Yamaha TT 600 R 1997 Service Information Download | Manualshive

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Summary of Contents for TT 600 R 1997

Page 1: ...__ a YAMAHA TT 600 R 97 4 h i SERVICE INFORMATION ...

Page 2: ...s booklet together withthe mi crofiches of the Service Manual TT 600 R 97 SERVICE MANUAL 5CH ME1 TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE GROUP BELGARDA S p A f 4 _ l T600 R 97 SERVICE INFORMATION 01997 BelgardaS p A 1 edition September 1997 All rights reserved Any reprinting or unauthorised use without the written permissionof Belgarda S p A is expressly prohibited Printed in Italy BCH ...

Page 3: ...orts to improve allits models Important alteratlons or changes to pro cedures characteristics will be communicated to all Yamaha dealers and published in future editions of this manual NOTE Specifications and designare subject to change without notice v PARTICULARLY IMPORTANT INFORMATION The manual includes the following symbols and relative remarks This safety alert symbol means ATTENTION BECOME ...

Page 4: ...o 17 are used to identi fy the specifications appearing In the text 10 Possible to maintain with engine mounted 11 Fllling fluid 12 Lubricant 13 Special tool 14 Tightening 15 Wear limit clearance 16 Engine speed 17 12 V A L 1 4 Illustrated symbols 18 to 23 in theexploded diagrams indicate the types of lubricants and lubri cation points 18 Apply englne oil 19 Apply gear oil 20 Apply molybdenum disu...

Page 5: ... MAINTENANCE SPECIFICATIONS CHASSIS CHASSIS TIGHTENING TORQUES MAINTENANCE SPECIFICATIONS ELECTRICAL GENERAL SPECIFICATIONS ABOUT TIGHTENING TORQUES LUBRICATION POINTSAND LUBRICANT TYPE CABLEROUTING 2 5 10 14 17 19 21 23 24 26 PERIODIC INSPECTIONS AND ADJUSTMENTS PERIODIC MAINTENANCE LUBRICATION INTERVALS 30 EXPLODED DIAGRAM CARBURETOR 33 ELECTRICAL WIRING DIAGRAM 35 W ...

Page 6: ...TION VEHICLE IDENTIFICATIONNUMBER The vehicle identification number 1 is stamped into the right sideof the steering head pipe MODEL COLOUR IDENTIFICATION LABEL The modelkolour identification label 1 is affixed to the rear frame This information will be needed to order spare parts d e ...

Page 7: ...I I I I I l I I I I I I I I I I SAk 1Qhl46 I I I I I I I SA220A 40 I I I I I I I I I I l l I I I I I I I SAL 20hl56 I I I I l I I 1 I I I l I I l I I I I l API standard I Oil capacity Engine oil Periodic oil change With oil fllter replacement Oil tank Total amount Air filter I7 _ __ __ __ _ _ Standard TT 600 R DJOI 5CH1 2 250 mm 845 mm 1 225 mm 945 mm 1 480 mm 325 mm 3 100 rnm left 3 300 mm right ...

Page 8: ...ckbone frame 114 mm and removable rear frame Tyres Type With tube Size 90 90 21 54R 90190 21 545 rear 130 90 18 69R 130180 18 66R 140 80 18 70R 130180 18 668 Manufacturer model front rear MlCHELlN BAJA or T63 PlRELLl MT21 or MT70 MlCHELlN BAJA or T63 PlRELLl MT21 or MT70 Maximum load except motorcycle Tire pressure cold tire 180 kg Rider only 100 kPa 1 OO kgicm 1 OO bar rear 100 kPa 1 OO kg cm2 1 ...

Page 9: ...el 280 mm Rear wheel travel 280 mrn Electric system Type Without battery W C D I digital Ignition system Generator A C magneto 12V Headlight type Bulb wattage x quantity Quartz bulb halogen Headlight Headlight only forAustralian market 1 2 V 6 O W l 5 5 W 1 2 v 1 2 w x 1 Turn indicator light 1 2 v 1 2 w x 1 High beam indicatorlight 1 2 V 1 2 W X l Neutral indicator light 1 2 v 3 w x 1 Meter light ...

Page 10: ...re size Measurement point a 94 97 95 02 rnm a 50 rnrn TlEi 95 1 mm _ I I I Camshaft Advance method Camshaft outer diameter Backlash between camshaft and cap Cam dimensions 1 w Intake Exhaust Camshaft runout limit A B C A 8 C JL It i l A Chain advance left 22 967 22 980 mrn 0 020 0 054 mrn 36 47 36 57 mm 30 06 30 16 mm 6 41 rnm 36 62 36 72 rnrn 30 11 30 21 mm 6 51 rnm _ I _ I __ _ __ _ ___ _ 0 03 m...

