2004 YAMAHA TT600RE lock

ENGENGINE ASSEMBLY AND SETTING
5-71
CLUTCH
1. Install:
•Plain washer
•Spring
•Push lever (1)
Screw (push lever): 12 Nm (1.2 mkg)
2. Install:
•Push rod (1)
•Primary driven gear comp. (2)
•Thrust plate (3)
•Clutch boss (4)
•Lock washer (5)
•Nut (6) (clutch boss)
•Clutch boss spring (7)
•Clutch plate (8)
•Friction plate (9)
•Ball (10)
•Pressure plate (11)
•Compression spring (12)
•Screw (pressure plate) (13)
Nut (clutch boss): 90 Nm (9.0 mkg)
Pressure plate screw: 8 Nm (0.8 mkg)
NOTE:
•To tighten the nut (clutch boss), lock the clutch
drum with the special tool (14).
Clutch holding tool: P/N. 90890-04086
•Bend the lock washer tab along the face of the
nut.
WARNING
Always use a new lock washer.
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ENGINE REASSEMBLY
5-76
ENG
ENGINE REASSEMBLY
To reassemble the engine, repeat the procedures
described in the paragraph “ ENGINE REMOVAL”
in this chapter in reverse order. Pay attention to
the following points.
1. Install:
•Sprocket (1)
•Drive chain Nut (sprocket): 110 Nm (11.0 mkg)
Drive chain slack: 30 ~ 40 mm
Screw (sprocket cover):10 Nm (1.0 mkg)
Use LOCTlTE ®
Screw (shift ptidal): 10 Nm (1.0 mkg)
Screw (footrest): 48 Nm (4.8 mkg)
NOTE:
Bend the lock washer tab along the face of the
nut.
WARNING
Always use a new lock washer.
2. Install:
•Cover (sprocket)
•Shift pedal
•Footrest (L)
3. Adjust:
•Drive chain slack
See section “DRIVE CHAIN SLACK
INSPECTION AND ADJUSTMENT” in
CHAPTER
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CARBCARBURETOR REMOVAL
6-1
CARBURETOR
CARBURETOR REMOVAL
Order Job name/Part name Q.ty Remarks Carburetor removal Remove the parts in order.
Seat Refer to “SEAT, FUEL TANK AND REAR
COWLING" section in CHAPTER 3.
Fuel pipe NOTE:
Fuel tank Be sure the cap is properly tightened and the fuel cock is in the “OFF” position before
removing the fuel tank.
1 Lock nut 4 Loosen.
2 Throttle cable adjuster 2 Screw.
3 Throttle cable 2
4 Hose clamp 2 Loosen.
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CARBURETOR ASSEMBLY
6-12
CARB
Primary carburetor
1. Install:
•Needle jet (1)
•Connecter comp. (2)
NOTE:
Check that the connecter comp. (1) is in the posi-
tion shown in the figure.
2. Install:
•Throttle valve
3. Install:
•Spring
•Throttle shaft
NOTE:
Assemble the spring as shown in the illustration.
4. Install:
•Screw (connecter comp.)
NOTE:
Turn the throttle shaft clockwise (1/2 turn) to pre-
load the spring and then, holding it in position,
assemble the screw (connecter comp.).
Screw (connecter camp.): 2 Nm (0.2 mkg)
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CARBURETOR ASSEMBLY
6-14
CARB
10. Install:
•Float pin (1)
NOTE:
Assemble the float pin in the opposite direction to
the arrow.
11. Measure:
•Float height (a)
Out of specification ➔Adjust.
Float height: 27.0 - 29.0 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Measurement and adjustment:
•Hold the carburetor upside down.
•Measure the distance from the joint plane of
the float chamber (without the gasket) and the
top of the float.
NOTE:
The float arm must rest on the neeedle valve
without being pressed.
•If the float height is out of tolerance, check the
valve seat and the needle valve.
•If either is worn, replace both.
•If both are perfect, adjust the float height by
bending the wing tab of the float itself (1).
•Recheck the float height.
12. Install:
•Float chamber
Screw (float chamber): 2 Nm (0.2 mkg)
13. Adjust:
•Pilot air screw (1)
Adjustment:
•Turn the screw until it is slightly locked.
•Unscrew by 3 and 1/2 turns.
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SWITCH CHECK
7-6
ELEC

