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Yamaha TT 600 spare parts-the complete portfolio for all air cooling generation from 1983 to 2005
If there is a machine that has poured the spirit of air-cooled single-cylinder rallies into a series layout that is suitable for road and off-road, then it is that Yamaha TT 600. From the 34K prototype of the early eighties to the Euro 2 Homologation of the 4GV series 2005, the basic recipe remained the same: keep the weight low, the maintenance simply, the punch strong-and the smile under the helmet guarantees. But it is precisely this smile that depends on whether Nicasil-Cylinder, FCR flat slide, WP damping and MOSFET electrics work flawlessly. In the following 3,000 word roadmap, we present each component that makes your TT 600 on the Kickstart, which is happy to be happy, regardless of whether you are one 59x restore one DJ01 trim on rally or hers 4GV as a daily driver.
1 | From 34k to 4GV-25 years of TT history
✓ 34K (1981–1982): 562 cm³, 34 mm VM carburetor, 43 mm Kyb fork, drum brakes. Only appeared in Japan / US as TT 600 H.
✓ 59x (1983–1989): 595 cm³, dual carburetor (VM 34 + 30), 43 mm fork, 4-speed up to ’85, 5-speed from ’86.
✓ 3SW S / SC (1993–1997): E-starter, double loop frame, dough y30p CV carburetor, 45 hp.
✓ DJ01 (1998–2002): FCR-41, WP chassis, removable aluminum underground, 47 hp, 47 Nm.
✓ 4GV (2003–2005): Euro-2, battery, 200-W-Lima, soft-limiter 8 250 RPM.
2 | Similarities of all engines-spare parts basis
Regardless of the year of construction and type code, all TT 600 engines share a number of core components-a blessing for today's spare parts hunter:
- ✓ Basic SOHC four-valve head -Identical valve dø (7 mm) & valve guides. Shims Ø 26 mm (59x / 3sw), Ø 9, 48 mm (DJ01 / 4GV).
- ✓ Nicasil-cylinder running socket 97 × 84 mm -Athena, Wössner or Nikasil-Re-Plating compatible.
- ✓ Tax chain did 219 FHV, 104–110 members each.
- ✓ coupling: identical inner hub + friction discs; Springs differ only in the preload.
3 | Generation 34k / 59x (1983–1989)-Dual carburetor & kick legend
Anyone who has a 59x loves the rough character of the dual carburetor: primarily VM34SS + secondary VM30SS, vacuum-controlled. The weak point are Rubber suction nozzlethat network and throw cracks after 40 years. Replacement encloses:
✓ Suction socket set 59x-13586/96 (Viton mixture).
✓ Piston ring set 59x-1103-00 (+0.5 mm & +1.0 mm).
✓ Tax chain 104 L + Auto-Spanner 59x-12210-00.
✓ Kick-Freienslauf roll replacement 59x-15517-00.
Tuning tip: 140 HD / 75 SEK-HD + SR racing pot = +4 hp; Oil cooler reduces head-temp to <95 ° C at summer heat.
4 | Generation 3SW S / SC (1993–1997)-E-Starter, double loop, CV carburetor
The street-oriented 3sw brought electric starters, double pipe frames, 12-volt-Lima 210 W and CV carburetor. Frequent spare parts Needs:
✓ Stay coupling 3SW-15517-00 + new springs.
✓ Starter engine 3SW-81890-00-coal brush kit.
✓ Teikei Y30P Rebuild - membranes, nozzles, swimmers.
✓ Exhaust seal 3SW-14613-00-graphite, heat festival.
5 | Generation DJ01 (1998–2002)-FCR & White-Power
The DJ01 stands for racing-DNA Straight from the showroom: flat slide-fcr, removable aluminum underground, WP chassis. Spare parts essentials:
✓ FCR-41 Rebuild kit (pump membrane, double nozzle, O-rings).
✓ Piston ring set Ø 95 mm 4GV-1103-00.
✓ WP fork simmer rings 43 × 54 × 11 + SKF dust caps.
✓ MOSFET controller SH847-constant 14.4 V, 30 A.
6 | Generation 4GV (2003–2005)-Euro-2, battery & soft-limiter
The 4GV introduces battery, soft-limiter and Euro 2 exhaust. Many DJ01 parts fit, but you need:
✓ Lambda-Kat pot (Euro-2) 4GV-14711-00.
