yamaha tt 600 r

Transcription

yamaha tt 600 r

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YAMAHA
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TT 600 R :97
4‘“*hi
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SERVICE
INFORMATION
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1;
INTRODUCTION
This booklet has been created
in order to provide further information aboutthe Yamaha l
T 600 R ('97) model.
For a full understanding of the information on the service procedures, use this booklet together with the microfiches of the Service Manual.
TT 600 R ('97) SERVICE MANUAL: 5CH-ME1
TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLE GROUP
BELGARDA S.p.A.
f,,'
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-_4
lT 600 R '97
SERVICE INFORMATION
0 1997 BelgardaS.p.A.
1"'edition, September 1997
All rights reserved.
Any reprinting or unauthorised use
without the written permission of
Belgarda S.p.A. is expressly prohibited.
Printed in Italy
BCH-SEI
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WARNING
This manual has been written by Belgarda S.p.A. mainly for use by Yamaha dealers and their skilled
mechanics. It is impossibleto provide a mechanic withall the information necessary in a single manual.
Presumably, though, the people who use this manual for the maintenance and repair
of Yamaha motorcycles will already have elementary knowledge of the principles of mechanics and the procedures for
motorcycle repair techniques. Without this knowledge, repair or maintenance work on this model could
prove inefficient and/or dangerous.
Belgarda S.p.A. makes constant effortsto improve allits models. Important alteratlonsor changes to procedures characteristics will be communicated to all Yamaha dealers and published in future editions of
this manual.
NOTE:
Specifications and design are subject to change without notice.
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PARTICULARLY IMPORTANT INFORMATION
The manual includes the following symbols and relative remarks:
~~
safety
This
alert symbol means: ATTENTION! BECOME
ALERT!
TY IS INVOLVED!
.
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'CAUTION:.,,
NOTE:
YOUR SAFE-
The WARNING symbolIndicatesspecialprocedures
severe
injury
orrider
the
death
to
orperson
the
Inspecting
motorcycle.
to befollowed to avoid
or repairing
the
CAUTION
indicates
special
precautions
to
be
taken
motorcycle.
to avoid
damage
to
the
NOTE
A provides
key
information
designed
e r.
to make
procedures
easier
or
clear-
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Illustrated symbols(IO) to (17) are used to identify the specifications appearingIn the text.
(1 0) Possible to maintain with engine mounted
(11) Fllling fluid
(12) Lubricant
(1 3) Special tool
(14) Tightening
(15) Wear limit, clearance
(16) Engine speed
(1 7) 12, V, A
63
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Illustratedsymbols (1) to (9) aredesigned as
thumb tabs to indicate the chapter's number and
content.
(1) General information
(2) Specifications
(3) Perlodic inspection and adjustment
(4) Engine
(5) Cooling system
(6) Carburetion
(7) Chassis
(8) Electrical
(9) Troubleshooting
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ILLUSTRATED SYMBOLS
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Illustrated symbols (18) to (23) in theexploded
diagrams indicate the types of lubricants and lubrication points.
(18 ) Apply englne oil
(19) Apply gear oil
(20) Apply molybdenum disulfide oil
(21) Apply wheel bearing grease
(22) Apply lightweight lithium-soap base grease
(23) Apply molybdenum disulfide grease
Illustrated symbols (24) to (25) in the exploded
diagramsindicatethewhere
to applylocking
agent (24) and when to install new parts (25).
(24) Apply locking agent (LOCTITE@)
(25) Use new one
~
INDEX
GENERAL INFORMATION
VEHICLE
IDENTIFICATION
Y
‘W
.....................................................................................
SPECIFICATIONS
GENERAL SPECIFICATIONS ..................................................................................
MAINTENANCE SPECIFICATIONS - ENGINE ........................................................
LUBRICATION LAYOUT ..........................................................................................
ENGINE - TIGHTENING TORQUES ........................................................................
MAINTENANCE SPECIFICATIONS - CHASSIS ......................................................
CHASSIS - TIGHTENING TORQUES ......................................................................
MAINTENANCE SPECIFICATIONS - ELECTRICAL ................................................
GENERAL SPECIFICATIONS ABOUT TIGHTENING TORQUES ........................
LUBRICATION POINTS AND LUBRICANT TYPE .................................................
CABLEROUTING ....................................................................................................
1
2
5
10
14
17
19
21
23
24
26
PERIODIC INSPECTIONSAND ADJUSTMENTS
PERIODICMAINTENANCE/LUBRICATION INTERVALS ........................................
30
EXPLODED DIAGRAM
CARBURETOR ..................................................................................................
33
ELECTRICAL
WIRING
DIAGRAM
35
...............................................................................................
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VEHICLE
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G E N l
IDENTIFICATION
INFO
GENERAL INFORMATION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number (1) is stamped
into the right sideof the steering head pipe.
MODEL/COLOUR IDENTIFICATION LABEL
The modelkolour identification label (1) is affixed
to the rear frame. This information will be needed
to order spare parts.
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GENERAL SPECIFICATIONS
M
SPECIFICATIONS
__
Dimensions:
Overall length
Overall wldth
Overall height
Seat height
Wheel base
Minimum ground clearance
Minimum turning radius
__
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Baslc weight:
Withoiland full fuel tank
__
Engine:
Englne type
Cylinder arrangement
Displacement
Bore x stroke
Compression ratio
Starting system
TT 600 R: DJOI (5CH1)
2,250 mm
845 mm
1,225 mm
945 mm
1,480 mm
325 mm
3,100 rnm (left)
3,300 mm (right)
150 kg
Air cooled, 4-stroke, 4-valve, SOHC
Forward-inched single cylinder
595 cm3
95 x 84 mm
851
Kick-starter
+
I
Standard
_-
Model code
u
-
-
Item
-_
Dry sump with separate oil tank
Lubrication system
_.
-
-
-
-
-
-
Oil type or grade:
Engine oil
-20°-100 0"
.
