2004 YAMAHA TT600RE maintenance

EASB0001
NOTICE
This manual was produced by the Belgarda S.p.A. primarily for use by Yamaha dealers and their quali-
fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore,
anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic
understanding of mechanics and the techniques to repair these types of vehicles. Repair and mainte-
nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit
for use.
Belgarda S.p.A. is continually striving to improve all of its models. Modifications and significant changes
in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in
future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE-
TY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death
to
the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE:A NOTE provides key information to make procedures easier or clearer.
CAUTION:
WARNING
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SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS............................................................................................ 2-1
MAINTENANCE SPECIFICATIONS....................................................................................2-4
ENGINE ........................................................................................................................2-4
CHASSIS ....................................................................................................................2-12
ELECTRICAL ..............................................................................................................2-17
GENERAL TORQUE SPECIFICATIONS............................................................................2-19
CONVERSION TABLE........................................................................................................2-19
LUBRICATION POINTS AND LUBRICANT TYPES..........................................................2-20
ENGINE ......................................................................................................................2-20
CHASSIS ....................................................................................................................2-21
LUBRICATION LAYOUT....................................................................................................2-22
CABLE ROUTING..............................................................................................................2-26
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SPECMAINTENANCE SPECIFICATIONS
2-4
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head
Max. warpage ••• 0.03 mm
Cylinder
Bore 94.970 - 95.020 mm 95.10 mm
Measuring point 50 mm •••
Camshaft
Drive system Chain drive (left)
Camshaft cap inside diameter 23.000 - 23.021 mm •••
Camshaft journal diameter 22.967 - 22.980 mm •••
Camshaft-journal-to-camshaft-cap
clearance 0.020 - 0.054 mm •••
Camshaft lobe dimensions:
Intake-measurement A 36.470 - 36.570 mm •••
Intake-measurement B 30.060 - 30.160 mm •••
Intake-measurement C 6.41 mm •••
Exhaust-measurement A 36.620 - 36.720 mm •••
Exhaust-measurement B 30.110 - 30.210 mm •••
Exhaust-measurement C 6.51 mm •••
Max. camshaft runout ••• 0.030 mm
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SPECMAINTENANCE SPECIFICATIONS
2-5
Item Standard Limit
Timing chain
Model/number of links 75-010/126
Tensioning system Automatic
Rocker arm/rocker arm shaft
Arm inside diameter 12.000 - 12.018 mm •••
Shaft outside diameter 11.976 - 11.991 mm •••
Arm-to-shaft clearance 0.009 - 0.042 mm •••
Valve, valve seat, valve guide
Valve clearance (cold) intake 0.05 - 0.10 mm •••
exhaust 0.12 - 0.17 mm •••
Valve dimensions:
Valve head diameter A intake 36.90 - 37.10 mm •••
exhaust 31.90 - 32.10 mm •••
Valve face width B intake 2.260 mm •••
exhaust 2.260 mm •••
Valve seat width C intake 1.00 - 1.20 mm 1.80 mm
exhaust 1.00 - 1.20 mm 1.80 mm
Valve margin thickness D intake 1.00 - 1.40 mm 0.80 mm
exhaust 0.80 - 1.20 mm 0.65 mm
Valve stem diameter intake 6.975 - 6.990 mm 6.995 mm
exhaust 6.955 - 6.970 mm 6.925 mm
Valve guide inside
diameter intake 7.000 - 7.012 mm 7.042 mm
exhaust 7.000 - 7.012 mm 7.042 mm
Valve stem to valve
guide clearance intake 0.010 - 0.037 mm 0.08 mm
exhaust 0.030 - 0.057 mm 0.10 mm
Valve stem runout ••• 0.010 mm
Valve seat width intake1.10 mm 1.80 mm
exhaust 1.10 mm 1.80 mm
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SPECMAINTENANCE SPECIFICATIONS
2-6
Item Standard Limit
Valve spring
Inner spring:
Free length intake40.10 mm 38.10 mm
exhaust 40.10 mm 38.10 mm
Installed length
(valve closed) intake22.70 mm •••
exhaust 22.70 mm •••
Compressed spring force
(installed)intake164.80 - 190.20 N •••
16.80 - 19.39 kg •••
exhaust 164.80 - 190.20 N •••
16.80 - 19.39 kg •••
Spring tilt intakeintake •••2.5 °/1.7 mm
exhaust ••• 2.5 °/1.7 mm
Winding direction
(top view)intakeClockwise
exhaust Clockwise
Outer spring:
Free length intakeintake43.80 mm 38.10 mm
exhaust 43.80 mm 38.10 mm
Installed length
(valve closed)intake34.20 mm •••
exhaust 34.20 mm •••
Compressed spring force intake71.60 - 87.30 N •••
(installed)7.3 - 8,9 kg •••
exhaust 149.10 - 182.40 N •••
15.2 - 18.6 kg •••
Spring tilt intake •••2.5 °/1.7 mm
exhaust ••• 2.5 °/1.9 mm
Winding direction
(top view)intakeCounterclockwise
exhaust Counterclockwise
Piston
Piston-to-cylinder clearance 0.045 - 0.065 mm 0.15 mm
Diameter D 94.915 - 94.965 mm •••
Height H 5.0 mm •••
Piston pin bore inside diameter 22.004 - 22.015 mm •••
Offset 2.00 mm •••
Offset direction Intake side
Piston pin outside diameter 21.991 - 22.000 mm •••
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SPECMAINTENANCE SPECIFICATIONS
2-7
Item Standard Limit
Piston ring
Top ring:
Ring type Barrel
Dimensions (B x T) 1.20 x 3.80 mm •••
End gap
(installed) 0.30 - 0.45 mm 0.70 mm
Ring side clearance 0.040 - 0.080 mm 0.130 mm
2
ndring:
Ring type Plain
Dimensions (B x T) 1.20 x 3.80 mm •••
End gap
(installed) 0.30 - 0.45 mm 0.80 mm
Ring side clearance 0.030 - 0.070 mm 0.130 mm
Oil ring:
Dimensions (B x T) 2.50 x 3.40 mm •••
End gap
(installed) 0.20 - 0.70 mm •••
Ring side clearance 0.020 - 0.060 mm •••
Crankshaft
Width A 74.95 - 75.00 mm •••
Max. runout C ••• 0.030 mm
Big end side clearance D 0.350 - 0.650 mm •••
Big end radial clearance 0.010 - 0.025 mm •••
Small end free play F 0.80 mm •••
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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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2-9
SPECMAINTENANCE SPECIFICATIONS
Cylinder head tightening steps:
Crankcase tightening steps:
Right crankcase Left crankcase
ENGINE
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