2004 YAMAHA TT600RE engine

ENGENGINE DISASSEMBLY
5-15
•Be careful not to damage surfaces in con-
tact with the crankcase.
•Use a soft hammer to hit the engine
crankcase. Only hit the reinforced parts.
Do not hit the surface in contact with the
gasket. Work slowly and carefully. Be care-
ful to perform the separation uniformly. If
one end locks, remove pressure from the
thrust screw, realign and recommence. If it
is impossible to separate the crankcase,
check that all screws and components
have been disassembled. Do not use force.
CAUTION:
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ENGINE DISASSEMBLY
5-16
ENG
GEARBOX AND TRANSMISSION
1. Remove:
•Guide bar (1)
•Shift cam (2)
•Selector fork # 3 (3)
•Selector fork # 2 (4)
•Selector fork # 1 (5)
2. Remove:
•Transmission assembly unit (1)
3. Remove:
•Shift shaft # 1 (1)
•Shift shaft # 2 (2)
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ENGENGINE DISASSEMBLY
5-17
BALANCER SHAFT AND CRANKSHAFT
1. Remove:
•Balancer shaft (1)
2. Remove:
•Crankshaft (1)
NOTE:
•Remove the crankshaft by using the
crankcase separating tool (2).
Crankcase separating tool: P/N. 90890-01135
•Tighten the separating tool bolts, making sure
that the tool body is parallel with the engine
crankcase. If necessary, a screw may be
backed out slightly to level tool body.
OIL STRAINER
NOTE:
It is advisable to replace the oil strainer every time
the engine is disassembled.
1. Remove:
•Oil strainer (1)
•Oil passage cover (2)
•Gasket
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ENGINE DISASSEMBLY
5-18
ENG
ROCKER ARMS
NOTE:
The rocker arms may be examined with the
engine installed by removing the following parts.
•Seat
•Fuel tank
•Cylinder head cover
1. Remove:
•Cap (1)
2. Remove:
•Bolts (1) (rocker shaft)
3. Remove:
•Rocker shaft
•Rocker arms
NOTE:
Remove the rocker shaft using sliding hammer (1)
and weight (2).
Sliding hammer bolt: P/N. 90890-01083
Weight: P/N. 90890-01084
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ENGENGINE DISASSEMBLY
5-19
VALVES
NOTE:
The valves may be inspected with the engine
installed by removing the following parts.
•Seat
•Fuel tank
•Exhaust pipe
•Carburetor
•Cylinder head cover
•Cylinder head
1. Check:
•Valve seal
Leakage from valve seats’ Inspect the
valve surface, the seat and seat width.
See section “VALVE SEAT INSPECTION
AND REPAIR”.
NOTE:
Check the valve seal before assembling the inter-
nal parts of the cylinder head (valves, valve
springs, spring retainer etc).
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Inspection steps:
•Pour clean solvent (1) into the intake and
exhaust ports.
•Check the valve seal. There must be no blow-
bys from the valve seats (2).
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ENGINE DISASSEMBLY
5-20
ENG
2. Remove:
•Cotters (1)
•Top spring retainer (2)
•Internal spring (3)
•External spring (4)
•Lower spring retainer (5)
•Valve (6)
•Valve stem seal (7)
NOTE:
Mark each part and its position so that each may
reassembled as before.
NOTE:
Compress the valve spring using tool (8) to
remove the cotters. Valve spring compressor: P/N. 90890-04019
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ENGENGINE ASSEMBLY AND SETTING
5-41
ENGINE ASSEMBLY AND SETTING
VALVES AND ROCKER ARMS
(1) Rocker arm n. 2
(2) Wave washer
(3) Rocker shaft (intake)
(4) Rocker arm n. 1
(5) Valve cotters
(6) Upper valve spring retainer
(7) Oil seal
(8) Inner valve spring
(9) Outer valve spring (10) Valve (intake)
(11) Lower valve spring retainer
(12) Rocker shaft (exhaust)
(13) Rocker arm n. 4
(14) Rocker arm n. 3
(15) Rocker shaft (exhaust)
(16) Valve (exhaust)
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ENGINE ASSEMBLY AND SETTING
5-42
ENG
VALVES
1. Burrs:
•Valve stem tip
(leave the valve stem tip with an oil stone).
2. Lubricate:
•Valve stem and oil seal (apply high quality
molybdenum disulfide oil)
3. Install:
•Oil seal (1)
•Valves (2)
•Lower valve spring retainer (3)
•Inner valve spring (4)
•Outer valve spring (5)
•Upper valve spring retainer (6)
NOTE:
Install the innner and outer springs with the widest
thread upwards.
4. Install:
•Valve cotters (1)
NOTE:
Compress the valve spring with the specific tool
(2) to fit the cotters.
Valve spring compressor: P/N. 90890-04019
(7) Higher pitch
(8) Lower pitch
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