2004 YAMAHA TT600RE wheel

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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1-6
GEN
INFO
SPECIAL TOOLS
Tool No.
90890-01083Rocker arm shaft puller bolt
These tools are used when removing the
rocker arm shafts.
Tool name / Usage Illustration
90890-01084Weight
These tools are used when removing the
rocker arm shafts.
90890-04019Valve spring compressor
These tools are used when removing or
installing the valve and the valve spring.
90890-012257 mm (0.28 in) valve guide puller
This tool is used to remove the valve guides.
90890-040177 mm (0.28 in) valve guide installer
This tool is necessary to install the valve
slides properly.
90890-012277 mm (0.28 in) valve guide reamer
This tool is used to re-ream the new valve
guide.
90890-01311Valve adjusting tool
This tool is necessary for adjusting valve
clearance.
90890-01701Rotor holder
This tool is used for loosing and tightening
the rotor nut.
90890-01362Rotor screw puller
This tool is used to disassemble the magne-
to flywheel rotor.
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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
2-2
Item Standard Limit
Spark plug
Manufacturer/model NGK/DPR8EA-9 or NGK/DPR9EA-9
Gap 0.8–0.9 mm •••
Clutch typeWet. Multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 71/34 (2.088)
Secondary reduction system Chain drive
Secondary reduction ratio 47/15 (3.133)
Number of drive chain sprocket
teeth (front/rear) 15/47
Transmission type Constant mesh 5-speed
Operation Left foot
Gear ratio 1
st2.583
2nd1.588
3rd1.200
4th0.955
5th0.792
Chassis
Frame type Open cradle backbone frame/detachable
rear frame
Caster angle 27° •••
Trail 117 mm •••
Tires
Front:
Type With tube
Size 90/90-21-(54R) / 90/90-21-(54S)
Manufacturer/model Pirelli / MT70 - Michelin / T63
Rear:
Type With tube
Size 130/80-18-(66R) / 130/80-18-(66S)
Manufacturer/model Pirelli / MT70 - Michelin / T63
Maximum load* 180 kg •••
Tire air pressure
(measured on cold tires):
Up to 90 kg* Front 200 kPa; 2.00 kgf/cm
2; 2.00 bar •••
Rear 220 kPa; 2.20 kgf/cm2; 2.20 bar •••
90 kg–maximum* Front 210 kPa; 2.10 kgf/cm2; 2.10 bar •••
Rear 240 kPa; 2.40 kgf/cm2; 2.40 bar •••
Off-road riding Front 150 kPa; 1.50 kgf/cm2; 1.50 bar •••
Rear 160 kPa; 1.60 kgf/cm2; 1.60 bar •••
High-speed riding Front 210 kPa; 2.10 kgf/cm2; 2.10 bar •••
Rear 240 kPa; 2.40 kgf/cm2; 2.40 bar •••
* Total weight of rider, passenger,
cargo and accessories
Wheels
Front:
Type Spoke wheel
Size 21” x 1.85
Rear:
Type Spoke wheel
Size 18” x MT 2.50
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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
2-12
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
2-14
Tightening
Part to be tightened Thread torque
Remarkssize
N·mm·kg
Engine mounting and rear frame:
Engine front/Stay engine M10 x 1.25 64 6.4
Stay engine (engine front)/Frame M10 x 1.25 64 6.4
Engine rear under/Frame M10 x 1.25 68 6.8
Engine top/Stay engine M10 x 1.25 64 6.4
Engine protector/Frame M6 x 1.0 7 0.7
Chain tensioner top/Frame M8 x 1.25 23 2.3
Chain tensioner under/Frame M8 x 1.25 23 2.3
Frame/Rear frame (upper) M8 x 1.25 23 2.3
Frame/Rear frame (under) M8 x 1.25 23 2.3
Rear frame/Air filter assy M6 x 1.0 5 0.5
Front fork and steering:
Handle crown/Inner tube M8 x 1.25 28 2.8
Handle crown/Steering shaft M28 x 1.5 4 0.4 See “NOTE”
Steering shaft/Ring nut M36 x 1.5 115 11.5
Holder handle upper/Crown handle M8 x 1.25 20 2.0
Holder handle under/Crown handle M10 x 1.5 40 4.0
Front fork under bracket/Inner tube M8 x 1.25 23 2.3
Front master cylinder/Cap M4 x 0.7 1.5 0.15
Front master cylinder/Handle M6 x 1.0 9 0.9
Union bolt tightening M10 x 1.0 20 2.0
Front fender/Front fork M6 x 1.0 7 0.7
Stay headlight/Handle crown M6 x 1.0 10 1.0
Stay headlight/Bracket meter M6 x 1.0 6 0.6
Headlight/Stay headlight M6 x 1.0 10 1.0
Rear arm and cushion:
Pivot shaft/Frame M14 x 1.5 90 9.0
Arm relay/Frame M10 x 1.25 60 6.0
Arm relay/Rod connecting M10 x 1.25 52 5.2
Arm relay/Shock absorber M10 x 1.25 59 5.9
Rod connecting/Rear arm M12 x 1.25 66 6.6
Shock absorber upper/Frame M12 x 1.25 66 6.6
Seal guard/Rear arm M6 x 1.0 4 0.4
Support chain/Rear arm M6 x 1.0 9 0.9
Chain case/Rear arm M6 x 1.0 9 0.9
Front wheel:
Front wheel shaft/Front fork M16 x 1.5 59 5.9
Axle holder//Front fork M6 x 1.0 9 0.9
Rear wheel:
Rear wheel shaft/Nut M18 x 1.5 115 11.5
Clutch hub/Sprocket M10 x 1.25 48 4.8
Tightening torques
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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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