2004 YAMAHA TT600RE engine oil

ENGINE OIL TANK FILTER CLEANING
3-26
INSP
ADJ
ENGINE OIL TANK FILTER CLEANING
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Drain:
•Engine oil
See section “ENGINE OIL REPLACE-
MENT”.
2. Remove:
•Seat
•Rear cowling
See section “SEAT, FUEL TANK AND
REAR COWLING”.
•Rear wire harness
•Exhaust muffler
•Exhaust pipe
•Rear shock absorber
See section “REAR SHOCK ABSORBER”
in Chapter 4.
•Joint air cleaner clamps
•Rear frame
•Engine oil tank
3. Loosen:
•Stay (rear left side cover) fastening
screws
4. Remove:
•Oil tank cap (1)
•Oil return hose (2)
•Oil return hose flange (4) fastening screw
(3)
•Oil delivery hose flange (6) fastening
screws (5)
•Oil tank filter (7)
•OR gaskets (8)
5. Clean:
•Oil tank filter (with solvent)
•Oil tank (with solvent)
NOTE:
After cleaning the inside of the oil tank, remove
the remaining solvent.
6. Inspect:
•OR gaskets
Damaged ➔Replace.
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INSP
ADJ
ENGINE OIL TANK FILTER CLEANING
3-27
7. Reassemble:
•OR gaskets
•Oil tank filter
•Oil delivery hose flange fastening screws
Screw (oil delivery hose flange):
10 Nm (1.0 mkg)
Screw (oil return hose flange):
35 Nm (3.5 mkg)
•Oil return hose
•Oil return hose flange fastening screws
8. Tighten:
•Stay (rear left side cover) fastening
screws
9. Reassemble:
•Engine oil tank
•Rear frame
•Joint air cleaner clamps
•Rear shock absorber
See section “REAR SHOCK ABSORBER”
in Chapter 4.
•Exhaust pipe
•Exhaust muffler
•Rear wire harness
•Rear cowling
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
10. Fill:
•Engine oil
See section “ENGINE OIL REPLACE-
MENT”.
11. Reassemble:
•Engine tank capScrew (seat):
10 Nm (1.0 mkg)
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DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT/
DRIVE CHAIN LUBRICATION
3-36
INSP
ADJ
Rear wheel axle nut:
115 Nm (11.5 mkg)
•Turn each adjusting bolt exactly the same
amount to maintain correct axle alignment.
There are marks on each side of the
swingarm. Use these marks to align the rear
wheel.
DRIVE CHAIN LUBRICATION
The chain consists of many parts which work with
each other. If the chain is not maintained properly,
it will wear out quickly. Therefore, the chain must
be serviced regularly. This service is especially
necessary when riding in dusty areas. This motor-
cycle has a drive chain with small rubber O-Rings
between the chain plates. Steam cleaning, high-
pressure washing and certain solvents can dam-
age these O-Rings. Use only kerosene to clean
the drive chain. Wipe it dry, and thoroughly lubri-
cate it with SAE 80 ~ 90W motor oil or special lu-
bricant for O-Ring chains. Do not use any other lu-
bricants on the drive chain. They may contain sol-
vents that could damage the O-Rings.
Recommended lubricant:
SAE 80W/90 engine oil or
special lubricant for
O-Ring chains.
(1) O-Rings
•Loosen the axle nut (1).
•Loosen the locknuts (2) on each side. To tight-
en the chain, turn the chain adjusting bolts (3)
in direction (a). Loosen the locknuts on each
side. To loosen the chain, turn the chain
adjusting bolts in direction (b) and push the
wheel forward.
•After adjusting, tighten the locknuts (2). Then
tighten the axle nut (1) to the specified torque.
a
b
2
13
➩➩
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CHASFRONT FORK
4-45
OIL CAPACITY (IN EACH FORK LEG): 650 cm3
RECOMMENDED OIL:
Liqui Moly Racing suspension oil SAE 7,5
FRONT FORK OIL LEVEL
STANDARD 180 mm
MINIMUM 190 mm
MAXIMUM 170 mm
From top of inner tube with inner tube fully com-
pressed without spring.
MINIMUM FORK SPRING FREE LENGTH:
530 mm
INNER TUBE BENDING LIMIT:
0.2 mm
1. Park the motorcycle on a level surface.
2. Raise the front wheel by placing a suitable support under the engine.
3. Remove:
•Front wheel
Refer to “FRONT WHEEL REMOVAL”
section.
4. Remove:
•Inner tube protector
•Protector guide
•Gear unit assembly and cable
•Brake caliper and hose
5. Loosen:
•Cap bolt
•Pinch bolt (upper and lower bracket)
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
FRONT FORK REMOVAL
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DRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-84
CHAS
3. Inspect:
•Seal rings (1) (drive chain)
Damaged ➔Replace drive chain.
•Rollers (2)
•Lateral plates (3)
Damage/Wear ➔Replace drive chain.
4. Lubricate:
•Drive chain
Lubricant for drive chain: SAE 80W/90 engine oil or special
lubricant for O-Ring chains.
5. Inspect:
•Drive chain
Rigid ➔Clean and lubricate, replace if
necessary.
6. Inspect:
•Drive sprocket
•Rear wheel sprocket
Wear over 1/4 tooth (1) ➔Replace.
Teeth bent ➔Replace.
(2) Undamaged tooth profile
(3) Roller
(4) Sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
How to replace the rear wheel sprocket:
With wheel removed:
1. Remove:
•Hub (1)
•Sprocket fastening bolts (2)
•Rear wheel sprocket (3)
2. Install:
•New sprocket (3)
•Sprocket fastening bolts (2)
•Hub (1)
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ENG
CHAPTER 5. ENGINE
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
MUFFLER, EXHAUST PIPE, ENGINE PROTECTOR, DRIVE SPROCKET,
CRANKCASE COVER, DRIVE SPROCKET AND SHIFT PEDAL . . . . . . . . . . . . . . . 5-1
ENGINE MOUNTING BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CYLINDER HEAD, CYLINDER, CAMSHAFT AND PISTON . . . . . . . . . . . . . . . . . . . . 5-5
INTERMEDIATE STARTER GEAR, CRANKCASE COVER (L)
AND GENERATOR STATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
CRANKCASE COVER (R), CLUTCH, PRIMARY DRIVE GEAR
AND BALANCER SHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
OIL PUMP AND SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
AC GENERATOR AND TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
CRANKCASE(R). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
GEARBOX AND TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
BALANCER SHAFT AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
OILSTRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
VALVESEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
ROCKER ARMS AND ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
CAMSHAFT CHAIN AND SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
CAMSHAFT CHAIN GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
PISTONPIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
OILPUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
PRIMARY TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
TRANSMISSION AND GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
SHIFT SHAFT AND STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
STARTER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
BALANCER SHAFT DRIVE
AND DRIVEN GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
BEARING AND OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
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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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