2004 YAMAHA TT600RE warning

ENGENGINE ASSEMBLY AND SETTING
5-69
BALANCER SHAFT GEAR AND PRIMARY
TRANSMISSION GEAR
1. Install:
•Key (1)
•Balancer shaft gear (2)
•Plate (3)
•Lock washer (4)
•Nut (5) (balancer shaft gear)
•Washer (6)
•Key (7)
•Plate (8)
•Balancer shaft drive gear (9)
•Plate (10)
•Primary drive gear (11)
•Lock washer (12)
•Nut (13) (primary drive gear)
Nut (balancer shaft gear): 60 Nm (6.0 mkg)
Nut (primary drive gear): 120 Nm (12.0 mkg)
NOTE:
When installing the drive gear, align the mark on
it (14) with that of the balancer shaft gear (15).
WARNING
Always use a new lock washer.
NOTE:
To tighten nuts (5) and (13), keep the AC genera-
tor rotor still with the special tool (16).
Sheave holder: P/N. 90890-01701
Be careful not to touch the jutting part (17) of
the rotor with the sheave holder.
2. Bend the lock washer tab along the face of the nut.
CAUTION:
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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 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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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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ELECLIGHT INSPECTION
7-9
When removing a bulb be careful to hold the
bulbholder or its housing firmly. Never pull the
cable, as it might detach from the terminal
inside the connector.
CAUTION:
WARNING
Keep inflammable products and hands well
away from bulbs when they are on (danger of
burns and fire). Do not touch the bulb before it
is cool.
2. Check the continuity between the bulb termi- nals.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Control procedure:
•Set the tester selector to Ωx 1”.
•Connect the tester terminals to the bulb pins.
Take, for example, a three pin bulb as shown
in the figure. First check continuity between
pins (1) and (2), connecting tester terminal (+)
to pin (1) and terminal (–) to pole (2). Then
check the continuity between poles (1) and
(3), again connecting tester terminal (+) to
pole (1), and terminal (–) to pole (3). If the
tester indicates “ ∞”, even in one case only, the
bulb must be replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. . Check the bulb attachment by installing a test bulb. Furthermore, during inspection of
the bulbs, connect the tester terminals to the
respective socket cables and check continuity
as described.
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ELECELECTRICAL STARTING SYSTEM
7-25
IT RUNS
IT FAILS TO RUN The starter is defective. Repair or replace.
IT FAILS TO RUNThe starter relay is defective. Replace.
3. Starter
•Connect the positive terminal of the bat-
tery (1) and the starter cable (2) using a
connection cable (3) *.
•Check the functioning of the starter.
WARNING
• A wire that is used as a jumper lead must have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
burn.
• This check is likely to produce sparks, therefore make sure that no flammable
gas or fluid is in the vicinity.
*
*
4. Starter relay.
•Disconnect the starter relay connector.
•Connect the battery and frame to the
starter relay connector, using a connec-
tion cable (1) as shown.
Battery terminal (+) (2) ➔
Red/Black terminal (3)
Frame ➔Blue/White terminal (4)
•Check the functioning of the starter.
*
IT RUNS
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ELECSIGNAL SYSTEM
7-53
DIAGNOSTICS
•THE FLASHER LIGHTS, BRAKE LIGHT AND/OR WARNING LIGHTS FAIL TO TURN ON.
•THE HORN FAILS TO SOUND.
Procedure
Check:
1. Fuse
2. Battery
3. Main switch
4. Harness connections (entire system of con- nections)
NOTE:
•Before starting inspections, remove the following parts:
1. Seat
2. Rear cowling
3. Cowling (headlight)
4. Tail light cover
•To check for operating faults use the following special tools.
Pocket tester: P/N. 90890-03112
1. Fuse
•Check the fuse for continuity.
Refer to “CHECKING THE FUSES” in
Chapter 3.
•Is the fuse OK?
YES
2. Battery.
•Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in Chapter 3.
Min. open-circuit voltage:
12.8 V or more at 20°C (68°F)
•Is the battery OK?
NO
Replace the fuse.
NO
•Clean the battery terminals.
•Recharge or replace the battery.
YES
*
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