Yamaha TT 600 R 1997 Bedienungs- und Montageanleitung

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YAMAHA

600

:97

‘“*hi

SERVICE

INFORMATION

~~--

~--

~ ~~ ~~~~

___

INTRODUCTION

This booklet has been createdinorder

provide further information abouttheYamaha

600

('97)

model.

For a

full

understanding of

the

information on theservice procedures, usethis booklet together withthe mi-

crofiches

the Service Manual.

600

('97)

SERVICE

MANUAL:

5CH-ME1

TECHNICAL PUBLICATIONS

SERVICE DIVISION

MOTORCYCLE GROUP

BELGARDA S.p.A.

f,,'

'<*

600

'97

SERVICE INFORMATION

1997 Belgarda

S.p.A.

1"'edition, September 1997

Any reprinting or unauthorised use

without the written permission

Belgarda S.p.A. isexpressly prohibited.

Printed in Italy

BCH-SEI

WARNING

Thismanual has beenwritten by BelgardaS.p.A. mainly foruse by Yamaha dealersandtheirskilled

mechanics. It is impossible

provide a mechanic with

all

the information necessaryin a single manual.

Presumably, though, the people who use this manual for the maintenance and repair

Yamaha motor-

cycles will already have elementary knowledge of the principles

mechanics and the procedures for

motorcycle repair techniques. Without this knowledge, repair or maintenance workon this model could

prove inefficient and/or dangerous.

Belgarda S.p.A. makes constant effortsto improve allitsmodels. Important alteratlonsor changes

pro-

cedures characteristics will be communicated

all Yamaha dealers and published in future editions

this manual.

NOTE:

Specifications and designare subject to change without notice.

PARTICULARLY IMPORTANT INFORMATION

The manual includes the following symbols and relative remarks:

Thissafety alert symbol means: ATTENTION! BECOMEALERT! YOUR SAFE-

INVOLVED!

The WARNING symbolIndicatesspecialprocedures to befollowed

avoid

severeinjury or deathtotherider or thepersonInspecting or repairingthe

motorcycle.

'CAUTION:.,,

CAUTIONindicatesspecialprecautionstobetaken

avoiddamagetothe

motorcycle.

NOTE:

ANOTEprovideskeyinformationdesigned

makeprocedureseasierorclear-

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ILLUSTRATED

SYMBOLS

Illustratedsymbols

(1)

(9)

aredesigned as

thumb tabs

indicate the chapter's number and

content.

(1)

General information

(2)

Specifications

(3)

Perlodic inspection and adjustment

(4)

Engine

(5)

Cooling system

(6)

Carburetion

(7)

Chassis

(8)

Electrical

(9)

Troubleshooting

Illustrated symbols

(IO)

(17)

are used to identi-

fy the specifications appearingInthe text.

Possibleto maintainwith engine mounted

(11)

Fllling fluid

(12)

Lubricant

3) Special

tool

(14)

Tightening

(15)

Wear limit, clearance

(16)

Engine speed

12,

'14'

Illustrated symbols

(18)

(23) in theexploded

diagrams indicatethe types

lubricants and lubri-

cation points.

Apply englne

oil

Apply gear

oil

(20)

Apply molybdenum

disulfide

oil

(21)

Apply wheel bearinggrease

(22)

Apply lightweight lithium-soap base grease

(23)

Apply molybdenum disulfide grease

Illustrated symbols

(24)

(25)

in the exploded

diagramsindicatethewhere

applylocking

agent(24)andwhen

installnewparts

(25).

(24) Apply locking agent (LOCTITE@)

(25)

Use

new one

INDEX

GENERAL INFORMATION

VEHICLEIDENTIFICATION

.....................................................................................

SPECIFICATIONS

GENERALSPECIFICATIONS

..................................................................................

MAINTENANCESPECIFICATIONS

ENGINE

........................................................

LUBRICATION LAYOUT

..........................................................................................

ENGINE

TIGHTENING TORQUES

........................................................................

MAINTENANCESPECIFICATIONS

CHASSIS

......................................................

CHASSIS

TIGHTENING TORQUES

......................................................................

MAINTENANCESPECIFICATIONS

ELECTRICAL

................................................

GENERAL SPECIFICATIONS ABOUT TIGHTENING TORQUES

........................

LUBRICATION POINTSAND LUBRICANT TYPE

.................................................

CABLEROUTING

....................................................................................................

PERIODIC INSPECTIONSAND ADJUSTMENTS

PERIODICMAINTENANCE/LUBRICATION INTERVALS

........................................

EXPLODEDDIAGRAM

CARBURETOR

..................................................................................................

ELECTRICAL

WIRINGDIAGRAM

...............................................................................................

‘W

..--~~~

~____

~~-..~

VEHICLE IDENTIFICATION

GENl

INFO

GENERAL INFORMATION

VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATIONNUMBER

The vehicleidentificationnumber

(1)

stamped

into the right side

the steering head pipe.

MODEL/COLOURIDENTIFICATION

LABEL

The modelkolour identification label

(1)

is affixed

to the rear frame. This information will be needed

order spare parts.

