AND ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
CRANKSHAFT AND BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
TRANSMISSION AND GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
ENGINE OIL PUMP AND OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
ENGINE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
SHIFT SHAFT AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
PISTON AND RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
CAMSHAFT AND TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
PISTON, CYLINDER, CYLINDER HEAD AND CAMSHAFT . . . . . . . . . . . . . . . . . . . 5-59
AC GENERATOR.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
OIL FILTER AND OIL HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
BALANCER SHAFT GEAR AND PRIMARY
TRANSMISSION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
STARTER GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
STARTER NEUTRAL GEAR AND CRANKCASE COVER (L) . . . . . . . . . . . . . . . . . 5-74
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
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ENGINE REMOVAL
5-2
ENG
Order Job name/Part name Q.ty Remarks Drain the engine oil (refer to “ENGINE OIL
REPLACEMENT” section in CHAPTER
3). Remove the seat, the fuel tank and
the rear cowling (refer to “SEAT, FUEL
TANK AND REAR COWLING” section in
CHAPTER 3).
1 Battery leads connector 1 Disconnect.
2 Muffler 1
3 Exhaust pipe 1
4 Engine protector 1
5 Shift pedal 1
6 Drive sprocket crankcase cover 1
7 Drive sprocket 1 Displace the drive chain.
8 Clutch cable 1 Disconnect.
9 Plug cap 1 Disconnect.
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ENGENGINE DISASSEMBLY
5-9
4. Remove:
•Crankcase cover gasket (1) (L)
•Centring pins
•Seal ring and O-ring
•Gasket
6. Remove:
•Cable clamp (1)
•Coil (2)
•Stator (3)
CRANKCASE COVER (R), CLUTCH, PRIMARY
DRIVE GEAR AND BALANCER SHAFT GEAR
NOTE:
The clutch, the primary gear and the balance gear
may be inspected with the engine installed by
removing the following parts.
•Footrest (R)
•Oil delivery hose screw
5. Remove:
•Intermediate starter gear (1)
•Bearing (2)
•Distributor shaft (3)
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ENGINE DISASSEMBLY
5-10
ENG
2. Remove:
•Compression spring (1)
•Pressure plate (2)
•Ball (3)
•Friction plate (4)
•Clutch plate (5)
•Clutch boss spring (6)
•Clutch boss (7)
•Thrust plate (8)
•Clutch shroud (9)
•Push rod (10)
1. Remove:
•Engine oil delivery hose screw
•Copper washer
•Oil filter cover (1)
•Oil filter
•Seal ring and O-Ring
•Crankcase cover (2) (R)
NOTE:
•Before loosening the nut (11) (clutch shroud),
straighten the washer lock tab.
•To loosen the nut (clutch boss), block the
clutch boss using the special tool (12).
Clutch holding tool: P/N. 90890-04086
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ENGINE DISASSEMBLY
5-12
ENG
OIL PUMP AND SHIFT LEVER
NOTE:
The oil pump and shift lever may be checked with
the engine installed by removing the following
parts:
•Footrest (R)
•Oil delivery hose screw
•Crankcase (R)
•Clutch
1. Remove:
•Circlip (1)
•Oil pump gear (2)
•Oil pump (3)
•O-rings (4)
2. Remove:
•Circlip (1) (from drive shaft)
•Ring (2)
•Circlip (3)
3. Remove:
•Circlip (1)
•Shift lever (2)
•Spring (3)
•Flat washer (4)
4. Remove:
•Stopper lever (1)
•Ring (2)
•Spring (3)
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ENGINSPECTION AND REPAIR
5-33
PISTON PIN
1. Check:
•Piston pin
Blue colour/Grooves ➔Replace and
check lubrication system.
External diameter (pin): 21.991 ~ 22.000 mm
Clearance between piston pin and pin
seat on piston: 0.004 ~ 0.024 mm
: 0.07 mm
2. Measure:
•External diameter (a) of pin
Out of specification ➔Replace.
3. Measure:
•Clearance between piston pin and pin
seat
Out of specification ➔Replace.
Clearance between piston pin and
piston = Diameter of pin seat on piston (b) –
Diameter of pin (a)
CLUTCH
1. Inspect:
•Clutch gear assy teeth
Cracks/Pitting (on edges):
Moderate ➔Burr.
Accentuated ➔Replace clutch gear assy.
NOTE:
Pitting of the gear assy teeth causes irregular
functioning.
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INSPECTION AND REPAIR
5-34
ENG
2. Inspect:
•Clutch gear assy bearing
Damaged ➔Replace.
3. Inspect:
•Groove in clutch boss.
Pitting:
Moderate ➔Burr.
Accentuated ➔ Replace clutch boss.
NOTE:
Pitting of the clutch boss grooves causes irregular
functioning.
4. Measure:
•Thickness of friction plates
Out of specification ➔Replace all plates.
Thickness Wear
limit
Type “A” 2.94 ~ 3.06 mm 2.8 mm
(2 parts)
Type “B” 2.72 ~ 2.88 mm 2.6 mm
(6 parts)
5. Measure:
•Deformation of clutch plates
Out of specification ➔Replace all plates.
Clutch plates deformation: : 0.2 mm
Clutch push rod runout:: 0.2 mm
6. Measure:
•Runout limit of clutch push rod.
Turn clutch push rod on two V blocks.
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ENGINSPECTION AND REPAIR
5-35
7. Measure:
•Free length of clutch compression springs
(a)
Out of specification ➔Replace all springs.
OIL PUMP
1. Measure:
•Clearance between rotors (a)
(Between the internal rotor (1) and the
external rotor (2))
•Side clearance (b)
(Between the external rotor (2) and the
pump stator (3))
Out of specification ➔Replace oil pump.
Free length of clutch compression
spring (a): 42.8 mm
Oil pump clearances:
Clearance between 0.12 mm
rotors (a) : 0.2 mm
Side clearance (b) 0.03 ~ 0.08 mm
: 0.15 mm
2. Inspect:
•Oil pump drive gear (1)
•Oil pump driven gear (2)
Wear/Cracks/Damage ➔Replace.
PRIMARY TRANSMISSION
1. Inspect:
•Primary drive gear teeth (1)
•Primary driven gear teeth (2)
Wear/Damage ➔Replace both gears.
Excess noise during functioning ➔
Replace both gears.
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