Yamaha TT600R User manual

YAMAHA

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TT600R

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M.Y 1997-2007

SERVICE MANUAL

EAS00007 HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex-

planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out

with the individual steps in sequential order.

1The manual is divided into chapters.An abbreviation and symbol in the upper right corner of each page

indicate the current chapter.

Refer to "SYMBOLS".

2Each chapter is divided into sections. The current section title is shown at the top of each page, except

in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s) appears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-

moval and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a dis-

assembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to "SYMBOLS".

7Ajob instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts,

notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequentially.

ILLUSTRATED SYMBOLS

The following symbols are not relevant to every

vehicle.

Illustrated symbols 1to 8are printed on the top

right of each page and indicate the subject of

each chapter.

1General information

2Specifications

3Periodic inspections and adjustments

4Chassis

5Engine

6Carburetor

7Electrical system

8Troubleshooting

Illustrated symbols 9to yare used to identify

the specifications appearing in the text.

9Can be serviced with engine mounted

0Filling fluid

qLubricant

wSpecial tool

eTorque

rWear limit, clearance

tEngine speed

yElectrical data

Illustrated symbols uto sin the exploded dia-

grams indicate the types of lubricants and lubrica-

tion points.

uApply engine oil

iApply gear oil

oApply molybdenum disulfide oil

pApply wheel bearing grease

aApply lightweight lithium-soap base grease

sApply molybdenum disulfide grease

Illustrated symbols dto fin the exploded dia-

grams indicate the following:

dApply locking agent (LOCTITE®)

fReplace the part

GEN

INFO SPEC

INSP

ADJ CHAS

ENG CARB

ELEC TRBL

SHTG

New

uoi

psa

GENERAL INFORMATION

TABLE OF CONTENTS

GEN

INFO 1

SPECIFICATIONS SPEC 2

PERIODIC INSPECTION

AND ADJUSTMENTS INSP

ADJ 3

ENGINE ENG 5

CARBURETION CARB 6

CHASSIS CHAS 4

ELECTRICAL ELEC 7

TROUBLESHOOTING TRBL

SHTG 8

E004000

GEN

INFO

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION ......................................................................................1-1

VEHICLE IDENTIFICATION NUMBER..........................................................................1-1

MODEL LABEL..............................................................................................................1-1

IMPORTANT INFORMATION ..............................................................................................1-2

PREPARATION FOR REMOVAL PROCEDURES ........................................................1-2

REPLACEMENT PARTS ..............................................................................................1-2

GASKETS, OIL SEALS AND O-RINGS ........................................................................1-2

LOCK WASHERS/PLATES AND COTTER PINS ........................................................1-3

BEARINGS AND OIL SEALS ........................................................................................1-3

CIRCLIPS ......................................................................................................................1-3

CHECKING OF CONNECTIONS ........................................................................................1-4

SPECIAL TOOLS..................................................................................................................1-5

GEN

INFO

1-1

GEN

INFO

VEHICLE IDENTIFICATION

GENERAL INFORMATION

VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1is stamped in-

to the frame.

MODEL LABEL

The model label 1is affixed to the frame under

the seat.

This information will be needed to order spare

parts.

GEN

INFO

IMPORTANT INFORMATION

1-2

EB101000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES

1. Remove all dirt, mud, dust and foreign materi-

al before removal and disassembly.

2. Use proper tools and cleaning equipment.

Refer to the “SPECIAL TOOLS” section.

3. When disassembling the machine, always

keep mated parts together. This includes

gears, cylinders, pistons and other parts that

have been “mated” through normal wear.

Mated parts must always be reused or

replaced as an assembly.

4. During machine disassembly, clean all parts

and place them in trays in the order of disas-

sembly. This will speed up assembly and

allow for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EB101010

REPLACEMENT PARTS

1. Use only genuine Yamaha parts for all

replacements. Use oil and grease recom-

mended by Yamaha for all lubrication jobs.

Other brands may be similar in function and

appearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS

1. Replace all gaskets, seals and O-rings when

overhauling the engine. All gasket surfaces,

oil seal lips and O-rings must be cleaned.

2. Properly oil all mating parts and bearings dur-

ing reassembly. Apply grease to the oil seal

lips.

This manual suits for next models

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