Page 11: ...X 36 9 37 1 rnm 2 26 mrn EX 2 26 rnrn B face wldth IN 31 9 32 1 rnrn C seat width IN 1 0 1 2 mrn 1 8 rnm EX 1 0 1 2 rnrn 1 8 rnm I D margin thickness IN 1 O 1 4 rnrn 0 8 rnrn Stern outside diameter IN 6 975 6 990 mrn 6 955 rnm EX 6 955 6 970 mm 6 925 rnrn Guide lnslde diameter IN 7 000 7 01 2 rnrn 7 042 rnrn EX 7 000 7 012 mm 7 042 rnrn ____ ____ ____ ____ EX 0 65 rnm 0 8 1 2 rnrn u 0 08 rnrn 0 01...

Page 12: ...IN d 0 0 EX Counterclockwise ____ Counterclockwise ____ Piston Piston to cylmder clearance 94 915 94 965 mm Plston size D 0 1 mm 0 045 0 065 mm B ___ c H t D Measuring point H ____ 2 mm Piston allowance ____ 96 0 mm 4 oversize ____ 95 5 mm 2 oversize ____ 5mm Piston pin off centring Intake side W Piston pin bore lnslde diameter 22 004 22 015mm ____ Piston pin outslde diameter ____ 21 995 22 000 mm...

Page 13: ...mrn ____ ____ Crankshaft F Crank width A 0 8 mrn Small end backlash IF 0 35 0 65mm Big end side clearance D 0 03 rnrn Runout limit C 74 95 75 00 mm __ _ u ___ ____ Balancing weight Advance method Straight toothgear __ Clutch Friction plate Thickness 2 72 2 88 mm Quantity 6 parts Wear limit Frlctlon plate Thickness 2 94 3 06 rnrn Quantity 2 parts Wear hmit Clutch plate Thickness 1 2 rnm Quantity 7 ...

Page 14: ...y carburetor 0 2 60 Secondary carburetor 0 2 60 W Main air let M A J Jet needle J N Needle let M N Cutaway C A Pilot outlet P O 54 Pilot jet P J 0 0 8 Pilot air jet PA J 4 0 74 Starter jet G S 0 2 5 Valve seat size V S 3 1 2 112 revs approx open Pilot screw P S 3 0 5 0 Bypass B P P u 0 1 x 2 Bypass 1 B P 0 0 8 Fuel level F L 6 8 mm Float helght F H 27 29 mm Idle speed Englne idle speed 1 150 1 450...

Page 15: ...CATION LAYOUT m LUBRICATION LAYOUT 1 Oil tank 2 Oil pump 3 Oil filter oil tank 4 Oilstrainer engine 5 Oil vapourretrievalhose 6 Oil blow by retrievalhose A DELIVERY B RETRIEVAL W u m I Dl A 9 I X d 5 3 2 I I ...

Page 16: ... LUBRICATION LAYOUT p p q 1 Oil pump 2 Oil filter 3 Camshaft 4 Oildeliveryhose 5 Maindrivingshaft 6 Drive shaft A DELIVERY B RETRIEVAL g z j j i i z a X I ipi w I ...

Page 17: ...LUBRICATIONLAYOUT M 1 Oil filter A DELIVERY 2 Camshaft B RETRIEVAL 3 Connectingrodpin 4 Maindrivingshaft 5 Secondarydrive shaft 6 Drain plug v u j i I I i i L El 1 4 ...

Page 18: ... _ LUBRICATION LAYOUT m 1 Oil pump A DELIVERY 2 Oil filter e RETRIEVAL 3 Oil delivery hose 4 Transmission 5 Oil stramer rn y yp 4 m X f qg S W x Y v U f 2 5 L 4 L J I I ...

Page 19: ...MAINTENANCESPECIFICATIONS S P E C 1 ENGINE Cylinder head tightening steps L Crankcase tightening steps W Left crankcase Right crankcase ...

Page 20: ...cket head screw Crown nut Nut Hexagon socket head screw Hexagon nut Hexagon nut Hexagon nut Washer based bolt Hexagon socket head screw Washer based screw Hexagon socket head screw Hexagon socket head screw Pan screw Washer based screw Hexagon socket head screw Hexagon screw Pan screw Hexagon nut Hexagon nut Hexagon screw Bolt Hexagon screw Pan head screw I Tlghtenlng Thread torque ILiJRemarks siz...

Page 21: ...w Hexagon screw Washer based screw Washer based nut Pan head screw Hexagon socket head screw I Nut nylon I Washer based screw Hexagon socket head screw Stud bolt Hexagon socket head screw Hexagon socket head screw Hexagon socket head screw Flat headscrew Washer based screw Hexagon nut Hexagon nut Thread size M6 x 1 0 M 6 x 1 0 M12 x 1 25 M8 x 1 25 M6 x 1 0 M6 x 1 O M6 x 1 0 M6 x 1 0 M6 x 1 0 M8 x ...

