oil type 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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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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SPECGENERAL SPECIFICATIONS
2-3
Item Standard Limit
Brakes
Front:
Type Single Ø 267 mm disk brake,
2 x 28 mm
Operation Right hand
Fluid DOT 4
Rear:
Type Single Ø 220 mm disk brake,
1 x 34 mm caliper
Operation Right foot
Fluid DOT 4
Suspension
Front Telescopic fork Outside tube
dia. 46 mm
Rear Deltabox Swingarm with
adjustable shock absorber
Spring/shock absorber
Front Coil spring / oil damper
RearCoil spring / gas-oil damper, spring
preload adjustable
Wheel travel
Front 230 mm •••
Rear 230 mm •••
Electrical system
Ignition system Transistorized coil ignition (digital)
Charging system:
Type A.C. magneto
Standard output 14V, 13.5A at 5.000 r/min •••
Battery:
Model GT9B-4
Voltage, capacity 12V, 8Ah •••
Headlight typeQuartz bulb (halogen)
Bulb voltage, wattage x quantity
Headlight 12V 60W / 55W x 1 •••
Tail/brake light 12V 5W / 21W x 1 •••
Turn signal light 12V 10W x 4 •••
Auxiliary light 12V 5W x 1 •••
Meter lighting 12V 3W x 1 •••
Turn signal indicator light 12V 1.2W x 1 •••
Neutral indicator light 12V 1.2W x 1 •••
Auxiliary indicator light 12V 1.2W x 1 •••
High beam indicator light 12V 1.2W x 1 •••
Fuse20A •••
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SPECMAINTENANCE SPECIFICATIONS
2-7
Item Standard Limit
Piston ring
Top ring:
Ring type Barrel
Dimensions (B x T) 1.20 x 3.80 mm •••
End gap
(installed) 0.30 - 0.45 mm 0.70 mm
Ring side clearance 0.040 - 0.080 mm 0.130 mm
2
ndring:
Ring type Plain
Dimensions (B x T) 1.20 x 3.80 mm •••
End gap
(installed) 0.30 - 0.45 mm 0.80 mm
Ring side clearance 0.030 - 0.070 mm 0.130 mm
Oil ring:
Dimensions (B x T) 2.50 x 3.40 mm •••
End gap
(installed) 0.20 - 0.70 mm •••
Ring side clearance 0.020 - 0.060 mm •••
Crankshaft
Width A 74.95 - 75.00 mm •••
Max. runout C ••• 0.030 mm
Big end side clearance D 0.350 - 0.650 mm •••
Big end radial clearance 0.010 - 0.025 mm •••
Small end free play F 0.80 mm •••
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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
2-12
Item Standard Limit
Steering
Steering bearing type Taper roller bearing
Lock to lock angle (left) 45° •••
Lock to lock angle (right) 45° •••
Front suspension
Front fork travel 277 - 283 mm •••
Fork spring free length 530 mm •••
Spring rate (K1) 7.0 N/mm (0.71 kgf/mm) •••
Spring stroke (K1) 330 mm •••
Spring rate (K2) 11.2 N/mm (1.14 kgf/mm) •••
Optional spring available No
Recommended oil Liqui Moly Racing suspension oil SAE 7,5
Quantity 650 cc •••
Level 180 mm •••
< min - max > 170-190 mm (from upper edge of inner •••
tube, fully compressed without spring)
Rear suspension
Rear shock absorber assembly travel 83 mm
Spring free length 224 mm •••
Installed length 211 mm ± 1.5 mm
Spring rate (K) 80 N/mm (8.1 kgf/mm) •••
Optional spring available No
Swingarm
Free play limit (at the end of
the swingarm)-radial ••• 1.0 mm
Free play limit (at the end of
the swingarm)-axial 0.4 - 0.7 mm •••
Front wheel
Wheel type Spoke wheel
Rim size 21 x 1.85
Rim material Aluminium
Max. radial wheel runout 1.0 mm •••
Max. lateral wheel runout 0.5 mm •••
Rear wheel
Wheel type Spoke wheel
Rim size 18 x MT2.50
Rim material Aluminium
Max. radial wheel runout 1.0 mm •••
Max. lateral wheel runout 0.5 mm •••
CHASSIS
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SPECMAINTENANCE SPECIFICATIONS
2-17
Item Standard Limit
Ignition system
Ignition timing (B.T.D.C.) 12° / 1,300 r/min •••
Advanced timing (B.T.D.C.) 31° / 7,500 r/min •••
Advancer type Electrical type
Transistorized coil ignition
Pickup coil resistance 230 Ω± 20% L/Y-G/W •••
T.C.I. unit model/manufacturer TNDF09 / NIPPON DENSO
Ignition coil
Model/manufacturer JO300 / NIPPON DENSO
Primary coil resistance 4 Ω± 15% •••
Secondary coil resistance 13 kΩ± 20% •••
Spark plug cap
Material Resin
Resistance 10 kΩ•••
Charging system
Type A.C. magneto
Model/manufacturer TLMZ48 / NIPPON DENSO
Standard output 14.0 V 13.5 A 5,000 r/min •••
Stator coil resistance 0.65 Ω± 20% W-W •••
Rectifier/regulator
Regulator type Semi conductor-short circuit
Model/manufacturer SH629A-12/SHINDENGEN
No load regulated voltage 14.5 ± 0.4 V •••
Rectifier capacity 25 A •••
Withstand voltage 240 V •••
Battery
Specific gravity 1.320 •••
Electric starting system
System type Constant mesh
Starter motor:
Model/manufacturer SM-13/MITSUBA
Power output 0.80 kW •••
Armature coil resistance 0.03 - 0.04 Ω•••
Brush overall length 10.0 mm 5 mm
Brush spring force 8.82 N (899 gf) •••
Commutator diameter 28.0 mm 27 mm
Mica undercut (depth) 0.70 mm •••
Starter relay:
Model/manufacturer MS5F-721 / JIDECO
Amperage 180 A •••
Coil resistance 4,4 Ω± 5% •••
ELECTRICAL
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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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2-21
SPECLUBRlCATlON POINTS AND LUBRICANT TYPE
CHASSIS
Lubrication points (part name) Lubricant type
Gear unit (tachometer)
Oil seal edges (completely)
Wheel axle (front and rear wheels)
Rear wheel hub and clutch
Bearings brasses (rear arm) and bearing push cover
Front footrest
Pivot points (brake pedal and shift pedal)
Bearings (steering head)
Pivot points (brake lever and clutch lever)
Clutch cable end
Pivot points (sidestand)
Grease nipples (rear arm-front axle)
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CHECKING THE BRAKE FLUID LEVEL
3-32
INSP
ADJ
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
•Place the motorcycle on a suitable stand.
•Make sure that the motorcycle is upright.
2. Check:
•Brake fluid level
Below the minimum level mark a➔Add
the recommended brake fluid to the prop-
er level.
[A] Front brake
[B] Rear brake
WARNING
•Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
•Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
•When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
Brake fluid may damage painted surfaces and
plastic parts. Therefore, always clean up any
spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the reservoir
is horizontal.
CAUTION:
Recommended brake fluid:
DOT4





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