Yamaha TT 600 RE (5CH5) [2004] Werkstatthandbuch,Service Manual, english.pdf

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2004
TT600RE
SERVICE MANUAL
5CH5-ME1
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EASB0000
TT600RE
SERVICE MANUAL
© 2003 by Belgarda S.p.A.
First edition, July 2003
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Belgarda S.p.A.
is expressly prohibited.
Printed in Italy
 
EASB0001
NOTICE
This manual was produced by the Belgarda S.p.A. primarily for use by Yamaha dealers and their quali-
fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore,
anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic
understanding of mechanics and the techniques to repair these types of vehicles. Repair and mainte-
nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit
for use.
Belgarda S.p.A. is continually striving to improve all of its models. Modifications and significant changes
in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in
future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE-
TY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
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EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex-
planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out
with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page
indicate the current chapter.
Refer to "SYMBOLS".
2 Each chapter is divided into sections. The current section title is shown at the top of each page, except
in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s) appears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-
moval and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a dis-
assembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to "SYMBOLS".
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts,
notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequentially.
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1
2
ILLUSTRATED SYMBOLS
The following symbols are not relevant to every
vehicle.
Illustrated symbols 1 to 8 are printed on the top
right of each page and indicate the subject of
each chapter.
1 General information
2 Specifications
3 Periodic inspections and adjustments
4 Chassis
5 Engine
6 Carburetor
7 Electrical system
8 Troubleshooting
GEN
INFO
SPEC
3
4
INSP
ADJ
CHAS
5
6
ENG
CARB
7
8
?
ELEC
TRBL
SHTG
Illustrated symbols 9 to y are used to identify
the specifications appearing in the text.
9 Can be serviced with engine mounted
0 Filling fluid
q Lubricant
w Special tool
e Torque
r Wear limit, clearance
t Engine speed
y Electrical data
9
0
q
w
e
r
t
y
u
i
o
Illustrated symbols u to s in the exploded dia-
grams indicate the types of lubricants and lubrica-
tion points.
u Apply engine oil
i Apply gear oil
o Apply molybdenum disulfide oil
p Apply wheel bearing grease
a Apply lightweight lithium-soap base grease
s Apply molybdenum disulfide grease
p
a
s
d
f
Illustrated symbols d to f in the exploded dia-
grams indicate the following:
d Apply locking agent (LOCTITE ® )
f Replace the part
New
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