This manual covers the TT-R600RE, an electric start dual-sport motorcycle produced for the 2003, 2004, 2005, and 2006 model years. Known for its 595cc 4-stroke engine, 5-speed transmission, and robust chassis, the TT-R600RE is engineered for versatile performance, suitable for both trail riding and general road use. The legacy in motorcycle manufacturing is evident in the TT-R series, which builds upon a heritage of competition and off-road capability. The TT-R600RE variant offers the convenience of electric starting, enhancing its user-friendliness. This Service and Repair Manual provides comprehensive guidance for owners, mechanics, and technicians. It details routine maintenance procedures, including oil changes, filter replacements, and chain adjustments, as well as in-depth repair instructions for all major systems such as the engine, fuel system, transmission, electrical system, suspension, and brakes. The manual also includes troubleshooting guides for common issues, technical specifications, and disassembly/reassembly procedures, empowering users to maintain and repair their TT-R600RE effectively and confidently. 🏷️ Basic Information Identification Make: Yamaha Model: TT-R600RE Model Variant: RE (Electric Start) Codes Product Code Indicator: PDF Download 👋 Introduction Market Position Target Audience: Owners of the Yamaha TT-R600RE, DIY mechanics, independent repair shops seeking comprehensive service data. Competitive Analysis Value Proposition: Provides essential, factory-level information for maintaining and repairing the TT-R600RE, enabling cost savings and ensuring proper upkeep. Key Features Manual Utility: Empowers users to perform maintenance and repairs confidently, reducing reliance on expensive dealer services. 📋 Manual Details Coverage Areas Covered Model Years: 2003, 2004, 2005, 2006 Page Count Estimated Page Count: 300-400 Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, top-end and bottom-end components, valve train, piston/cylinder, crankshaft, lubrication system, cooling system. Fuel System: Carburetor (Mikuni BSR36-33) service, cleaning, adjustment, fuel tank, fuel lines, fuel filter replacement. Transmission: Clutch operation and adjustment, gearbox inspection and repair, shift mechanism, transmission oil specifications and change intervals. Electrical System: Ignition system diagnostics and troubleshooting, stator, CDI unit, lighting, wiring diagrams, battery maintenance, charging system, electric starter system. Suspension: Front forks (Kayaba 43mm USD) service, seal replacement, oil level and type, rear shock absorber adjustment and rebuild, linkage maintenance. Brakes: Front and rear brake system service, caliper overhaul, brake pad replacement, brake fluid type and bleeding procedures, master cylinder inspection. Chassis And Bodywork: Frame inspection, steering head bearing maintenance, swingarm and rear wheel bearing service, body panel removal and installation, seat, fuel tank, fenders. Procedures Included Maintenance: Routine maintenance checks, oil changes, filter replacements, spark plug service, chain adjustment and lubrication, brake system checks. Troubleshooting: Detailed diagnostic charts for common starting, running, electrical, and mechanical issues. Repair: Step-by-step repair instructions for all major components and systems. Disassembly Reassembly: Comprehensive guides for dismantling and reassembling all motorcycle systems. Technical Specifications: Torque values, clearances, fluid capacities, electrical specifications, measurement data. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, with detailed diagnostic procedures. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Searchability: Typically searchable text within the PDF for quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 4-valve Displacement: 595 cc (595cm3) Bore X Stroke: 95.0 mm x 81.2 mm Compression Ratio: 9.2 : 1 Performance Horsepower: Approx. 45-48 HP (varies by market and specific tuning) Torque: Approx. 50 Nm (varies by market) Fuel System Carburetor Model: Mikuni BSR36-33, Constant Velocity Fuel Type: Unleaded gasoline, minimum 87 octane (RON+MON)/2 (AKI) Lubrication System Oil Type: SAE 20W-40 or 10W-30 API SG classification motorcycle oil Oil Capacity With Filter: 2.3 L (2.4 US qt) Cooling System Cooling Method: Air-cooled 🔧 Transmission Standard Transmission Type: Constant Mesh, 5-speed Clutch Type: Wet, multiple disc Features Final Drive: Chain drive Transmission Oil Type: Yamaha Super Performance SAE 80W API GL-4 Transmission Oil Capacity: 0.7 L (0.74 US qt) 📐 Dimensions Exterior Overall Length: 2225 mm (87.6 in) Overall Width: 825 mm (32.5 in) Overall Height: 1210 mm (47.6 in) Seat Height: 900 mm (35.4 in) Wheelbase: 1460 mm (57.5 in) Weights Dry Weight: 135 kg (297.6 lbs) Wet Weight: Approx. 149 kg (328.5 lbs) (with all fluids) Fuel Tank Capacity: 13 L (3.4 US gal) 🛡️ Safety Features Ratings Safety Standards: Meets applicable safety regulations for its class and time of manufacture. Active Features Braking System: Front: Hydraulic disc brake, Rear: Hydraulic disc brake. Lighting: Halogen headlight, tail light, brake lights, turn signals. Passive Features Frame Construction: Steel semi-double cradle frame. 💡 Technology Features Infotainment Instrumentation: Analog speedometer, tachometer, odometer, trip meter, and indicator lights. Driver Assistance Ride Aids: None (standard mechanical systems). Connectivity Connectivity Features: None (basic motorcycle design). 🔧 Maintenance Service...