Primary Coverage:
Service, Repair, Workshop
Specific Systems Covered:
General Information, Routine Maintenance, Specifications, Periodic Checks and Adjustments, Lubrication, Cooling System, Transmission, Drive Chain, Sprockets, Engine Specifications, Engine Removal and Installation, Fuel System, Steering System, Shocks, Body Work, Intake & Exhaust, Electrical System, Advanced Troubleshooting, Wiring Diagram
Estimated Page Count:
Extensive (Full Factory Service Manual)
Type:
Factory Service Manual / Workshop Manual
File Format:
PDF Download
Engine Service:
Complete overhaul, top-end and bottom-end procedures, cylinder head, piston, crankshaft, camshaft, valve train, timing, oil pump, oil seals, gaskets.
Fuel System Service:
Carburetor disassembly, cleaning, adjustment, jetting, fuel pump, fuel lines, fuel tank maintenance.
Cooling System Service:
Radiator, coolant, hoses, thermostat, water pump maintenance and repair.
Transmission And Drivetrain:
Clutch operation, gear shifting mechanisms, internal transmission components, output shaft, drive chain adjustment and replacement, sprocket inspection and replacement.
Electrical System:
Ignition system (CDI, spark plug, coil), starting system (starter motor, solenoid, battery), lighting system (headlight, taillight, turn signals), charging system (alternator, rectifier/regulator), wiring harness, fuses, switches, diagnostic procedures.
Chassis And Suspension:
Front fork (oil change, seal replacement, spring inspection), rear shock absorber (rebuild, adjustment), swingarm, bearings, steering head bearings, wheel bearings.
Brakes:
Front and rear brake caliper service, brake pad replacement, brake disc inspection, brake fluid flush, master cylinder service.
Bodywork And Fairings:
Removal and installation of plastic components, seat, fuel tank cover, fenders.
Troubleshooting Guide:
Comprehensive diagnostic flowcharts and step-by-step troubleshooting for common and uncommon issues across all systems.
Repair Instructions:
Detailed, illustrated instructions for disassembly, cleaning, inspection, repair, assembly, and adjustment of all major components.
Maintenance Schedules:
Recommended service intervals for oil changes, filter replacements, chain lubrication, valve clearance checks, brake inspections, etc.
Torque Specifications:
Precise torque values for all fasteners and critical components.
Wiring Diagram Interpretation:
Detailed wiring schematics provided to aid in diagnosing and repairing electrical faults.
Depth:
Factory-level diagnostic and repair procedures, suitable for independent mechanics and experienced DIY enthusiasts.
Component Rebuild:
Instructions for complete disassembly and rebuilding of major engine components, transmission, and suspension elements.
Compatibility:
All Versions of Windows AND Mac
Printability:
Yes, all pages are printable
Binding:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Required Software:
Adobe PDF Reader
Diagrams And Illustrations:
Includes detailed diagrams, illustrations, and wiring schematics.
Searchability:
Searchable text for quick information retrieval.
Illustrations Type:
Step-by-step instructions, diagrams, and illustrations.
Engine Type:
Single-cylinder, four-stroke, SOHC (Single Overhead Camshaft), 4-valve
Displacement:
Approximately 595cc (exact figure may vary slightly by sub-model/region)
Horsepower:
Typically in the range of 40-45 HP (estimate, specific dyno figures vary)
Torque:
Approximately 35-40 lb-ft (estimate)
Fuel Delivery:
Carburetor (e.g., Mikuni BST40 or similar) for earlier models, potentially EFI on later variations of similar platforms, though TT600RE typically carbureted.
Oil Type Recommendation:
Yamalube 4 (or equivalent JASO MA rated 10W-40 or 20W-50 motorcycle oil), specific viscosity dependent on ambient temperature.
Cooling Method:
Air-cooled
Engine Removal And Installation
Procedure Availability:
Detailed guide for engine removal and installation from the motorcycle chassis.
Engine Oil Change:
Every 3,000-5,000 km (1,800-3,000 miles) or annually, whichever comes first. Specific interval for demanding use may be shorter.
Air Filter Cleaning:
Check every 1,000 km (600 miles), clean/replace as needed, more frequently in dusty conditions.
Spark Plug Replacement:
Inspect every 5,000 km (3,000 miles), replace as needed based on condition and gap.
Valve Clearance Check:
Initial check at 1,000 km (600 miles), then every 5,000-10,000 km (3,000-6,000 miles).
Engine Oil Capacity:
Approximately 2.3 liters (2.4 US qt) with oil filter change.
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, drive chain and sprockets due to off-road use.
Carburetor Tuning:
Carburetors can require periodic cleaning and adjustment to maintain optimal performance, especially after long periods of storage or significant changes in altitude/temperature.
