Yamaha TT600 TT600RE 2003 2004 2005 2006 Service Manual

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Taper: Motorcycle

Distributeur:

UGS: 66355

Mots clés: 2003 2004 2005 2006 Marine Motorcycle Sterndrive TT600 TT600RE Yamaha

Variantes de produits

Description

The TT600RE, produced between 2003 and 2006, represents a robust and versatile dual-sport motorcycle, building upon an esteemed series lineage. Engineered for both on-road commuting and off-road exploration, this model is recognized for its reliable 595 cc four-stroke, single-cylinder engine and its durable construction, making it a capable machine for a variety of riding conditions. Its design emphasizes a balance of performance and practicality, reflecting a commitment to quality and rider experience. This comprehensive workshop service manual provides detailed information for the repair and overhaul of TT600 and TT600RE models. Covering essential systems such as the engine, fuel, ignition, lubrication, electrical, and transmission, along with chassis components and bodywork, this manual is an indispensable resource. It includes step-by-step repair instructions, routine maintenance procedures, troubleshooting guides, and critical technical specifications, empowering technicians and owners to maintain and effectively repair their vehicle to ensure optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

TT600RE

Model Variant:

TT600

Generation

Generation Codes:

4GV1 (for TT600RE, 2003-2006)

Codes

Production Years Covered:

2003, 2004, 2005, 2006

👋 Introduction

Market Position

Target Audience:

Mechanical technicians, experienced DIY enthusiasts, and Yamaha owners seeking detailed service information

Competitive Analysis

Value Proposition:

Provides dealership-level service information, enabling cost savings and professional-quality repairs

Key Features

Accuracy Assurance:

Endeavors to ensure accuracy with reliable information for optimal vehicle performance

Completeness:

Considered a complete service manual containing all necessary repair instructions

User Empowerment:

Empowers owners to perform informed and knowledgeable repairs like a professional

📋 Manual Details

Coverage Areas

Primary Focus:

Repair and overhaul of Yamaha TT600 and TT600RE models

Additional Coverage:

Proprietary component repair instructions from respective manufacturers

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Language

Primary Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine repair, overhaul, and disassembly

Fuel System:

Carburetor (likely Mikuni BST series), fuel pump, fuel lines, fuel tank

Ignition System:

CDI ignition system, spark plug specifications, timing

Lubrication System:

Oil pump, oil filter, oil specifications, lubrication points

Exhaust System:

Exhaust pipe, muffler, gasket replacement

Electrical System:

Wiring diagrams, battery, charging system, lighting, starter system, sensors

Transmission:

Gearbox disassembly, inspection, assembly, clutch operation

Chassis:

Frame, suspension (front forks, rear shock absorber), steering system

Bodywork:

Fairings, seat, fuel tank, fenders, panels

Brakes:

Front and rear brake system inspection, service, and fluid replacement

Wheels And Tires:

Wheel bearing service, tire specifications, spoke tensioning

Procedures Included

Routine Maintenance:

Tune-ups, oil changes, filter replacements, chain adjustment, spark plug checks

Troubleshooting:

Diagnostic procedures for common issues and system malfunctions

Repair Overhaul:

Detailed step-by-step instructions for component repair and complete disassembly/reassembly

Installation:

Procedures for removing and installing various components

Technical Depth

Diagnostic Capabilities:

Advanced diagnostics, including system checks and fault finding

Rebuild Scope:

Comprehensive engine and transmission rebuild procedures

Special Tools:

Identification and usage instructions for specialized Yamaha service tools

Safety Emphasis:

Highlights safety precautions denoted by WARNING, CAUTION, and NOTE symbols

📊 Manual Specifications

File Format

Quality:

High-resolution PDF, suitable for digital viewing and printing

Print Quality

Printable:

Binding Type

Format Type:

Digital Download (PDF)

Paper Type

Delivery Method:

Electronic Delivery via Email

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Single Cylinder, SOHC, 4-valve

Displacement:

595 cc (This is a common displacement for the TT600 series, specific 'RE' variant may vary slightly, confirm with manual)

Bore X Stroke:

95.0 mm x 81.4 mm (Typical for TT600 engine, confirm with manual)

Performance

Compression Ratio:

Approximately 9.5:1 (Typical, confirm with manual)

Horsepower Output:

Around 45-50 HP (Estimate based on common configurations, specific 'RE' variant may differ)

Torque Output:

Approximately 45-50 Nm (Estimate, confirm with manual)

Fuel System

Carburetor Type:

Mikuni BSR36 (Typical for TT600RE, confirm with manual)

Fuel Capacity:

Approx. 9 Liters (Check manual for exact capacity)

Lubrication System

Oil Capacity:

Approx. 1.6 Liters (Dry sump system, confirm with manual)

Recommended Oil Type:

Yamalube 4 (10W-40) or equivalent API SG or higher, JASO MA certified motorcycle oil (Confirm with manual)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Optional

Type:

Features

Clutch:

Wet, multi-plate

Final Drive:

Chain drive

Fluid Specifications

Transmission Oil Type:

Yamalube Gear Oil (API GL-4, SAE 80W) or equivalent (Confirm with manual)

📐 Dimensions

Exterior

Length:

Approx. 2235 mm (Confirm with manual)

Width:

Approx. 830 mm (Confirm with manual)

Height:

Approx. 1250 mm (Confirm with manual)

Weights

Dry Weight:

Approx. 145 kg (Confirm with manual)

Wet Weight:

Approx. 155 kg (Estimate, includes fluids, confirm with manual)

🛡️ Safety Features

Ratings

Safety Features Overview:

Focus on safe operation and maintenance procedures as outlined in the manual

Active Features

Braking System:

Hydraulic disc brakes front and rear

Lighting:

Headlight, taillight, brake light, turn signals

Passive Features

Frame Construction:

Steel cradle frame

💡 Technology Features

Infotainment

Instrumentation:

Analog speedometer, tachometer, odometer, trip meter, and indicator lights

Driver Assistance

N/A (This is a traditional motorcycle, not equipped with electronic driver assistance systems)

Connectivity

N/A (No integrated connectivity features)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km or 6 months, whichever comes first (Confirm with manual)

Air Filter Cleaning:

Every 6,000 km or as needed in dusty conditions (Confirm with manual)

Spark Plug Replacement:

Every 10,000 km or as needed (Confirm with manual)

Fluid Specifications

Brake Fluid Type:

DOT 4 hydraulic brake fluid (Confirm with manual)

Coolant Type:

N/A (Air-cooled engine)

Known Issues

Common Wear Items:

Clutch wear, chain and sprockets, wheel bearings, fork seals

Carburetor Tuning:

May require periodic adjustment or cleaning due to its dual-sport nature and potential for off-road use

Technical Tips

Torque Wrench Usage:

Emphasized for ensuring fasteners are tightened to specification for safety and longevity

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Company, known for performance motorcycles and sporting goods

Model Evolution

Tt Series Lineage:

The TT600RE is part of Yamaha's long-standing dual-sport lineage, evolving from earlier off-road focused models.

Re Designation:

The 'RE' often signifies specific factory modifications or upgrades, potentially including enhanced suspension or engine tuning.

Production

Manufacturing Origin:

Typically manufactured in Japan or other Yamaha global facilities (confirm with manual for specific country of origin)

🏆 Awards & Recognition

Recognitions

General Reputation:

The TT600 series is generally well-regarded for its robust engine and versatility in dual-sport applications, though specific awards are not commonly listed for individual model years.