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$AEiOWj30
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I SAk 1Qhl46
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; ':SA220A/40:*
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API standard:
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Oil capacity:
Engine oil
Periodic oil change
With oil fllter replacement
Oil tank
Total amount
Air filter
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10" 20" 30" 40"50"C
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2.7 L
2.8 L
2.6 L
3.3 L
-.
-
Fuel:
TY Pe
Tank capaclty
Reserve
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Type API Service " S E , "SF" or equivalent
Oiled filter element
Regular unleaded gasoline
10 L
2.1 L
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Item
W
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Standard
~
Carburetor:
Type
Manufacturer
Y30PV-2ATK
TElKEl
Spark plug:
Type
Manufacturer
Electrode gap
DPR8EA-S/DPRSEA-9
NGK
0.8 0.9 mm
-
Clutch type
...-
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reductlon system
Secondary reduction ratio
Transmission type
Operation
1I'
ratio Gear
2M
3 d
4'h
5'h
Frame,
Frame type
Straight-tooth gears
74/31(2.387)
Chain drive
44/15 (2.933)
Constant mesh 5-speed
Left foot operation
30/13 (2.308)
27/17 (1.588)
24/20 (1.200)
21/22 (0.954)
19/24 (0.792)
Tyres:
Type
Size
rear
Manufacturer/model
front
rear
-
Maximum load* except motorcycle
Tire pressure (cold tire):
Rider
With tube
90/90-21"-54R / 90190-21"-545
130/90-18-69R / 130180-18-66R
140/80-18-70R / 130180-18-668
PlRELLl MT21 or MT70
MlCHELlN BAJA or T63
PlRELLl MT21 or MT70
MlCHELlN BAJA or T63
180 kg
rear
150 kPa (1.50 kg/cm', 1.50 bar)
180 kPa (1.80 kg/cm2, 1.80 bar)
rear
200 kPa (2.00 kg/cm', 2.00 bar)
220 kPa (2.20 kg/cm2, 2.20 bar)
With
maximum
load*
front
Off-road
rear
100 kPa (1.OO kg/cm2, 1.OO bar)
100 kPa (1.OO kgicm', 1 .OO bar)
* Load is the total weight of cargo,
passenger, and accessories.
brake
Brakes:
Front
brake
Rear
'4~
Open-cradle backbone frame
and removable rear frame
26" 30'
114 mm
Caster angle
Trail
only
Wet, multi-dlsc
operation
operation
Single dla. 267 mm disk brake
Right hand operation
Single dia. 220 mm disk brake
Right foot operation
d
Item
Suspension:
Front suspension
Rear suspension
Shock absorber:
Front shock absorber
Rear shock absorber
‘W
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!Giq-q
Standard
Adjustable telescopic fork (dia. 43 mm)
DELTA-BOX SWINGARM
Adjustable /Coil spring /Oil damper
Adjustable / Coil spring / Oil-gas damper
with separated tank
Wheel travel:
Front wheel travel
Rear wheel travel
280 mrn
280 mm
Electric system:
Type
Ignition system
Generator
Without battery
C.D.I. (digital)
A.C. magneto 12V
Headlight type
Quartz bulb (halogen)
Bulb wattage x quantity:
Headlight
Headlight (only for Australian market)
Tail /brake light
Flasher light
Front marker light
Meter light
Neutral indicator light
High beam indicatorlight
Turn indicator light
12V6OWl55W
12V35W135W
12V5Wl21w
12VlOWx4
12v5wx1
12v3wx1
12V1,2WXl
12v1,2wx1
12v1,2wx1
.
~~
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1-
MAINTENANCE SPECIFICATIONS
ENGINE
Itern
1*
Cylinder head:
Warp limit
* The lines show where you have
to site the
measuring
slide
Standard
I
Limit
I
----
0.03 mm
I
rule.
Cylinder:
Bore size
Measurement point (a)
-
95.1 mm
94.97 95.02 rnm
(a) = 50 rnrn
TlEi
I
Camshaft:
Advance method
Camshaft outer diameter
Backlash between camshaft and cap
Cam dimensions
--_-
-
-
1
u
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Chain advance (left)
22.967 22.980 mrn
0.020 0.054 mrn
I
----
__--
_-__
1
4
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Intake
i
l
A
36.47- 36.57 mm
30.06 30.1 6 mm
6.41 rnm
36.62-36.72 rnrn
30.11 -30.21 mm
6.51 rnm
"A"
-
-*"B
Exhaust
Camshaft
runout limit
"C"
'A"
"8"
"C"
_
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_
----JL--
-
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----
-_----___---_--0.03 mm
~~
W
Timing chain
Timing cham type/
Llnk number
Timing chaln adjustment method
75-010
126
Automatic
---_
____
Rocker arm/ rocker armshaft,
12.000 rnrn 12.018 rnm
Rocker arm inner diameter
11.976 rnrn 11.991 rnrn
Rocker shaft outer diameter
Rocker arm-to-rocker armshaft clearance 0.009 rnm 0.042 rnrn
-
.___
-
Valves, valve seat, valve guide:
clearance
Valve
(cold)
IN
EX
Valve dlmensions
0.05
0.12
.___
____
- 0.10 rnrn
- 0.17 rnrn
____
_-_-
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“C“
[)()
”A”
Llrnrt
Standard
Itern
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“D“
Seat width Face
diameter
Head
“ Adiameter
head
wldth
“B” face
width
“C” seat
I’D” margin
thickness
Stern
outside
diameter
Guide
lnslde
diameter
Stem-to-gulde
clearance
u
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
1.1 rnrn
1.1rnrn
IN
Stem runout limit
Valve
widthseat
Valve spring:
length
EX
Free
size
Position
closed) (valve
-
36.9 37.1 rnm
31.9 32.1 rnrn
2.26 rnrn
2.26 mrn
1.0- 1.2 mrn
1.0- 1.2 rnrn
1.O 1.4 rnrn
0.8 1.2 rnrn
6.975 6.990 mrn
6.955 6.970 mm
7 000 7.01 2 rnrn
7.000 7.012 mm
0.010 0.037 rnrn
0.025 0.052 rnrn
IN
EX
IN
EX
IN
____
____
____
____
-
-
____
1.8 rnm
1.8 rnm
0.8 rnrn
0.65 rnm
6.955 rnm
6,925 rnrn
7.042 rnrn
7.042 rnrn
0.08 rnrn
-
0.10 rnrn
0.01 rnrn
1.8 rnrn
1.8 rnrn
Inner spring
Outer spring
40.1mm
40.1mm
22.7 mm
22.7 mm
43.8 rnrn
43.8 mrn
34.2 rnm
34.2 rnrn
38.1 rnm
38.1mm
____
___A
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Item
p-qq
Standard
Compressed pressure
(spring Installed)
IN
EX
IN
EX
Tilt
-
164.8 190.2 N
16.80 19 39 kg
164.8 190.2 N
16.80-1939 kg
-___
____
Limit
Outer spring Inner spring
-
71.6 87.3 N
7.3 8.9 kg
149.1 182.4 N
15.2 18.6 kg
____
____
0 0
Winding sense
(top wew)
IN
EX
Piston:
Piston to cylmder clearance
Plston size "D"
B
-.
