🏷️ Basic Information

Make:

Yamaha

Model:

TT-600 RE

Product Type:

Factory Service Manual / Repair Manual

Model Codes:

TT600RE (likely variations exist based on region/specific market)

👋 Introduction

Vehicle Segment:

Dual-sport / Enduro motorcycle, designed for off-road capability with road-legal features.

Target Audience:

Enthusiasts seeking a capable off-road machine with the versatility for occasional road use; owners and mechanics responsible for maintenance and repair.

Key Competitors:

KTM EXC series, Honda XR-R series, Suzuki DR-Z series, Kawasaki KLX series during the same production period.

Engine Type:

Liquid-cooled, four-stroke, single-cylinder engine.

Suspension:

Long-travel, high-quality suspension components (e.g., USD front forks, adjustable rear monoshock) for off-road performance.

Performance Orientation:

Built for agility and robustness in demanding off-road conditions.

Purpose:

To provide comprehensive diagnostic, repair, and maintenance information for professional technicians and skilled DIY owners, ensuring proper upkeep and performance of the Yamaha TT-600 RE.

📋 Manual Details

Applicable Years:

2003, 2004, 2005, 2006

Estimated Page Count:

Varies, but typical factory service manuals for this era and model are 300-600+ pages

Type:

Factory Service Manual (FSM)

Language:

English

Format:

PDF (Digital Download)

📖 Manual Coverage

Engine:

Engine disassembly, assembly, tuning, diagnosis, lubrication, cooling system, valve clearance adjustment, piston, crankshaft, cylinder head, camshaft, oil pump, etc.

Fuel System:

Carburetor (likely Keihin or similar), fuel tank, fuel pump (if applicable for RE model), fuel lines, fuel filter replacement and cleaning

Transmission:

Clutch operation, gear shifting mechanism, transmission disassembly and assembly, lubrication, gear inspection, shift drum and forks

Electrical System:

Ignition system (CDI), starter motor, charging system (stator, regulator/rectifier), lighting, battery, wiring diagrams, fuse box, troubleshooting electrical faults

Chassis And Suspension:

Front forks (KYB or similar USD forks), rear shock absorber (likely adjustable), swingarm, linkages, steering head bearings, wheel bearings, spoke tensioning

Brakes:

Front and rear brake caliper overhaul, master cylinder repair, brake line replacement, brake pad specifications, bleeding procedures, rotor inspection

Exhaust System:

Exhaust pipe and muffler inspection, gasket replacement, mounting hardware

Cooling System:

Radiator, fan (if applicable), coolant type and capacity, thermostat, hoses

Frame And Bodywork:

Frame inspection, subframe, body panels, seat, fuel tank removal and installation, fairings (if any)

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, chain adjustment and lubrication, brake fluid changes, coolant flushes, spark plug replacement, air filter cleaning/replacement

Troubleshooting:

Diagnostic flowcharts, common problem identification and solutions, electrical system fault finding, engine performance issues

Repair:

Complete engine rebuild, transmission repair, suspension overhaul, brake system repair, electrical component replacement, carburetor tuning and rebuilding

Installation:

Replacement of major components (e.g., engine, transmission, suspension parts), accessory installation guidelines

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, clearances, and diagnostic procedures.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely searchable text (OCR'd if originally scanned)

Printability:

Printable pages

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Four-stroke, SOHC, liquid-cooled, single-cylinder.

Displacement:

Approximately 595 cc (exact displacement may vary slightly by specific market tuning).

Bore X Stroke:

Typically around 95.0 mm x 81.4 mm (refer to manual for exact figures).

Compression Ratio:

Likely in the range of 10.0:1 to 11.5:1 (refer to manual for exact figures).

Horsepower:

Estimated 45-50 HP at peak RPM (actual figures vary by region and tuning).

Torque:

Estimated 40-45 Nm at peak RPM (actual figures vary by region and tuning).

Carburetor:

Single Keihin CV (Constant Velocity) carburetor, likely 40mm or similar, with an accelerator pump for improved throttle response.

Fuel Capacity:

Typically around 10-12 liters (refer to manual for exact figure).

Oil Type:

API SE, SF, SG or higher, SAE 10W-40 or 20W-50 motorcycle specific oil (refer to manual for precise specification and viscosity).

Oil Capacity:

Approximately 1.8 - 2.0 liters (with filter change, refer to manual for exact figure).

🔧 Transmission

Type:

5-speed constant mesh manual transmission.

Clutch:

Wet, multi-plate clutch, cable-actuated.