✓ CDI 4GV-85540-00-Soft-Limiter 8 250 RPM.
✓ Stator 4GV-81410-00-200 W.
✓ Life battery (1 kg) + DC-CDI-TRACHT FOR MAP-Tuning.
7 | Electrics & ignition - evolution & contemporary upgrades
59x & 34k Run over batteryos via AC-CDI-light output 35 W. From DJ01 A 180 W-Stator replaces the low-output. 4GV delivers 200 W. Today:
- ✓ Electrex G70 / G75-Staren -200 W plug-in.
- ✓ SH847 controller - Mosfet, 14.4 V constant.
- ✓ Ignitech DC-CDI -Programmable, launch-limiter.
- ✓ LED-H4 20 W - saves 40 W, ABE.
8 | Foreers
While 59x & 3SW do with KYB drives (43-/45 mm), DJ01 and 4GV shine as standard with WP components. Common tuning recipes:
✓ Progressive Wilbers feathers - 0.46 → 0.64 kg/mm.
✓ SKF Low friction kits-reduced lettling moment.
✓ YSS MZ456 / M46 spring legs-Zug + High / Low print.
✓ Öhlins Nix-Cartridge-plug-in, adjustable externally.
9 | Maintenance plan - across generations
| service | Interval street | Intervall off-road | Parts / tools |
|---|---|---|---|
| Oil + filter | 2 500 km | 40 h | 10W-50 Ester + HF145 |
| Valve game | 5,000 km | — | Shim Ø 26 mm or 9.48 mm |
| Control chain | 10,000 km | 5,000 km of sand | Did 219-FHV + car clamp |
| Carburetor | 10,000 km | Rally every year | VM / Teikei / FCR kit |
| Swinging/steering head warehouse | 15,000 km | 10,000 km | HK needle bearing / all-balls cone rolls |
| Fork oil | 15,000 km | 10,000 km of sand | 5 W / 7.5 W racing fluid |
10 | Typical weaknesses & solution packages
✓ Nicasil detachment -Oil too hot → oil cooler, ester oil, re-plating (long court).
✓ Kick-free run slips - Replace feathers + roles, ramps "undercut".
✓ FCR pump membrane porous -Viton kit, avoid E10.
✓ Pickup cable break -Silicone litters, shrink hose adhesive.
✓ WP fork Stick-Slip -SKF kit, air-free, Shim-Stack update.
✓ Brake disc washing - Oversize 320 mm, sintering HH.
11 | Performance & comfort upgrades
- ✓ STRAB 7-row oil cooler --10 ° C oil, longer Nicasil status.
- ✓ Excel rims 1.85 × 21 / 2.50 × 18 - 800 g less rotating mass.
- ✓ 320 mm oversize brake - 30 % shorter braking distance on asphalt.
- ✓ Life battery + LED 20 W - --2 kg & 50 W light reserve.
- ✓ Öhlins Nix-cartridge -External train & pressure, plug-&-ride.
- ✓ Acerbis Rally-tank 23 L -+250 km range, HD-PE, transparent.
12 | Parts supply, community & nos sources
Yamaha continues to deliver basic parts (pistons, sealing rates, crankshafts, clutch, lima). Specialized dealers - Off-the-road (De), Ttraiders (US), Trail tech (IT)-blankets WP service, rally tanks, oversize brakes. The forums tt-club.de, Advrider and groups "Yamaha TT 600 R / RE" share CAD files for carbon skidplates, 3-D printed intake snorkeling and laser-cut cast kits. NOS stocks can be found on Ebay classified ads and French charging lists (Leboncoin.fr) under "Pièces TT600".
13 | Conclusion - Kick it, Race it, Keep it alive
The Yamaha TT 600 embodies 25 years of air-cooled rally spirit. Whether dual carburetor purist (59x), e-start tourer (3SW) or WP factory pilot (DJ01/4GV)-every generation rewards thorough maintenance with spontaneous gas response, wheelie-friendly torque, indestructible chassis and a driving feeling that never completely copy modern injection children. Our selection of TT 600 spare parts -from the piston ring to the oversize brake-your machine makes your machine fit for the next kick start, the next gravel road and the next grin under the helmet. Keep the Air Cooled Spirit Alive-with the right parts.
Now browse - and equip your TT 600 with everything you need for the next adventure!