--
---
Counterclockwise
-
0.045 0.065 mm
94.91 5 94.965 mm
4" oversize
Piston allowance
Piston pin off-centring
Piston pin bore lnslde diameter
Piston pin outslde diameter
____
2.5"/1.7 mm
2.5"/1.9 mm
____
Counterclockwlse
____
0 1 mm
.___
c
-H
t
5 mm
95.5 mm 2" oversize
96.0 mm
2 mm
Intake side
22.004 22.015 mm
21.995 22.000 mm
-
____
____
____
____
W'
____
____
Piston rings:
Top ring.
P?B
TY Pe
Sizes (B x T)
End gap (installed)
Slde clearance (installed)
'd
-
D
Measuring point "H"
Counterclockwise
Counterclockwise
_-__
Barrel
1.2 x 3.2 mm
0.15 0.30 mm
0.03 0.07 mm
-
-_-__-0.7 mm
0.1 3 mm
m
Limit
Standard
Itern
2nd ring:
0
3
L-T-1
TY Pe
Sizes (B x T)
End gap (installed)
Side clearance (Installed)
Oil ring:
Plat
1.2 x 3.8 mm
0.30 0.45 mm
0.03 0.07 mm
-
__-_
0.8 rnm
0.13 mm
E
I
B
L
T-l
W
2.5 x 3.4 mrn
0.02 0.06 mm
Slzes (B x T)
End gap (installed)
-
____
____
Crankshaft:
F
‘u
Crank width “ A
Runout limit “ C ’
Big end side clearance“D”
Small end backlash
‘IF’
Balancing weight:
Advance method
Clutch:
Friction plate:
Thickness
Quantity
Wear limit
Frlctlon plate:
Thickness
Quantity
Wear hmit
Clutch plate:
Thickness
Quantity
Wear limit
- 75 00 mm
0.35 - 0.65 mm
74.95
__-_
0.03 rnrn
___-
0.8 mrn
____
Straight-tooth gear
__--
2.72 -2.88 mm
6 parts
____
____
__--
2.6 mm
-
2.94 3.06 rnrn
2 parts
__--
__--
_---
28mrn
1.2 rnm
7 parts
____
____
___-
0.2 mm
e
ew
size
__.
._~
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W
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Llmlt
Standard
Item
Clutch spring:
Clutch spring free length
Quantlty
Clutch houslng:
Thrust backlash
____
34.9 mm
5 parts
--__
-
Transmission:
Main axle
off-centring limlt
Drive axle
off-centring limlt
Shift cam:
TY Pe
Carburetor:
I.D. mark
Main jet
Primary carburetor
Secondary carburetor
Main air let
Primary carburetor
Jet
Primary carburetor
Needle let
Primary carburetor
Cutaway
Pilot air jet
Pilot jet
Pilot outlet
Bypass 1
Bypass
Pilot
seat Valve
Starter jet
Fuel level
Float helght
~
~
0.070 0.071 mm
Inner cam pushtng Clutch release system
____
____
____
0.08 mm
_-__
0.08 mm
Drum with cam and guide bar
W“
5CH, 00
(M.J.)
# 150
# 130
(M.A.J.)
1.0
0 0.9
0
(J.N.)
5C5A - 315
5Y 18 - 315
(M.N.)
0 2.60
(C.A.)
(PA J )
(P.J )
(P.O.)
(B.P.)
(B.P.P.)
(P.S.)
(V.S.)
(G.S.)
(F.L.)
(F.H.)
0 2.60
4.0
0 0.8
# 54
0 0.8
0 1 x2
3.0/5.0
3 1/2 + 112 revs approx., open
0 2.5
# 74
6 8 mm
27 29 mm
u.