Gear Ratios:

Specific gear ratios will be detailed in the manual. Designed for strong low-end and mid-range power delivery suitable for off-road use.

Final Drive:

Chain drive (typically 520 or 525 pitch chain).

Transmission Oil:

Engine oil is typically used for lubrication of the transmission and clutch assembly. Refer to manual for engine oil specifications.

📐 Dimensions

Length:

Refer to manual for exact dimensions.

Width:

Refer to manual for exact dimensions.

Height:

Refer to manual for exact dimensions.

Wheelbase:

Approximately 1480 mm (refer to manual for exact figure).

Dry Weight:

Approximately 130-135 kg (refer to manual for exact figure).

Wet Weight:

Approximately 145-150 kg (with all fluids, refer to manual for exact figure).

Front Fork Travel:

Typically around 280-300 mm.

Rear Shock Travel:

Typically around 280-300 mm.

🛡️ Safety Features

Crash Safety:

Motorcycle safety ratings are not applicable in the same way as automobiles. Focus is on rider protection through design and component integrity.

Brakes:

Disc brakes front and rear, providing reliable stopping power. ABS was not a common feature on this type of dirt-biased dual-sport in this era.

Lighting:

Headlight, taillight, brake light, turn signals (depending on market configuration) for visibility.

Frame Design:

Robust steel frame designed for off-road durability and handling.

Ergonomics:

Designed for rider control and comfort during off-road riding.

💡 Technology Features

Dashboard:

Analog speedometer and tachometer, odometer, trip meter, indicator lights (neutral, turn signals, oil pressure, high beam). Minimal electronic features.

Rider Aids:

None. This is a mechanically focused motorcycle with no electronic rider aids like traction control or ABS.

Bluetooth Wifi:

Not applicable. No built-in connectivity features.

Ignition System:

CDI (Capacitor Discharge Ignition) system for reliable spark.

🔧 Maintenance

Oil Change:

Every 3,000-5,000 km or 6-12 months (refer to manual for specific intervals based on riding conditions).

Air Filter Cleaning:

Every 1,000-2,000 km, especially in dusty conditions. More frequent inspection recommended.

Spark Plug Replacement:

Every 6,000-10,000 km, or as needed based on inspection. Use recommended NGK plug.

Chain Lubrication And Adjustment:

Every 500-1000 km, and before long rides. Check for slack and wear.

Valve Clearance Check:

Every 10,000-15,000 km (refer to manual for exact interval and specification).

Coolant:

Yamaha Yamalube Coolant or equivalent ethylene glycol-based antifreeze/coolant mixture (50/50 ratio with distilled water). Capacity approximately 1.0 liter.

Brake Fluid:

DOT 4 or DOT 5.1 (refer to manual for specific recommendation). Flush and replace every 2 years or as specified.

Carburetor Jetting:

Can sometimes require fine-tuning for optimal performance, especially at different altitudes or after modifications. Accelerator pump can require adjustment or cleaning.

Cam Chain Tensioner:

Some Yamaha single-cylinder engines of this era can develop a noisy cam chain tensioner over time, requiring replacement or adjustment. Check for rattling noise.

Suspension Seals:

Like any off-road focused bike, fork seals can wear and leak, requiring replacement. Regular inspection and cleaning are crucial.

Electrical Connections:

Corrosion or loose connections in the electrical system can lead to intermittent faults. Regular inspection of wiring harness connectors is advised.

📚 Vehicle History

Yamaha Motorsport:

Yamaha has a long and successful history in motorcycle racing (MotoGP, motocross, enduro) and performance off-road motorcycles, which influences the design and engineering of models like the TT-600 RE.

Tt Series:

The TT designation has been used by Yamaha for many years for their off-road focused motorcycles. The TT-600 RE is an evolution of previous XT and TT models, incorporating advancements in suspension and engine technology for improved performance.

Manufacturing Location:

Likely manufactured in Japan or other Yamaha global production facilities. Specifics may vary by market.

Model Run:

The TT-600 RE was produced roughly from the early 2000s until around 2006, before being largely superseded by the WR series for more hardcore off-road use or the XT series for more adventure-oriented dual-sport use.

🏆 Awards & Recognition

Off Road Capability:

While specific awards for the TT-600 RE are unlikely to be widely documented, Yamaha's TT series has a strong reputation among off-road riders for durability and performance in its class.

Owner Satisfaction:

Generally positive among owners who value its robust nature and off-road prowess, though market appeal may be niche compared to more modern dual-sports.