Page 22: ...im size Rim material Rim runout limit radial lateral Drive chain Type manufacturer Number of links Chain slack Standard Taper rolllng bearmg 277 283 mm 530 mm 4 6 Nimm 0 46kgimm 330 mm 615 cc 160 mm 150 170 mm from upper edge of inner tube fully compressed without spring 01 SUSPENSION OIL 105 mm 250 mm 231 5 mm 65 Nlmm 6 5 kgimm None 1 400 kPa 14 0 kg cm2 14 0bar ____ 0 4 0 7 mm Spoke wheel 1 85 x...

Page 23: ...iameter 13 mm __ ____ ___ u Rear brake Type Single disc _ __ Disc outside Pad thickness Wear limit 9 mm diameter x thickness 220 x 5 mm ___ _ __ __ 1 2 mm I L I 1 Master cylinder inside diameter DOT 4 Brake fluid type 34 mm Caliper cylinder outside diameter 12 7 mm ____ _ ___ Front brake lever Brake pedal lever Adjustable __ L 10 rnm below Brake pedal posltlon the footrest plane ___ Clutch lever C...

Page 24: ...brackevframe Rear master cylinder frame Rear master cylindedbrake hose Rear caliper oilbleed Rear brake calipedbrake hose Part name Washer based screw Nut nylon Washer based screw Washer based screw Nut Nut Screw Hexagon socket head screw Hexagon socket head screw Pan screw Unlon bolt Hexagon socket head screw Screw Washer based screw Union bolt Hexagon socket head pan screw Washer based screw Was...

Page 25: ... Front stay and frame Washer based screw M10 x 1 25 64 6 4 Front stay and engine Washer based screw M10 x 1 25 64 6 4 Upper stay and frame Washer based screw M10 x 1 25 64 6 4 Upper stay and engine Washer based screw M10 x 1 25 64 6 4 Rear lower stay frame Washer based screw M10 x 1 25 64 6 4 Englne protectoriframe Screw M6 x 1 O 10 1 0 Framehear frame Nut nylon M8 x 1 25 23 2 3 Rear footredframe ...

Page 26: ...eed r min Ignitionunit Magneto model Manufacturer Pickup coil resistance _ _ TLMZ89 NIPPONDENSO ____ GreenhVhite Blue Black Colour 192 288 52 at 20 C 68 F CDI unit Model Manufacturer IQCB21 NIPPONDENSO Ignition coil Model Manufacturer Primary winding resistance Secondary winding resistance J0144 TJ0371 NIPPONDENSO 1 04 1 495 i 2 at 20 C 68 F 14 88 22 32 kQ at 20 C 68 F ___ Spark plug cap Type Manu...

Page 27: ...pe Short circuitsemiconductors __ No load regulated voltage 240 V Withstand voltage 25 A Capacity 14 1 14 9 V ____ Rectifier ___ ____ Smooth condenser W ____ ADP 26 SHINDENGEN Model Manufacturer Capacity Voltage 5 440 8 160 VF150 V ____ Horn Type Manufacturer 1 5 A Maximum amperage 10 14 V C C Voltage Plat LEONELLI ____ ____ ____ Flasher relay Type Semi translstors Model Manufacturer 75 95 cycle m...

Page 28: ...hten those units with many fastenings by following a progressive cross sequence until the final tight ening torque is obtained Unless otherwise speci fied thetighteningtorquesgiven are meant for clean and dry threads All components must be at ambient temperature A General specification Nm mkg 10 m m 13 0 130 16 rnm 22 mm 8 5 85 14 mm 19 mm 5 5 55 12 mm 17 mm 3 0 30 10 mm 14 mm 1 5 15 8 mm 12 mm 0 ...

Page 29: ...la i Oil seal valve stem end Rocker shaft and rocker arm la la Cam and bearing camshaft la Rotor and rotor housing oil pump I I _ I L Push rod clutch Bonding agent rapld seal adheave Rod housing coupled surfaces la Shift shaft 1Q Shift cam and bearing gearshiftcam Shift forks and bar la Idle gear transmission la Sliding gear transmlssion 1Q Primary driven gear and main shaft 5 Coupled surfaces cyl...

Page 30: ... _ LUBRICATION POINTS AND LUBRICANT TYPE ISPECI p1 CHASSIS Lubrication points part name Lubrlcant type I I W I r ...

