2004 YAMAHA TT600RE width

SPECGENERAL SPECIFICATIONS
2-1
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
ModelTT600RE: 5CH5
Dimensions
Overall length 2,220 mm •••
Overall width 865 mm •••
Overall height 1,195 mm •••
Seat height 890 mm •••
Wheelbase 1,480 mm •••
Ground clearance 280 mm •••
Minimum turning radius 3,300 mm (right)
3,100 mm (left) •••
Basic weight (with oil and full
fuel tank)164.5 kg •••
Engine
Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement Forward inclined single cylinder
Displacement 595 cm
3•••
Bore x stroke 95.0 x 84.0 mm •••
Compression ratio 8.5 : 1 •••
Starting system Electric starter
Lubrication system Dry sump with separate oil tank
Engine oil
Type
Temp. °CSAE20W40SE or SAE10W30SE •••
Recommended engine oil classification API Service SE, SF, SG or higher •••
Quantity:
Without oil filter cartridge
replacement 2.4 L •••
With oil filter cartridge
replacement 2.5 L •••
Total amount (dry engine) 3.0 L •••
Air filterWet type element
Fuel
Type Regular unleaded gasoline
Fuel tank capacity 10 L •••
Fuel reserve amount 3.0 L •••
Carburetor
Manufacturer TEIKEI
Model x quantity Y30PV-2ATK x 1
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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
2-7
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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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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INSPECTION AND REPAIR
5-24
ENG
3. Measure:
•Valve seat width (a)
Out of specification ➔Renew valve seat.
Valve seat width (a):
Intake: 1.0 ~ 1.2 mm
: 1.8 mm
Exhaust: 1.0 ~ 1.2 mm : 1.8 mm
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Measurement steps:
•Apply Prussian blue (Dykem) to the valve
seat.
•Install the valve in the cylinder head.
•Press the valve onto the housing through the
guide to leave a clear outline.
•Measure the width of the valve seat. Where
there is contatc between valve and seat the
Prussian blue is wiped away.
•If the valve seat is too narrow, wide or off-cen-
tre, the valve seat must be renewed.
4. Renew:
•Valve seat
Use the special tool (1) to renew the valve
seat with 30°, 45° and 60° mills.
Turning the cutter, maintain uniform pressure
(about 4-5 kg) to avoid leaving marks on the
valve seat.
CAUTION:
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ENGINSPECTION AND REPAIR
5-25
Mill the valve seat as follows:
Section Cutter
A30°
B45°
C60°
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Valve seat faults recorded by analysing the
valve seal surface:
[A] If the valve surface resembles that shown in
the figure, this means that the valve seat is
centred on the surface but is too wide.
Intervention Desired effect
on the valve seat
Cutter 30°
Reduce valve seat
type: 60° width to 1.0 mm
Intervention
Desired effect
on the valve seat
Cutter 30° (before) Centring of seat and
type: attainment of 1.0 mm
45° width
Intervention Desired effect
on the valve seat
Cutter 60° (first) Centring of seat and
type: attainment of 1.0 mm
45° width
Intervention Desired effect
on the valve seat
Cutter Centring of seat and
type: 45° attainment of 1.0 mm
width
[B] If the valve surface is like this, it means that
the valve seat is centred on the valve surface
but is too narrow.
[C] If the valve surface is like this, it means that the valve seat is too narrow and close to the
edge of the valve.
[D] If the valve surface is like this, it means that the valve seat is too narrow and situated low
down near the lower edge of the valve sur-
face.
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ENGINSPECTION AND REPAIR
5-27
•Apply Prussian blue (Dykem) to the valve seal
surface.
•Install the valve in the cylinder head.
•Press the valve onto the housing through the
guide to leave a clear outline.
•Measure the valve seat width once more. If
the width of the valve is out of specification
alter and relap.

VALVE SPRINGS
1. Measure:
•Free width of valve springs (a)
Out of specification ➔Replace.
Free width of valve springs
(intake and exhaust):
Internal spring External spring 40.1 mm 43.8 mm
Valve spring load:
Internal spring (intake and exhaust) 164.8 ~ 190.2 N
(16.80 ~ 19.39 kgf) at 22.7 mm
External spring (intake) 71.6 ~ 87.3 N
(7.3 ~ 8.9 kgf) at 34.2 mm
External spring (exhaust) 149.1 ~ 182.4 N
(15.2 ~ 18.6 kgf) at 34.2 mm
2. Measure:
•Spring load
Out of specification ➔Replace.
(b) Length of loaded spring
3. Measure:
•Inclination of spring (a)
Out of specification ➔Replace.
Spring inclination limit:
Internal spring External spring 2.5°/1.7 mm 2.5°/1.9 mm
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ENGINSPECTION AND REPAIR
5-39
CRANKSHAFT
1. Measure:
•Width of crank (A)
Out of specification ➔Replace crankshaft.
Width of crank: 74.95 ~ 75.00 mm
Crankshaft runout:: 0.03 mm
Connecting rod small end clearance:0.8 mm
Connecting rod big end clearance:0.35 ~ 0.65 mm
•Runout (B)
Out of specification ➔Replace crankshaft
and/or crank bearing.
•Connecting rod small end clearance (C)
Out of specification ➔Replace connecting
rod big end bearing, connecting rod pin
and/or connecting rod.
•Side clearance (D)
Out of specification ➔Replace connecting
rod.
Crankshaft assembly procedure:
The passages of crankshaft (1) oil and con-
necting rod pin (2) oil must coincide with a tol-
erance of less than 1.0 mm.
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