Yamaha TT600R User manual

YAMAHA
──────────
TT600R
──────────
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
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.