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: Bicycle | Size: 10.9 MB
Table of contents
General Information3................................................................................................................................................................
Specifications3................................................................................................................................................................
Chassis3................................................................................................................................................................
Engine3................................................................................................................................................................
Troubleshooting3................................................................................................................................................................
Illustrated Symbols3................................................................................................................................................................
Table Of Contents4................................................................................................................................................................
Gen Info6................................................................................................................................................................
Vehicle Identification Number9................................................................................................................................................................
Model Label9................................................................................................................................................................
Important Information10................................................................................................................................................................
Preparation For Removal Procedures10................................................................................................................................................................
Replacement Parts10................................................................................................................................................................
Gaskets, Oil Seals And O-rings10................................................................................................................................................................
Lock Washers/plates And Cotter Pins11................................................................................................................................................................
Bearings And Oil Seals11................................................................................................................................................................
Circlips11................................................................................................................................................................
Checking Of Connections12................................................................................................................................................................
Special Tools13................................................................................................................................................................
Chapter 2. Specifications20................................................................................................................................................................
General Specifications20................................................................................................................................................................
Maintenance Specifications23................................................................................................................................................................
Electrical36................................................................................................................................................................
General Torque Specifications38................................................................................................................................................................
Conversion Table38................................................................................................................................................................
Lubrication Layout41................................................................................................................................................................
Cable Routing45................................................................................................................................................................
Insp Adj50................................................................................................................................................................
Chapter 3. Periodic Inspection And Adjustments53................................................................................................................................................................
Introduction53................................................................................................................................................................
Periodic Maintenance/lubrication Intervals53................................................................................................................................................................
Seat, Fuel Tank And Rear Cowling55................................................................................................................................................................
Removal55................................................................................................................................................................
Installation55................................................................................................................................................................
Valve Clearance Adjustment56................................................................................................................................................................
Drive Chain Adjustment59................................................................................................................................................................
Idle Speed Adjustment59................................................................................................................................................................
Throttle Cable Free Play Adjustment60................................................................................................................................................................
Spark Plug Inspection61................................................................................................................................................................
Ignition Timing Check63................................................................................................................................................................
Compression Inspection64................................................................................................................................................................
Engine Oil Level Check67................................................................................................................................................................
Engine Oil Replacement69................................................................................................................................................................
Engine Oil Pressure Check73................................................................................................................................................................
Clutch Adjustment73................................................................................................................................................................
Air Filter Cleaning76................................................................................................................................................................
Fuel Filter Cleaning77................................................................................................................................................................
Engine Oil Tank Filter Cleaning78................................................................................................................................................................
Suction Hose And Manifold Inspection80................................................................................................................................................................
Fuel Line Inspection80................................................................................................................................................................
Exhaust System Inspection81................................................................................................................................................................
Adjusting The Front Brake82................................................................................................................................................................
Adjusting The Rear Brake83................................................................................................................................................................
Checking The Brake Fluid Level84................................................................................................................................................................
Brake Pad Wear Inspection85................................................................................................................................................................
Brake Hosing Inspection85................................................................................................................................................................
Brake Circuit Bleeding86................................................................................................................................................................
Drive Chain Slack Inspection And Adjustment87................................................................................................................................................................
Drive Chain Lubrication88................................................................................................................................................................
Front Fork Inspection89................................................................................................................................................................
Adjusting The Front Fork89................................................................................................................................................................
Rear Shock Absorber Adjustment90................................................................................................................................................................
Steering Inspection92................................................................................................................................................................
Tyre Inspection93................................................................................................................................................................
Wheel Inspection96................................................................................................................................................................
Spoke Inspection And Tightening96................................................................................................................................................................
Cable Inspection97................................................................................................................................................................
Lever And Pedal Lubrication97................................................................................................................................................................
Sidestand Lubrication98................................................................................................................................................................
Rear Suspension Lubrication98................................................................................................................................................................
Electrical System99................................................................................................................................................................
Checking And Charging The Battery99................................................................................................................................................................
Checking The Fuses105................................................................................................................................................................
Replacing The Headlight Bulbs106................................................................................................................................................................
Replacing The Turn Indicator Light Bulb108................................................................................................................................................................
Replacing The Tail/brake Light Bulb109................................................................................................................................................................
Chas111................................................................................................................................................................
Front Wheel And Brake Disc114................................................................................................................................................................
Front Wheel And Brake Disc Removal114................................................................................................................................................................
