2004 YAMAHA TT600RE lock

INSPECTION AND REPAIR
5-22
ENG
VALVES AND VALVE GUIDES
1. Measure:
•Clearance between stem and guide
Clearance between stem and guide =
Internal diameter of valve guide (a) –
Diameter of valve stem (b)
Out of specification ➔Replace valve guide.
Clearance between stem and guide:
Intake: 0.010 ~ 0.037 mm
: 0.08 mm
Exhaust: 0.030 ~ 0.057 mm : 0.10 mm
(1) Bore gauge
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Replacement steps:
NOTE:
Heat the cylinder head in an oven at 100°C to
facilitate the removal and installation of the guides
and to maintain correct locking interference.
•Remove the valve guide using the special
punch (1).
•Install the new guide using the special instal-
lation tool (2).
•After installing the valve guide, bore with spe-
cial tool (3) to obtain valve-guide free play.
Valve guide remover (7 mm): P/N. 90890-01225
Valve guide installer: P/N. 90890-04017
Valve guide reamer (7 mm): P/N. 90890-01227
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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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•Install the starter rim on the gear and hold
the gear firm.
•When turning the gear rim in a clockwise
direction (A), the gear and rim must be
meshed. Otherwise, the gear is faulty and
must be replaced.
•When the gear rim is turned in a anti-
clockwise direction (B), it must turn freely.
Otherwise, the gear is faulty and must be
replaced.
INSPECTION AND REPAIR
5-38
ENG
STARTER TRANSMISSION
1. Check:
•Starter clutch functioning (1).
Turn the clutch in the direction indicated
by the arrow.
Irregular functioning/Damage ➔ Replace
the clutch.
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2. Inspect:
•Starter neutral gear teeth (1)
•Starter neutral gear teeth (2)
•Starter rim teeth (3)
Burrs/Shavings/Roughness/Wear ➔
Replace.
3. Inspect:
•Starter rim (contact surfaces)
Pitting/Wear/Damage ➔ Replace.
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ENGINE ASSEMBLY AND SETTING
5-50
ENG
CRANKCASE
(1) Crankcase (R)
(2) Crankcase (L)
(3) Crankcase ventilation hose
(4) Dowel pin
(5) Dowel pin
(6) Dowel pin
(7) Bearing cover plate
(8) Collar
(9) Lock plate
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ENGENGINE ASSEMBLY AND SETTING
5-61
7. Install:
•Dowel pins (1)
•O-Ring (2)
•Gasket (3) (cylinder head)
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Cylinder head:
Screw (l), (2), (3) and (4): 29 Nm (2.9 mkg)
Nut (5) and (6): 22 Nm (2.2 mkg)
Screw (7): 10 Nm (1.0 mkg)
8. Install:
•Cylinder head
NOTE:
Tighten screws beginning with the one with the
lowest number.
9. Install:
•Chain stopper guide
•Camshaft
•Cam chain sprocket
Timing chain installation:
•Install the cam chain on the cylinder head as
illustrated (compression phase timing).
•Run the cam shaft in an anticlockwise direc-
tion until the mark on the crankcase (1) and
the point on the cam chain gearwheel (2) are
aligned.
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ENGINE ASSEMBLY AND SETTING
5-66
ENG
AC GENERATOR
1. Install:
•Woodruff key (1)
•Washer (2)
•Bearing (3)
•Rotor (4)
•Washer (5)
•Nut (6)
NOTE:
When installing the AC generator rotor, check that
the woodruff key fits properly into its seat on the
crankshaft. Apply a thin layer of lithium soap-
based grease on the conical tip of the crankshaft.
2. Tighten:
•Nut (rotor) Nut (rotor): 120 Nm (12.0 mkg)
NOTE:
To tighten the nut, lock the rotor with the special
tool (1).
Sheave holder: P/N. 90890-01701
Be careful not to touch the jutting edges (2) on
the rotor with the sheave holder.
CAUTION:
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ENGINE ASSEMBLY AND SETTING
5-68
ENG
BALANCER SHAFT GEAR AND PRIMARY TRANSMISSION GEAR
(1) Straight key
(2) Balancer shaft gear
(3) Breather plate
(4) Lock washer
(5) Nut
(6) Plate washer
(7) Straight key
(8) Plate (9) Balancer shaft drive gear
(10) Plate
(11) Primary drive gear
(12) Lock washer
(13) Nut
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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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