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Yamaha TT 600 R 4GV spare parts-the last air-cooled rally rocket from Iwata
With the TT 600 R 4GV Yamaha said goodbye to 2003 by the era of air-cooled big singles, without the character of the DJ01 too Watering: the same 595 cm³ heart, but revised crankshaft, Modernized FCR carburettus, Euro-2-compatible exhaust system and Improved WP spring elements. The result: 45 hp, 52 Nm and 135 kg Full-fueled-ready, work singles and modern 450s in the off-road area to make old look. But the most robust TT also needs first -class Yamaha TT 600 R 4GV spare parts, with it Do not rattling the piston rings, Nicasil shines and FCR slide silk-soft slide. In nine chapters and around 1,700 words, this guide holds this guide Everything together that screwdrivers, tourers and rally pilots need to know.
1 | Evolution & Typcodes - from DJ01 to 4GV
The DJ01 (1998–2002) set standards as a air-cooled WP-Werk-Racer.
In 2003 Yamaha moved die 4GV to: identical
Frame geometry, however
Euro-2-kat exhaust, lambda-free FCR mapping and reinforced
Crank. Serial numbers begin with
JYACK Followed by "4GV". To distinguish:
✓ 2003-WP fork Gold-Tin, FCR-41 Ø 41 mm, 47 mm Keihin pump nozzle.
✓ 2004 - silver fork, New CDI (4GV-85540-00) with Soft-Rev-Cut 8 250 RPM.
✓ 2005 - last series, gray frame, Brake discs punched + staggered carrier sleeve.
2 | Motor & intake-FCR boost with Euro-2-fine tuning
The 4GV engine retains 97 × 84 mm dimension, but receives Separated supplied oil galleries for single and outlet cams and double cooling ribs in the outlet area. The Keiin FCR-41MX-Toppel carburetor await with 170 main nozzle, 45-leaf run, needle OBDVP-3 and 1¾ air screw rotations. Important spare parts:
✓ Piston ring set Ø 95 mm OEM 4GV-1103-00; Wössner 8245D hardened.
✓ Nicasil-cylinder sleeve Athena Cyl-600-4GV, plateau hug, keep oil drilling.
✓ Tax chain did 219 FHV 110 members + nietschloss; Exchange from 10,000 km of off-road.
✓ FCR rebuild K-kit 41fcr: pump membrane, O-rings, nozzles, axles.
Mapping tip: Open SR racing pot → 175 HD / 48 LD, needle OBDVP-4; Oil cooler kit lowers oil ≥ 10 ° C. Oil change 10W-50 esters all 2,500 km or 40 operating hours. Valve game 0.10 / 0.15 mm every 5,000 km; Shim Ø 9.48 mm (Hotcams set).
3 | Electrics, CDI & alternator - reliable spark
4GV relies on 200 W lighting machine (Stator 4GV-81410-00), MOSFET controller and 12-V lead 4 AH-for the first time battery! CDI has soft-limiter at 8 250 RPM and error code blinkers. Upgrades:
✓ Electrex G75-Stator-220 W, Plug-in.
✓ SH847AA controller-constant 14.4 V.
✓ Ignitech DC-CDI-two Ignition curves, launch-limiter.
✓ LED-H4 20 W-3,000 lm, 45 W reserve for GPS & heating handles.
4 | Chassis & brakes-WP performance for recharging
Fully adjustable WP-USD fork 43 mm and WP spring bone deliver 300/310 mm travel. Achieve noticeable improvements New Shim stacks and more progressive springs. Brakes: 297 mm Wave before, 245 mm wave at the back. Replacement & tuning parts:
✓ SKF low-friction simmering rings 43 × 54 × 11, +SKF dust caps.
✓ Wilbers springs 0.48 → 0.64 kg/mm + Motorex 5 W 560 ml / Holm.
✓ YSS M46 strut- High/low-speed printing, hydraulic preload.
✓ Braking SK2-320 braking disc + 4-piston adapter, coverings Ebc HH.
5 | Maintenance plan & wear
| Service point | interval | Parts / fluid |
|---|---|---|
| Motor oil + filter | 2 500 km / 40 h | Motul 7100 10W-50, HF145 |
| Valve game | 5,000 km | Shim Ø 9.48 mm |
| FCR service | 10,000 km | Rebuild kit K-41fcr |
| Control chain | 10,000 km | Did 219-FHV 110 L |
| Fork oil | 15,000 km | Motorex Racing 5 W, 560 ml |
| Swinging and steering head bearings | 10,000 km | HK 2212 / All-Balls 22-1006 |
6 | Typical weaknesses & solutions
✓ Nicasil detachment
Oil cooler & Ester oil; For new plating.
✓ Pickup cable break
Silicone line 0.75 mm², shrink hose W/ glue.
✓ FCR membrane porous
Viton pump membrane, no E10 winter camp.
✓ WP fork air cushion
Stick-Slip-> SKF seals & 2 bar air-free.
7 | Sensible upgrades-Rally-Ready in 2025
- ✓ STRAB 7-row oil cooler - Oil ≤ 100 ° C Even with a desert temp.
- ✓ Excel rims 1.85/2.50 -800 g lighter, compatible tubeless.
- ✓ 320 mm oversize brake - 25 % shorter braking distance on asphalt.
- ✓ Life battery 1.2 kg -DC conversion + LED navigation power.
- ✓ Öhlins Nix-cartridge - Train & print external; Plug-in.
8 | Parts supply & scene
Yamaha continues to deliver essential parts: sealing rates, Course shaft, piston, Nicasil-cylinder. Accessory markets - Offshheroad, Ttraiders, XR-Land -offer rally tanks, carbon skid plates and 3-D printed air filter cages. Community sources (tt-club.de, Advrider) Share CAD files For speedometers, rally towers and ABS rings. Search of use used: Ebay classifieds, FB groups "Yamaha TT-600 R / RE" -There are WP forks, OEM rims and rare 4GV CDIs.
9 | Conclusion - a kick, a thrust, a permanent grin
The TT 600 R 4GV Is the crowning glory of all air -cooled TT series: FCR bite, WP chassis and rally frame in a package, This is lighter than many modern 450s. With high quality TT 600 R 4GV spare parts -from the Nicasil cylinder over Iridium candle up to the oversize brake-remains Kick-start charm, the wheelie torque and the rally DNA. Kick it. Race it. Love it.
Browse now-and prepare your 4GV for the next kick start moment!