Yamaha TT 600 R 1997 Operating and installation instructions

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YAMAHA
TT 600 R :97
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INFORMATION

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1;
INTRODUCTION
This booklet has been createdinorder to provide further information abouttheYamaha lT 600 R ('97) model.
For a
full understanding of the information on theservice procedures, usethis booklet together withthe mi-
crofiches
of the Service Manual.
TT 600 R ('97) SERVICE MANUAL: 5CH-ME1
TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLE GROUP
BELGARDA S.p.A.
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lT 600 R '97
SERVICE INFORMATION
0 1997 Belgarda S.p.A.
1"'edition, September 1997
All rights reserved.
Any reprinting or unauthorised use
without the written permission
of
Belgarda S.p.A. isexpressly prohibited.
Printed in Italy
BCH-SEI
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WARNING
Thismanual has beenwritten by BelgardaS.p.A. mainly foruse by Yamaha dealersandtheirskilled
mechanics. It is impossible
to provide a mechanic with all the information necessaryin a single manual.
Presumably, though, the people who use this manual for the maintenance and repair
of Yamaha motor-
cycles will already have elementary knowledge of the principles
of mechanics and the procedures for
motorcycle repair techniques. Without this knowledge, repair or maintenance workon this model could
prove inefficient and/or dangerous.
Belgarda S.p.A. makes constant effortsto improve allitsmodels. Important alteratlonsor changes
to pro-
cedures characteristics will be communicated
to all Yamaha dealers and published in future editions of
this manual.
NOTE:
Specifications and designare subject to change without notice.
\
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PARTICULARLY IMPORTANT INFORMATION
The manual includes the following symbols and relative remarks:
~~ . Thissafety alert symbol means: ATTENTION! BECOMEALERT! YOUR SAFE-
TY
IS INVOLVED!
m The WARNING symbolIndicatesspecialprocedures to befollowed to avoid
v severeinjury or deathtotherider or thepersonInspecting or repairingthe
motorcycle.
'CAUTION:.,, CAUTIONindicatesspecialprecautionstobetaken to avoiddamagetothe
motorcycle.
NOTE: ANOTEprovideskeyinformationdesigned to makeprocedureseasierorclear-
e
r.

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ILLUSTRATED SYMBOLS
Illustratedsymbols (1) to (9) aredesigned as
thumb tabs
to indicate the chapter's number and
content.
(1) General information
(2) Specifications
(3) Perlodic inspection and adjustment
(4) Engine
(5) Cooling system
(6) Carburetion
(7) Chassis
(8) Electrical
(9) Troubleshooting
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Illustrated symbols (IO) to (17) are used to identi-
fy the specifications appearingInthe text.
(1 0) Possibleto maintainwith engine mounted
(11) Fllling fluid
(12) Lubricant
(1 3) Special tool
(14) Tightening
(15) Wear limit, clearance
(16) Engine speed
(1 7) 12, V, A
L
'14'
Illustrated symbols (18) to (23) in theexploded
diagrams indicatethe types
of lubricants and lubri-
cation points.
(1 8) Apply englne oil
(1 9) Apply gear oil
(20) Apply molybdenum disulfide oil
(21) Apply wheel bearinggrease
(22) Apply lightweight lithium-soap base grease
(23) Apply molybdenum disulfide grease
Illustrated symbols
(24) to (25) in the exploded
diagramsindicatethewhere
to applylocking
agent(24)andwhen
to installnewparts (25).
(24) Apply locking agent (LOCTITE@)
(25) Use new one

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INDEX
GENERAL INFORMATION
VEHICLEIDENTIFICATION ..................................................................................... 1
Y
SPECIFICATIONS
GENERALSPECIFICATIONS ..................................................................................
MAINTENANCESPECIFICATIONS - ENGINE ........................................................
LUBRICATION LAYOUT ..........................................................................................
ENGINE - TIGHTENING TORQUES ........................................................................
MAINTENANCESPECIFICATIONS - CHASSIS ......................................................
CHASSIS - TIGHTENING TORQUES ......................................................................
MAINTENANCESPECIFICATIONS - ELECTRICAL ................................................
GENERAL SPECIFICATIONS ABOUT TIGHTENING TORQUES ........................
LUBRICATION POINTSAND LUBRICANT TYPE .................................................
CABLEROUTING ....................................................................................................
2
5
10
14
17
19
21
23
24
26
PERIODIC INSPECTIONSAND ADJUSTMENTS
PERIODICMAINTENANCE/LUBRICATION INTERVALS ........................................ 30
EXPLODEDDIAGRAM
CARBURETOR .................................................................................................. 33
ELECTRICAL
WIRINGDIAGRAM ............................................................................................... 35
‘W

