YAMAHA TT600R Manuals

Manuals and User Guides for YAMAHA TT600R. We have 1 YAMAHA TT600R manual available for free PDF download: Service Manual

YAMAHA TT600R Service Manual

YAMAHA TT600R Service Manual (380 pages)

M.Y 1997-2007

Brand: YAMAHA | Category: Motorcycle | Size: 10.9 MB

Table of Contents

Table of Contents

4
- Chassis
  3
- Engine
  3
- General Information
  3
- Specifications
  3
- Troubleshooting
  3
  - Illustrated Symbols
    3
  - Table of Contents
    4
  - Gen Info
    6
- Chapter 1
  9
- Model Label
  9
- Vehicle Identification Number
  9
- Important Information
  10
  - Preparation for Removal Procedures
    10
  - Replacement Parts
    10
  - Gaskets, Oil Seals and O-Rings
    10
  - Lock Washers/Plates and Cotter Pins
    11
  - Bearings and Oil Seals
    11
  - Circlips
    11
- Checking of Connections
  12
- Special Tools
  13
Spec Chapter 2. Specifications

18
- Chapter 2. Specifications
  20
- General Specifications
  20
- Maintenance Specifications
  23
  - Engine
    23
  - Chassis
    31
  - Electrical
    36
- Conversion Table
  38
  - Engine
    39
  - Chassis
    40
- General Torque Specifications
  38
- Lubrication Layout
  41
- Cable Routing
  45
- Insp Adj
  50
Adj Periodic Inspection and Adjustments Chapter 3.

51
- Chapter 3. Periodic Inspection and Adjustments
  53
- Introduction
  53
- Periodic Maintenance/Lubrication Intervals
  53
- Seat, Fuel Tank and Rear Cowling
  55
  - Removal
    55
  - Installation
    55
- Engine
  56
  - Valve Clearance Adjustment
    56
  - Drive Chain Adjustment
    59
  - Idle Speed Adjustment
    59
  - Throttle Cable Free Play Adjustment
    60
  - Spark Plug Inspection
    61
  - Ignition Timing Check
    63
  - Compression Inspection
    64
  - Engine Oil Level Check
    67
  - Engine Oil Replacement
    69
  - Engine Oil Pressure Check
    73
  - Clutch Adjustment
    73
  - Air Filter Cleaning
    76
  - Fuel Filter Cleaning
    77
  - Engine Oil Tank Filter Cleaning
    78
  - Suction Hose and Manifold Inspection
    80
  - Fuel Line Inspection
    80
  - Exhaust System Inspection
    81
- Chassis
  82
  - Adjusting the Front Brake
    82
  - Adjusting the Rear Brake
    83
  - Checking the Brake Fluid Level
    84
  - Brake Pad Wear Inspection
    85
  - Brake Hosing Inspection
    85
  - Brake Circuit Bleeding
    86
  - Drive Chain Slack Inspection and Adjustment
    87
  - Drive Chain Lubrication
    88
  - Front Fork Inspection
    89
  - Adjusting the Front Fork
    89
  - Rear Shock Absorber Adjustment
    90
  - Steering Inspection
    92
  - Tyre Inspection
    93
  - Wheel Inspection
    96
  - Spoke Inspection and Tightening
    96
  - Cable Inspection
    97
  - Lever and Pedal Lubrication
    97
  - Sidestand Lubrication
    98
  - Rear Suspension Lubrication
    98
- Electrical System
  99
- Chas
  111
Chas Chapter 4. Chassis

112
- Chapter 4
  114
- Front Wheel and Brake Disc
  114
- Front Wheel and Brake Disc Removal
  114
- Front Wheel Disassembly
  116
- Front Wheel Inspection
  116
- Brake Disc Inspection
  118
- Front Wheel Assembly
  119
- Front Wheel Installation
  119
- Wheel Static Balance Adjustment
  119
- Front Brake
  121
  - Brake Pad Removal
    121
  - Brake Pad Replacement
    122
  - Master Cylinder
    124
  - Master Cylinder Inspection
    126
  - Master Cylinder Assembly
    126
  - Master Cylinder Installation
    127
  - Brake Caliper
    129
  - Brake Caliper Disassembly
    131
  - Caliper Inspection
    131
  - Caliper Assembly
    132
  - Caliper Installation
    132
- Rear Wheel and Brake Disc
  134
  - Rear Wheel and Brake Disc Removal
    134
  - Rear Wheel Disassembly
    136
  - Rear Wheel Inspection
    136
  - Brake Disc Inspection
    137
  - Rear Wheel Assembly
    138
  - Rear Wheel Installation
    138
  - Wheel Static Balance Adjustment
    140
- Rear Brake
  142
  - Brake Pad Removal
    142
  - Brake Pad Replacement
    142
  - Master Cylinder
    145
  - Master Cylinder Inspection
    146
  - Master Cylinder Assembly
    146
  - Master Cylinder Installation
    147
  - Brake Pedal Removal
    148
  - Brake Caliper
    149
  - Brake Caliper Disassembly
    151
  - Caliper Inspection
    151
  - Caliper Installation
    152
- Front Fork
  155
  - Front Fork Removal
    155
  - Front Fork Disassembly
    156
  - Front Fork Removal
    158
  - Oil Replacement
    159
  - Cleaning the Dust Seal
    162
  - Seal and Bush Replacement
    163
  - Oil Leakage from Dust Seal
    169
  - Anomalous Hydraulic Braking
    169
  - Front Fork Inspection
    170
  - Front Fork Installation
    172
  - Front Fork Adjustment
    172
- Steering
  174
  - Steering Removal
    177
  - Steering Inspection
    178
  - Steering Installation
    178
- Rear Shock Absorber
  182
  - Note on Disposal
    185
  - Shock Absorber Removal
    186
  - Shock Absorber Inspection
    187
  - Shock Absorber Adjustment
    187
- Swingarm
  189
  - Swingarm Removal
    190
  - Swingarm Inspection
    191
  - Lateral Free Play Adjustment
    192
  - Swingarm Installation
    193
- Drive Chain, Drive Sprocket and Rear Wheel Sprocket
  195
  - Drive Chain Removal
    195
  - Drive Chain Inspection
    196
  - Drive Chain Installation
    198
- Eng
  200
Eng Chapter 5. Engine

