Segment:
Dual-sport motorcycle, known for its off-road prowess and versatility
Target Audience:
Enthusiasts and owners seeking to maintain and repair their Yamaha TT-R600RE, DIY mechanics
Competitors:
Honda XR650L, Kawasaki KLR650, Suzuki DR650SE
Design Philosophy:
Robust, air-cooled engine with strong off-road capabilities, suitable for adventure riding and trail use
Value Proposition:
Empowers owners to perform maintenance and repairs, saving significant costs compared to dealership service.
Quality:
Professional-grade, in-depth service and repair manual.
Engine:
Complete engine overhaul, disassembly, inspection, assembly, tuning, timing
Fuel System:
Carburetor identification, disassembly, cleaning, adjustment, fuel pump, fuel tank, fuel lines
Cooling System:
Radiator, hoses, thermostat, coolant flow, fan operation (if applicable)
Exhaust System:
Muffler, header pipe, catalytic converter (if present), mounting and inspection
Transmission:
Gearbox operation, clutch inspection and replacement, shifting mechanism, transmission oil service
Chassis:
Frame inspection, swingarm, linkages, bearing service
Suspension:
Front forks (disassembly, oil change, seal replacement), rear shock absorber service, spring rates, damping adjustments
Brakes:
Front and rear brake system overhaul, caliper service, pad replacement, rotor inspection, brake fluid bleeding, master cylinder
Electrical System:
Wiring diagrams, ignition system, lighting, charging system (stator, rectifier/regulator), battery service, starter motor
Controls:
Throttle cable, clutch cable, brake lever, shifter linkage adjustment and maintenance
Bodywork And Trim:
Panel removal and installation, seat, fuel tank mounting, fenders
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, spark plug replacement
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts
Repair:
Step-by-step repair instructions for all major components and systems, including full engine and transmission rebuilds
Disassembly And Assembly:
Detailed procedures for component removal and installation, including torque specifications
Diagnostics:
Identification of electrical faults, mechanical issues, and performance problems with diagnostic routines
Depth:
Comprehensive, from basic maintenance to complete engine and transmission overhauls
Diagnostic Tools:
Recommendations for specialized tools and diagnostic equipment
Specifications:
Includes detailed technical specifications, tolerances, and measurement data for all components
Wiring Diagrams:
Full, color-coded electrical wiring schematics for comprehensive system diagnosis
Engine Type:
Four-stroke, SOHC, 4-valve, Air-cooled
Displacement:
595 cc (36.3 cubic inches)
Bore X Stroke:
95.0 mm x 81.0 mm (3.74 in x 3.19 in)
Compression Ratio:
9.5:1 (Typical)
Horsepower Peak:
Approx. 40-45 HP (Varies by market and specific tuning)
Torque Peak:
Approx. 45-50 Nm (Varies by market and specific tuning)
Carburetor:
Mikuni BSR36 (likely), single CV carburetor
Fuel Capacity:
Approx. 10-12 Liters (2.6-3.2 Gallons)
Fuel Type:
Unleaded gasoline, Octane rating 87 or higher
Oil Change Interval:
Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first (refer to manual for exact specification).
Air Filter Cleaning:
Check/clean every 1,000-2,000 km (600-1,200 miles), replace as needed.
Spark Plug Replacement:
Recommended every 10,000-15,000 km (6,000-9,000 miles).
Valve Clearance Check:
Initial check at 1,000 km, then every 6,000-10,000 km (3,700-6,000 miles).
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 20W-40 API Service SG or higher (refer to manual for exact spec).
Engine Oil Capacity:
Approx. 2.5 - 2.8 Liters (2.6 - 3.0 US qt) with filter change.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Fork Oil Type:
Yamaha Fork Oil G-10 or equivalent (refer to manual for viscosity and quantity).
Transmission Oil Type:
Yamalube Gear Oil (or equivalent) SAE 80 API GL-3 (refer to manual for specific type).
Common Wear Items:
Clutch plates, fork seals, steering head bearings, wheel bearings, chain and sprockets.
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring periodic adjustments or re-jetting.
Electrical Connections:
Corrosion on connectors can lead to intermittent electrical issues, especially in humid or salty environments.
Yamaha Offroad Legacy:
Yamaha has a long and successful history in off-road racing and dual-sport motorcycles, with models like the XT and TT series establishing a strong reputation for durability and performance.
Tt R Lineage:
The TT-R series evolved from Yamaha's earlier TT models, focusing on user-friendliness and accessibility for off-road enthusiasts while retaining robust engineering.
Production Period:
The TT-R600RE model was produced for a specific period, with the manual covering the 2003-2006 model years.
Manufacturing Location:
Typically manufactured in Japan or other Yamaha global facilities.
