![Yamaha TT600RE (2004) [278/382] Engine assembly and setting](/img/pdf.png)
Yamaha TT600RE (2004) [278/382] Engine assembly and setting
![Yamaha TT600RE (2004) [278/382] Engine assembly and setting](/views2/1121411/page278/bg116.png)
ENGINE ASSEMBLY AND SETTING
5-74
ENG
STARTER NEUTRAL GEAR AND CRANKCASE
COVER (L))
1. Install:
•
Stator winding (1)
•
Pick-up coil (2)
•
Cable clamp (3)
2. Install:
•
Bearing (1)
•
Intermediate starter gear 2 (2)
Screws (stator and coil):
7 Nm (0.7 mkg)
Use LOCTITE ®
Screw (cable clamp):
7 Nm (0.7 mkg)
3. Install:
•
Centring pin (1)
•
Gasket (2)
•
O-Ring (3)
•
Crankcase cover (L) (4)
•
Plugs
Bolt (crankcase cover):
10 Nm (1.0 mkg)
WARNING
Always use a new gasket.
Содержание
- Table of contents 1
- Important manual information 3
- Notice 3
- How to use this manual 4
- Gen info 5
- Illustrated symbols 5
- Insp adj 5
- Trbl shtg 5
- Carburetion 6
- Chassis 6
- Electrical 6
- Engine 6
- General information 6
- Periodic inspection and adjustments 6
- Specifications 6
- Table of contents 6
- Troubleshooting 6
- Chapter 1 general information 9
- Gen info 9
- General information 9
- Gen info 11
- General information 11
- Vehicle identification 11
- Gen info 12
- Important information 12
- Gen info 13
- Important information 13
- Checking of connections 14
- Gen info 14
- Gen info 15
- Special tools 15
- 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 15
- Tool name usage illustration 15
- Tool no 15
- Gen info 16
- Special tools 16
- Tool name usage illustration 16
- Tool no 16
- Gen info 17
- Special tools 17
- Tool no tool name usage illustration 17
- Gen info 18
- Special tools 18
- Tool no tool name usage illustration 18
- Chapter 2 specifications 20
- Specifications 20
- General specifications 22
- Specifications 22
- General specifications 23
- General specifications 24
- Engine 25
- Maintenance specifications 25
- Maintenance specifications 26
- Maintenance specifications 27
- Maintenance specifications 28
- Maintenance specifications 29
- Engine 30
- Maintenance specifications 30
- Maintenance specifications 31
- Tightening torques 31
- Maintenance specifications 32
- Chassis 33
- Maintenance specifications 33
- Maintenance specifications 34
- Maintenance specifications 35
- Tightening torques 35
- Maintenance specifications 36
- Final tighten the ring nut at the torque of 4 nm 0 mkg 37
- Maintenance specifications 37
- Note 1 first tighten the ring nut approximately 38 nm 3 mkg by using the torque wrench then loosen the ring nut one turn 37
- Electrical 38
- Maintenance specifications 38
- Maintenance specifications 39
- A b general torque 40
- A distance between flats b outside thread diameter 40
- All specification data in this manual are listed in si and metric units use this table to convert metric unit data to imperial unit data 40
- Conversion table 40
- General torque specifications 40
- General torque specifications conversion table 40
- Metric multiplier imp 40
- Mm 0 3937 0 8 in 40
- Mm 0 3937 in 40
- Mm 10 mm 30 3 40
- Mm 12 mm 55 5 40
- Mm 14 mm 85 8 40
- Mm 16 mm 130 13 40
- Mm 6 mm 6 0 40
- Mm 8 mm 15 1 40
- N m m kg 40
- Nut bolt specifications 40
- This chart specifies torque for standard fasteners with standard i s o pitch threads torque specifi cations for special components or assemblies are provided for each chapter of this manual to avoid warpage tighten multi fastener assemblies in a crisscross fashion in progressive stages until the specified torque is reached unless otherwise specified torque specifications require clean dry threads components should be at room tempera ture 40
- Engine 41
- Lubrlcatlon points and lubricant type 41
- Lubrlcatlon points and lubricant types 41
- Chassis 42
- Lubrlcatlon points and lubricant type 42
- Lubrication layout 43
- Lubrication layout 44
- Lubrication layout 45
- Lubrication layout 46
- Cable routing 47
- Cable routing 48
- Cable routing 49
- Cable routing 50
- Chapter 3 periodic inspection and adjustments 53
- Insp adj 53
