XT 600 A/AC SERVICE MANUAL © 1990 by Yamaha Motor Corporation, U.S.A. 1st Edition, January 1990 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-07-43NOTICE 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, 0 it is assumed that persons using this book to perform maintenance and repairs on Yamaha motor- cycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the motorcycle will operate as designed. If there is any question about a service procedure, it is im- perative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his motor- cycle and to conform with federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized ‘Yamaha dealers and will, where applicable, appear in future editions of this manual. NOTE: This Service Manual contains information regarding periodic maintenance to the emission control system for the XT600EA/EAC. Please read this material carefully. TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE GROUP YAMAHA MOTOR CO., LTD. PARTICULARLY IMPORTANT ANT INFORMATION This material is distinguished by the following notation. A The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! PNUZGDINE] Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander,or a person inspecting or repairing the motorcycle. CAUTION: A CAUTION. indicates special precautions that must be taken to avoid " damage to the motorcycle. NOTE: A NOTE provides key information to make procedures easier or clearer.HOW TO USE THIS MANUAL CONSTRACTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols") Ist title D: This is a chapter with its symbol on the upper right of each page. 2nd title @ : This title appears on the upper of each page on the left of the chapter symbol. (For the chapter "Periodic inspection and adjustment” the 3rd title appears.) 3rd title @ : This is a final title. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The infor- mation has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections. A set of particularly important procedure @) is placed between a line of asterisks ”*” with each procedure preceded by “@ IMPORTANT FEATURES * Data and a special tool are framed in a box preceded by a relevant symbol @) . * An encircled numeral @) indicates a part name, and an encircled alphabetical letter data or an alignment mark (@), the others being indicated by an alphabetical letter in a box * A condition of a faulty component will precede an arrow symbol and the course of action re- quired the symbol @. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in idet ying correct disassembly and assembly procedures. oo eo—f|| |SPEC SPEC! PP | ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols (D to @ are designed as thumb tabs to indicate the chapter's number and content, Q General information ® Specifications @ Periodic inspection and adjustment @ Engine ®) Carburetion © Chassis D Electrical ® Troubleshooting Illustrated symbols @) to ( are used to identify the specifications appearing in the text. @ Filling fluid Lubricant Special too! Tightening Wear limit, clearance Engine speed aVA Illustrated symbols (@ to @ in the exploded dia- gram indicate grade of lubricant and location of lubrication point. ® Apply engine cil Apply gear oil ‘Apply molybdenum disulfide oil ‘Apply wheel bearing grease ‘Apply lightweight lithium-soap base grease Apply molybdenum disulfide grease ‘Apply locking agent (LOCTITE®)INDEX [ TROUBLESHOOTING GENERAL INFORMATION | SPECIFICATIONS ~ a | PERIODIC INSPECTION AND ADJUSTMENT age [ ENGINE OVERHAUL heey CARBURETION = CHASSIS neg ELECTRICAL ae ?CONTENTS CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER. ENGINE SERIAL NUMBER IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY. 