2004 YAMAHA TT600RE wheel

ENGENGINE DISASSEMBLY
5-13
AC GENERATOR AND TIMING CHAIN
NOTE:
The AC generator may be inspected with the
engine installed by removing the following parts:
•Crankcase (L)
1. Remove:
•Nut (1)
•Washer (2)
•Rotor (3) (with starter gear)
•Bearing (4)
•Shim adjustment washer (5)
•Key (6)
NOTE:
To loosen the nut (rotor), lock the rotor with the
special tool (7).
Sheave holder: P/N. 90890-01701
Flywheel puller:P/N. 90890-01362
Be careful not to touch the jutting edges (8) on
the rotor with the special tool.
CAUTION:
NOTE:
Remove the rotor with the puller (1).
2. Remove:
•Chain guide (1)
•Timing chain (2)
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ENGINE ASSEMBLY AND SETTING
5-46
ENG
TRANSMISSION
(1) Sprocket
(2) Oil seal
(3) Bearing
(4) Second wheel gear
(5) Secondary shaft
(6) Fifth wheel gear
(7) Third wheel gear
(8) Fourth wheel gear
(9) First wheel gear (10) Bearing
(11) Bearing
(12) Second sprocket gear
(13) Fifth sprocket gear
(14) Third sprocket gear
(15) Fourth sprocket gear
(16) Main shaft
(17) Bearing
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ENGENGINE ASSEMBLY AND SETTING
5-61
7. Install:
•Dowel pins (1)
•O-Ring (2)
•Gasket (3) (cylinder head)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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
5-62
ENG
•Install the gear wheel with the timing marks as
shown in the figure and tighten the screws on
the gear wheel by hand.
(3) Upper cylinder head surface
(4) Timing marks
(5) Upper position mark
•When pushing the chain tensioner be sure
that the marks on the cam chain sprocket are
aligned with the top surface of the cylinder
head.
•If the marks are aligned, tighten the cam chain
sprocket bolts.
Bolt (cam chain sprocket): 20 Nm (2.0 mkg)
•If the marks are not aligned, replace the chain
sprocket mating piston and chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
10. Apply:
•Yamaha Bond N° 1215 ®
(1)
(on the mating surfaces)
Sigillante (Quick Gasket) ®
Yamaha bond N° 1215 ®
:
P/N. 90890-85505
11. Install:
•Dowel pins (2)
12. Install:
•Cap
•Cylinder head cover
NOTE:
Cross-tighten the screws repeatedly.
Bolt (cylinder head cover): 10 Nm (1.0 mkg)
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UNSTABLE STEERING
8-7
TRBL
SHTG
?
Handlebar
Steering PROBABLE CAUSES•Assembled crooked or incorrectly
•Handlebar crown assembled incorrectly
•Lower bracket crooked
•Lower steering column installed incorrectly
(threaded ring nuts not tightened correctly)
•Bearing or bearing tracks damaged
Front fork
•Oil level not the same in both tubes
•Spring broken
•Front fork crooked
Tyres
•Tyre pressure incorrect for type of road
•Tyre pressure incorrect
•Tyres worn non-uniformly
Wheels
•Wheels balanced incorrectly
•Wheel deformed
•Bearing loose
•Wheel axle deformed or loose
•Wheels excessively off-centre
Frame
•Deformed
•Head tube damaged
•Ball track installed incorrectly
Rear shock absorber
•Spring yielded
•Spring preloaded
•Oil leak
Rear arm
•Bushes or bearings consumed
•Deformed or damaged
Drive chain
•Chain set incorrectly
UNSTABLE STEERING
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