1985-1986 Yamaha TT600N TT600S Motorcycle Service Manual

Description

This 1985-1986 Yamaha TT600N Motorcycle Service Manual is a reproduction of the original, out of print, service manual. This manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1985-1986 Yamaha TT600N Motorcycles. This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha TT600 motorcycles have a basic understanding of the mechanical concepts and procedures inherent in machine repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and / or unsafe.

Table of Contents
General Information
Machine Identification
Vehicle Identification Number
Engine Serial Number
Important Information
All Replacement Parts
Gaskets, Oil Seals, and O-Rings
Lock Washers / Plates and Cotter Pins
Bearings and Oil Seals
Circlips
Special Tools
For Tune-Up
For Engine Service
For Chassis Service
For Electrical Components

Periodic Inspections and Adjustments
Introduction
Periodic Maintenance / Lubrication
Engine
Valve Clearance Adjustment
Idling Speed Adjustment
Throttle Cable Adjustment
Fuel Line Inspection
Air Filter Cleaning
Engine Oil Level Inspection
Engine Oil Replacement
Oil Pressure Inspection
Decompression Cable Adjustment
Compression Pressure Measurement
Chassis
Fuel Cock Cleaning
Engine Oil Tank Strainer Cleaning
Front Brake Adjustment
Front Brake Pad Inspection
Brake Fluid Level Inspection
Rear Brake Adjustment
Clutch Adjustment
Drive Chain Slack Check
Drive Chain Slack Adjustment
Drive Chain Lubrication
Steering Head Inspection
Steering Head Adjustment
Front Fork Oil Change
Front Fork Adjustment
Rear Shock Absorber Adjustment
Wheel Bearings Check
Cable Inspection and Lubrication
Swingarm and Relay Arm Lubrication
Tires Check
Wheels Check
Electrical
Ignition Timing Check
Spark Plug Inspection
Headlight Bulb Replacement
Headlight Beam Adjustment

Engine Overhaul
Engine Removal
Preparation for Removal
Seat and Fuel Tank
Exhaust Pipe
Carburetor
Oil Hoses and Clutch Cable
Drive Chain and Footrest (right)
Engine Removal
Disassembly
Cylinder Head
Cylinder
Piston
CDI Magneto
Clutch
Oil Pump
Kick Axle
Shift Shaft
Crankcase
Transmission
Crankshaft
Oil Strainer
Inspection and Repair
Rocker Arms and Rocker Arm Shafts
Camshaft
Cam Chain
Cam Sprocket and Cam Drive Sprocket
Chain Dampers
Cam Chain Tensioner
Cylinder Head
Valve, Valve Guide, and Valve Seat
Cylinder
Piston, Piston Ring, and Piston Pin
Kick Starter
Primary Gears
Clutch
Oil Pump
Crankshaft
Transmission
Bearings
Circlips and Washers

Engine Assembly and Adjustment
Crankshaft
Balancer and Oil Strainer
Shifter and Transmission
Crankcase
Shift Shaft
Kick Axle
Oil Pump
Clutch
Piston
Cylinder
Cylinder Head
CDI Magneto
Remounting Engine

Carburetor
Sectional View
Removal
Disassembly
Inspection
Assembly
Installation
Adjustment

Chassis
Front Wheel
Removal
Inspection
Installation
Rear Wheel
Removal
Inspection
Installation
Front Brake
Caliper Pad Replacement
Caliper Disassembly
Master Cylinder Disassembly
Brake Inspection and Repair
Brake Reassembly
Air Bleeding
Brake Disc Installation
Front Fork
Removal
Disassembly
Inspection
Assembly
Installation
Steering Head
Removal
Inspection
Assembly
Rear Shock Absorber
Handling Notes
Notes on Disposal
Removal
Inspection
Assembly
Swingarm
Inspection
Removal
Adjustment
Inspection and Lubrication
Assembly
Drive Chain and Sprockets
Removal
Inspection
Assembly

Electrical
Tt600 Im Circuit Diagram
Electrical Components
Ignition System
Circuit Diagram
Troubleshooting
Ignition Timing Check
Ignition Spark Gap Test
Spark Plug Inspection
“engine Stop” Switch Test
Ignition Coil Resistance Test
Pick-Up Coil Resistance Test
Source Coil Resistance Test
Lighting System
Circuit Diagram
Troubleshooting
AC lighting Circuit Output Test
“lights” Switch Test
Lighting Coil Resistance Test

Appendices
Specifications
General Specifications
Maintenance Specifications
General Torque Specifications
Definition of Units
Lubrication Diagram
Cable Routing
Tt600 N Wiring Diagram