- Periodic inspection and adjustements 53
- Insp adj 54
- Insp adj 55
- Introduction 55
- Introduction periodic maintenance lubrication intervals 55
- Periodic inspection and adjustments 55
- Periodic maintenance lubrication intervals 55
- This chapter includes all information necessary to perform recommended inspections and adjustments these preventive maintenance procedures if followed will ensure more reliable vehicle operation and a longer service life the need for costly overhaul work will be greatly reduced this information applies to vehicles already in service as well as to new vehicles that are being prepared for sale all service techni cians should be familiar with this entire chapter 55
- Insp adj 56
- Introduction periodic maintenance lubrication intervals 56
- Items marked with an asterisk should be performed by a yamaha dealer as they require special tools data and technical skills 56
- 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 56
- Insp adj 57
- Seat fuel tank and rear cowling 57
- Engine 58
- Insp adj 58
- Valve clearance adjustment 58
- Insp adj 59
- Valve clearance adjustment 59
- Insp adj 60
- Valve clearance adjustment 60
- Drive chain adjustment idle speed adjustment 61
- Insp adj 61
- Insp adj 62
- Throttle cable free play adjustment 62
- Insp adj 63
- Spark plug inspection 63
- Insp adj 64
- Spark plug inspection 64
- Ignition timing check 65
- Insp adj 65
- Compression inspection 66
- Insp adj 66
- Compression inspection 67
- Insp adj 67
- Compression inspection 68
- Insp adj 68
- Engine oil level check 69
- Insp adj 69
- Engine oil level check 70
- Insp adj 70
- Engine oil replacement 71
- Insp adj 71
- Engine oil replacement 72
- Insp adj 72
- Engine oil replacement 73
- Insp adj 73
- Engine oil replacement 74
- Insp adj 74
- Engine oil pressure check clutch adjustment 75
- Insp adj 75
- Clutch adjustment 76
- Insp adj 76
- Clutch adjustment 77
- Insp adj 77
- Air filter cleaning 78
- Insp adj 78
- Air filter cleaning fuel filter cleaning 79
- Insp adj 79
- Engine oil tank filter cleaning 80
- Insp adj 80
- Engine oil tank filter cleaning 81
- Insp adj 81
- Insp adj 82
- Suction hose and manifold inspection fuel line inspection 82
- Cranckcase ventilation hose inspection exhaust system inspection 83
- Insp adj 83
- Adjusting the front brake 84
- Chassis 84
- Insp adj 84
- Adjusting the rear brake 85
- Insp adj 85
- Checking the brake fluid level 86
- Insp adj 86
- Brake pad wear inspection brake hosing inspection 87
- Insp adj 87
- Brake circuit bleeding 88
- Insp adj 88
- Drive chain slack inspection and adjustment 89
- Insp adj 89
- Drive chain slack inspection and adjustment drive chain lubrication 90
- Insp adj 90
- Front fork inspection front fork adjustment 91
- Insp adj 91
- Insp adj 92
- Rear shock absorber adjustment 92
- Insp adj 93
- Rear shock absorber adjustment 93
- Insp adj 94
- Steering inspection 94
- Insp adj 95
- Steering inspection tyre inspection 95
- Insp adj 96
- Tyre inspection 96
- Insp adj 97
- Tyre inspection 97
- Insp adj 98
- Wheel inspection spoke inspection and tightening 98
- Cable inspection lever and pedal lubrication 99
- Insp adj 99
- Insp adj 100
- Sidestand lubrication rear suspension lubrication 100
- Checking and charging the battery 101
- Electrical system 101
- Insp adj 101
- Checking and charging the battery 102
- Insp adj 102
- Checking and charging the battery 103
- Insp adj 103
- Checking and charging the battery 104
- Insp adj 104
- Checking and charging the battery 105
- Insp adj 105
- Checking and charging the battery 106
- Insp adj 106
- Checking the fuses 107
- Insp adj 107
- Checking the fuses replacing the headlight bulbs 108
- Insp adj 108
- Insp adj 109
- Replacing the headlight bulbs 109
- Insp adj 110
- Replacing the turn indicator light bulb 110
- Insp adj 111
- Replacing the tail brake light bulb 111
- Chapter 4 chassis 114
- Chassis 114
- Chassis 116
- Front wheel and brake disc 116
- Front wheel and brake disc 117
- Front wheel and brake disc 118
