2004 YAMAHA TT600RE engine oil

ENGENGINE ASSEMBLY AND SETTING
5-55
PISTON AND RINGS
(1) Ring (upper)
(2) Ring (lower)
(3) Scraper
(4) Piston
(5) Piston pin
(6) Circlip PISTON SIZE:
94.915 ~ 94.965 mm
PISTON RING END GAP:
TOP: 0.30 ~ 0.45 mm
2ND: 0.30 ~ 0.45 mm
OIL: 0.20 ~ 0.70 mm
PISTON RING SIDE CLEARANCE:
TOP: 0.04 ~ 0.08 mm
2ND: 0.03 ~ 0.07 mm
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ENGENGINE ASSEMBLY AND SETTING
5-59
PISTON, CYLINDER, CYLINDER HEAD AND
CAMSHAFT
1. Apply:
•4-stroke engine oil
(on piston pin).
2. Install:
•Piston (1)
•Pin (2)
•Circlip (3)
NOTE:
•Arrow (4) on the piston must point towards the
front of the engine.
•Before installing the piston pin circlips, cover
the crankcase with a clean cloth to prevent
foreign bodies falling into it.
WARNING
Always use new circlips for the piston pin.
3. Install:
•Dowel pins (1)
•O-Ring (2)
4. Install:
•Gasket (1) (cylinder)
NOTE:
Install the cylinder gasket as shown in the illustra-
tion.
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ENGINE ASSEMBLY AND SETTING
5-60
ENG
5. Offset the piston ring end gaps as illustrated in the figure.
NOTE:
•Check that the marks and numbers stamped
by the manufacturer on the piston rings face
upwards.
•Before installing the cylinder, lubricate the pis-
ton rings liberally with 4-stroke engine oil.
(1) Upper ring
(2) Scraper (lower ring)
(3) Scraper (upper ring)
(4) Lower ring
6. Install:
•Cylinder (1)
NOTE:
•Install the cylinder to the piston with one hand
while one hand while compressing the piston
rings with the other.
•Bind the timing chain with wire and slip it
through the appropriate slot.
Cylinder:
Screw (2): 10 Nm (1.0 mkg)
Cap nut (3): 42 Nm (4.2 mkg)
Nut (4): 42 Nm (4.2 mkg)
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ENGENGINE ASSEMBLY AND SETTING
5-65
AC GENERATOR
(1) Rotor
(2) Pick-up coil
(3) Stator winding PICKUP COIL RESISTANCE:
230 Ω± 20% at 20°C (68°F)
(Blue/Yellow - Green/White)
CHARGING COIL RESISTANCE:
0.65 Ω ± 20% at 20°C (68°F)
(White - White)
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ENGENGINE ASSEMBLY AND SETTING
5-67
OIL FILTER AND OIL HOSES
(1) Oil filter
(2) Filter cover
(3) Oil hose
(4) Oil hose
(5) Oil delivery hose
(6) Oil drain plug
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ENGINE ASSEMBLY AND SETTING
5-72
ENG
NOTE:
Install the friction and clutch plates to the clutch
boss, beginning and ending with a friction plate.
•The two friction plates (type A) (15) with
the widest internal diameter should be
assembled in second and last place.
•The clutch boss spring (16) should be
placed inside the second friction plate.
CAUTION:
Friction plate
Type “A” Type “B”
Quantity 2 6
Internal 116 mm 113 mm
diameter “D”
NOTE:
Align the mark on the clutch boss (17) with the
arrow (18) on the pressure plate.
3. Adjust:
•Clutch (free play)
See section “CLUTCH ADJUSTMENT” in
CHAPTER 3.
4. Install:
•Straight key
•Gasket
•Crankcase cover (right) (1)
•O-Ring
•Oil filter
•Filter cover (2) (with O-Ring)
See section “Engine oil replacement (with
oil filter change)” in CHAPTER 3.
Bolt (crankcase cover): 10 Nm (1.0 mkg)
16
15
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ENGINE ASSEMBLY AND SETTING
5-74
ENG
STARTER NEUTRAL GEAR AND CRANKCASE
COVER (L))
1. Install:
•Stator winding (1)
•Pick-up coil (2)
•Cable clamp (3)
2. Install:
•Bearing (1)
•Intermediate starter gear 2 (2) Screws (stator and coil):
7 Nm (0.7 mkg)
Use LOCTITE ®
Screw (cable clamp): 7 Nm (0.7 mkg)
3. Install:
•Centring pin (1)
•Gasket (2)
•O-Ring (3)
•Crankcase cover (L) (4)
•Plugs
Bolt (crankcase cover): 10 Nm (1.0 mkg)
WARNING
Always use a new gasket.
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ENGENGINE REASSEMBLY
5-77
4. Install:
•Oil delivery hose (1) Union bolt: 18 Nm (1.8 mkg)
Screw (tappet cover): 10 Nm (1.0 mkg)
Air bleeder screw (oil filter cover): 5 Nm (0.5 mkg)
Amount of oil: Camshaft0.1 litres
Oil filter housing 0.06 litres
5. Remove:
•Tappet cover (intake)
•Air bleeder screw (oil filter cover)
6. Apply:
•4-stroke engine oil
•(on the top side of the camshaft and in the
oil filter housing).
Liberally apply 4-stroke engine oil in the oil
passage in the crankcase to prevent damage
to the engine.
CAUTION:
7. Install:
•Tappet cover (intake)
•Air bleeder screw (oil filter cover)
8. Adjust:
•Clutch cable free play Free play (at end of lever): 10 ~ 15 mm
See section “CLUTCH ADJUSTMENT” in
CHAPTER 3.
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