User Manuals: Yamaha XT 600 A Motorcycle

Manuals and User Guides for Yamaha XT 600 A Motorcycle. We have 1 Yamaha XT 600 A Motorcycle manual available for free PDF download: Service Manual

Yamaha XT 600 A Service Manual

Yamaha XT 600 A Service Manual (352 pages)

Brand: Yamaha | Category: Motorcycle | Size: 112.61 MB

Table of Contents

Illustrated Symbols
4
Index
5
Table of Contents
6
Chapter 1

14
- Engine Serial Number
  14
- General Information
  14
- Motorcycle Identification
  14
- Vehicle Identification Number
  14
- Important Information
  15
  - Preparation for Removal and Disassembly
    15
  - All Replacement Parts
    16
    
    Gaskets, Oil Seals, and O-Rings
    16
    
    Lock Washers/Plates and Cotter Pins
    16
    
    Bearings and Oil Seals
    16
    
    Circlips
    17
- Special Tools
  17
  - For Tune up
    17
  - For Engine Service
    18
  - For Chassis Service
    21
  - For Electrical Components
    22
Chapter 2

23
- Specifications
  23
- General Specifications
  25
- Maintenance Specifications Engine
  26
  - Chassis
    33
  - Electrical
    37
- General Torque Specifications
  39
- Definition of Units
  39
- Lubrication Points and Lubricant Type
  40
  - Engine
    40
  - Chassis
    41
- Lubrication Diagram
  42
- Cable Routing
  46
- Emission Hose Routing
  50
- Periodic Inspection and Adjustment
  51
Chapter 3

51
Introduction

51
- Seat, Fuel Tank and Cover Removal
  52
General Maintenance/Lubrication

51
Seat. Fuel Tank and Cover

54
- Installation
  55
- Valve Clearance Adjustment
  56
Engine

56
- Valve Clearance Adjurtment
  58
- Cam Chain Adjustment
  59
- Idle Speed Adjustment
  59
- Throttle Cable Free Play Adjustment
  60
- Spark Plug Inspection
  61
- Spark Plug Inspection
  62
- Ignition Timing Check
  63
- Compression Pressure Measurement
  64
- Compression Measurement
  65
- Engine Oil Level Inspection
  66
- Engine Oil Replacement
  68
- Engine Oil Replacement
  71
- Oil Pressure Inspection
  72
- Clutch Adjustment
  73
- Cable Free Play Adjustment
  73
- Engine Oil Tank Strainer Cleaning
  75
- Air Filter Cleaning
  77
- Carburetor Joint Inspection
  78
- Fuel Line Inspection
  79
- Crankcase Ventilation Hose Inspection
  79
- Exhaust System Inspection
  79
- Canister Inspection (Xt600 Eac Only)
  80
- Front Brake Adjustment
  82
- Rear Brake Adjustment
  82
Chassis

82
- Brake Fluid Inspection
  83
- Brake Pad Inspection
  84
- Brake Light Switch Adjustment
  85
- Brake Hose Inspection
  85
- Air Bleeding
  85
- Drive Chain Slack Adjustment
  86
- Drive Chain Slack Adjustment
  87
- Drive Chain Lubrication
  88
  - Front Fork Inspection
    88
  - Steering Head Adjustment
    89
  - Rear Shock Absorber Adjustment
    90
  - Tire Inspection
    91
  - Cable Inspection and Lubrication
    94
  - Wheel Inspection
    94
  - Lever and Pedal Lubrication
    95
  - Sidestand Lubrication
    95
  - Swingarm and Relay Arm Lubrication
    95
    
    Battery Inspection
    96
    
    Charging Method
    96
  - Battery Inspection
    99
    
    Charging Method Using a Variable-Current (Voltage) Type Charger
    100
    
    Charging Method Using a Constant-Voltage Type Charger
    101
    
    Charging Method Using a Constant Current Type Charger (Exclusive for MF Battery)
    102
  - Fuse Inspection
    103
  - Headlight Beam Adjustment
    104
    
    Headlight Beam Adjustment
    105
    
    Headlight Bulb Replacement
    105
  - Headlight Bulb Replacement
    106
- Electrical
  96
Chapter 4

107
- Engine Overhaul
  107
- Engine Removal
  107
  - Battery Lead
    107
  - Engine Oil
    107
  - Seat and Fuel Tank
    107
  - Carburetor
    108
  - Clutch Cable
    108
  - Exhaust Pipe
    108
  - Hose and Lead
    109
  - Starter Motor
    109
  - Drive Chain
    110
  - Engine Protector
    110
  - Engine Removal
    110
  - Cylinder Head, Cylinder, Camshaft and Piston
    112
  - Starter Idle Gear and Crankcase Cover (Left)
    115
  - Clutch, Primary Drive Gear and Balancer Gear
    116
  - Oil Pump and Shift Lever
    118
  - A.C. Magneto and Cam Chain
    119
  - Crankcase (Right)
    121
  - Shifter and Transmission
    122
  - Balancer and Crankshaft
    123
  - Oil Strainer
    123
  - Rocker Arm
    124
  - Valve
    126
  - Inspection and Repair
    127
  - Valve and Valve Guide
    128
- Engine Disassembly
  112
Inspection and Repair

