2004 YAMAHA TT600RE Service Manual

INSP
ADJ
SEAT, FUEL TANK AND REAR COWLING
3-3
SEAT, FUEL TANK AND REAR COWLING
Order Job name/Part name Q.ty Remarks
Seat, fuel tank and rear cowling Remove the parts in order.
removal
1 Seat 1
2 Fuel pipe 1NOTE:
Be sure the cap is properly tightened
and the fuel cock is in the “OFF” position
before removing the tank.
3 Fuel tank 1
4 Lamp connector 1 Disconnect.
5 Rear cowling 1NOTE:
Widen the rear cowling body sides carefully
to extract rear cowling from the chassis.
Reverse the removal procedure for instal-
lation.
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VALVE CLEARANCE ADJUSTMENT
3-4
INSP
ADJ
ENGINE
VALVE CLEARANCE ADJUSTMENT
NOTE:
•Valve clearance must be adjusted when the
engine is at ambient temperature.
•Adjust valve clearance with the piston under
compression at top dead centre (T.D.C.).
WARNING
Hold the motorcycle firmly in place to prevent
it falling over during the operation.
1. Remove:
•Seat
•Fuel tank
See the section “ SEAT, FUEL TANK AND
REAR COWLING”.
2. Disconnect:
•Spark plug cap (1)
3. Remove:
•Spark plug
•Tappet cover (2) (intake)
•Tappet covers (3) (exhaust)
When removing the spark plug and tappet
cover, be careful not to drop foreign objects
inside the engine.
4. Remove:
•Cap (1)
•Cap (2)
CAUTION:
5. Turn the crankshaft anticlockwise using a
wrench.
1
2
3
12
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INSP
ADJ
VALVE CLEARANCE ADJUSTMENT
3-5
6. Align:
•Reference mark “T” on the flywheel (1)
with the fixed reference mark on the
crankcase (2).
NOTE:
Check that the piston is under compression at top
dead centre (T.D.C.).
(3) Ignition timing reference mark
7. Check:
•Valve clearance
Out of specification ➔Adjust.
Valve clearance (cold):
Intake:
0.05 ~ 0.10 mm
Exhaust:
0.12 ~ 0.17 mm
8. Adjust:
•Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Adjustment:
•Loosen the lock nut (1).
•Fit a thickness gauge (2) between the rocker
arm and the valve stem.
•Turn the adjuster (1) clockwise or anticlock-
wise using the special tool (2) to obtain the
required clearance.
Special tool:
P/N. 90890-01311
•Holding the adjuster firmly in place, lock tight-
en lock nut.
Lock nut:
14 Nm (1.4 mkg)
•Measure valve clearance.
If the clearance is incorrect, repeat the previ-
ous stages to achieve the required value.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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VALVE CLEARANCE ADJUSTMENT
3-6
INSP
ADJ
9. Reassemble:
•Caps
•Tappet cover (intake)
•Tappet covers (exhaust)
•Spark plug
Tappet cover (exhaust):
12 Nm (1.2 mkg)
Bolt (tappet cover - intake):
10 Nm (1.0 mkg)
Spark plug:
18 Nm (1.8 mkg)
NOTE:
The tappet cover (intake) should be mounted with
arrow (1) pointing upwards.
10. Connect:
•Spark plug cap
11. Reassemble:
•Fuel tank
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
Seat screws:
10 Nm (1.0 mkg)
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INSP
ADJDRIVE CHAIN ADJUSTMENT
IDLE SPEED ADJUSTMENT
3-7
DRIVE CHAIN ADJUSTMENT
The drive chain does not need to be adjusted.
IDLE SPEED ADJUSTMENT
1. Start the engine and let it heat.
2. Connect:
•The inductive engine speed indicator to
the spark plug cable
Special tool:
P/N. 90890-03113
Engine idle speed:
1,150 ~ 1,450 rpm
3. Check:
•The engine idle speed.
Out of specification ➔Adjust.
4. Adjust:
•Engine idle speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjustment:
•Turn the throttle stop screw (1) either way to
obtain the idle speed required.
Screwing (a) Increases idle speed
Unscrewing (b) Decreases idle speed
NOTE:
After setting the idle speed, adjust the accelerator
cable free play.
5. Disconnect:
•Inductive engine speed indicator
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THROTTLE CABLE FREE PLAY ADJUSTMENT
3-8
INSP
ADJ
THROTTLE CABLE FREE PLAY
ADJUSTMENT
NOTE:
Before adjusting the throttle cable free play, adjust
the engine idle speed.
1. Remove:
•Seat
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING”.
2. Check:
•Throttle cable free play (a)
Out of specification ➔Adjust.
Throttle cable free play:
3 ~ 5 mm (at the grip flange)
3. Adjust:
•Throttle cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjustment:
•Loosen the throttle cable (2) lock nuts (1).
•Turn the adjuster (3) clockwise or anticlock-
wise to obtain the required free play.
•If after loosening the adjuster by 5 mm, the
free play is still not correct, tighten the
adjuster (4) on the throttle cable (5) once
more.
•Tighten the lock nuts.
(1), (6) Lock nuts
4. Reassemble:
•Fuel tank
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
a
Seat screws:
10 Nm (1,0 mkg)
2
1
3
6
4
5
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INSP
ADJ
SPARK PLUG INSPECTION
3-9
SPARK PLUG INSPECTION
1. Remove:
•Seat
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING”.
2. Disconnect:
•Spark plug cap
3. Remove:
•Spark plug (1)
Before removing the spark plug, use com-
pressed air to blow away any dirt accumulat-
ed in the spark plug wells to prevent it from
falling into the cylinder.
When removing the spark plug, be careful not
to drop foreign objects inside the engine.
4. Inspect:
•Type of spark plug
Incorrect ➔Replace.
CAUTION:
CAUTION:
Standard spark plug:
DPR8EA-9 (N.G.K.) or DPR9EA-9 (N.G.K.)
5. Inspect:
•Electrodes (1)
Wear and tear/damage ➔Replace.
•Insulator (2)
Normal insulator (2) colour is light tan.
6. Clean the spark plug with a suitable tool and a
steel brush.
7. Measure:
•Spark plug electrode gap (a)
Use a wire or thickness gauge.
Out of specification ➔Regap.
Electrode gap:
0.8 ~ 0.9 mm
1
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SPARK PLUG INSPECTION
3-10
INSP
ADJ
8. Lock tighten:
•Spark plug
Before installing the spark plug, clean the
surface and thread.
Spark plug:
18 Nm (1.8 mkg)
Seat screws:
10 Nm (1.0 mkg)
NOTE:
Tighten the spark plug by hand before torquing to
specification.
9. Connect:
•Spark plug cap
10. Install:
•Fuel tank
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
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