engine oil YAMAHA TT600RE 2004 Service Manual

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
INFOSPEC
INSP
ADJCHAS
ENGCARB
ELECTRBL
SHTG
New
12
34
?
56
78
90
qw
er
ty
uoi
psa
df
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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.
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SPECGENERAL SPECIFICATIONS
2-1
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
ModelTT600RE: 5CH5
Dimensions
Overall length 2,220 mm •••
Overall width 865 mm •••
Overall height 1,195 mm •••
Seat height 890 mm •••
Wheelbase 1,480 mm •••
Ground clearance 280 mm •••
Minimum turning radius 3,300 mm (right)
3,100 mm (left) •••
Basic weight (with oil and full
fuel tank)164.5 kg •••
Engine
Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement Forward inclined single cylinder
Displacement 595 cm
3•••
Bore x stroke 95.0 x 84.0 mm •••
Compression ratio 8.5 : 1 •••
Starting system Electric starter
Lubrication system Dry sump with separate oil tank
Engine oil
Type
Temp. °CSAE20W40SE or SAE10W30SE •••
Recommended engine oil classification API Service SE, SF, SG or higher •••
Quantity:
Without oil filter cartridge
replacement 2.4 L •••
With oil filter cartridge
replacement 2.5 L •••
Total amount (dry engine) 3.0 L •••
Air filterWet type element
Fuel
Type Regular unleaded gasoline
Fuel tank capacity 10 L •••
Fuel reserve amount 3.0 L •••
Carburetor
Manufacturer TEIKEI
Model x quantity Y30PV-2ATK x 1
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SPECMAINTENANCE SPECIFICATIONS
2-8
Item Standard Limit
Ballancer
Ballancer drive method Gear
Clutch
Clutch release method Inner push, cam push
Friction plate thickness 2.72 - 2.88 mm •••
Wear limit ••• 2.60 mm
Plate quantity 6 pcs
Friction plate thickness 2.94 - 3.06 mm •••
Wear limit ••• 2.8 mm
Plate quantity 2 pcs
Clutch plate thickness 1.20 mm •••
Plate quantity 7 pcs
Max. warpage ••• 0.20 mm
Clutch spring free length 42.8 mm •••
Plate quantity 5 pcs
Clutch housing thrust clearance 0.070 - 0.071 mm •••
Transmission
Max. main axle runout ••• 0.08 mm
Max. drive axle runout ••• 0.08 mm
Shift mechanism type Cam drum and guide bar
Carburetor
ID mark 5CH5 10
Main jet #1:#150 #2:#145
Main air jet #1:1.0 #2:0.9
Jet needle #1:5C5A-3/5 #2:5Y18-3/5
Needle jet 2.600
Cutaway 4.00
Pilot air jet 1 # 0.8 mm
Pilot jet # 50
Bypass 1 # 1.0
Pilot screw turns out 2-3/4 +/- 1/2
Valve seat size 2.5
Starter jet 1 # 74
Float height 6.0 - 8.0 mm •••
Engine idle speed1,150-1,450 r/min •••
CO% 1.5 - 3 •••
Intake vacuum 30.6-33.36 kPa - 230-250 mm Hg •••
Lubrication systemDry sump
Oil filter type Paper type
Oil pump:
Oil pump type Trochoid type
Inner rotor to outer rotor tip clearance 0.12 mm 0.20 mm
Outer rotor to pump housing
clearance 0.030 - 0.080 mm 0.150 mm
Bypass valve opening pressure 80.0 - 120.0 kPa (0.8 - 1.2 kgf/cm
2) •••
Relief valve operating pressure 80.0 - 120.0 kPa (0.8 - 1.2 kgf/cm2) •••
Oil pressure (hot) 13.0 kPa (0.13 kgf/cm2)/1,300 r/min •••
Pressure check location Oil filter chamber •••