- Front wheel and brake disc 119
- Front wheel and brake disc 120
- Front wheel and brake disc 121
- Front wheel and brake disc 122
- Front brake 123
- Front brake 124
- Front brake 125
- Front brake 126
- Front brake 127
- Front brake 128
- Front brake 129
- Front brake 130
- Front brake 131
- Front brake 132
- Front brake 133
- Front brake 134
- Front brake 135
- Rear wheel and brake disc 136
- Rear wheel and brake disc 137
- Rear wheel and brake disc 138
- Rear wheel and brake disc 139
- Rear wheel and brake disc 140
- Rear wheel and brake disc 141
- Rear wheel and brake disc 142
- Rear wheel and brake disc 143
- Rear brake 144
- Rear brake 145
- Rear brake 146
- Rear brake 147
- Rear brake 148
- Rear brake 149
- Rear brake 150
- Rear brake 151
- Rear brake 152
- Rear brake 153
- Rear brake 154
- Rear brake 155
- Rear brake 156
- Front fork 157
- Front fork 158
- Front fork 159
- Front fork 160
- Front fork 161
- Front fork 162
- Front fork 163
- Front fork 164
- Front fork 165
- Front fork 166
- Front fork 167
- Front fork 168
- Front fork 169
- Front fork 170
- Front fork 171
- Front fork 172
- Front fork 173
- Front fork 174
- Front for 175
- Steering 176
- Steering 177
- Steering 178
- Steering 179
- Steering 180
- Steering 181
- Steering 182
- Steering 183
- Rear shock absorber 184
- Rear shock absorber 185
- Rear shock absorber 186
- Rear shock absorber 187
- Rear shock absorber 188
- Rear shock absorber 189
- Rear shock absorber 190
- Swingarm 191
- Swingarm 192
- Swingar 193
- Swingarm 194
- Swingarm 195
- Swingarm 196
- Drive chain drive sprocket and rear wheel sprocket 197
- Drive chain drive sprocket and rear wheel sprocket 198
- Drive chain drive sprocket and rear wheel sprocket 199
- Drive chain drive sprocket and rear wheel sprocket 200
- Drive chain drive sprocket and rear wheel sprocket 201
- Chapter 5 203
- Engine 203
- Engine 205
- Engine removal 205
- Engine removal 206
- Engine removal 207
- Engine removal 208
- Engine disassembly 209
- Engine disassembly 210
- Engine disassembly 211
- Engine disassembly 212
- Engine disassembly 213
- Engine disassembly 214
- Engine disassembly 215
- Engine disassembly 216
- Engine disassembly 217
- Engine disassembly 218
- Engine disassembly 219
- Engine disassembly 220
- Engine disassembly 221
- Engine disassembly 222
- Engine disassembly 223
- Engine disassembly 224
- Inspection and repair 225
- Inspection and repair 226
- Inspection and repair 227
- Inspection and repair 228
- Inspection and repair 229
- Inspection and repair 230
- Inspection and repair 231
- Inspection and repair 232
- Inspection and repair 233
- Inspection and repair 234
- Inspection and repair 235
- Inspection and repair 236
- Inspection and repair 237
- Inspection and repair 238
- Inspection and repair 239
- Inspection and repair 240
- Inspection and repair 241
- Inspection and repair 242
- Inspection and repair 243
- Inspection and repair 244
- Engine assembly and setting 245
- Engine assembly and setting 246
- Engine assembly and setting 247
- Engine assembly and setting 248
- Engine assembly and setting 249
- Engine assembly and setting 250
- Engine assembly and setting 251
- Engine assembly and setting 252
- Engine assembly and setting 253
- Engine assembly and setting 254
- Engine assembly and setting 255
- Engine assembly and setting 256
- Engine assembly and setting 257
- Engine assembly and setting 258
- Engine assembly and setting 259
- Engine assembly and setting 260
- 1 cylinder head cover 2 o ring 3 tappet cover intake 4 tappet covers exhaust 5 o ring 6 cap 261
- 7 cylinder head 8 valve guide intake valve 9 valve guide exhaust valve 10 spark plug 11 dowel pin 261
- Cylinder head 261
- Engine assembly and setting 261
- Engine assembly and setting 262
- Engine assembly and setting 263
- Engine assembly and setting 264
- Engine assembly and setting 265
- Engine assembly and setting 266
- Engine assembly and setting 267
- Engine assembly and setting 268
- Engine assembly and setting 269