Front Wheel Disassembly116................................................................................................................................................................
Front Wheel Inspection116................................................................................................................................................................
Brake Disc Inspection118................................................................................................................................................................
Front Wheel Assembly119................................................................................................................................................................
Front Wheel Installation119................................................................................................................................................................
Wheel Static Balance Adjustment119................................................................................................................................................................
Front Brake121................................................................................................................................................................
Brake Pad Removal121................................................................................................................................................................
Brake Pad Replacement122................................................................................................................................................................
Master Cylinder124................................................................................................................................................................
Master Cylinder Inspection126................................................................................................................................................................
Master Cylinder Assembly126................................................................................................................................................................
Master Cylinder Installation127................................................................................................................................................................
Brake Caliper129................................................................................................................................................................
Brake Caliper Disassembly131................................................................................................................................................................
Caliper Inspection131................................................................................................................................................................
Caliper Assembly132................................................................................................................................................................
Caliper Installation132................................................................................................................................................................
Rear Wheel And Brake Disc134................................................................................................................................................................
Rear Wheel And Brake Disc Removal134................................................................................................................................................................
Rear Wheel Disassembly136................................................................................................................................................................
Rear Wheel Inspection136................................................................................................................................................................
Rear Wheel Assembly138................................................................................................................................................................
Rear Wheel Installation138................................................................................................................................................................
Rear Brake142................................................................................................................................................................
Brake Pedal Removal148................................................................................................................................................................
Front Fork155................................................................................................................................................................
Front Fork Removal155................................................................................................................................................................
Front Fork Disassembly156................................................................................................................................................................
Oil Replacement159................................................................................................................................................................
Cleaning The Dust Seal162................................................................................................................................................................
Seal And Bush Replacement163................................................................................................................................................................
Oil Leakage From Dust Seal169................................................................................................................................................................
Anomalous Hydraulic Braking169................................................................................................................................................................
Front Fork Installation172................................................................................................................................................................
Front Fork Adjustment172................................................................................................................................................................
Steering174................................................................................................................................................................
Steering Removal177................................................................................................................................................................
Steering Installation178................................................................................................................................................................
Rear Shock Absorber182................................................................................................................................................................
Note On Disposal185................................................................................................................................................................
Shock Absorber Removal186................................................................................................................................................................
Shock Absorber Inspection187................................................................................................................................................................
Shock Absorber Adjustment187................................................................................................................................................................
Swingarm189................................................................................................................................................................
Swingarm Removal190................................................................................................................................................................
Swingarm Inspection191................................................................................................................................................................
Lateral Free Play Adjustment192................................................................................................................................................................
Swingarm Installation193................................................................................................................................................................
Drive Chain, Drive Sprocket And Rear Wheel Sprocket195................................................................................................................................................................
Drive Chain Removal195................................................................................................................................................................
Drive Chain Inspection196................................................................................................................................................................
Drive Chain Installation198................................................................................................................................................................
Eng200................................................................................................................................................................
Engine Removal203................................................................................................................................................................
Muffler, Exhaust Pipe, Engine Protector, Drive Sprocket Crankcase Cover, Drive Sprocket And Shift Pedal203................................................................................................................................................................
Engine Mounting Bolt206................................................................................................................................................................
Engine Disassembly207................................................................................................................................................................
Cylinder Head, Cylinder, Camshaft And Piston207................................................................................................................................................................
Intermediate Starter Gear, Crankcase Cover (l) And Generator Stator210................................................................................................................................................................
Crankcase Cover (r), Clutch, Primary Drive Gear And Balancer Shaft Gear211................................................................................................................................................................
Oil Pump And Shift Lever214................................................................................................................................................................
Ac Generator And Timing Chain215................................................................................................................................................................
Crankcase(r)216................................................................................................................................................................
Gearbox And Transmission218................................................................................................................................................................
Balancer Shaft And Crankshaft219................................................................................................................................................................
Oilstrainer219................................................................................................................................................................
Rocker Arms220................................................................................................................................................................
Valves221................................................................................................................................................................
Inspection And Repair223................................................................................................................................................................
Cylinder Head223................................................................................................................................................................
Valves And Valve Guides224................................................................................................................................................................
Valveseat225................................................................................................................................................................
Valve Springs229................................................................................................................................................................
Camshaft230................................................................................................................................................................
Rocker Arms And Rocker Shaft230................................................................................................................................................................