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SPECMAINTENANCE SPECIFICATIONS
2-11
Tightening
Part torque
Part to be tightened
nameThread size Remarks
Nm mkg
Stator (pick-up coil) Hexagon socket
head screw M6 x 1.0 7 0.7
Engine oil pipe 1 Hexagon socket
head screw M6 x 1.0 10 1.0
Engine oil pipe 2 Union screw M12 x 1.25 35 3.5
Oil delivery pipe Union bolt M8 x 1.25 18 1.8
Carburetor joints Hexagon socket
head screw M6 x 1.0 10 1.0
Air filter case (frame) Hexagon screw M6 x 1.0 10 1.0
Air filter case (frame) Washer based
screw M6 x 1.0 10 1.0
Exhaust pipe Washer based
nut M6 x 1.0 10 1.0
Exhaust pipe protector Pan head (+)
screw M6 x 1.0 7 0.7
Muffler Hexagon socket
head screw M8 x 1.25 23 2.3
Muffler (band) Nut, nylon M8 x 1.25 23 2.3
Muffler Washer based
screw M8 x 1.25 23 2.3
Crankcase Hexagon socket
head screw M6 x 1.0 10 1.0
Crankcase Stud bolt M10 x 1.25 20 2.0
Crankcase cover (right) Hexagon socket
head screw M6 x 1.0 10 1.0
Crankcase cover (left) Hexagon socket
head screw M6 x 1.0 10 1.0
Sprocket cover Hexagon socket
head screw M6 x 1.0 10 1.0
Stop washer (bearing) Flat headscrew M6 x 1.0 7 0.7
Pressure plate Washer based
screw M6 x 1.0 8 0.8
Clutch housing Hexagon nut M20 x 1.0 90 9.0
Primary drive gear Hexagon nut M20 x 1.0 120 12.0
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SPECMAINTENANCE SPECIFICATIONS
2-15
Tightening
Part to be tightened Thread torque
Remarkssize
N·mm·kg
Front brake:
Front hub/Disc brake M6 x 1.0 12 1.2
Front caliper/Front fork M8 x 1.25 25 2.5
Front caliper/Bleeder tightening M10 x 1.0 14 1.4
Union bolt tightening (front) M10 x 1.0 20 2.0
Rear brake:
Rear hub/Disc brake M6 x 1.0 12 1.2
Rear master cylinder/Frame M6 x 1.0 10 1.0
Rear stop switch/Rear master cylinder M10 x 1.0 20 2.0
Rear caliper/Bleeder tightening M10 x 1.0 14 1.4
Protector rear caliper/Rear caliper M6 x 1.0 10 1.0
Union bolt tightening (rear) M10 x 1.0 20 2.0
Rear brake tank reserve/Air cleaner assy M6 x 1.0 5 0.5
Brake pedal/Frame M10 x 1.25 48 4.8
Sidestand/Footrest:
Sidestand mounting bolt/Frame M12 x 1.25 40 4.0
Sidestand mounting bolt/Nut M12 x 1.25 40 4.0
Sidestand switch/Frame M5 x 0.8 8 0.8
Rear footrest/Rear frame M8 x 1.25 30 3.0
Bracket 1 (main footrest)/Frame M10 x 1.25 48 4.8
Bracket 2 (main footrest)/Frame M10 x 1.25 48 4.8
Footrest cover/Footrest M6 x 1.0 10 1.0
Seat, fuel tank and oil tank:
Seat/Frame M6 x 1.0 10 1.0
Bolt (guide seat)/Fuel tank M6 x 1.0 5 0.5
Fuel tank/Rear frame M6 x 1.0 12 1.2
Damper fuel tank (front)/Frame M8 x 1.25 15 1.5
Fuel tank/Fuel cock M6 x 1.0 7 0.7
Oil tank/Sub-oil tank M6 x 1.0 7 0.7
Union bolt (oil hose 2)/Oil tank assy/Engine M12 x 1.25 35 3.5
Oil hose 1/Oil tank/Engine M6 x 1.0 10 1.0
Oil tank/Rear frame M12 x 1.5 20 2.0
Frame, rear fender compl. and lights:
Rear fender compl. (under)/Rear frame M6 x 1.0 2 0.2
Rear fender compl. (upper)/Rear frame M6 x 1.0 7 0.7
Bracket, license/Rear frame M6 x 1.0 10 1.0
Bracket, license/Rear flasher M6 x 1.0 10 1.0
Horn/Frame M6 x 1.0 13 1.3
Regulator/Frame M8 x 1.25 7 0.7
Igniton coil/Frame M5 x 0.8 13 1.3
