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TT600RE 2004
Yamaha TT600RE 2004 User Manual
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ENG
ENGINE DISASSEMBL
Y
5-5
ENGINE DISASSEMBL
Y
CYLINDER HEAD, CYLINDER, CAMSHAFT
AND PISTON
NOTE:
The cylinder head, cylinder
, camshaft and piston
can be examined with the engine installed by
removing the following parts.
•
Seat
•
Fuel tank
•
Rear cowling
•
Carburetor
•
Exhaust pipe
1.
Remove:
•
Spark plug (1)
•
T
appet cover (2) (intake)
•
T
appet covers (3) (exhaust)
•
Cylinder head cover (4)
•
Cap (5)
•
Pins (6)
2.
Loosen:
•
Bolt (1) (chain tensioner)
3.
Remove:
•
Chain tensioner (2)
208
210
Table of Contents
Table of Contents
6
Chassis
5
Engine
5
General Information
5
Specifications
5
Troubleshooting
5
Table of Contents
6
Gen Info
8
Model Label
11
Vehicle Identification Number
11
Gaskets, Oil Seals and O-Rings
12
Important Information
12
Preparation for Removal Procedures
12
Replacement Parts
12
Bearings and Oil Seals
13
Circlips
13
Lock Washers/Plates and Cotter Pins
13
Checking of Connections
14
Special Tools
15
Spec Chapter 2. Specifications
20
Chapter 2. Specifications
22
General Specifications
22
Engine
25
Maintenance Specifications
25
Chassis
33
Electrical
38
Conversion Table
40
General Torque Specifications
40
Engine
41
Chassis
42
Lubrication Layout
43
Cable Routing
47
Insp Adj
52
Insp Adj Periodic Inspection and Adjustments Chapter 3.
53
Chapter 3. Periodic Inspection and Adjustments
55
Introduction
55
Periodic Maintenance/Lubrication Intervals
55
Installation
57
Removal
57
Seat, Fuel Tank and Rear Cowling
57
Engine
58
Valve Clearance Adjustment
58
Drive Chain Adjustment
61
Idle Speed Adjustment
61
Throttle Cable Free Play Adjustment
62
Spark Plug Inspection
63
Ignition Timing Check
65
Compression Inspection
66
Engine Oil Level Check
69
Engine Oil Replacement
71
Clutch Adjustment
75
Engine Oil Pressure Check
75
Air Filter Cleaning
78
Fuel Filter Cleaning
79
Engine Oil Tank Filter Cleaning
80
Fuel Line Inspection
82
Suction Hose and Manifold Inspection
82
Exhaust System Inspection
83
Adjusting the Front Brake
84
Chassis
84
Adjusting the Rear Brake
85
Checking the Brake Fluid Level
86
Brake Hosing Inspection
87
Brake Pad Wear Inspection
87
Brake Circuit Bleeding
88
Drive Chain Slack Inspection and Adjustment
89
Drive Chain Lubrication
90
Adjusting the Front Fork
91
Front Fork Inspection
91
Rear Shock Absorber Adjustment
92
Steering Inspection
94
Tyre Inspection
95
Spoke Inspection and Tightening
98
Wheel Inspection
98
Cable Inspection
99
Lever and Pedal Lubrication
99
Rear Suspension Lubrication
100
Sidestand Lubrication
100
Checking and Charging the Battery
101
Electrical System
101
Checking the Fuses
107
Replacing the Headlight Bulbs
108
Replacing the Turn Indicator Light Bulb
110
Replacing the Tail/Brake Light Bulb
111
Chas
113
Chas Chapter 4. Chassis
114
Front Wheel and Brake Disc
116
Front Wheel and Brake Disc Removal
116
Front Wheel Disassembly
118
Front Wheel Inspection
118
Brake Disc Inspection
120
Front Wheel Assembly
121
Front Wheel Installation
121
Wheel Static Balance Adjustment
121
Brake Pad Removal
123
Front Brake
123
Brake Pad Replacement
124
Master Cylinder
126
Master Cylinder Assembly
128
Master Cylinder Inspection
128
Master Cylinder Installation
129
Brake Caliper
131
Brake Caliper Disassembly
133
Caliper Inspection
133
Caliper Assembly
134
Caliper Installation
134
Rear Wheel and Brake Disc
136
Rear Wheel and Brake Disc Removal
136
Rear Wheel Disassembly
138
Rear Wheel Inspection
138
Brake Disc Inspection
139
Rear Wheel Assembly
140
Rear Wheel Installation
140
Wheel Static Balance Adjustment
142
Brake Pad Removal
144
Brake Pad Replacement
144
Rear Brake
144
Master Cylinder
147
Master Cylinder Assembly
148
Master Cylinder Inspection
148
Master Cylinder Installation
149
Brake Pedal Removal
150
Brake Caliper
151
Brake Caliper Disassembly
153
Caliper Inspection
153
Caliper Installation
154
Front Fork
157
Front Fork Removal
157
Front Fork Disassembly
158
Front Fork Removal
160
Oil Replacement
161
Cleaning the Dust Seal
164
Seal and Bush Replacement