-
Idle speed:
Englne idle speed
1,150
Lubrication system:
011
filter type
011
pump type:
“A” or “B” tip clearance
Side clearance
Shunt valve calibration pressure
Safety valve calibration pressure
Oil pressure (hot)
Pressure checkpoint
Paper
Trochoid
0.12 mm
0.03 0 08 mm
80 120 kPa (0.82 122 kgflcm2)
80 120 kPa (0.82 122 kgf/cmz)
13 kPa/1,300 r/mm (0.13 kgficmzi1,300 r/min)
Oil filter chamber
-
- 1:450 rimin
-
_-_-
-
0.2 mm
0.15 mm
..._
____
----
~~
LUBRICATION LAYOUT
m
LUBRICATION LAYOUT
(1)
(2)
(3)
(4)
(5)
(6)
[A] DELIVERY
[B] RETRIEVAL
Oil tank
Oilpump
Oil filter (oil tank)
Oilstrainer(engine)
Oil vapourretrievalhose
Oil blow-by retrievalhose
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~~~
LUBRICATION LAYOUT
(1)
(2)
(3)
(4)
(5)
(6)
Oil pump
Oil filter
Camshaft
Oildeliveryhose
Maindrivingshaft
Driveshaft
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[A]
DELIVERY
[B] RETRIEVAL
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LUBRICATION LAYOUT
(1)
(2)
(3)
(4)
(5)
(6)
Oil filter
Camshaft
Connectingrodpin
Maindrivingshaft
Secondarydrive shaft
Drain plug
M
[A] DELIVERY
[B] RETRIEVAL
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-
. . _ ~
LUBRICATION LAYOUT
(1) Oil
(2) Oil filter
(3) Oil delivery hose
~~
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[A] DELIVERY
[e] RETRIEVAL
(4) Transmission
(5) Oil stramer
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ENGINE
Cylinder head tightening steps:
L’
Crankcase tightening steps:
W
Left crankcase
Right crankcase
~~~~
_
~~
_
~
~
~
1-
Tightening torques
I
Part to be tightened
Cylinder head
Cylinder head
Cylinder head
Cylinder head
Cylinder head:
Cap (oil check)
Spark plug
Cylinder head cover
Tappet cover (Intake)
Tappet cover (exhaust)
Cylinder
Cylinder
Cyllnder
Weight drive gear
Rotor (A.C. magneto)
Lock nut (valve adjusting screw)
Cam chain sprocket
Cam chain stopper guide
Cam chain stopper guide
Rocker shaft
Oil pump
Oil deliveryhetrieval pipe
Oil drainlng pipe
Oil filter cover
Bleed screw (oil filter cover)
Push lever (clutch)
Push rod (clutch)
Sprocket
Lock washer (oil seal)
Stop lever
Shift cam
Stator
-
Part
name
Washer based
bolt
Stud bolt
Hexagon socket
head screw
Stud bolt
Union bolt
-
Hexagon socket
head screw
Hexagon socket
head screw
-
Crown nut
Nut
Hexagon socket
head screw
Hexagon nut
Hexagon nut
Hexagon nut
Washer based
bolt
Hexagon socket
head screw
Washer based
screw
Hexagon socket
head screw
Hexagon socket
head screw
Pan screw
Washer based
screw
Hexagon socket
head screw
Hexagon screw
Pan screw
Hexagon nut
Hexagon nut
Hexagon screw
Bolt
Hexagon screw
Pan head
(+) screw
~
Thread
size
M8 x 1.25
M10 x 1.25
ILiJ
Tlghtenlng
torque
1
29
20
2.9
2.0
M6 x 1.0
M6 x 1.0
10
1.0
0.7
M6 x 1.0
M12x 1.25
7
18
0.7
M6 x 1.0
10
1.0
M6 x 1.0
M32 x 1.5
M8 x 1.25
M I 0 x 1.25
10
12
22
42
1.0
1.2
2.2
4.2
M6 x 1.0
M16 x 1 .O
M14 x 1.5
M6 x 1 .O
10
60
120
14
1.0
60
12.0
1.4
M7 x 1.O
20
2.0
M6 x 1 .O
10
1.0
M16 x 1 0
20
2.0
M6 x 1.O
10
1.0
M6 x 1.O
M6 x 1.O
10
7
1.0
0.7
M14 x 1 5
30
3.0
M6 x 1.0
M5 x 0.8
M8 x 1.0
M6 x 1 .O
M18x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.O
10
5
12
8
110
10
10
10
M5 x 0.8
5
~
7
Remarks
I
1.8
W.
W
1.o
0.5
1.2
0.8
11.0
1.o
1.o
1.o
0.5
A
~
pl-+l
I
Thread
size
Part
name
Tightening
torque
Nrn
I
-
Remarks
rnkg
-
-I
Hexagon socket
head screw
Hexagon socket
head screw
Stator (pick-up coil)
Engine oil pipe 1
u
M6 x 1.0
7
M6x10
0.7
II
Engine oil pipe 2
M12 x 1 25
35
lo 3.5
1.0
Oil delivery pipe
Carburetor joints
Union bolt
M8 x 1.25
18
M6 x 1.0
M6 x 1.O
10
10
1.0
M6 x 1.0
10
1.0
M6 x 1.0
M6 x 1.0
10
1.0
7
0.7
M8 x 1.25
M8 x 1.25
23
23
2.3
2.3
M8 x 1.25
23
2.3
M6 x 1.O
M10 x 1.25
10
20
1.0
2.0
M6 x 1.O
10
1.0
M6 x 1.O
10
1.0
Hexagon socket
head screw
Hexagon screw
Washer based
screw
Washer based
nut
Pan head
Exhaust pipe
Exhaust pipe protector
(+) screw
Hexagon socket
head screw
Muffler
Muffler (band)
Muffler
Crankcase
Crankcase
Crankcase cover (rlght)
Crankcase cover (left)
L
I
Union screw
Air filter case (frame)
Air filter case (frame)
Sprocket cover
Stop washer (bearing)
Pressure plate
Clutch housing
Prlrnary drive gear
I
Nut,
nylon
Washer based
screw
Hexagon socket
head screw
Stud bolt
Hexagon socket
head screw
Hexagon socket
head screw
Hexagon socket
head screw
Flat
headscrew
Washer based
screw
Hexagon nut
Hexagon nut
-
I
fi
1.8
1.0
1
&
t
&
. G
z
L
1.0
a
&
1
M6 x 1 .O
10
I
M6 x 1.O
7
0.7
M6 x 1.O
M20 x 1.O
M20 x 1.O
8
08
90
9.0
120
12.0
d
~~~~~~
~~
~~
-
~~
~
1-
CHASSIS
Steering:
Bearing type
Front suspension:
Front fork travel
Fork spring free length
Spring rate
Stroke
Oil amount x inner tube
011level
cl min max >
Taper rolllng bearmg
277
(K)
Oil type
rate
Rear arm.
