Segment:
Dual-sport/Enduro motorcycle
Target Audience:
Owners seeking to perform their own maintenance and repairs, as well as professional motorcycle technicians.
Competitors:
Honda XR series, Suzuki DR-Z series, Kawasaki KLR series (depending on specific market and sub-segment focus).
Vehicle Strengths:
Robust engine, capable off-road suspension, reliable performance for dual-sport use.
Manual Value Proposition:
Enables owners to maintain their TT-R600RE effectively, reducing reliance on costly dealership services and ensuring longevity.
Engine Overhaul:
Complete disassembly, inspection, repair, and reassembly of the engine and its components.
Fuel System:
Carburetor service, fuel pump (if applicable), fuel lines, fuel filter replacement.
Ignition System:
CDI unit, ignition coil, spark plug service, timing checks.
Transmission And Clutch:
Clutch operation, transmission disassembly/reassembly, gear inspection, lubrication.
Suspension System:
Front fork (telescopic) disassembly, service, oil replacement, fork seals. Rear shock absorber service, linkage maintenance.
Braking System:
Front and rear brake caliper service, hydraulic system bleeding, pad replacement, rotor inspection.
Electrical System:
Wiring diagrams, lighting system, battery service, charging system (stator, regulator/rectifier), starter motor.
Cooling System:
Oil cooler service and inspection (if applicable), oil change procedures.
Exhaust System:
Muffler and pipe inspection, gasket replacement.
Chassis And Frame:
Frame inspection, steering head bearing service, swingarm maintenance.
Wheels And Tires:
Tire inspection and replacement, wheel bearing service, spoke tensioning.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, general lubrication.
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues.
Engine Rebuild:
Detailed step-by-step instructions for engine disassembly, part inspection, and reassembly.
Suspension Overhaul:
Fork seal replacement, fork oil replenishment, rear shock absorber servicing.
Carburetor Tuning:
Cleaning, adjusting idle speed, jetting information for different altitudes/conditions.
Electrical Diagnostics:
Fault finding for ignition, lighting, and charging systems using wiring diagrams.
Brake System Service:
Brake fluid flush, caliper rebuild, pad and rotor replacement.
Wheel And Tire Replacement:
Tire mounting and balancing, wheel bearing replacement.
Depth:
Comprehensive, covering all aspects from basic maintenance to complete engine and chassis overhauls.
Diagnostic Information:
Includes troubleshooting charts and symptom-based diagnostics.
Torque Specifications:
Detailed torque values for all critical fasteners.
Clearances And Tolerances:
Specifications for valve clearances, piston-to-cylinder clearances, etc.
Engine Displacement:
595cc (approx.)
Engine Configuration:
Single-cylinder, 4-stroke
Bore X Stroke:
95.0 mm x 81.3 mm (typical for this engine)
Compression Ratio:
9.5:1 (typical)
Valvetrain:
SOHC, 4 valves
Cooling System:
Air-cooled (with oil cooler)
Horsepower Est:
Approx. 45-50 HP (at crank, depending on market tuning)
Torque Est:
Approx. 45-50 Nm (at crank, depending on market tuning)
Carburetor Type:
Mikuni TM40 (typical, flat-slide, constant velocity)
Fuel Capacity:
Approx. 14 Liters (3.7 US gallons)
Oil Type Recommendation:
Yamalube 4 (or equivalent API SG or higher, SAE 10W-40 or 20W-50 depending on ambient temperature)
Oil Capacity With Filter:
Approx. 2.0 Liters (2.1 US qt)
Engine Oil Change:
Every 5,000 km (3,000 miles) or annually, whichever comes first.
Air Filter Cleaning:
Every 5,000 km (3,000 miles), replace if damaged.
Spark Plug Check And Gap:
Every 10,000 km (6,000 miles).
Valve Clearance Check:
Every 10,000 km (6,000 miles).
Chain Lubrication And Adjustment:
Every 1,000 km (600 miles) or as needed.
Brake Fluid:
DOT 4 (refer to manual for specific Yamaha recommendation).
Carburetor Performance:
May require re-jetting for significant altitude changes; potential for clogging if fuel is not clean.
Suspension Seals:
Front fork seals can wear over time, leading to oil leaks; requires periodic inspection and replacement.
Clutch Wear:
Clutch plates can wear with aggressive use, requiring replacement as per service interval or performance degradation.
