Yamaha TT 600 R 1997 Operating and installation instructions

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YAMAHA
TT 600 R :97
4-
‘“*hi
.-
,. SERVICE
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.
f,,' .
'<* 4
-_
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
I -

~
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.
\
v
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
d
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

~
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

- ..--~~~ -. ~
~____ ~~-..~ ~
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.
d
e

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
I
u
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
I r $AEiOWj30 ; ; I
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IIII
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/,lIIIII
,,I, ,I
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,I I I ; ':SA220A/40:* I
IIIIIIII
Ill I I I I *(
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II1I!IIl
IIlIIIIl
API standard:
I
~
Oilcapacity:
Engine oil
Periodic oil change
With
oil fllter replacement
Oil tank
Total amount
Air filter
I
7~
-
_-
__
__
__
-_
_.
-.
-.
-
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
I I
-
-
-
-
-
-
-
-
-
_
-

~-~
GENERAL SPECIFICATIONS Wl
Item I Standard
~
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
'4~
d

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
w
Tail/brake light 12V35W135W
t
u

. ~~ ~~
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
_I_
I
----
__--
_-__
----
-_--
----
___-
----
_---
0.03 mm
u
4

~~
MAINTENANCE SPECIFICATIONS Wl
Itern
Llrnrt
Standard
Timing chain
Timing cham type/
Automatic
Timing chaln adjustment method
75-01
0
Llnk number 126
---_
____
Rocker arm / rocker armshaft,
Rocker arm inner diameter 11.976rnrn
- 11.991 rnrn
Rocker shaft outer diameter 12.000
rnrn - 12.018 rnm
0.009 rnm - 0.042 rnrn
Rocker arm-to-rocker armshaft clearance
.___
.___
____
Valves, valve seat, valve guide:
Valveclearance(cold)
IN
Valve dlmensions 0.12
- 0.17 rnrn EX
0.05 - 0.10 rnrn
____
_-_-
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“C“
“D“
”A”
HeaddiameterFacewidthSeatwidthMarginthickness
“A headdiameter IN
EX
36.9 - 37.1 rnm
2.26
mrn
EX 2.26
rnrn
“B” facewldth IN
31.9 - 32.1 rnrn
“C” seatwidth IN
1.0- 1.2 mrn
1.8 rnm
EX 1.0- 1.2
rnrn
1.8 rnm
I’D” marginthickness IN
1 .O - 1.4 rnrn
0.8 rnrn
Sternoutsidediameter IN
6.975 - 6.990 mrn 6.955
rnm
EX 6.955 - 6.970 mm 6,925
rnrn
Guidelnsldediameter IN
7 000 - 7.01 2 rnrn 7.042
rnrn
EX 7.000
- 7.012 mm 7.042 rnrn
____
____
____
____
EX 0.65
rnm
0.8 - 1.2 rnrn
u
0.08 rnrn
0.010 - 0.037 rnrn
Stem-to-guldeclearance
IN
EX 0.01
rnrn
____
Stem runout limit
0.10 rnrn
0.025 - 0.052 rnrn
Valve seatwidth IN
1.8 rnrn
1.1rnrn
EX
1.8 rnrn
1.1 rnrn
Valve spring: Outer spring
Inner spring
Freelength
IN
38.1 rnm
43.8 rnrn
40.1mm
EX 40.1mm
34.2 rnrn
22.7 mm
(valveclosed)EX 34.2
rnm
22.7 mm
Positionsize
IN
38.1mm
43.8 mrn
____
___-
A

~ ~~ ~ ~~~ ~ ~~~~~~
MAINTENANCE SPECIFICATIONS p-qq
Item Limit
Standard
Compressed pressure 71.6
- 87.3 N
164.8 - 190.2 N
(springInstalled) IN
Outer spring Inner spring
16.80
- 1939 kg 7.3
- 8.9 kg
_-__
EX
149.1 - 182.4 N
164.8
- 190.2 N
16.80-1939 kg 15.2
- 18.6 kg
____
Tilthmit* IN
2.5"/1.7 mm
____ -___
2.5"/1.9 mm
EX
____
____
Winding sense Counterclockwise Counterclockwlse
(topwew) IN
'd
00
EX
Counterclockwise
____
Counterclockwise
____
Piston:
Piston to cylmder clearance 94.91
5 - 94.965 mm
Plston size
"D"
01mm
0.045
- 0.065 mm
B
.___
c
-. - - - - - -
-
H
t
D
Measuring point "H"
____
2 mm
Piston allowance
____
96.0 mm 4" oversize
____
95.5 mm 2" oversize
____
5 mm
Piston pinoff-centring Intake side
W'
Piston pin bore lnsldediameter 22.004
- 22.01 5 mm
____
Piston pinoutslde diameter
____
21.995 - 22.000 mm
Piston rings:
Top ring.
P?B
TY Pe Barrel
Sizes
(B x T)
End gap (installed) 0.1
3 mm
0.03
- 0.07 mm
Slde clearance (installed)
0.7 mm
0.1
5 - 0.30 mm
-_--
1.2 x 3.2 mm
__--

