YAMAHA TT600RE 2004 Service Manual

TT600RE
2004
5CH5-ME1
SERVICE MANUAL
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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
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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
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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".
7A job 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.
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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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GENERAL INFORMATION
TABLE OF CONTENTS
GEN
INFO
1
SPECIFICATIONS
SPEC2
PERIODIC INSPECTION
AND ADJUSTMENTS
INSP
ADJ
3
ENGINE
ENG5
CARBURETION
CARB6
CHASSIS
CHAS4
ELECTRICAL
ELEC7
TROUBLESHOOTINGTRBL
SHTG
8
?
E004000
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1
GEN
INFO
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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
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GEN
INFO
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