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VEHICLE IDENTIFICATION GENl INFO
GENERAL INFORMATION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATIONNUMBER
The vehicleidentificationnumber (1) is stamped
into the right side
of the steering head pipe.
MODEL/COLOURIDENTIFICATION LABEL
The modelkolour identification label (1) is affixed
to the rear frame. This information will be needed
to order spare parts.
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GENERAL SPECIFICATIONS M
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code
Dimensions:
Overall length
Overall wldth
Overall height
Seat height
Wheel base
Minimum ground clearance
Minimum turning radius
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Baslc weight:
I Withoiland full fuel tank
I
Engine:
Englne type
Cylinder arrangement
Displacement
Bore
x stroke
Compression ratio
+
Starting system
Lubrication system
I
.
L
Oil type or grade:
Engineoil
-20°-100 0" 10" 20" 30" 40"50"C
IIIIIIII
III(II4I
,I111111
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API standard:
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Oilcapacity:
Engine oil
Periodic oil change
With
oil fllter replacement
Oil tank
Total amount
Air filter
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Standard
TT 600 R: DJOI (5CH1)
2,250 mm
845 mm
1,225 mm
945 mm
1,480 mm
325 mm
3,100 rnm (left)
3,300 mm (right)
150 kg
Air cooled, 4-stroke,4-valve,
SOHC
Forward-inched single cylinder
595 cm3
95
x 84 mm
851
Kick-starter
Dry sump with separate oil tank
Type API Service
"SE, "SF" or equivalent
2.7 L
2.8
L
2.6 L
3.3 L
Oiled filter element
Fuel:
TY Pe
Tank capaclty
Reserve
Regular unleaded gasoline
10 L
2.1 L
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GENERAL SPECIFICATIONS Wl
Item I Standard
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Carburetor:
Type Y30PV-2ATK
Manufacturer TElKEl
Spark plug:
Type DPR8EA-S/DPRSEA-9
Manufacturer
NGK
Electrode gap
0.8 - 0.9 mm
Clutch type
Transmission:
Wet, multi-dlsc
...-
Primary reduction system
Primary reduction ratio Straight-tooth gears
30/13 (2.308)
Gearratio
1 I'
Left foot operation
Operation Constant mesh 5-speed
Transmission type 44/15 (2.933)
Secondary reduction ratio Chain drive
Secondary reductlon system 74/31(2.387)
2M
19/24 (0.792)
5'h
21/22 (0.954)
4'h 24/20 (1.200)
3d
27/17 (1.588)
Frame,
Frame type
Trail 26"
30'
Caster angle
Open-cradle backbone frame
114 mm
and removable rear frame
Tyres:
Type With tube
Sizefront 90/90-21"-54R
/ 90190-21"-545
rear 130/90-18-69R
/ 130180-1 8-66R
140/80-18-70R / 130180-18-668
Manufacturer/modelfront
rear MlCHELlN BAJA
or T63
PlRELLl MT21 orMT70
MlCHELlN BAJA
or T63
PlRELLl MT21
or MT70
Maximum load*
- except motorcycle
Tire pressure (cold tire):
180 kg
Rideronlyfront
100 kPa (1
.OO kgicm', 1 .OO bar)
rear
100 kPa (1 .OO kg/cm2, 1 .OO bar)
Off-roadfront
220 kPa (2.20 kg/cm2, 2.20 bar)
rear 200 kPa (2.00 kg/cm', 2.00 bar)
Withmaximumload*front
180 kPa (1 .80 kg/cm2, 1.80 bar)
rear
150 kPa (1.50 kg/cm', 1.50 bar)
* Load is the total weight of cargo,
passenger, and accessories.
Brakes:
Frontbraketype
Single dia. 220 mm disk brake
Rearbraketype
Single dla. 267
mm disk brake
operation
Right
foot operation
operation
Right hand operation
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GENERAL SPECIFICATIONS !Giq-q
Item
Standard
Suspension:
Front suspension DELTA-BOX SWINGARM
Rear suspension Adjustable telescopic fork (dia. 43
mm)
Shock absorber:
Front shock absorber Adjustable
/ Coil spring / Oil-gas damper
Rear shock absorber Adjustable
/Coil spring /Oil damper
with separatedtank
Wheeltravel:
Front wheel travel 280
mm
Rear wheel travel
280 mrn
Electric system:
Type Without battery
‘W
C.D.I. (digital)
Ignition system
Generator A.C. magneto 12V
Headlighttype
Bulb wattage x quantity: Quartz bulb(halogen)
Headlight
Headlight (only forAustralian market) 12V6OWl55W
12v1,2wx1Turn indicator light 12v1,2wx1
High beam indicatorlight 12V1,2WXl
Neutral indicator light 12v3wx1
Meter light 12v5wx1
Front marker light 12VlOWx4
Flasher light 12V5Wl21
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Tail/brake light 12V35W135W
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MAINTENANCE SPECIFICATIONS -1
MAINTENANCESPECIFICATIONS
ENGINE
-
Itern
Limit
Standard
I I I
Cylinder head:
Warp
limit
*
1 ----
* The lines show where you have
to site themeasuringslide rule. I
0.03 mm
1
Cylinder:
Bore
size
Measurement point (a)
94.97 - 95.02 rnm
(a) = 50 rnrn
TlEi
95.1 mm
--_-
I I I
Camshaft:
Advance method
Camshaft
outer diameter
Backlash between camshaft and
cap
Cam dimensions
1
w
Intake
Exhaust
Camshaft
runout limit
"A"
"B
"C"
'A"
"8"
"C"
-*- ----JL--
I tilA
Chain advance (left)
22.967 - 22.980 mrn
0.020 - 0.054 mrn
36.47- 36.57 mm
30.06 - 30.1 6 mm
6.41 rnm
36.62-36.72
rnrn
30.11 -30.21 mm
6.51 rnm
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0.03 mm
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