Page 31: ...wire 15 Meter wire harness throttle cables 3 Brake hose harness connector B Lay the brake hose 4 Throttle cables 10 Socket cover 16 Main switch wire throught the holder on the handle 5 Bands 1 1 Engine stop switch crown 6 Lighting wire connector 7 Brakeandengine harness connector harness connector harness 12 Headlightwire stop switch wire 13 Left turn light harness connector I I ...

Page 32: ...5 Throttie cables 13 Flasher relay 6 Tachometer oil tank C Fasten the fuel 7 Clutch cable 8 Clutch cabie hoider 16 Engineoilbreather 9 Clutch cable holder pipe to engine 011 11 Wireharnessband 12 Fuel pipe from fuel 18 Oil hose oil tank to the plate4 19 Oil hose engine to cables 5 cock B Attach throttle odometer cable 14 Sidestand switch 20 Condenser pipe 12 to the tank 15 A C generator wire 21 Di...

Page 33: ...e band 10 Main wire harness band 11 Rear brakeswitch wire harness 12 Rear brake fluid tank hose 13 Hosefrom rear 14 15 16 17 18 19 Rear brake hose holders Pipe Air breather pipe Spark plug ignltlon coil Rear shock absorber oil tank Shock absorber tank bands AI 7 Carburetor suction master cylinder Pipe to caliper p pl Insert the tachometer odometer cable into the band 3 and the holder 2 L 11 i 14 ...

Page 34: ...ail light wire A Insert the tail 2 CDI unit 6 Left turn wire harness damper 4 into the 3 Tail light wire harness 9 Air breather plpe frame then fasten carburetor the bracket 5 4 Tail damper harness harness bands 7 Rlght turn wire us 9 6 3 3 v k d ...

Page 35: ...il or specialfilter oil cracks or damage 0 0 0 0 0 0 0 0 3 0 Replace if necessary Check condition Clean Check for proper operation Adjust or replace the cable Check for proper operation Adjust if necessary Adjust lever free play Check and replace pads Replace brake fluid every 24 000 km Adjust pedal free play Check and replace pads Replace brake fluid every 24 000 km Check and adjust chain slack 0...

Page 36: ...m soap based grease for tightening Check all nuts bolts and screws Tight if necessary Check operation and for oil leakage Repair If necessary 3 0 0 0 0 0 0 L d I I 1 I I Rear shock Sidestand I I Sidestand switch f Check operation and for Replace if necessary Check for proper operation Repair if necessary oil leakage L Check for proper operation ReDlace If necessarv I 0 0 0 0 0 e 0 0 0 I 1 I I I I ...

Page 37: ...uent service if you are riding in unusually wet or dusty areas Should the motorcycle be frequently used off track it isadvised to replace engine oil every3 000 km NOTE Brake fluid replacement 1 Replace the brake fluid after disassembling the master cylinder or caliper cylinder Check the brake 2 Replace the master cylinder and caliper cylinder oil seals every two years 3 Replace the brake hoses eve...

Page 38: ... CARBURETOR pqq CARBURETOR MANUFACTURER TElKEl TYPE YSOPV 2ATK 1 L 0 w I I ...

Page 39: ...Gasket 27 Spring 42 Needle valve set 56 Pipe 31 Screw 45 Diaphragm 32 Screw 46 Needle set 1 17 Screw 33 Pipe 47 Needle set 2 18 Stop screw 34 Clip 48 Starter set 19 Nut 35 Main jet 1 49 Way 3 20 Screw 36 Mainnozzle1 50 Hose 21 Hose 37 Throttle 51 Hose 22 Diaphragm valve 52 Hose W 11 Screw 26 Spring washer 41 Pilot screw set 55 O ring SPECIFICATIONS Main jet W Starter let Needle jet 150 FIRST 130 S...

Page 40: ...ch 20 Horn 21 Directionindicatorlamp relay 22 Frontdirectionindicatorllghts 23 Controllight 24 Parkingindicatorlight 25 Highbeamlight 26 Directionindicatorlight 27 N neutrallight 28 Runnlng light 29 Drivingbeam dimmer light 30 Resistor B Br Ch Dg GY G L Or P R Sb w Y B R BAN B N Br B BrAN G B G R G W GN L R w I N R B RNV R N W L Y R Black Brown Chocolate Deep green Green Grey Blue Orange Pink Red ...

Page 41: ... i co r D In d m cu T 7 cu m w 7 0 I9 2 m m0 m m nn 0 E I 1 I 4 m J a m I m z J ...

Page 42: ...W W ELGARDA dlstrlbutrice escluswa per I ltalia 20050 Gerno di Lesmo MI Via Tinelli 67 69 Telefono 039 60961 Ricerca autornatica Realizzazione PGS Torm Stampa TipolrtografiaSAlNl Tnuggro ...

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