Yamaha 2004 TT600RE User manual

TT600RE
2004
5CH5-ME1
SERVICE MANUAL

EASB0000
TT600RE
SERVICE MANUAL
© 2003 by Belgarda S.p.A.
First edition, July 2003
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Belgarda S.p.A.
is expressly prohibited.
Printed in Italy

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

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
12
34
?
56
78
90
qw
er
ty
uoi
psa
df

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

1
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
1
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.

GEN
INFO
IMPORTANT INFORMATION
1-3
EB101030
LOCK WASHERS/PLATES AND COTTER PINS
1. Replace all lock washers/plates 1and cotter
pins after removal. Bend lock tabs along the
bolt or nut flats after the bolt or nut has been
tightened to specification.
EB101040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the man-
ufacturer’s marks or numbers are visible.
When installing oil seals, apply a light coating
of lightweight lithium base grease to the seal
lips. Oil bearings liberally when installing, if
appropriate.
1Oil seal
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.
1Bearing
CAUTION:
EB101050
CIRCLIPS
1. Check all circlips carefully before reassembly.
Always replace piston pin clips after one use.
Replace distorted circlips. When installing a
circlip 1, make sure that the sharp-edged
corner 2is positioned opposite the thrust 3
it receives. See sectional view.
4Shaft
OR

GEN
INFO
CHECKING OF CONNECTIONS
1-4
EB801000
CHECKING OF CONNECTIONS
Check the connectors for stains, rust, moisture,
etc.
1. Disconnect:
•connector
2. Check:
•connector
Moisture →Dry each terminal with an air
blower.
Stains/rust →Connect and disconnect the
terminals several times.
3. Check:
•connector leads
Looseness →Bend up the pin 1and con-
nect the terminals.
4. Connect:
•connector terminals
NOTE:
The two terminals “click” together.
5. Check:
•continuity (using a pocket tester)
NOTE:
•If there is no continuity, clean the terminals.
•When checking the wire harness be sure to
perform steps 1 to 3.
•As a quick remedy, use a contact revitalizer
available at most part stores.
•Check the connector with a pocket tester as
shown.

1-5
GEN
INFO
SPECIAL TOOLS
SPECIAL TOOLS
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.
Tool No.
90890-03113
Engine tachometer
This tool is needed for detecting engine rpm.
90890-03141
Timing light
This tool is needed for detecting ignition
timing.
90890-03112
Pocket tester
These instruments are invaluable for check-
ing the electrical system.
90890-06754
Ignition checker
This instrument is necessary for checking
the ignition system components.
Tool name / Usage Illustration
90890-03081
Compression gauge
These tools are used to measure the engine
compression.
90890-04082
Adapter (compression gauge)
This tool serves to measure the engine com-
pression.
90890-01312
Fuel level gauge
This gauge is used to measure the fuel level
in the float chamber.
90890-01304
Piston pin clip puller
This tool serves for removing the piston pin
clip.

1-6
GEN
INFO
SPECIAL TOOLS
Tool No.
90890-01083
Rocker arm shaft puller bolt
These tools are used when removing the
rocker arm shafts.
Tool name / Usage Illustration
90890-01084
Weight
These tools are used when removing the
rocker arm shafts.
90890-04019
Valve spring compressor
These tools are used when removing or
installing the valve and the valve spring.
90890-01225
7 mm (0.28 in) valve guide puller
This tool is used to remove the valve guides.
90890-04017
7 mm (0.28 in) valve guide installer
This tool is necessary to install the valve
slides properly.
90890-01227
7 mm (0.28 in) valve guide reamer
This tool is used to re-ream the new valve
guide.
90890-01311
Valve adjusting tool
This tool is necessary for adjusting valve
clearance.
90890-01701
Rotor holder
This tool is used for loosing and tightening
the rotor nut.
90890-01362
Rotor screw puller
This tool is used to disassemble the magne-
to flywheel rotor.

1-7
GEN
INFO
SPECIAL TOOLS
Tool No. Tool name / Usage Illustration
90890-04086
All-purpose clutch holder
This tool is used to lock the clutch, when the
clutch boss lock nut is being loosened or
tightened.
90890-01135
Crankcase separating tool
This tool is necessary to disassemble the
crankcase.
90890-01274
Crankshaft installation hose
This tool is used to install the crankshaft.
90890-01275
Crankshaft installation bolt
This tool is used to install the crankshaft.
90890-04059
#10 (M14) adapter
This tool is used to install the crankshaft.
90890-04081
Crank spacer
This tool is used to install the crankshaft.
90890-85505
SEALANT (QUICK GASKET) ®
Yamaha Bond No. 1215 ®
This sealant (adhesive) is used for crankcase
mating surfaces etc.
90890-01268
Ringnut wrench
This tool is used to loosen and tighten the
steering ringnut.
90890-01348
Ringnut wrench
This tool is used to loosen and tighten the
steering ringnut.

1-8
GEN
INFO
SPECIAL TOOLS
Tool No. Tool name / Usage Illustration
90890-11043
DU bush/oil seal guide
This tool is used to install the DU bush and
the fork oil seal.
90890-01326
T-handle
This tool is needed to loosen and tighten the
front fork damper rod holding bolt.
90890-01460
Front fork damper rod holder
This tool is needed to hold the front fork
damper rod when loosening and tightening
the holding bolt.

2
SPEC

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