 







 


1. Detach the main switch connector from the
harness connector.
When detaching the connector, do not pull by
the cables. This way the cables might discon-
nect from the terminals inside the connector
itself.
2. Check to see if any cables are disconnected from their terminal inside the connector.
Reconnect, if necessary.
NOTE:
If the connector is blocked up with mud or dust,
clean it with a jet of compressed air.
3. Use the connection table to check the combi- nation of colours for continuity (closed circuit).
In this example, continuity is as follows:
“R” and “Br” are continuous when the switch is
at ON.
“L” and “R/B” are continuous when the switch
is at ON.
“R” and “L” are continuous when the switch is
at PARK.
Note that there is no continuity (open circuit)
for any of the combinations of a colour differ-
ent from those mentioned and when the
switch is at OFF.
4. Check the switch component for continuity between “R” and “Br”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Control procedure:
•Repeatedly shift the switch key to the various
positions - ON, OFF and PARK.
•Shift the tester selector to “ Ωx1”.
•Connect the tester positive cable (+) to the
terminal of cable “R” of the connector, and the
negative cable (–) to cable terminal “Br”.
CAUTION
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LIGHT INSPECTION
7-8
ELEC
LIGHT INSPECTION (HEADLIGHTS,
TAIL LIGHT AND BRAKE LIGHTS,
DIRECTION INDICATOR LIGHTS,
INSTRUMENT LIGHTS, ETC)
Check the continuity between the bulb terminals to
see that they are undamaged.
BULB TYPES
The bulbs used are classified as shown to the left
according to type of attachment.
(B) is H4 type halogen bulb (12V - 55/60W) and it
is used for headlight.
Avoid touching the glass part of a bulb. Keep it
free from oil; otherwise, the transparency of
the glass, life of the bulb, and luminous flux will
be adversely affected. If oil gets on a bulb,
thoroughly clean it with a cloth moistened with
alcohol or lacquer thinner.
(A) and (C) are used mainly for headlights.
(D) is used mainly for direction indicator lights and
the rear and braking lights.
(E) and (F) are used especially for instrument and
other indication lights.
BULB INSPECTION
1. Remove the bulb.
NOTE:
•Bulbs of type (B) and (C) use special supports
(bulbholders). Remove the bulbholder before
removing the bulb. Most of these bulbholders
may be removed by turning in an anticlockwise
direction.
•Most bulbs of type (A), (D) and (E) may be
removed from their housing by pushing them
and turning them in an anticlockwise direction.
•Bulbs of type (F) may be removed simply by
pulling them out.
CAUTION:
A
F
CB
ED
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DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS/ OVERHEATING OF ENGINE
8-9
TRBL
SHTG
?
PROBABLE CAUSES
•Indicator lamp relay defective
•Insufficient battery capacity
(battery almost flat)
•Incorrect bulb
•Main switch or direction indicator switch defec-
tive
DELAYED TURNING ON OF INDICATORS
PROBABLE CAUSES
•Battery flat
•Main switch or horn switch defective
•Horn wrongly set
•Defective horn
•Harness cut off
THE HORN FAILS TO WORK
OVERHEATING OF ENGINE
PROBABLE CAUSES
•Incorrect bulb
•Indicator lamp relay defective
EXCESSIVE INDICATOR
INTERMITTENCE FREQUENCY
Ignition system
Fuel feed system PROBABLE CAUSES
•Incorrect electrode gap of spark plug
•Spark plug thermal gradation wrong
•Ignition unit defective
•Incorrect carburetor main jet (incorrect setting)
•Incorrect fuel level
•Air filter element obstructed
Engine compression
•Excess of carbon deposits
Engine oil
•Incorrect oil level
•Incorrect oil viscosity
•Incorrect oil gradation
Brake
•Pads fail to return freely (remains blocked)
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