2004 YAMAHA TT600RE check engine

1-5
GEN
INFO
SPECIAL TOOLS
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the
appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or impro-
vised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
90890-03113Engine tachometer
This tool is needed for detecting engine rpm.
90890-03141Timing light
This tool is needed for detecting ignition
timing.
90890-03112Pocket tester
These instruments are invaluable for check-
ing the electrical system.
90890-06754Ignition checker
This instrument is necessary for checking
the ignition system components.
Tool name / Usage Illustration
90890-03081Compression gauge
These tools are used to measure the engine
compression.
90890-04082Adapter (compression gauge)
This tool serves to measure the engine com-
pression.
90890-01312Fuel level gauge
This gauge is used to measure the fuel level
in the float chamber.
90890-01304Piston pin clip puller
This tool serves for removing the piston pin
clip.
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SPECMAINTENANCE SPECIFICATIONS
2-8
Item Standard Limit
Ballancer
Ballancer drive method Gear
Clutch
Clutch release method Inner push, cam push
Friction plate thickness 2.72 - 2.88 mm •••
Wear limit ••• 2.60 mm
Plate quantity 6 pcs
Friction plate thickness 2.94 - 3.06 mm •••
Wear limit ••• 2.8 mm
Plate quantity 2 pcs
Clutch plate thickness 1.20 mm •••
Plate quantity 7 pcs
Max. warpage ••• 0.20 mm
Clutch spring free length 42.8 mm •••
Plate quantity 5 pcs
Clutch housing thrust clearance 0.070 - 0.071 mm •••
Transmission
Max. main axle runout ••• 0.08 mm
Max. drive axle runout ••• 0.08 mm
Shift mechanism type Cam drum and guide bar
Carburetor
ID mark 5CH5 10
Main jet #1:#150 #2:#145
Main air jet #1:1.0 #2:0.9
Jet needle #1:5C5A-3/5 #2:5Y18-3/5
Needle jet 2.600
Cutaway 4.00
Pilot air jet 1 # 0.8 mm
Pilot jet # 50
Bypass 1 # 1.0
Pilot screw turns out 2-3/4 +/- 1/2
Valve seat size 2.5
Starter jet 1 # 74
Float height 6.0 - 8.0 mm •••
Engine idle speed1,150-1,450 r/min •••
CO% 1.5 - 3 •••
Intake vacuum 30.6-33.36 kPa - 230-250 mm Hg •••
Lubrication systemDry sump
Oil filter type Paper type
Oil pump:
Oil pump type Trochoid type
Inner rotor to outer rotor tip clearance 0.12 mm 0.20 mm
Outer rotor to pump housing
clearance 0.030 - 0.080 mm 0.150 mm
Bypass valve opening pressure 80.0 - 120.0 kPa (0.8 - 1.2 kgf/cm
2) •••
Relief valve operating pressure 80.0 - 120.0 kPa (0.8 - 1.2 kgf/cm2) •••
Oil pressure (hot) 13.0 kPa (0.13 kgf/cm2)/1,300 r/min •••
Pressure check location Oil filter chamber •••
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INSP
ADJ
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENTS
INTRODUCTION..........................................................................................................3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS........................................3-1
SEAT, FUEL TANK AND REAR COWLING................................................................3-3
REMOVAL ............................................................................................................3-3
INSTALLATION ....................................................................................................3-3
ENGINE........................................................................................................................3-4
VALVE CLEARANCE ADJUSTMENT ..................................................................3-4
DRIVE CHAIN ADJUSTMENT ..............................................................................3-7
IDLE SPEED ADJUSTMENT ................................................................................3-7
THROTTLE CABLE FREE PLAY ADJUSTMENT ................................................3-8
SPARK PLUG INSPECTION ................................................................................3-9
IGNITION TIMING CHECK ................................................................................3-11
COMPRESSION INSPECTION ..........................................................................3-12
ENGINE OIL LEVEL CHECK ..............................................................................3-15
ENGINE OIL REPLACEMENT ............................................................................3-17
ENGINE OIL PRESSURE CHECK ....................................................................3-21
CLUTCH ADJUSTMENT ....................................................................................3-21
AIR FILTER CLEANING ......................................................................................3-24
FUEL FILTER CLEANING ..................................................................................3-25
ENGINE OIL TANK FILTER CLEANING ............................................................3-26
SUCTION HOSE AND MANIFOLD INSPECTION..............................................3-28
FUEL LINE INSPECTION ..................................................................................3-28
CRANKCASE VENTILATION HOSE INSPECTION ..........................................3-29
EXHAUST SYSTEM INSPECTION ....................................................................3-29
CHASSIS....................................................................................................................3-30
ADJUSTING THE FRONT BRAKE ....................................................................3-30
ADJUSTING THE REAR BRAKE ......................................................................3-31
CHECKING THE BRAKE FLUID LEVEL ............................................................3-32
BRAKE PAD WEAR INSPECTION ....................................................................3-33
BRAKE HOSING INSPECTION ..........................................................................3-33
BRAKE CIRCUIT BLEEDING ............................................................................3-34
DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT..................................3-35
DRIVE CHAIN LUBRICATION ............................................................................3-36
FRONT FORK INSPECTION ..............................................................................3-37
ADJUSTING THE FRONT FORK ......................................................................3-37
REAR SHOCK ABSORBER ADJUSTMENT ......................................................3-38
STEERING INSPECTION ..................................................................................3-40
TYRE INSPECTION ............................................................................................3-41
WHEEL INSPECTION ........................................................................................3-44
SPOKE INSPECTION AND TIGHTENING ........................................................3-44
CABLE INSPECTION..........................................................................................3-45
LEVER AND PEDAL LUBRICATION ..................................................................3-45
SIDESTAND LUBRICATION ..............................................................................3-46
REAR SUSPENSION LUBRICATION ................................................................3-46
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INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
3-2
INSP
ADJ
ODOMETER READING (x 1,000 km)
ANNUAL N0. ITEM CHECK OR MAINTENANCE JOB
110 2030 40CHECK
18 * Rear brake• Check operation, fluid level and vehicle for fluid leakage. ✓✓✓ ✓
Rear shock
• Check operation and shock absorber for oil leakage.
19
*absorber ✓✓✓ ✓
assemblysull’ammortizzatore.
Rear suspension
• Check operation.
✓✓✓ ✓
20*
relay arm and
connecting arm
• Lubricate with lithium-soap-based grease.
✓✓
pivoting points
• Check starter (choke) operation.
21 * Carburator
• Adjust engine idling speed.✓✓ ✓✓ ✓ ✓
22 Engine oil• Change.
✓✓ ✓✓ ✓ ✓
• Check oil level and oil leakage.
23Engine oil filter
• Replace.✓✓✓
element
24 *Front and rear •
brake switches• Check operation.✓✓ ✓✓ ✓ ✓
Moving parts
25
and cables• Lubricate. ✓✓✓ ✓ ✓
Throttle grip • Check operation and free play.
26 * housing and • Adjust the throttle cable free play if necessary.
✓✓✓ ✓ ✓
cable • Lubricate the throttle grip housing and cable.
27 *Muffler and
• Check the screw clamp for looseness. ✓
exhaust pipe
28 *Lights, signals • Check operation.
✓✓ ✓✓ ✓ ✓
and switches• Adjust headlight beam.
* Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance is per-
formed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake system:
• Check the brake fluid level regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
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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
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:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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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