2004 YAMAHA TT600RE warning

CHASREAR SHOCK ABSORBER
4-73
SHOCK ABSORBER REMOVAL
WARNING
Support the motorcycle securely to prevent it
from falling over.
1. Park the motorcycle on a level surface.
2. Remove:
•Seat
•Rear cowling
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING” in CHAPTER 3.
3. Disconnect:
•Battery leads
8. Remove:
•Upper mounting bolt (1)
•Rear shock absorber
1
NOTE:
First, disconnect the negative lead, then the posi-
tive lead.
4. Remove:
•Exhaust pipe assembly
•Rear frame
•Air filter case
5. Raise the rear wheel placing a suitable sup- port under the engine.
6. Remove:
•Rear wheel
Refer to “REAR WHEEL REMOVAL” sec-
tion.
7. Remove:
•Shock absorber fastening nut (1)
•Lower mounting bolt
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DRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-82
CHAS
DRIVE CHAIN, DRIVE SPROCKET AND
REAR WHEEL SPROCKET
NOTE:
Before removing the drive chain, drive sprocket
and rear wheel sprocket, it is necessary to meas-
ure the free play and length of the 10 links in the
chain.
DRIVE CHAIN REMOVAL
1. Park the motorcycle upright on an even sur- face.
2. Remove:
•Shift pedal (1)
•Cover (2) (drive sprocket)
3. Remove:
•Drive sprocket (1)
NOTE:
•Before removing the sprocket nut, straighten
the tab on the lock washer.
•Loosen the nut with the rear brake pulled.
4. Raise the rear wheel placing a suitable sup- port under the engine.
WARNING
Set the motorcycle up securely to prevent it
falling over.
5. Remove:
•Rear wheel
•Rear wheel sprocket
•Hub
•Damper
•Spacer
Refer to “REAR WHEEL REMOVAL” sec-
tion.


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CHASDRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
4-85
3. Tighten:
•Rear wheel sprocket fastening bolts
Rear wheel sprocket fastening bolts: 48 Nm (4.8 mkg)
Nut (drive sprocket): 110 Nm (11.0 mkg)
Nut (swingarm pivot shaft): 90 Nm (9.0 mkg)
Nut (frame-relay arm): 60 Nm (6.0 mkg)
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DRIVE CHAIN INSTALLATION
Perform “REMOVAL” operations in reverse order.
Pay special attention to the following points.
1. Install:
•Drive chain
•Swingarm
2. Install:
•Rear wheel
Refer to “REAR WHEEL INSTALLATION”
section.
3. Install:
•Drive sprocket
WARNING
Always use a new lock washer.
NOTE:
•Tighten the drive sprocket nut with the rear
brake pulled.
•After tightening the nut, bend the tab on the
lock washer once more over the faces of the
nut.
4. Adjust:
•Drive chain slack
Refer to “DRIVE CHAIN SLACK ADJUST-
MENT” section in CHAPTER 3.
Drive chain slack: 30 ~ 40 mm
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ENGENGINE REMOVAL
5-1
ENGINE
ENGINE REMOVAL
MUFFLER, EXHAUST PIPE, ENGINE PROTECTOR, DRIVE SPROCKET CRANKCASE COVER,
DRIVE SPROCKET AND SHIFT PEDAL
Order Job name/Part name Q.ty Remarks
Muffler, exhaust pipe, engine Remove the parts in order.
protector, drive sprocket crankcase
cover, drive sprocket and shift
pedal removal Park the motorcycle in a stable and level
position.
WARNING
Securely support the motorcycle so there
is no danger of it falling over.
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INSPECTION AND REPAIR
5-36
ENG
TRANSMISSION AND GEARBOX
1. Inspect:
•Shift fork pin (1)
•Shift fork pawl (2)
Lines/Creases/Wear ➔Replace.
2. Inspect:
•Shift cam groove
•Shift cam pins
Wear/Damage ➔Replace.
3. Check:
•Shift fork movement
Rough functioning ➔Replace shift forks
and/or guide bars.
4. Inspect:
•Guide bar
Turn on a flat surface.
Curvature ➔Replace.
WARNING
Do not attempt to straighten the deformed
guide bar.
5. Measure:
•Transmission shaft eccentricity.
Use the centring tool and micrometer.
Out of specification ➔Replace bent shaft.
Transmission shaft eccentricity: : 0.08 mm
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ENGENGINE ASSEMBLY AND SETTING
5-51
ENGINE OIL STRAINER
1. Install:
•Oil strainer (1)
•Oil passage cover (2)
Screw (oil strainer): 7 Nm (0.7 mkg)
Screw (oil passage cover): 7 Nm (0.7 mkg)
WARNING
Always use a new gasket.
Yamaha bond N° 1215 ®
:
P/N. 90890-85505
2 Install:
•Dowel pin (2)
3. Assemble the left crankcase to the right. Beat gently with a soft hammer.
NOTE:
Turn the shift cam as shown in the figure so that
it does not interfere with the crankcase during
assembly.
CRANKCASE
1. Apply:
•Yamaha bond N° 1215 ®
(1)
(on the crankcase mating surfaces)
Before installing and tightening the fastening
screws, be sure that the transmission is work-
ing properly by hand, turning the shift cam in
both directions.
CAUTION:
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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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ENGENGINE ASSEMBLY AND SETTING
5-63
13. Install:
•Chain tensioner
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Assembly steps:
•Remove the chain tensioner screw (1), the
washer (2) and the spring (3).
•Release the chain tensioner unidirectional
cam (4) and push the thrust rod (5).
•Install the chain tensioner in the cylinder with
a new gasket.
Screw (chain tensioner body): 10 Nm (1.0 mkg)
Chain tensioner screw: 20 Nm (2.0 mkg)
WARNING
Always use a new gasket.
•Install the spring, the washer and the chain
tensioner.
14. Adjust:
•Valve clearance Valve clearance: Intake0.05 ~ 0.10 mm
Exhaust 0.12 - 0.17 mm
See section “VALVE CLEARANCE
ADJUSTMENT” in CHAPTER 3.
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