This manual covers the TT600, specifically the TT600RE model, for the production years 2003 through 2007. As a dual-sport motorcycle, the TT600RE is recognized for its robust single-cylinder, four-stroke engine, renowned for durability and off-road prowess. Its engineering quality and reliability are hallmarks of a long-standing heritage in motorcycle manufacturing, making it a capable machine for both on-road and off-road adventures. This comprehensive factory service manual provides in-depth information essential for the maintenance and repair of your TT600RE. It details general information, routine maintenance procedures, periodic checks and adjustments, lubrication, and specifications for all major systems, including the engine, fuel system, cooling system, transmission, drivetrain, electrical system, steering, suspension, and brakes. The manual includes detailed troubleshooting guides, repair instructions with diagrams and illustrations, maintenance schedules, torque specifications, and wiring diagrams, empowering owners and technicians to keep the motorcycle in optimal condition. 🏷️ Basic Information Identification Make: Yamaha Model: TT600 Model Variant: TT600RE Model Years Covered: 2003, 2004, 2005, 2006, 2007 Codes Vehicle Type: Dual-Sport Motorcycle 👋 Introduction Market Position Target Audience: Owners of Yamaha TT600/TT600RE motorcycles (2003-2007) with basic mechanical skills and independent service professionals. Competitive Analysis Value Proposition: Provides dealership-level repair and maintenance information, enabling significant cost savings on repairs and maintenance. Key Features Accuracy: Vehicle-specific, not generic; exact same information used by authorized dealers. Completeness: Covers all major topics, complete and intact without missing or corrupt parts/pages. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Workshop Specific Systems Covered: General Information, Routine Maintenance, Specifications, Periodic Checks and Adjustments, Lubrication, Cooling System, Transmission, Drive Chain, Sprockets, Engine Specifications, Engine Removal and Installation, Fuel System, Steering System, Shocks, Body Work, Intake & Exhaust, Electrical System, Advanced Troubleshooting, Wiring Diagram Page Count Estimated Page Count: Extensive (Full Factory Service Manual) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service: Complete overhaul, top-end and bottom-end procedures, cylinder head, piston, crankshaft, camshaft, valve train, timing, oil pump, oil seals, gaskets. Fuel System Service: Carburetor disassembly, cleaning, adjustment, jetting, fuel pump, fuel lines, fuel tank maintenance. Cooling System Service: Radiator, coolant, hoses, thermostat, water pump maintenance and repair. Transmission And Drivetrain: Clutch operation, gear shifting mechanisms, internal transmission components, output shaft, drive chain adjustment and replacement, sprocket inspection and replacement. Electrical System: Ignition system (CDI, spark plug, coil), starting system (starter motor, solenoid, battery), lighting system (headlight, taillight, turn signals), charging system (alternator, rectifier/regulator), wiring harness, fuses, switches, diagnostic procedures. Chassis And Suspension: Front fork (oil change, seal replacement, spring inspection), rear shock absorber (rebuild, adjustment), swingarm, bearings, steering head bearings, wheel bearings. Brakes: Front and rear brake caliper service, brake pad replacement, brake disc inspection, brake fluid flush, master cylinder service. Bodywork And Fairings: Removal and installation of plastic components, seat, fuel tank cover, fenders. Procedures Included Troubleshooting Guide: Comprehensive diagnostic flowcharts and step-by-step troubleshooting for common and uncommon issues across all systems. Repair Instructions: Detailed, illustrated instructions for disassembly, cleaning, inspection, repair, assembly, and adjustment of all major components. Maintenance Schedules: Recommended service intervals for oil changes, filter replacements, chain lubrication, valve clearance checks, brake inspections, etc. Torque Specifications: Precise torque values for all fasteners and critical components. Wiring Diagram Interpretation: Detailed wiring schematics provided to aid in diagnosing and repairing electrical faults. Technical Depth Depth: Factory-level diagnostic and repair procedures, suitable for independent mechanics and experienced DIY enthusiasts. Component Rebuild: Instructions for complete disassembly and rebuilding of major engine components, transmission, and suspension elements. 📊 Manual Specifications File Format Compatibility: All Versions of Windows AND Mac Print Quality Printability: Yes, all pages are printable Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) Software Requirements Required Software: Adobe PDF Reader Features Diagrams And Illustrations: Includes detailed diagrams, illustrations, and wiring schematics. Searchability: Searchable text for quick information retrieval. Illustrations Type: Step-by-step instructions, diagrams, and illustrations. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, SOHC (Single Overhead Camshaft), 4-valve Displacement: Approximately 595cc (exact figure may vary slightly by sub-model/region) Performance Horsepower: Typically in the range of 40-45 HP (estimate, specific dyno figures vary) Torque: Approximately 35-40 lb-ft (estimate) Fuel System Fuel Delivery: Carburetor (e.g., Mikuni BST40 or similar) for earlier models, potentially EFI on later variations of similar platforms, though TT600RE typically carbureted. Lubrication Oil Type Recommendation: Yamalube 4 (or equivalent JASO MA rated 10W-40 or 20W-50 motorcycle oil), specific viscosity dependent on ambient temperature. Cooling System Cooling Method: Air-cooled Engine Removal And Installation Procedure Availability: Detailed guide for engine removal and installation from the motorcycle chassis. 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Features Clutch Type: Wet, multi-disc clutch Final Drive: Chain drive 📐 Dimensions Weights Dry Weight: Approximately 130-135 kg (287-298 lbs) - exact figure varies Wet Weight: Approximately 145-150 kg (320-331 lbs) - estimated with...