Clearancerear
hmrt
- 283 mm
530 mm
4.6 Nimm (0.46 kgimm)
330 mm
615 cc
160 mm
150 170 mm (from upper edge
of inner tube, fully compressed
without spring)
"01" SUSPENSION OIL
-
-
Rear suspension:
Shock absorber stroke
Spring free length
Fitting-length
Spring
Optional spring
Gas pressure
(K)
end
arm
side to side
105 mm
250 mm
231.5 mm
65 Nlmm (6.5 kgimm)
None
1.400 kPa (14.0 kg/cm2, 14.0bar)
____
0.4
- 0.7 mm
Front wheel:
Type
Rim size
Rim material
Rim runout
limit
Limit
Standard
Item
Spoke wheel
1.85 x 21"
Aluminium
radial
lateral
1 .O mm
0.5 mm
____
____
____
____
____
____
____
Ld
--__
107 mm
-___
____
____
---1 mm
____
-___
-___
-_-_
2 mm
2 mm
~
Rear wheel:
TY Pe
Rim size
Rim material
Rim runout
limit
Drive chain:
Type/manufacturer
Number of links
Chain slack
Spoke wheel
250x18
Aluminium
radial
lateral
1.O mm
0.5 mm
520/135 ORHIXRING-REGINA CHAIN
112
30 40 mm
-
_--_
_-__
_-_2 rnm
2 mm
--_---_
____
V'
Front brake:
TY Pe
Disc outside
diameter x thickness
Pad thickness
Wear hmit
F
If.
'
If
II
Single disc
267 x 4 mm
7.5 mm
____
I
I
13 mm
28 mm x 2 (elastic fastener)
DOT 4
Single disc
Type
Disc outside
diameter x thickness
Pad thickness
Wear limit
220 x 5 mm
9 mm
I
I
Master cylinder inside diameter
Caliper cylinder outside diameter
Brake fluid type
Front brake lever
L
Brake pedal lever
Brake pedal posltlon
____
_______
* = 1 mm
Rear brake,
L
Limit
1,
Master cylinder lnslde diameter
Caliper cylinder outside diameter
Brake fluid type
u
l
Standard
Item
r
W
__-____
____-__
___-
_-__
--__
* = 1.2 mm
12.7 mm
____
-_--
1 %
34 mm
DOT 4
-___
Adjustable
__--
10 rnm (below
the footrest plane)
___-
--__
Clutch lever:
Clutch lever free play
2.0
- 3.0 mm
Throttle grip:
Throttle cable free play
3.0
- 5.0 mm
(at the grip flange)
____
~~~
~
~
~
~~~
~~~~~
-
Tightening torques
Front forWhandlebar:
Handle crown and inner tube
Handle crown and
handle lower holder
Under bracket and inner tube
Handle lower holder
Upper steering ring nut and
handle upper holder
Upper steering ring nut
and steerlng axle
Lower steering ring nut
and steerlng axle
Front fork:
Cap bolt (inner tube)
Lower compression valve (cap)
Wheel axle protector
Front brake master cylinder:
Master cylinder bracket
Reservoir cap
Front master cylinderibrake hose
Front brake caliper:
Caliper holder
Oil bleed screw
Brake caliper and front fork
Front brake calipedbrake hose
Front & rear brake discihub
Front wheel axle
Rear brake pedal
Footrest brackevframe
Rear master cylinder/frame
Rear master cylindedbrake hose
Rear caliper (oil bleed)
Rear brake calipedbrake hose
Part
name
Washer based
screw
~
T!y:d
gr:“:
~
m
torque
M8 x 1.25
28
2.8
M l O x 1.5
40
4.0
Nut, nylon
Washer based
screw
Washer based
screw
M8 x 1.25
22
2.2
M8 x 1.25
20
2.0
Nut
M36 x 1.O
115
11.5
-
M28 x 1.5
-
M28 x 1.5
Nut
Screw
Hexagon socket
head screw
M43 x 1.O
M24x 1.0
20
32
2.0
M6 x 1 .O
9
0.9
M6 x 1 .O
M4 x 0.7
M I 0 x 1.0
9
0.9
1.5
20
0.1 5
20
M8 x 1.25
M10 x 1.0
25
14
2.5
1.4
M8 x 1.25
M l O x 1.0
25
20
2.5
M6 x 1.0
M16x 1.5
12
59
1.2
5.9
MlOx 125
45
45
M10 x 1.25
45
4.5
Hexagon socket
head screw
Pan screw
Unlon bolt
Hexagon socket
head screw
Screw
Washer based
screw
Union bolt
Hexagon socket
head pan screw
-
Washer based
screw
Washer based
screw
Hexagon socket
head screw
(barrel)
Screw
Screw
Screw
M6 x 1.O
M10 x 1.0
M10 x 1.0
M10 x 1.0
,
kJ
3.2
2.0
10
1.o
20
2.0
14
20
1.4
2.0
w’
Driven sprockethear hub
Rear shock absorber.
Shock absorber (upper)/frame
Shock absorber (lower)
Rear arm:
Pivot shaft Nut
Articulation,
Connecting rodlrear arm
Relay arm/frame
Connectmg rodhelay arm
L
Chain support:
Chaln supporVrear arm
Chain protectorichain support
Chain casehear arm Screw
Engine stay
Front stay and frame
Part
Hexagon socket
head pan screw
Hexagon socket
head screw
Bolt
Thread
size name
I
Tightenmg
torque
Nm
mkg
M12 x 1.75
M l O x 1.25
50
6.5
50
M I 6 x 1.5
85
8.5
Bolt
65
Bolt
Bolt
50
50
5
6.5
5.0
50
05
9
3
9
0.9
0.3
0.9
64
6.4
64
6.4
M12 x 1.25
M l O x 1.25
M10 x 1.25
Screw Cham sealM6
gardhear
x 1 .O arm
Washer based
screw M6
Pan screw M6
Remarks
M8 x 1.25
30
3.0
M18 x 1.5 Nut Rear
axle
115wheel
11.5
x 1.0
x 1.0
M6xlO
Washer based
1.25
screw M10 x
Front stay and engine
Washer based
screw
M10 x 1 25
Upper stay and frame Washer based
screw M10 x
1.25
Upper stay and engine Washer based
screw
M10 x 1.25
Rear lower stay/frame
Washer based
screw M10 x 1.25
Screw
M6 x
1 .O
Englne protectoriframe
Framehear frame
Nut, nylon
M8 x 1.25
Rear footredframe
Screw M8 x
1.25
Fuel tank:
Fuel tanklframe
Screw
M6 x 1.0
Fuel cock Pan head
M6 x 1.O
(+) screw
Seat.