201
- Chapter 5
  203
- Engine Removal
  203
- Muffler, Exhaust Pipe, Engine Protector, Drive Sprocket Crankcase Cover, Drive Sprocket and Shift Pedal
  203
- Engine Mounting Bolt
  206
- Engine Disassembly
  207
  - Cylinder Head, Cylinder, Camshaft and Piston
    207
  - Intermediate Starter Gear, Crankcase Cover (L) and Generator Stator
    210
  - Crankcase Cover (R), Clutch, Primary Drive Gear and Balancer Shaft Gear
    211
  - Oil Pump and Shift Lever
    214
  - Ac Generator and Timing Chain
    215
  - Crankcase(R)
    216
  - Gearbox and Transmission
    218
  - Balancer Shaft and Crankshaft
    219
  - Oilstrainer
    219
  - Rocker Arms
    220
  - Valves
    221
- Inspection and Repair
  223
  - Cylinder Head
    223
  - Valves and Valve Guides
    224
  - Valveseat
    225
  - Valve Springs
    229
  - Camshaft
    230
  - Rocker Arms and Rocker Shaft
    230
  - Camshaft Chain and Sprocket
    231
  - Camshaft Chain Guide
    232
  - Cylinder and Piston
    232
  - Piston Rings
    234
  - Pistonpin
    235
  - Clutch
    235
  - Oilpump
    237
  - Transmission and Gearbox
    238
  - Starter Transmission
    240
  - Crankshaft
    241
  - Balancer Shaft Drive and Driven Gears
    242
  - Crankcase
    242
  - Bearing and Oil Seal
    242
- Engine Assembly and Setting
  244
  - Valves
    244
  - Rocker Arms
    245
  - Crankshaft and Balancer Shaft
    246
  - Transmission
    248
  - Gearbox
    249
  - Transmission and Gearbox
    250
  - Engine Oil Pump and Oil Strainer
    251
  - Crankcase
    252
  - Engine Oil Strainer
    253
  - Crankcase
    253
  - Shift Shaft and Oil Pump
    254
  - Timing Chain
    256
  - Piston and Rings
    257
  - Cylinder
    258
  - Cylinder Head
    259
  - Camshaft and Timing Chain
    260
  - Piston, Cylinder, Cylinder Head and Camshaft
    261
  - Ac Generator
    267
  - Oil Filter and Oil Hoses
    269
  - Balancer Shaft Gear and Primary Transmission Gear
    270
  - Clutch
    272
  - Starter Gears
    275
  - Starter Neutral Gear and Crankcase Cover (L)
    276
- Engine Reassembly
  278
- Carb
  281
- Elec
  300
Elec Chapter 7 Electrical

301
- Electrical Circuit Diagram
  303
- Chapter 7 Colour Code
  304
- Electrical Components
  305
- Switch Check
  307
  - Switch Connection
    307
  - Main Switch Inspection
    307
- Light Inspection (Headlights, Tail Light and Brake Lights, Direction Indicator Lights, Instrument Lights, Etc)
  310
  - Bulb Types
    310
  - Bulb Inspection
    310
- Ignition System
  313
  - Circuit Diagram
    313
  - Diagnostics
    315
- Electrical Starting System
  323
  - Circuit Diagram
    323
  - Starting Circuit Operation
    325
  - Diagnostics
    326
  - Starter Motor
    332
- Charging System
  337
  - Circuit Diagram
    337
  - Diagnostics
    339
- Light System
  343
  - Circuit Diagram
    343
  - Diagnostics
    345
  - Light System Inspection
    348
  - Circuit Diagram
    353
  - Diagnostics
    355
  - Signal System Control
    357
- Trbl Shtg
  367
? Trbl Shtg Chapter 8° Troubleshooting

368
- Chapter 8 °
  370
- Failure to Start/Difficulties in Starting
  370
- Fuel System
  370
- Electrical System
  371
- Poor Engine Compression
  371
- Poor Performance at Idle Speed
  372
- Unsatisfactory Performance at Medium-High Speed
  372
- Difficulties in Shifting
  373
  - Shifting Impossible
    373
  - The Shift Pedal Fails to Move
    373
  - Disengaging Gears
    373
- Clutch Slides or Fails to Release
  374
  - Clutch Slides
    374
  - Clutch Fails to Release
    374
- Defective Brakes
  375
  - Poor Braking
    375
- Oil Leaks or Malfunctioning of Front Fork
  375
  - Oil Leaks
    375
  - Malfunctioning
    375
- Unstable Steering
  376
- Defective Functioning of Lights and Indicators
  377
- Overheating of Engine
  378

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