- Engine assembly and setting 270
- Engine assembly and setting 271
- Engine assembly and setting 272
- Engine assembly and setting 273
- Engine assembly and setting 274
- Engine assembly and setting 275
- Engine assembly and setting 276
- Engine assembly and setting 277
- Engine assembly and setting 278
- Engine assembly and setting 279
- Engine reassembly 280
- Engine reassembly 281
- Engine reassembly 282
- Carburetor 284
- Chapter 6 carburetor 284
- Carburetor 286
- Carburetor removal 286
- Carburetor removal 287
- Carburetor 288
- Type y30pv 2atk manufacturer teikei 288
- Carburetor 289
- Carburetor 290
- Carburetor disassembly 291
- Carburetor disassembly 292
- Carburetor disassembly 293
- Carburetor inspection 294
- Carburetor inspection 295
- Carburetor assembly 296
- Carburetor assembly 297
- Carburetor assembly 298
- Carburetor assembly 299
- Carburetor assembly 300
- Carburetor assembly 301
- Fuel level adjustment carbure tor installed 301
- Chapter 7 303
- Electrical 303
- Electrical 305
- Electrical circuit diagram 305
- Ext cord 305
- Head light 305
- Main harness 305
- Electrical circuit diagram 306
- Electrical components 307
- Electrical components 308
- Switch check 309
- Switch check 310
- Switch check 311
- Light inspection 312
- Light inspection headlights tail light and brake lights direction indicator lights instrument lights etc 312
- Light inspection 313
- Circuit diagram 315
- Ext cord 315
- Head light 315
- Ignition system 315
- Main harness 315
- Ignition system 316
- Ignition system 317
- Ignition system 318
- Ignition system 319
- Ignition system 320
- Ignition system 321
- Ignition system 322
- Ignition system 323
- Circuit diagram 325
- Electrical starting system 325
- Ext cord 325
- Head light 325
- Main harness 325
- Electrical starting system 326
- Electrical starting system 327
- Electrical starting system 328
- Electrical starting system 329
- Electrical starting system 330
- Electrical starting system 331
- Electrical starting system 332
- Electrical starting system 333
- Electrical starting system 334
- Electrical starting system 335
- Electrical starting system 336
- Electrical starting system 337
- Charging system 339
- Charging system circuit diagram 339
- Ext cord 339
- Head light 339
- Main harness 339
- Charging system 340
- Charging system 341
- Charging system 342
- Charging system 343
- Ext cord 345
- Head light 345
- Light system 345
- Light system circuit diagram 345
- Main harness 345
- Light system 346
- Light system 347
- Light system 348
- Light system 349
- Light system 350
- Light system 351
- Light system 352
- Light system 353
- Circuit diagram 355
- Ext cord 355
- Head light 355
- Main harness 355
- Signal system 355
- Signal system 356
- Signal system 357
- Signal system 358
- Signal system 359
- Signal system 360
- Signal system 361
- Signal system 362
- Signal system 363
- Signal system 364
- Signal system 365
- Signal system 366
- Signal system 367
- Chapter 8 troubleshooting 370
- Trbl sht 370
- Troubleshooting 370
- Failure to start difficulties in starting 372
- Trbl sht 372
- Troubleshooting 372
- Failure to start difficulties in starting 373
- Trbl sht 373
- Poor performance at idle speed 374
- Poor performance at idle speed unsatisfactory performance at medium high speed 374
- Trbl sht 374
- Unsatisfactory performance at medium high speed 374
- Difficulties in shifting 375
- Trbl sht 375
- Clutch slides or fails to release 376
- Trbl sht 376
- Defective brakes 377
- Defective brakes oil leaks or malfunctioning of front fork 377
- Oil leaks or malfunctioning of front fork 377
- Trbl sht 377
- Trbl sht 378
- Unstable steering 378
- Defective functioning of lights and indicators 379
- Trbl sht 379
- Defective functioning of lights and indicators overheating of engine 380
- Overheating of engine 380
- Trbl sht 380
- Electrical system diagram 382
- Tt600re wiring diagram 382
- Wiring diagram 382
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