Seat and frame Washer based
screw
M6 x 1.0
Clutch cableicrankcase cover Hexagon socket
head screw
M6 x 1 .O
Voltage regulator
Button head
screw
M6 x 1.O
Meter:
Upper stay/handle crown
Hexagon screw M6
x 1.0
Horn
Hexagon screw M6 x
1.0
NOTE:
1 . Flrst tighten the ring nut approximately
38 Nm (3.8 mkg) by using the torque
nut one turn.
2 Final tighten the ring nut at the torque
of 4 Nm (0 4 mkg).
‘W
(SPECII
65
64
6.4
64
6.4
64
10
23
64
20
1.0
23
2.0
7
0.7
7
07
10
1.0
10
1.0
7
0.7
10
1.0
0.7
7
wrench, then loosen the ring
I
~~~~~~
~
.
..
~
~~
- -
~~~~~~
~~
~~~~~~~~
~
~
~~~~~~~~~
~
ELECTRICAL
Item
Standard
Limit
I
Ignition system:
lgnltlon timing (B.T.D.C.)
Advanced timing (B.T.D.C.)
Advanced type
I
-___
11O at 1,300 r h i n
34" at 4,750 r/min
Electrical type
_--_
____
50
40
W'
h
v)
a,
g 30
m
=
a,
m
._
=
20
-
lo
E
.c
I:
0
..c
U-J
-
0
-10
0 1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
Engine speed (r/min)
14'
Ignition unit:
Magneto model / Manufacturer
Pickup coil resistance /
1
-
I
CDI unit:
Model/Manufacturer
----
____
QCB21/NIPPONDENSO
Ignition coil.
Model / Manufacturer
Primary winding resistance
Secondary winding resistance
J0144 (TJ0371) / NIPPONDENSO
1.04 1.495 i
2 at 20°C (68°F)
14.88 22.32 kQ at 20°C (68°F)
Spark plug cap:
Type / Manufacturer
Resistance
T-137 / TOKAI DENS0
10 kR at 20°C (68°F)
Charglng system:
Type
_-_-
TLMZ89 / NIPPONDENSO
192 288 52 at 20°C (68" F)
GreenhVhite - Blue/Black Colour
___-
-
----
----
I
magneto
A.C.
1 ________
1
____
W
‘W
l
Limlt
Standard
Item
A.C. generator:
Normal output
Stator coil resistance I
Colour
F
LMZ89 I NIPPONDENSO
14 V, 13 A at 5.000 rlmin
0.608 0.912 R at 20°C (68°F)
(White - White)
-
_--_---
_-__
_-__
Regulator / Rectifier:
Model I Manufacturer
Regulator:
Type
No load regulated voltage
Rectifier:
Capacity
Withstand voltage
25 A
240 V
Smooth condenser:
Capacity / Voltage
ADP-26 / SHINDENGEN
5,440 8,160 VF 1 5 0 V
____
____
Horn:
Type / Manufacturer
Voltage
Maximum amperage
Plat / LEONELLI
10 14 V C.C.
1.5 A
____
____
____
Flasher relay:
Type
Automatic stop device
Flasher frequency
Power
Semi-translstors
FB222M / NIPPONDENSO
None
75 95 cycle/mln
lOWX2+3.4W
SH629/A-12 / SHINDENGEN
Short-circuit semiconductors
14.1 14 9 V
-
__--
____
.___
____
-
-
-
____
_--.___
____
____
~
~
~
~
~
~.
~-~
~
...__.
~~
_
_
~~
.
~
~
...~~~-
~~~
~~~~
m
GENERAL SPECIFICATIONS ABOUT TIGHTENING TORQUES
ABOUT TIGHTENING TORQUES
7
A
ThistableIndicatesthetighteningtorquesfor
standard attachments with ISO-pitch thread.
Torque specifications for special components or
units are indicated In the related sections of this
manual. In order to avoidanydamage,tighten
those units with many fastenings by following a
progressive cross sequence, until the final tightening torque is obtained. Unless otherwise specified, the tightening torques given
are meant for
clean and dry threads. All components must
be at
ambient temperature.
(Nut)
B
(Bolt)
10 m m
6 mm
6
0.6
12 mm
8 mm
15
1.5
14 mm
10 mm
30
3.0
17 mm
12 mm
55
5.5
19 mm
14 mm
85
8.5
16 rnm
22 mm
I
L
p
General specification
about tightening torques
Nm
mkg -
I
130
I
13.0
I
-
-
tia’
A
I
I
A: Distance between flat parts
B: External thread dlameter
W
LUBRICATION POINTS AND LUBRICANT TYPE
l=l
I
I
t
PI
I
ENGINE
Lubricant type
Lubrication points (part name)
Oil seal edges (completely)
5
Rod pins
-la
-la
Rod (big end)
1
4
Plston and piston rings
-la
Hub (werght drive sprocket)
-1Q
Bearlng retainer
Rocker shaft and rocker arm
-la
+la
-la
-la
Cam and bearing (camshaft)
--I@
Rotor and rotor housing
_ (oil
. pump)
.
. .
-la
Plston ain
Valve stem and gulde
i/
Oil seal (valve stem end)
I
Push rod (clutch)
Primary driven gear and main shaft
I
-5
-1Q
Shift forks and bar
-la
+la
-la
Shift cam and bearing (gearshift cam)
-1Q
Shift shaft
-la
Sliding gear (transmlssion)
Idle gear (transmission)
Rod housing coupled surfaces
Bonding agent (rapld seal adheave)@
Yamaha bond No. 1215@
Coupled surfaces (cylinder head and cyllnder head cover)
Bonding agent (rapid seal adhesive)@
Yamaha bond No. 1215@
L/
-
-
~
I
~
~~
_. - ~.
~
~~
~
~~~~~
.
...
~~~~~~~~
~~~
~
~
.- .