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. CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE CHASSIS ELECTRICAL GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS LUBRICATION POINTS AND LUBRICANT TYPE, ENGINE CHASSIS. LUBRICATION DIAGRAM CABLE ROUTING EMISSION HOSE ROUTING (XT6OOEAC ONLY) att 1-3 24 24 an 215 218 218 219 2-20 2.24 2:28CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION 34 GENERAL MAINTENANCE/LUBRICATION............... 8d SEAT, FUEL TANK AND COVER ce 82 REMOVAL 32 INSTALLATION ce BB ENGINE 36 VALVE CLEARANCE ADJURTMENT ........... 36 CAM CHAIN ADJUSTMENT. 39 IDLE SPEED ADJUSTMENT 39 THROTTLE CABLE FREE PLAY ADJUSTMENT 340 SPARK PLUG INSPECTION ant IGNITION TIMING CHECK 3.43 % COMPRESSION MEASUREMENT 344 ENGINE OIL LEVEL INSPECTION bee B16 ENGINE OIL REPLACEMENT 348 OIL PRESSURE INSPECTION . 3:22 CLUTCH ADJUSTMENT. vee 3B o ENGINE OIL TANK STRAINER CLEANING 3.25 AIR FILTER CLEANING 1. 327 Cansuneton JON WSPECTION <3 Leans JS) FUEL LINE INSPECTION . 3:29 CRANKCASE VENTILATION HOSE INSPECTION 3-29 & EXHAUST SYSTEM INSPECTION 1829 CANISTER INSPECTION (XT600 EAC ONLY) 3.30 6 CHASSIS 332 FRONT BRAKE ADJUSTMENT 3:32 = REAR BRAKE ADJUSTMENT ...... . 3.32 BRAKE FLUID INSPECTION : 333 | ELEC WE BRAKE PAD INSPECTION cee 384 BRAKE LIGHT SWITCH ADJUSTMENT 3:35 BRAKE HOSE INSPECTION 3.35 °? AIR BLEEDING . 3:35 TRBL DRIVE CHAIN SLACK ADJUSTMENT 336 | GFR 8 DRIVE CHAIN LUBRICATION 3:38FRONT FORK INSPECTION STEERING HEAD ADJUSTMENT REAR SHOCK ABSORBER ADJUSTMENT TIRE INSPECTION WHEEL INSPECTION CABLE INSPECTION AND LUBRICATION LEVER AND PEDAL LUBRICATION SIDESTAND LUBRICATION SWINGARM AND RELAY ARM LUBRICATION: ELECTRICAL BATTERY INSPECTION FUSE INSPECTION HEADLIGHT BEAM ADJUSTMENT . HEADLIGHT BULB REPLACEMENT. CHAPTER 4. ENGINE OVERHAUL ENGINE REMOVAL .... ENGINE OIL SEAT AND FUEL TANK BATTERY LEAD . CARBURETOR CLUTCH CABLE EXHAUST PIPE STARTER MOTOR HOSE AND LEAD DRIVE CHAIN .... ENGINE PROTECTOR ENGINE REMOVAL ENGINE DISASSEMBLY CYLINDER HEAD, CYLINDER, CAMSHAFT AND PISTON .. STARTER IDLE GEAR AND CRANKCASE COVER (LEFT) CLUTCH, PRIMARY DRIVE GEAR AND BALANCER GEAR .... OIL PUMP AND SHIFT LEVER A.C. MAGNETO AND CAM CHAIN CRANKCASE (RIGHT) SHIFTER AND TRANSMISSION BALANCER AND CRANKSHAFT OIL STRAINER ROCKER ARM VALVE - 3:38 3.39 -3-40 341 344 346 345 345 2345 3-46 346 3-53 -3-55 3:55INSPECTION AND REPAIR 421 CYLINDER HEAD : 4-21 VALVE AND VALVE GUIDE 4-22 VALVE SEAT 4-23 VALVE SPRING . 14-27 CAMSHAFT. 4-28 ROCKER ARM AND ROCKER ARM SHAFT 4.28 CAM CHAIN AND CAM SPROCKET 4-29 CAM CHIN GUIDE 4-30 CYLINDER AND PISTON 4-30 PISTON RING ........ — seven 4B2 PISTON PIN . . 4-33 CLUTCH . 14-33 iL PUMP, — Seer 14-35 PRIMARY DRIVE coy. se 4B5 TRANSMISSION AND SHIFTER Ec 4-36 SHIFT SHAFT STOPPER LEVER ey STARTER DRIVE pean 4-38 CRANKSHAFT 4-39 BALANCER DRIVE GEAR AND BALANCER GEAR tevees eo BB CRANKCASE ......... vee4-40 BEARING AND OIL SEAL 4-40 ENGINE ASSEMBLY AND ADJUSTMENT 441 VALVE seas gages 4 AZ ROCKER ARM sees CRANKSHAFT AND BALANCER ...... 4-45 TRANSMISSION AND SHIFTER ee ae OIL STRAINER oteenetst 461 CRANKCASE ...... coe 14-51 SHIFT LEVER AND OIL PUMP 4-52 CAM CHAIN seers PISTON, CYLINDER, CYLINDER HEAD AND CAMSHAFT 4-59 A.C. MAGNETO ere 4-66 BALANCER GEAR, PRIMARY DRIVE GEAR, CLUTCH AND OIL FILTER STARTER IDLE GEAR AND CRANKCASE COVER (LEFT) REMOUNTING ENGINE . saves oA 7B, 4-70 sir (KS)