MAINTENANCESPECIFICATIONS m
Itern Limit
Standard
2nd
ring:
03
L-T-1
TY Pe Plat
Sizes
(B x T)
0.1 3 mm
0.03 - 0.07 mm
Side clearance (Installed) 0.8rnm
0.30 - 0.45mm
End gap (installed) 1.2
x 3.8 mm
__-_
Oilring:
EIB
W
L T-l
Slzes (B x T)
0.02 - 0.06 mm
End gap (installed)
2.5 x 3.4 mrn
____
____
Crankshaft:
-
F
Crank width “A
0.8 mrn
Small end backlash ‘IF’
0.35 - 0.65 mm
Big end side clearance
“D”
0.03 rnrn
Runout limit “C’
74.95 - 75 00 mm
__-_
‘u
___-
____
Balancing weight:
Advance method Straight-toothgear
__--
Clutch:
Frictionplate:
Thickness 2.72 -2.88 mm
Quantity
6 parts
Wear limit
Frlctlonplate:
Thickness 2.94
- 3.06 rnrn
Quantity
2 parts
Wear hmit
Clutch plate:
Thickness
1.2 rnm
Quantity 7 parts
Wear limit
____
____
__--
2.6 mm
__--
__--
_---
28mrn
____
____
___-
0.2 mm

~
~~~~~
~~ ._~ __ . ~ ~ ~~~
MAINTENANCE SPECIFICATIONS Wl
Item
Llmlt
Standard
Clutch spring:
Clutch springfree length
Clutch houslng:
5 parts
Quantlty 34.9 mm
Inner cam pushtng Clutch release system
0.070 - 0.071 mm
Thrust backlash
____
--__
____
____
Transmission:
Main axle
Drive axle
off-centringlimlt
0.08 mm
_-__
off-centringlimlt
0.08 mm
____
Shift cam:
TY Pe
Drum with cam and guide bar
Carburetor:
I.D. mark
5CH, 00
Mainjet (M.J.)
Primary carburetor
# 150
Secondary carburetor
# 130
Primary carburetor
0 1.0
Secondary carburetor
0 0.9
Primary carburetor
5C5A - 315
Secondary carburetor
5Y 18 - 315
Primary carburetor
0 2.60
Secondary carburetor
0 2.60
W“
Main airlet (M.A.J.)
Jetneedle
(J.N.)
Needlelet (M.N.)
Cutaway (C.A.)
Pilot outlet (P.O.)
# 54
Pilotjet (P.J
)
0 0.8
Pilot air jet (PA J) 4.0
# 74
Starterjet
(G.S.)
0 2.5
Valveseatsize
(V.S.)
3 1/2 + 112 revs approx., open
Pilotscrew (P.S.)
3.0/5.0
Bypass (B.P.P.)
u.<
0 1 x2
Bypass
1 (B.P.)
0 0.8
Fuel level (F.L.)
6 - 8 mm
Float helght (F.H.) 27
- 29 mm
Idle speed:
Englne idle speed
1 ,150 - 1 :450 rimin
_-_-
Lubrication system:
011 filter type Trochoid
011 pump type: Paper
“A” or “B” tip clearance 0.15
mm
0.03 - 0 08 mm
Side clearance 0.2 mm
0.12 mm
Shunt valve calibrationpressure
13 kPa/1,300 r/mm (0.13 kgficmzi1,300 r/min)
Oil pressure (hot)
80 - 120 kPa (0.82 - 122 kgf/cmz)
Safety valvecalibrationpressure
80 - 120 kPa(0.82 - 122 kgflcm2)
----
Pressure checkpoint
Oil filter chamber
..._
____

~~
LUBRICATION LAYOUT m
LUBRICATION LAYOUT
(1) Oil tank
(2) Oilpump
(3) Oil filter (oil tank)
(4) Oilstrainer(engine)
(5) Oil vapourretrievalhose
(6) Oil blow-by retrievalhose
[A] DELIVERY
[B] RETRIEVAL
W
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5
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3
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2
-
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~ ~ ~~~ ~~~ ~
LUBRICATION LAYOUT ppq
(1) Oil pump
(2) Oil filter
(3) Camshaft
(4) Oildeliveryhose
(5) Maindrivingshaft
(6) Driveshaft
[A] DELIVERY
[B] RETRIEVAL
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LUBRICATIONLAYOUT M
(1) Oil filter [A] DELIVERY
(2) Camshaft [B] RETRIEVAL
(3) Connectingrodpin
(4) Maindrivingshaft
(5) Secondarydrive shaft
(6) Drain plug
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1
4

~~
-
.._~ ~~
LUBRICATION LAYOUT m
(1) Oilpump [A] DELIVERY
(2) Oil filter [e] RETRIEVAL
(3) Oil delivery hose
(4) Transmission
(5) Oil stramer
rn """;y:yp"""4
m
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2
5
-
L.4'
LJ
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MAINTENANCESPECIFICATIONS /SPEC1
ENGINE
Cylinder headtightening steps:
L’
Crankcase tightening steps:
W
Left crankcase Right crankcase