~
~~~~
~~~
ISPECI
~
~~
~
~
1
p
CHASSIS
I
Lubrication points (part name)
Lubrlcant type
..
I
W'
Ir'
~~
CABLE ROUTING
F
l
CABLE ROUTING
Clutch
(1)
cable
(2)
Brakehoseholder
connector
harness
(3)hose
Brake
(4)
Throttle
cables
(1( 5 ) Bands
(6)
Lighting
wire
harness
(7)
Brakeandengine
stop switch wire
harness
(8) Tachometer/
(14) Right turn
light
odometerconnector
cable
cable
(9)
Complete wire
(10) Socket
cover
1) Engine
crown.
stop switch
connector
[A] clutch
the
Lay
(15) Meter wire harness
hose
brake the
[B]
(16) Main switch wire
harness connector
in front of the
throttle cables.
Lay
throught the holder
on the handle
(12) Headlight wire
harness connector
(13) Left turn light
connector
v
u
I
I
~~
~
~~~
~~- ~ - - .. _ - _ _
. .
-~
- ~
1-
CABLE ROUTING
(1) Front
brake
hose
(2)
guard
(3)
(4)
(5)
(6)
(7)
(IO)Throtte
cables
(17) Engine oil breather [A]
(to air cleaner
behind
the
Brakehoseholder
it fastenandguard
case)
(11) Wire harness band
Left tube
(12) Fuel pipe from fuel (18) Oil hose (oil tank to
Plastic plate engine)
[B]
cock
(19)Oil hose
(engine to
Throttie cables
(1 3) Flasher
relay
[C]
tank)
oil
Tachometer/
(14) Sidestand
switch
(20)
Condenser
odometer cable
(15)A.C. generator wire (21)Diode
Clutchcable
harness (engine)
holder
pipe
Lay the
brake
hose
left tube
the plate 4.
Attachthrottle
cables 5 .
Fasten
the
fuel
pipe 12
tank.
the
to
of
(8) Clutch
cabie hoider (16) Engineoilbreather
(9) Clutch
cable
holder
pipe
(to
engine
011
k) engine) (on
1
td
13
-4'
9
~
CABLE ROUTING
~
p-pl
~
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Tachometer/
odometer cable
Tachometer/
odometer cable
holder
Tachometer/
odometer cable
band
Right tube guard
Spark plug cable
Horn
Carburetorsuction
Pipe
caliper
(8)
(9)
Decompressor
cable
(1 4) Rear brake hose
Decompressor
cable band
(1 5 ) Pipe
(16) Air breather pipe
(10) Main wire
harness band
(11) Rear brake switch
wire harness
(12) Rear brake fluid
tank hose
(13)
. . Hose from rear
master cylinder
to
L
11
i/
14
holders
(17) Spark plug ignltlon
coil
(18 ) Rear shock
absorber oil tank
(19) Shock absorber
tank.bands
[AI
Insert the
tachometer/
odometer cable
into the band 3 and
the holder 2
~
~~
CABLE ROUTING
(1) Rectifler
(2) CDI unit
(3) Tail
harness
wire
light
(5) Bracket
(6) wire
turn
Left
harness bands
(4) Tail
harness
damper
(7)
Rlght turn
wire
(8)
Tail light wire
harness
(9)
Air breather
plpe
(carburetor)
~
p-pq
[A] the
Insert
tail
the4 into
damper
frame then fasten
the bracket 5.
‘.us:
9
k d
6
3
v
3
~~~
PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
I
lNSP
ADJ
PERIODIC INSPECTIONSAND ADJUSTMENTS
PERIODIC MAINTENANCWLUBRICATION INTERVALS
=
-
-
EVERY
ROUTINE
ITEM
11,000km
6 months 12monthsi
-
-
I Fuelline
Check fuel hose for
cracks or damage.
Replace if necessary.
Check condition.
Spark plug
Clean
or replace if necessary.
Check valve clearance.
Valve clearance
Adjust
if necessary.
Wash with water and biodegradable
Air filter
liquid soap, smear with SAE 20Wi50
engine oil or specialfilter oil.
Check condition.
Air filter case
Clean.
Check for proper operation.
Adjust
or replace the cable.
Clutch
I
Decompression
Adjust
if necessary.
device
I
Adjust lever free play.
Front
Check and replace pads
brake system
if necessary.
Replace brake fluid every 24,000 km
- or 24 months.
Adjust pedal free play.
Check and replace pads
brake system
if necessary.
Replace brake fluid every 24,000 km
or
24 months.
I
Check and adjust chain slack
Drive chain
and alignment.
Clean and grease with SAE 80Wi90 engine
L011 or special lubricant for O-ring chains.
Check damage, balanclng, run-out,
Wheels
spoke tighteness.
Tight spokes and balance/
necessary.
if
reDlace
_.
Check
damage and minimum
Tires
tire tread depth.
Check bearing assembly
clearanceldamage.
Replace if damaged.
*I
r=
*I
u
0
0
u
0
0
0
0
9
-
3
0
-
0
0
-
0
0
-
0
0
-
~
*I
Real
*I
I
0
-
I
-1
0
-
L
I
*I
-
BREAK-IN 6,000 km 12,000 kmI
0
0
-
0
I
0
Every 500 km.
~
*I
7
*
*I
I
+
0
I
0
-
0
0
-
0
0
-
~~~
~
~
~
__
.
~.~~
-
~
~
~~~~
~
-
~
~~
~
~
._.
Em
0
lNSP
ADJ
~T
I
EVERY
:
I
ITEM
,
-
!
I
Grease nipple
bushes (rear
arm pivot
shaft)
-
Arm relay/
connecting
rod pivots
(rear
arm)
.
-.
Front
fork
*
I
!
!
f
Repair if necessary.
!
1
I
Carburetor
~
~
1
1
w
I
!
I*l
I 1
1
0
1
I
I
I
Ld
0
-
0
0
0
0
0
!
-1-
ReDlace If necessarv.
0
0
0
0
0
e
L
I
0
0
0
I
0
I
I
I
I
Check engine Idle speed,
synchronization and starter
EZinnecessarv.