Camshaft Chain And Sprocket231................................................................................................................................................................
Camshaft Chain Guide232................................................................................................................................................................
Cylinder And Piston232................................................................................................................................................................
Piston Rings234................................................................................................................................................................
Pistonpin235................................................................................................................................................................
Clutch235................................................................................................................................................................
Oilpump237................................................................................................................................................................
Transmission And Gearbox238................................................................................................................................................................
Starter Transmission240................................................................................................................................................................
Crankshaft241................................................................................................................................................................
Balancer Shaft Drive And Driven Gears242................................................................................................................................................................
Crankcase242................................................................................................................................................................
Bearing And Oil Seal242................................................................................................................................................................
Engine Assembly And Setting244................................................................................................................................................................
Crankshaft And Balancer Shaft246................................................................................................................................................................
Transmission248................................................................................................................................................................
Gearbox249................................................................................................................................................................
Engine Oil Pump And Oil Strainer251................................................................................................................................................................
Engine Oil Strainer253................................................................................................................................................................
Shift Shaft And Oil Pump254................................................................................................................................................................
Timing Chain256................................................................................................................................................................
Piston And Rings257................................................................................................................................................................
Cylinder258................................................................................................................................................................
Camshaft And Timing Chain260................................................................................................................................................................
Piston, Cylinder, Cylinder Head And Camshaft261................................................................................................................................................................
Ac Generator267................................................................................................................................................................
Oil Filter And Oil Hoses269................................................................................................................................................................
Balancer Shaft Gear And Primary Transmission Gear270................................................................................................................................................................
Starter Gears275................................................................................................................................................................
Starter Neutral Gear And Crankcase Cover (l)276................................................................................................................................................................
Engine Reassembly278................................................................................................................................................................
Carb281................................................................................................................................................................
Elec300................................................................................................................................................................
Electrical Circuit Diagram303................................................................................................................................................................
Colour Code304................................................................................................................................................................
Electrical Components305................................................................................................................................................................
Switch Check307................................................................................................................................................................
Switch Connection307................................................................................................................................................................
Main Switch Inspection307................................................................................................................................................................
Light Inspection (headlights, Tail Light And Brake Lights, Direction Indicator Lights, Instrument Lights, Etc)310................................................................................................................................................................
Bulb Types310................................................................................................................................................................
Bulb Inspection310................................................................................................................................................................
Ignition System313................................................................................................................................................................
Circuit Diagram313................................................................................................................................................................
Diagnostics315................................................................................................................................................................
Electrical Starting System323................................................................................................................................................................
Starting Circuit Operation325................................................................................................................................................................
Starter Motor332................................................................................................................................................................
Charging System337................................................................................................................................................................
Light System343................................................................................................................................................................
Light System Inspection348................................................................................................................................................................
Signal System Control357................................................................................................................................................................
Trbl Shtg367................................................................................................................................................................
Failure To Start/difficulties In Starting370................................................................................................................................................................
Fuel System370................................................................................................................................................................
Poor Engine Compression371................................................................................................................................................................
Poor Performance At Idle Speed372................................................................................................................................................................
Unsatisfactory Performance At Medium-high Speed372................................................................................................................................................................
Difficulties In Shifting373................................................................................................................................................................
Shifting Impossible373................................................................................................................................................................
The Shift Pedal Fails To Move373................................................................................................................................................................
Disengaging Gears373................................................................................................................................................................
Clutch Slides Or Fails To Release374................................................................................................................................................................
Clutch Slides374................................................................................................................................................................
Clutch Fails To Release374................................................................................................................................................................
Defective Brakes375................................................................................................................................................................
Poor Braking375................................................................................................................................................................
Oil Leaks Or Malfunctioning Of Front Fork375................................................................................................................................................................
Oil Leaks375................................................................................................................................................................
Malfunctioning375................................................................................................................................................................
Unstable Steering376................................................................................................................................................................
Defective Functioning Of Lights And Indicators377................................................................................................................................................................
Frequent Burning Of Bulb377................................................................................................................................................................
Direction Indicators Fail To Turn On377................................................................................................................................................................
Direction Indicators Fail To Turn Off377................................................................................................................................................................
Delayed Turning On Of Indicators378................................................................................................................................................................
Excessive Indicator Intermittence Frequency378................................................................................................................................................................
The Horn Fails To Work378................................................................................................................................................................
Overheating Of Engine378................................................................................................................................................................

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