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Model code

Dimensions:

Overall length

Overall wldth

Overall height

Seat height

Wheel base

Minimum ground clearance

Minimum turning radius

Baslc weight:

Withoiland full fuel tank

Engine:

Englne type

Cylinder arrangement

Displacement

Bore

stroke

Compression ratio

Starting

system

Lubrication system

Oil type or grade:

Engineoil

-20°-100

10"

20"

30"

40"50"C

IIIIIIII

III(II4I

,I111111

$AEiOWj30

; ;

IIII

,,I

/,lIIIII

,,I,

SAk

1Qhl46

;

':SA220A/40:*

IIIIIIII

Ill

I I

SAL

20hl56

I,/I,IIl

II1I!IIl

IIlIIIIl

API standard:

Oilcapacity:

Engine oil

Periodic oil change

With

oil

fllter replacement

Oil tank

Total amount

Air filter

Standard

600

DJOI

(5CH1)

2,250

845 mm

1,225 mm

945 mm

1,480 mm

325 mm

3,100

rnm (left)

3,300

mm (right)

150

Air cooled, 4-stroke,4-valve,

SOHC

Forward-inched single cylinder

595 cm3

84 mm

851

Kick-starter

Dry

sump with separate oil tank

Type API Service

"SE,

"SF"

or equivalent

2.7

2.8

2.6

3.3

Oiled filter element

Fuel:

TY Pe

Tank capaclty

Reserve

Regular unleaded gasoline

2.1

~-~

GENERAL

SPECIFICATIONS

Item

Standard

Carburetor:

Type Y30PV-2ATK

Manufacturer TElKEl

Spark plug:

Type DPR8EA-S/DPRSEA-9

Manufacturer

NGK

Electrode gap

0.8

0.9 mm

Clutch type

Transmission:

Wet, multi-dlsc

...-

Primary reduction system

Primary reduction ratio Straight-tooth gears

30/13

(2.308)

Gearratio

Left foot operation

Operation Constant mesh 5-speed

Transmission type 44/15 (2.933)

Secondary reduction ratio Chain drive

Secondary reductlon system 74/31(2.387)

19/24 (0.792)

5'h

21/22 (0.954)

4'h 24/20 (1.200)

27/17 (1.588)

Frame,

Frame type

Trail 26"

30'

Caster angle

Open-cradle backbone frame

114 mm

and removable rear frame

Tyres:

Type With tube

Sizefront 90/90-21"-54R

90190-21"-545

rear 130/90-18-69R

130180-1

8-66R

140/80-18-70R

130180-18-668

Manufacturer/modelfront

rear MlCHELlN BAJA

T63

PlRELLl

MT21

orMT70

MlCHELlN BAJA

T63

PlRELLl MT21

MT70

Maximum load*

except motorcycle

Tire pressure (cold tire):

180 kg

Rideronlyfront

100 kPa (1

.OO

kgicm', 1

.OO

bar)

rear

100

kPa (1

.OO

kg/cm2, 1

.OO

bar)

Off-roadfront

220 kPa (2.20 kg/cm2, 2.20 bar)

rear 200 kPa (2.00 kg/cm', 2.00 bar)

Withmaximumload*front

180

kPa

.80

kg/cm2, 1.80 bar)

rear

150

kPa

(1.50

kg/cm',

1.50

bar)

Load

the total weight

cargo,

passenger, and accessories.

Brakes:

Frontbraketype

Single dia. 220 mm disk brake

Rearbraketype

Single dla. 267

disk brake

operation

Right

foot

operation

Right hand operation

'4~

GENERAL

SPECIFICATIONS

!Giq-q

Item

Standard

Suspension:

Front suspension DELTA-BOX SWINGARM

Rear suspension Adjustable telescopic fork (dia. 43

mm)

Shock absorber:

Front shock absorber Adjustable

Coil spring

Oil-gas damper

Rear shock absorber Adjustable

/Coil

spring

/Oil

damper

with separatedtank

Wheeltravel:

Front wheel travel 280

Rear wheel travel

280

mrn

Electric system:

Type Without battery

‘W

C.D.I. (digital)

Ignition system

Generator A.C. magneto 12V

Headlighttype

Bulb wattage x quantity: Quartz bulb(halogen)

Headlight

Headlight (only forAustralian market) 12V6OWl55W

12v1,2wx1Turn indicator light 12v1,2wx1

High beam indicatorlight 12V1,2WXl

Neutral indicator light 12v3wx1

Meter light 12v5wx1

Front marker light 12VlOWx4

Flasher light 12V5Wl21

Tail/brake light 12V35W135W

~~ ~~

MAINTENANCE SPECIFICATIONS

-1

MAINTENANCESPECIFICATIONS

ENGINE

Itern

Limit

Standard

I I

Cylinder head:

Warp

limit

----

The lines

show

where you have

site

themeasuringslide rule.

0.03

Cylinder:

Bore

size

Measurement point

(a)

94.97

95.02

rnm

(a)

rnrn

TlEi

95.1

--_-

Camshaft:

Advance method

Camshaft

outer

diameter

Backlash between camshaft and

cap

Cam dimensions

Intake

Exhaust

Camshaft

runout

limit

"A"

"C"

'A"

"8"

"C"

-*-

----JL--

tilA

Chain advance

(left)

22.967

22.980

mrn

0.020

0.054 mrn

36.47-

36.57

30.06

30.1

6.41 rnm

36.62-36.72

rnrn

30.11 -30.21 mm

6.51 rnm

_I_

----

__--

_-__

----

-_--

----

___-

----

_---

0.03

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