2004 YAMAHA TT600RE engine oil

ENGENGINE REMOVAL
5-3
Order Job name/Part name Q.ty Remarks – Starter leads 2 Disconnect.
– Starter 1 Remove.
10 Connectors of engine wire harness 2 Disconnect. 11 Oil delivery hose 1 Disconnect.
12 Oil return hose 1 Disconnect.
13 Oil breather pipe (to oil tank) – Disconnect.
14 Oil breather pipe (to air filter box) – Disconnect. Reverse the removal procedure for
installation.
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ENGINE REMOVAL
5-4
ENG
Order Job name/Part name Q.ty Remarks
The engine and rear arm are assembled
together on the rear pivot shaft. When
removing the pivot shaft, it is thus
necessary to pay special care with the
rear arm.
1 Stay of oil tank – Remove the mounting screws (to engine).
2 Hose clamp (carburetor) 2 Loosen.
3 Pivot shaft (rear - top) 1
4 Engine mounting bolt 1 (rear - lower)
5 Engine stay (front - lower) 1
6 Engine stay (front - top/right/left) 1
7 Engine assembly 1
CAUTION:
ENGINE MOUNTING BOLT
NOTE:
Remove the engine from the lower side.
Reverse the removal procedure for
installation.
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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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ENGENGINE DISASSEMBLY
5-17
BALANCER SHAFT AND CRANKSHAFT
1. Remove:
•Balancer shaft (1)
2. Remove:
•Crankshaft (1)
NOTE:
•Remove the crankshaft by using the
crankcase separating tool (2).
Crankcase separating tool: P/N. 90890-01135
•Tighten the separating tool bolts, making sure
that the tool body is parallel with the engine
crankcase. If necessary, a screw may be
backed out slightly to level tool body.
OIL STRAINER
NOTE:
It is advisable to replace the oil strainer every time
the engine is disassembled.
1. Remove:
•Oil strainer (1)
•Oil passage cover (2)
•Gasket
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ENGENGINE ASSEMBLY AND SETTING
5-41
ENGINE ASSEMBLY AND SETTING
VALVES AND ROCKER ARMS
(1) Rocker arm n. 2
(2) Wave washer
(3) Rocker shaft (intake)
(4) Rocker arm n. 1
(5) Valve cotters
(6) Upper valve spring retainer
(7) Oil seal
(8) Inner valve spring
(9) Outer valve spring (10) Valve (intake)
(11) Lower valve spring retainer
(12) Rocker shaft (exhaust)
(13) Rocker arm n. 4
(14) Rocker arm n. 3
(15) Rocker shaft (exhaust)
(16) Valve (exhaust)
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ENGINE ASSEMBLY AND SETTING
5-42
ENG
VALVES
1. Burrs:
•Valve stem tip
(leave the valve stem tip with an oil stone).
2. Lubricate:
•Valve stem and oil seal (apply high quality
molybdenum disulfide oil)
3. Install:
•Oil seal (1)
•Valves (2)
•Lower valve spring retainer (3)
•Inner valve spring (4)
•Outer valve spring (5)
•Upper valve spring retainer (6)
NOTE:
Install the innner and outer springs with the widest
thread upwards.
4. Install:
•Valve cotters (1)
NOTE:
Compress the valve spring with the specific tool
(2) to fit the cotters.
Valve spring compressor: P/N. 90890-04019
(7) Higher pitch
(8) Lower pitch
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