Battery box/Rear frame M6 x 1.0 7 0.7
Igniter cover/Battery box M4 1 0.1
Main switch/Frame M24 x 1.0 1 0.1
Tail light (lense)/Rear fender compl. M3.5 1 0.1
Starter switch/Red wire M6 x 1.0 7 0.7
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2-20
SPECLUBRlCATlON POINTS AND LUBRICANT TYPE
LUBRlCATlON POINTS AND LUBRICANT TYPES
ENGINE
Lubrication points (part name) Lubricant type
Oil seal edges (completely)
Bearing retainer
Rod pins
Rod (big end)
Piston and piston rings
Hub (weight drive sprocket)
Piston pin
Valve stim and guide
Oil seal (valve stim end)
Rocker shaft and rocker arm
Cam and bearing (camshaft)
Rotor and rotor housing (oil pump)
Push rod (clutch)
Primary driven gear and main shaft
Sliding gear (transmission)
Idle gear (transmission)
Shift forks and bar
Shift cam and bearing (gearshift cam)
Shift shaft
Rod housing coupled surfaces Bonding agent (rapid seal adhesive)®
Yamaha bond No. 1215®
Coupled surfaces (cylinder head and cylinder head cover) Bonding agent (rapid seal adhesive)®
Yamaha bond No. 1215®
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2-22
SPECLUBRICATION LAYOUT
LUBRICATION LAYOUT
(1) Oil tank
(2) Oil pump
(3) Oil filter (oil tank)
(4) Oil strainer (engine)
(5) Oil vapour retrieval hose
(6) Oil blow-by retrieval hose[A] DELIVERY
[B] RETRIEVAL
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SPECCABLE ROUTING
2-27









































(1) Front brake hose
(2) Brake hose holder
(3) Left tube guard
(4) Plastic plate
(5) Throttle cables
(6) Tachometer/
odometer cable
(7) Clutch cable
(8) Clutch cable holder
(9) Throttle cables
holder
(10) Wire harness band(11) Fuel pipe from fuel
cock
(12) Flasher relay
(13) Main relay
(14) Sidestand switch
(15) Diodes (n. 3)
(16) A.C. generator wire
harness (engine)
(17) Engine oil breather
pipe (to engine oil
tank)
(18) Main switch(19) Oil hose (oil tank to
engine)
(20) Oil hose (engine to
oil tank)
(21) C.D.I. unit
(22) Starting motor plus
cable
(23) Starting motor
minus cable
(24) Battery
(25) Starting relay
(26) Fuse (reserve)
(27) Fuse (main)(28) Wire extension
(29) Battery plus cable
[A] Lay the brake hose
behind the left tube
guard and fasten it
down by means of
the plate 4.
[B] Attach throttle
cables 5.
[C] Fasten the fuel pipe
11 to the tank.
[D] Fit the 3 diodes
inside the chassis,
against the coil clip.
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SPECCABLE ROUTING
2-28
(1) Tachometer/
odometer cable
(2) Tachometer/
odometer cable
holder
(3) Tachometer/
odometer cable
band
(4) Right tube guard
(5) Spark plug cable
(6) Horn(7) Carburetor suction
pipe
(8) Main wire harness
band
(9) Rear brake switch
wire harness
(10) Rear brake fluid
tank hose
(11) Hose from rear
master cylinder to
caliper(12) Rear brake hose
holders
(13) Pipe
(14) Air breather pipe
(15) Spark plug ignition
coil
(16) Chassis ground
(17) Engine oil
breather pipe
(to air filer case)[A] Insert the
tachometer/
odometer cable into
the band 3 and the
holder 2.



















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