~~~~ ~~ __~~~~
MAINTENANCE SPECIFICATIONS -1
Tightening torques
-
Part to be tightened
Cylinder head
Cylinder head
Cylinder head
Cylinder head
Cylinder head:
Cap (oilcheck)
Spark plug
Cylinder headcover
Tappet cover (Intake)
Tappet cover (exhaust)
Cylinder
Cylinder
Cyllnder
Weight drive gear
Rotor (A.C. magneto)
Lock nut (valve adjusting screw)
Cam chain sprocket
Cam chain stopper guide
Cam chain stopper guide
Rocker shaft
Oil pump
Oil deliveryhetrievalpipe
Oil drainlng pipe
Oil filter cover
Bleed screw (oil filter cover)
Push lever (clutch)
Push rod (clutch)
Sprocket
Lock washer
(oil seal)
Stop lever
Shift cam
Stator
Part
name
-
Washer based
bolt
Stud bolt
Hexagon socket
head screw
Stud bolt
Union bolt
-
Hexagon socket
head screw
Hexagon socket
head screw
-
Crown nut
Nut
Hexagon socket
head screw
Hexagon nut
Hexagon nut
Hexagon nut
Washer based
bolt
Hexagon socket
head screw
Washer based
screw
Hexagon socket
head screw
Hexagon socket
head screw
Pan screw
Washer based
screw
Hexagon socket
head screw
Hexagon screw
Pan screw
Hexagon nut
Hexagon nut
Hexagon screw
Bolt
Hexagon screw
Pan head
(+) screw
I Tlghtenlng
~ Thread torque
ILiJ Remarks
size
I
M8 x 1.25
M10
x 1.25
M6 x
1.0
M6 x 1.0
M6 x 1.0
M12x 1.25
M6x 1.0
M6x 1.0
M32
x 1.5
M8 x 1.25
MI0 x 1.25
M6 x 1.0
M16 x
1 .O
M14 x 1.5
M6x
1 .O
M7x 1 .O
M6 x 1 .O
M16x 1 0
M6 x 1 .O
M6x 1 .O
M6 x 1 .O
M14 x 1 5
M6 x 1.0
M5 x 0.8
M8 x 1.0
M6 x 1 .O
M18x 1.0
M6 x
1.0
M6 x 1.0
M6 x1 .O
1 ~ 29 2.0
20 2.9
10
0.7
7
1.0
7
1.8
18
0.7
10 1.0
10
4.242 2.2
22 1.2
12
1.0
10
1.4
14
12.0 120 60
60
1.0
20 2.0
10 1.0
20
1.0 10
2.0
10
0.7
7
1.0
30 3.0
10
5
12
8
110
10
10
10
M5x
0.8 5
A
1 .o
0.5
1.2
0.8
11.0
1 .o
1 .o
1 .o
0.5
W.
W