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XT 600 AC
Yamaha XT 600 AC User Manual
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IENGI
~I
ENGINE
ASSEMBLY
AND
ADJUSTMENT
....
--------------------------------------------
OIL
STRAINER
AND
OIL
PUMP
~
Oil
strainer
2
Oil
pump
3
Oil
pump
gear
OIL
PUMP:
TIP
CLEARANCE:
A
0.12
mm
(0.005
in)
SIDE
CLEARANCE:
0.03-0.08
mm
(0.001-0.003
in)
4-49
154
156
Table of Contents
Default Chapter
4
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
4
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Yamaha XT 600 AC Specifications
General
Brand
Yamaha
Model
XT 600 AC
Category
Motorcycle
Language
English
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