165
Anomalous Hydraulic Braking
171
Oil Leakage from Dust Seal
171
Front Fork Inspection
172
Front Fork Adjustment
174
Front Fork Installation
174
Steering
176
Steering Removal
179
Steering Inspection
180
Steering Installation
180
Rear Shock Absorber
184
Note on Disposal
187
Shock Absorber Removal
188
Shock Absorber Adjustment
189
Shock Absorber Inspection
189
Swingarm
191
Swingarm Removal
192
Swingarm Inspection
193
Lateral Free Play Adjustment
194
Swingarm Installation
195
Drive Chain Removal
197
Drive Chain, Drive Sprocket and Rear Wheel Sprocket
197
Drive Chain Inspection
198
Drive Chain Installation
200
Eng
202
Eng Chapter 5. Engine
203
Engine Removal
205
Muffler, Exhaust Pipe, Engine Protector, Drive Sprocket Crankcase Cover, Drive Sprocket and Shift Pedal
205
Engine Mounting Bolt
208
Cylinder Head, Cylinder, Camshaft and Piston
209
Engine Disassembly
209
Intermediate Starter Gear, Crankcase Cover (L) and Generator Stator
212
Crankcase Cover (R), Clutch, Primary Drive Gear and Balancer Shaft Gear
213
Oil Pump and Shift Lever
216
Ac Generator and Timing Chain
217
Crankcase(R)
218
Gearbox and Transmission
220
Balancer Shaft and Crankshaft
221
Oilstrainer
221
Rocker Arms
222
Valves
223
Cylinder Head
225
Inspection and Repair
225
Valves and Valve Guides
226
Valveseat
227
Valve Springs
231
Camshaft
232
Rocker Arms and Rocker Shaft
232
Camshaft Chain and Sprocket
233
Camshaft Chain Guide
234
Cylinder and Piston
234
Piston Rings
236
Clutch
237
Pistonpin
237
Oilpump
239
Transmission and Gearbox
240
Starter Transmission
242
Crankshaft
243
Balancer Shaft Drive and Driven Gears
244
Bearing and Oil Seal
244
Crankcase
244
Engine Assembly and Setting
246
Valves
246
Rocker Arms
247
Crankshaft and Balancer Shaft
248
Transmission
250
Gearbox
251
Transmission and Gearbox
252
Engine Oil Pump and Oil Strainer
253
Crankcase
254
Crankcase
255
Engine Oil Strainer
255
Shift Shaft and Oil Pump
256
Timing Chain
258
Piston and Rings
259
Cylinder
260
Cylinder Head
261
Camshaft and Timing Chain
262
Piston, Cylinder, Cylinder Head and Camshaft
263
Ac Generator
269
Oil Filter and Oil Hoses
271
Balancer Shaft Gear and Primary Transmission Gear
272
Clutch
274
Starter Gears
277
Starter Neutral Gear and Crankcase Cover (L)
278
Engine Reassembly
280
Carb
283
Elec
302
Elec Chapter 7 Electrical
303
Electrical Circuit Diagram
305
Colour Code
306
Electrical Components
307
Main Switch Inspection
309
Switch Check
309
Switch Connection
309
Bulb Inspection
312
Bulb Types
312
Light Inspection (Headlights, Tail Light and Brake Lights, Direction Indicator Lights, Instrument Lights, Etc)
312
Circuit Diagram
315
Ignition System
315
Diagnostics
317
Circuit Diagram
325
Electrical Starting System
325
Starting Circuit Operation
327
Diagnostics
328
Starter Motor
334
Charging System
339
Circuit Diagram
339
Diagnostics
341
Circuit Diagram
345
Light System
345
Diagnostics
347
Light System Inspection
350
Circuit Diagram
355
Diagnostics
357
Signal System Control
359
Trbl Shtg
369
? Trbl Shtg Chapter 8° Troubleshooting
370
Failure to Start/Difficulties in Starting
372
Fuel System
372
Electrical System
373
Poor Engine Compression
373
Poor Performance at Idle Speed
374
Unsatisfactory Performance at Medium-High Speed
374
Difficulties in Shifting
375
Disengaging Gears
375
Shifting Impossible
375
The Shift Pedal Fails to Move
375
Clutch Fails to Release
376
Clutch Slides
376
Clutch Slides or Fails to Release
376
Defective Brakes
377
Malfunctioning
377
Oil Leaks
377
Oil Leaks or Malfunctioning of Front Fork
377
Poor Braking
377
Unstable Steering
378
Defective Functioning of Lights and Indicators
379
Direction Indicators Fail to Turn off
379
Direction Indicators Fail to Turn on
379
Frequent Burning of Bulb
379
Delayed Turning on of Indicators
380
Excessive Indicator Intermittence Frequency
380
Overheating of Engine
380
The Horn Fails to Work
380
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Yamaha TT600RE 2004 Specifications
General
Brand
Yamaha
Model
TT600RE 2004
Category
Motorcycle
Language
English
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