2004 YAMAHA TT600RE Service Manual

INSP
ADJ
3-11
IGNITION TIMING CHECK
IGNITION TIMING CHECK
1. Start the engine and let it heat.
2. Connect:
•Inductive rev counter
•Stroboscopic lamp to spark plug cable
Inductive engine speed indicator:
P/N. 90890-03113
Stroboscopic lamp:
P/N. 90890-03141
3. Remove:
•Cap (1)
In certain conditions, the oil might spray out
when the cap is removed. Be careful therefore
when removing the cap.
4. Check:
•Ignition advance
CAUTION:
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Check:
•Heat engine and let it run to the number of
revs required.
Engine idle speed:
1,150 ~ 1,450 rpm
•Check that reference (1) is in the mobile field
of reference (2) on the flywheel.
Incorrect ignition timing ➔ Check the ignition
coil unit.
NOTE:
Ignition timing cannot be adjusted.
5. Install:
•Cap
6. Remove:
•Stroboscopic lamp
•Inductive engine speed indicator


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3-12
INSP
ADJ
COMPRESSION INSPECTION
COMPRESSION INSPECTION
NOTE:
Insufficient compression causes a loss of per-
formance.
WARNING
Set the motorcycle firmly in place to prevent it
falling during the operation.
1. Remove:
•Seat
•Fuel tank
See section “SEAT, FUEL TANK AND
REAR COWLING”.
2. Check:
•Valve clearance
Out of specification ➔Adjust.
See section “VALVE CLEARANCE AD-
JUSTMENT”.
3. Install:
•Secondary fuel tank
4. Start engine and let it heat.
•Switch off engine.
5. Disconnect:
•Spark plug cap
6. Remove:
•Spark plug (1)
When removing the spark plug, be careful to
prevent foreign bodies from dropping inside
the engine.
CAUTION:
1
7. Apply:
•Pressure gauge (1)
•Adapter (2)
Pressure gauge:
P/N. 90890-03081
Adapter:
P/N. 90890-04082
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INSP
ADJ
3-13
COMPRESSION INSPECTION
Inspection:
•Turn the main switch to "ON".
•With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilized.
WARNING
While operating the starter, disconnect the
spark plug cap to avoid sparks.
•Compare the pressure reading with those in
the table.
Pressure under compression:
Standard
1,100 kPa (11 kg/cm
2, 156 psi)
Minimum
900 kPa (9 kg/cm
2, 128 psi)
Maximum
1.200 kPa (12 kg/cm
2, 171 psi)
8. Check:
•Pressure under compression
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•If the pressure reading is lower than minimum:
1) Add a few drops of oil to the cylinder through
the hole in the spark plug.
2) Measure the compression again.
3) Compare the new reading with the first, then
proceed according to the indications in the
table.
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3-14
INSP
ADJ
COMPRESSION INSPECTION
9. Remove:
•Secondary fuel tank
•Pressure gauge (with adapter)
10. Reassemble:
•Spark plug
See section “SPARK PLUG INSPEC-
TION”.
Spark plug:
18 Nm (1.8 mkg)
Seat screws:
10 Nm (1.0 mkg)
11. Connect:
•Spark plug cap
12. Reassemble:
•Fuel tank
•Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.Pressure under compression:
(after adding oil to the cylinder)
Reading Diagnosis
Pressure higherPiston worn or
than beforedamaged.
Pressure same Cylinder head or
as before piston rings, valves,
gaskets may be
faulty.
Pressure above Inspect cylinder
maximum value head, valve sur-
faces, piston rim to
check for carbon
deposits.
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INSP
ADJ
3-15
ENGINE OIL LEVEL CHECK
ENGINE OIL LEVEL CHECK
Do not put additives into the engine oil. The
latter also lubricates the clutch and additives
might cause it to slide.
WARNING
Never remove the oil tank cap when the
engine is hot. The boiling oil might spill over,
causing burns. Wait for the oil to cool to at
least 60°C (140°F) or thereabouts.
This model is fitted with a dry crankcase lubrica-
tion system. A feed pump delivers oil to the en-
gine; after fully lubricating the latter, the oil is re-
turned to the tank by a scavenge pump. The oil
level must therefore be checked in the oil tank.
1. Start the engine and warm up until the oil tem-
perature rises to approximately 60°C (140°F).
2. Idle the engine for at least 10 seconds while
keeping the motorcycle upright. After stop the
engine and check the oil level through the
level window (3) located on the left side of the
oil tank assy and(or) by oil level gauge.
NOTE:
Be sure the motorcycle is positioned straight up
when checking the oil level. A slight tilt toward the
side can result in false readings.
3. The oil level should be between the maximum
(1) and minimum (2) marks.
CAUTION:
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3-16
INSP
ADJ
ENGINE OIL LEVEL CHECK
If the oil level is below minimum ➔Add oil up
to maximum level.
Recommended oil:
SAE20W40SE or SAE10W30SE
Refer to the chart for selection of
the oils suited to the atmospheric
temperature.
API Standard:
API SE, SF, SG or higher grade
•Do not put in any chemical additives or use
oils with a grade of CD (a) or higher.
•Be sure not to use oils labeled “ENERGY
CONSERVING II” (b) or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
•Be sure no foreign material enters the
crankcase.
4. Reassemble the oil tank cap.
Never start the engine when the oil tank is
empty.
CAUTION:
CAUTION:
Oil capacity:
Total:
3.0 litres
Periodic oil change:
2.4 litres
With oil filter change:
2.5 litres
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INSP
ADJ
3-17
ENGINE OIL REPLACEMENT


ENGINE OIL REPLACEMENT
Do not put additives into the engine oil. The
latter also lubricates the clutch and additives
might cause it to slide.
WARNING
Never remove the oil tank cap when the
engine is hot. The boiling oil might spill over,
causing burns. Wait for the oil to cool to at
least 60°C (140°F) or thereabouts.
Engine oil replacement (without replacing filter
oil)
1. Warm up the engine for a few minutes.
2. Stop the engine. Place an oil pan under the
engine and remove the oil filler cap.
3. Remove the drain plug (1) and drain the
engine oil.
4. Remove two bolts (2) and O-ring of the oil
hose flange, and drain the oil from oil tank.
CAUTION:
7. Inspect:
•All gaskets
Damaged ➔Replace.
8. Reassemble:
•Oil filter cover bleeder screw
•Engine oil drain plug
•Oil tank hose and O-ring 5. Remove the air bleed screw (3) attached to
the oil filter cover (4).
6. Wait until the oil has completely drained.
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3-18
INSP
ADJ
ENGINE OIL REPLACEMENT
Fastening torques:
Drain plug (engine):
30 Nm (3.0 mkg)
Oil tank hose (flange):
10 Nm (1.0 mkg)
Oil filter cover air bleeder screw:
5 Nm (0.5 mkg)
9. Fill:
•Oil tank
Recommended oil:
SAE20W40SE or SAE10W30SE
Refer to the chart for selection of
the oils suited to the atmospheric
temperature.
API Standard:
API SE, SF, SG or higher grade
Oil capacity:
Periodic change = 2.4 litres
•Do not put in any chemical additives or
use oils with a grade of CD (a) or higher.
•Be sure not to use oils labeled “ENERGY
CONSERVING II” (b) or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
•Be sure no foreign material enters the
crankcase.
CAUTION:
10. Install:
•Oil tank tap
11. Check:
•Oil level
See section “ENGINE OIL LEVEL
CHECK”.
•Oil pressure
See section “ENGINE OIL PRESSURE
CHECK”.
•Oil leakage
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