I
I
0
0
0
0
I
I
Engine oil
Replace
(warm engine before draining).
0
0
Engine
- oil filter
Replace.
0
3
Engine oil
tank filter
Clean with solvent.
I
'3
I
Repair or replace if necessary.
* Lights
and switches
*
0
Check operation and for
oil leakage.
Sidestand
*I
0
~
I
Sidestand
switch
I
'3
Check all nuts, bolts and screws
for tightening.
Tight if necessary.
Check operation
and for oil
leakage.
Repair If necessary.
Rear shock
O
I
~
-
I
-
Check bearing for smooth
rotation/looseness.
Repair if necessary.
Grease every 24,000 km
or 24 months (lithium
soap-based grease).
Frame fastened
* fittings
I
0
I
*
~
Check rear arm system
for looseness.
Grease moderately
(Ilthium soap-based grease).
Adjust if necessary.
Steering
bearings
I
BREAK-IN 6,000 km 12,000 km
1,000km
6 months 12months
ROUTINE
I
~~
0
I
'3
l 0 I - l c I
I
1
I
I
I
Em
lNSP
ADJ
Items marked with an asterisk(*) requlre speclal tools, data and technical skills for servicing. Take the motorcycle to a Yamaha dealer or refer to Servlce Manual for the servicing of these parts.
NOTES:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Should the motorcycle be frequently used off-track,it is advised to replace engine oil every3,000 km.
~~
~
NOTE:
Brake fluid replacement:
1. Replace the brake fluid after disassembling the master cylinder or caliper cylinder. Check the brake
fluid level and add fluid as required.
2. Replace the master cylinder and caliper cylinder oil seals everytwo years.
3. Replace the brake hoses every four years, orif cracked or damaged.
L’
I W
~~
~~~
~~~~~~~~~~~~
~~
~~
~~
~
~
.~
~
CARBURETOR
~~~
~~~~
~
pqq
CARBURETOR
TYPE: YSOPV-2ATK
MANUFACTURER: TElKEl
0'
1 -
w
L
I
I
jet
CARBURETOR
(1)
spring
Carburetor
Throttle
(13)valve
Drain
(28)
valve
Stop
(43)
assembly
washer
Spring(2)
(14) Cover
(15) gasket
(3)
W
(29) Pipe
Throttle
(30) Pipe
(31)Screw
(1 6) Gasket
(17) Screw
(18) Stop screw
Float
(4)
(5)
screw set
Nut
Gasket,
nozzle
Float
pin
(19)Nut
(6) Floatchamber
gasket
(7) Screw
(8)Floatchamber
fastening screw
(23) Cover
(9)Springwasher
(24)Bracket
(10 ) Collar
(11) Spring
Screw
(26)
(25) O-ring
(12) Gasket
(27) Spring
(20)Screw
(21) Hose
(22)Diaphragm
washer
SPECIFICATIONS
Main jet
#150 FIRST
#130 SEC
Starter let
#74
Needle jet
5C5A-3/5 (FIRST)
5Y 18-3/5(SEC)
W
nozzleMain
pq-q
0
2.6
Pilot
Pilot air screw
3.5 -+ 0.5 revs
approx., open
Float height
27-29 mm
Fuel level
6-8 mm
Engine idle speed
1,150-1,450 r/min
Throttle valve housing
0
2.5 mm
(32) Screw
(33) Pipe
(44)
screw set
(45)Diaphragm
(46) Needle set 1
(47) Needle set 2
(34)Clip
(35) Main jet 1
(36) Main nozzle 1
(48) Starter set
(37) Throttle
valve
(51)Hose
(38) Pilot jet
(39)Main jet 2
(40) Main nozzle 2
screw
Pilot
(41)
set
Needle
set
valve
(42)
(49) Way 3
(50) Hose
(52)Hose
(53)Clip
(54)Breather
Pipe
O-ring
(55)
(56) Pipe
M
ELECTRICAL
m*(
ELECTRICAL
WIRING
COLOURS
1. CDI unit
2. Mainswitch
3. Frontbrakeswitch
4. Emergency stop engine switch
5. lgnrtioncoil
6. Earth
7 . Rear brake switch
8. Sidestandswitch
9. AC generator
10.
Adjuster/Rectifier
11. Smoothcondenser
12. Rear stop tailllight
13. Rear direction indicator lights
14.
Diode
15.Neutralswitch
16.Hornswitch
17. Direction indicator light switch
18. Driving beam/dimmer light switch
19. Lightsswitch
20. Horn
21. Direction indicator lamp relay
22. Front direction indicator llghts
23. Controllight
24. Parking indicator light
25. Highbeamlight
26. Direction indicator light
27. " N neutral light
28. Runnlng light
29. Drivingbeam/dimmer light
30. Resistor
B
Br
Ch
-
Black
Brown
Chocolate
Deep green
Dg G
Green
Grey
GY L
- Blue
Orange
Or
Pink
P
Red
R
Sky-blue
Sb
White
w
Yellow
Y
BlackfRed
B/R BlacWhlte
BAN Black/Yellow
BN BrowniBlack
Br/B BrowniWhite
BrAN Green/Black
GB Green/Red
G/R Greenmhlte
G/W G N - Green/Yellow
Blue/Red
L'R
w - BluelWhlte
I N - BlueIYellow
R/B Red/Black
RedWhite
RNV RedNellow
RN White/Blue
W/L Yellow/Red
Y/R -
-
w'
-
'W'
w
m
7
0
@I9
m
4J
m nn ??
cu
7
2 >0 m
1-
m 0
m
a
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I
m
I
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----
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co
m-
- z
---
r(D
In
d
m
>
‘J
cu
T-
W
W
?~ELGARDA
dlstrlbutrice escluswa per I’ltalia
20050 Gerno di Lesmo(MI) - Via Tinelli, 67/69
Telefono (039)60961 Ricerca autornatica
Realizzazione PGS - Torm
Stampa TipolrtografiaSAlNl - Tnuggro

yamaha tt 600 r

Transcription

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