128
- Valve Seat
  129
- Valve Spring
  133
- Camshaft
  134
- Rocker Arm and Rocker Arm Shaft
  134
- Cam Chain and Cam Sprocket
  135
- Cam Chin Guide
  136
- Cylinder and Piston
  136
- Piston Ring
  138
- Piston Pin
  139
- Clutch
  139
- Oil Pump
  141
- Primary Drive
  141
- Oil Pump Clearance
  141
- Transmission and Shifter
  142
- Shift Shaft Stopper Lever
  143
- Starter Drive
  144
- Starter Clutch Operation
  144
- Crankshaft
  145
- Balancer Drive Gear and Balancer Gear
  145
- Crankcase
  146
- Bearing and Oil Seal
  146
  - Engine Assembly and Adjustment
    147
  - Valve and Rocker Arm
    147
  - Valve
    148
- Crankshaft and Balancer
  151
Engine Assembly and Adjustment

151
- Transmission
  152
- Shifter
  153
- Transmission and Shifter
  154
- Oil Strainer and Oil Pump
  155
- Crankcase
  157
- Oil Strainer
  157
- Shift Lever and Oil Pump
  158
- Cam Chain
  160
  - Piston and Piston Ring
    161
  - Piston, Cylinder, Cylinder Head and Camshaft
    165
  - A.C. Magneto
    171
  - Balancer Gear and Primary Drive Gear
    173
  - Oil Filter and Oil Delivery Line
    175
- Balancer Gear, Primary Drive Gear, Clutch and Oil Filter
  176
- Starter Gear
  179
- Starter Idle Gear and Crankcase Cover (Left)
  180
- Remounting Engine
  181
  - Carburetor Sectional View
    188
  - Carburetor Removal
    189
  - Carburetor Disassembly
    190
  - Primary Carburetor
    191
  - Carburetor Inspection
    193
  - Carburetor Assembly
    195
  - Carburetor Installation
    200
  - Fuel Level Adjustment
    201
  - Front Wheel
    202
  - Front Wheel Removal
    203
  - Front Wheel Inspection
    204
  - Static Wheel Balance Adjustment
    206
  - Rear Wheel
    209
  - Rear Wheel Removal
    210
  - Rear Wheel Inspection
    211
  - Rear Wheel Installation
    212
  - Front and Rear Brake
    214
  - Brake Pad Replacement
    216
  - Caliper Disassembly
    221
  - Master Cylinder Disassembly
    224
  - Caliper Assembly
    230
  - Master Cylinder Assembly
    235
  - Front Fork
    240
  - Front Fork Removal
    241
  - Front Fork Disassembly
    242
  - Front Fork Assembly
    245
  - Front Fork Installation
    248
  - Steering Head and Handlebar
    249
  - Steering Head and Handlebar Removal
    250
  - Steering Head and Handlebar Inspection
    253
  - Rear Shock Absorber and Swingarm
    259
  - Rear Shock Absorber and Swingarm Removal
    262
  - Rear Shock Absorber and Swingarm Inspection
    265
  - Side Clearance Adjustment
    266
  - Rear Shock Absorber and Swingarm Installation
    268
  - Drive Chain and Sprocket
    272
  - Drive Chain and Sprocket Removal
    273
  - Drive Chain and Sprocket Inspection
    274
  - Drive Chain and Sprocket Installation
    277
  - XT600EA/EAC Circuit Diagram
    279
  - Color Code
    280
  - XT600EA/EAC Wiring Diagram
    280
  - Electrical Components
    281
  - Checking of Switches
    283
  - Checking Switch for Terminal Connection
    283
  - Switch Connection as Shown in Manual
    283
  - Checking Bulb Condition
    286
  - Checking of Bulbs
    286
  - Kinds of Bulbs
    286
  - Ignition System Circuit Diagram
    289
  - Ignition System Troubleshooting
    291
  - Electrical Starting System
    299
  - Starting Circuit Operation
    301
  - Electrical Starting System Troubleshooting
    302
  - Starter Motor Does Not Operate
    302
  - Charging System Circuit Diagram
    313
  - Charging System Troubleshooting
    315
  - The Battery Is Not Charged
    315
  - Lighting System Circuit Diagram
    319
  - Lighting System Troubleshooting
    321
  - Lighting System Check
    324
  - Signal System Circuit Diagram
    329
  - Signal System Troubleshooting
    331
  - Signal System Check
    333
  - Starting Failure/Hard Starting
    341
  - Poor Idle Speed Performance
    343
  - Poor Medium and High Speed Performance
    343
  - Change Pedal Does Not Move
    344
  - Faulty Gear Shifting
    344
  - Hard Shifting
    344
  - Jump-Out Gear
    344
  - Clutch Dragging
    345
  - Clutch Slipping
    345
  - Faulty Brake
    346
  - Front Fork Oil Leakage and Front Fork Malfunction
    346
  - Oil Leakage
    346
  - Poor Braking Effect
    346
  - Instable Handling
    347
  - Bulb Burnt out
    348
  - Faulty Signal and Lighting System
    348
  - Flasher Does Not Light
    348
  - Headlight Dark
    348
  - Flasher Winks Quicker
    349
  - Flasher Winks Slower
    349
  - Horn Is Inoperative
    349
  - Overheating
    349

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