Yamaha XT 600 AC Manuale utente

XT600

AIAC

SERVICE

MANUAL

Yamaha

Motor

Corporation,

U.S.A.

1st

Edition,

January

1990

All

rights

reserved.

Any

reprinting

unauthorized

use

without

the

written

permission

Yamaha

Motor

Corporation,

U.S.A. is expressly

prohibited.

Printed

in U.S.A.

PIN:

L1T-11616-07-43

NOTICE

This

manual was written

the

Yamaha

Motor

Company primarily

for

use by Yamaha dealers and

their

qualified mechanics.

not

possible

put

an entire mechanic's education into one manual,

is assumed

that

persons using this

book

perform maintenance and repairs on Yamaha

motor

cycles have a basic understanding

the

mechanical concepts and procedures inherent in

motorcycle

repair technology.

Without

such knowledge, attempted repairs

service

this model may render

unfit

use

and/or

unsafe.

This model has been designed and manufactured

perform

within

certain specifications in regard

performance

and emissions.

Proper

service

with

the

correct tools is necessary

ensure

that

the

motorcycle

will operate

designed.

there

any question about a service procedure,

is im-

perative

that

you

contact

a Yamaha dealer

for

any service

information

changes

that

apply

this

model. This

policy

intended

provide

the

customer

with

the

most

satisfaction

from

his

motor-

cycle and

conform

with

federal

environmental

quali

objectives.

Yamaha

Motor

Company, Ltd. is continually striving

improve all models manufactured

Yamaha.

Modifications

and significant changes in specifications or procedures will be forwarded

all Authorized

Yamaha dealers and will, where applicable, appear in

future

editions

this manual.

NOTE:

____________________________________________________________

This

Service Manual contains

information

regarding

periodic

maintenance

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

the

following

notation

AWARNING

NOTE:

The

Safety

Alert

Symbol

means

ATIENTION!

BECOME ALERT! YOUR

SAFETY IS

INVOLVED!

Failure

WARNING

instr

ctions

could

result in severe

injury

death

the

motorcycle

operator,

tander,or

a person inspecting

repairing

the

motorcycle.

A CAUTION indicates special

precautions

that

must

be taken

avoid

damage

the

motorcycle

A NOTE provides key

information

make

procedures easier

clearer.

HOW

USE

THIS

MANUAL

CONSTRACTION

THIS

MANUAL

This

manual

consists

chapters

for

the

main

categories

subjects.

(See

"Illustrated

symbols")

This

is a

chapter

with

its

symbol

the

upper

right

each

page.

title

2nd

title

@ :

This

title

appears

the

upper

each

page

th'8

left

the

chapter

symbol.

(For

the

chapter

Periodic

inspection

and

adjustment""

the

3rd

title

appears.)

3rd

title

® :

This

is a

final

title.

MANUAL

FORMAT

All

the

procedures

this

manual

are

organized

in a

sequential,

step-by-step

format.

The

infor-

mation

has

been

compiled

provide

the

mechanic

with

easy

read,

handy

reference

that

contains

comprehensive

explanations

all

disassembly,

repair,

assembly,

and

inspections.

set

particularly

important

procedure

@ is

placed

between

a line

asterisks"

with

each

procedure

preceded

" • ".

IMPORT

ANT

FEATURES

•

Data

and

special

tool

are

framed

in a

box

preceded

relevant

symbol

® .

•

encircled

numeral

indicates

part

name,

and

encircled

alphabetical

letter

data

alignment

mark

(J)

the

others

being

indicated

alphabetical

letter

in a

box

@ .

• A

condition

faulty

component

will

precede

arrow

symbol

and

the

course

action

re-

quired

the

symbol

®.

EXPLODED

DIAGRAM

Each

chapter

provides

exploded

diagrams

before

each

disassembly

section

for

ease in

identif-

ying

correct

disassembly

and

assembly

procedures

:=r

~'''

INSPECTION

AND

PAIR

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@ ,

ILLUSTRATED

SYMBOLS

(Refer

the

illustration)

Illustrated symbols

@ are designed

thumb

tabs

indicate the chapter's number and

content.

General information

(2)

Specifications

® Periodic inspection and adjustment

@ Engine

@ Carburetion

@ Chassis

(J)

Electrical

® Troubleshooting

Illustrated symbols ®

@ are used

identify

the specifications appearing in the text.

® Filling fluid

® Lubricant

@ Special

tool

(j)

Wear

limit, clearance

(j])

Engine speed

@n,V,A

Illustrated symbols @

@ in the exploded dia-

gram indicate grade

lubricant and location

lubrication point.

Apply

engine oil

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®I

INDEX

GENERAL

INFORMATION

GEN

INFO

SPECIFICATIONS

SPEC

PERIODIC

INSPECTION

AND

ADJUSTMENT

ENGINE

OVERHAUL

ENG

CARBURETION

CARB

c#::T0

too---

CHAS

CHASSIS

ELECTRICAL

TROUBLESHOOTING

CONTENTS

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION .

...

.....

...

.....

. .

...

. .

1-1

VEHICLE IDENTIFICATION NUMBER

.....

...

..............

.......

. . 1-1

ENGINE SERIAL NUMBER

...

. .

...

.....

...

. . . . . .

.. ..

1-1

IMPORTANT

INFORMATION

.....

...

.....

.......

....

. .

1-2

PREPARATION

FOR

REMOVAL

AND

DiSASSEMBLy

...

....

. .

.. ..

1-2

ALL REPLACEMENT PARTS ·.

...........

...

.......

...

.............

1-3

GASKETS, OIL SEALS,

AND

O-RINGS .

....

...

. .

......

1-3

LOCK WASHERS/PLATES

AND

COTTER PINS . . . .

..........

.. ..

. .

...

1-3

BEARINGS

AND

OIL SEALS. .

......

. . . . . .

....

. . .

....

··

·····

.1-3

CIRCLIPS . .

...

. . . . . .

....

.. ..

. .

...

.......

...

·1-4

SPECIAL

TOOLS·

...

. .

.....

...

. . . . .

.....

...

1-4

FOR

TUNE UP .

...

. .

......

...

. .

....

...

.. ..

.....

. .

....

1-4

FOR

ENGINE SERVICE

......

..............

..........

...

....

1-5

FOR

CHASSIS SERVICE.

...

.....

.. ..

. . .

.....

......

1-8

FOR

ELECTRICAL COMPONENTS. .

....

. .

........

...............

1-9

CHAPTER 2.

SPECIFICATIONS

GENERAL

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

MAINTENANCE

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4

ENGINE.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4

CHASSIS

.. .. ..

....

.....

... ...

.......

. . .

....

2-11

ELECTRICAL .

.....

. .

.. ..

....

......

. . . . 2-15

GENERAL TORQUE

SPECIFICATIONS

.......

.....

...

....

. 2-17

DEFINITION

UNITS

....

........

.......

. .

....

.....

2-17

LUBRICATION

POINTS

AND

LUBRICANT

TYPE

...

.....

.......

2-18

ENGINE

...

.......

....

...

....

...

.....

. . .

...

CHASSIS

. .

........

...

. .

.. ..

........

. .

...

2-19

LUBRICATION

DIAGRAM

. .

...

....

. .

.. ..

...

. 2-20

CABLE

ROUTING

...

.............

...

.. ..

. . . .

.....

. 2-24

EMISSION HOSE ROUTING (XT600EAC ONLYI

....

........

...

. . . 2-28

CHAPTER

PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION

....

..........

....

......

...

.......

. .

3-1

GENERAL MAINTENANCE/LUBRICATION .

....

..................

...

3-1

t-----

GEN

INFO

SEAT. FUEL TANK

AND

COVER .

.................

. .

....

3-2

REMOVAL

...

...........................................

3-2

INSTALLATION

.......

.....

...

........

....

......

.....

3-5

SPEC

ENGINE ..

....

.........

......

...

....

.. .. ..

....

3-6

VALVE CLEARANCE

ADJURTMENT

...............

. .

........

3-6

CAM

CHAIN

ADJUSTMENT.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9

IDLE SPEED

ADJUSTMENT

.....

.......

......

...

3-9

t-----

INSP

THROTTLE CABLE

FREE

PLAY

ADJUSTMENT

...

.......

....

3-10

ADJ

SPARK PLUG INSPECTION

...

.........

. .

......

............

3-11

IGNITION

TIMING

CHECK

...........

......

... ...

.. ..

. . 3-13

COMPRESSION

MEASUREMENT

............................

3-14

1----.....;

ENGINE OIL LEVEL INSPECTION.

......

.............

.....

3-16

ENGINE OIL REPLACEMENT

...

........

.....

...

. .

.......

. 3-18

ENG

OIL PRESSURE INSPECTION

.......

....

.....

. 3-22

CLUTCH

ADJUSTMENT

....

......

........

...

......

3-23

ENGINE OIL

TANK

STRAINER CLEANING

.....................

3-25 •

1-----

AIR FILTER CLEANING

....................................

3-27

CARBURETOR

JOINT

INSPECTION

....

...

.......

............

3-28

CARB

FUEL LINE INSPECTION

.........

. .

..............

3-29

CRANKCASE

VENTILATION

HOSE INSPECTION

...........

...

3-29

EXHAUST

SYSTEM INSPECTION

.........................

. 3-29

CANISTER INSPECTION (XT600

EAC

ONLY)

........................

3-30

CHAS

CHASSIS

..........

.....................................

3-32

FRONT BRAKE

ADJUSTMENT

.........

.......

.........

3-32

REAR

BRAKE

ADJUSTMENT

...............

.............

3-32

iii

BRAKE FLUID INSPECTION

................................

3-33

BRAKE PAD INSPECTION.

.....

. .

....

........

.....

BRAKE

LIGHT

SWITCH

ADJUSTMENT

.....

....

. .

....

...

3-35

BRAKE HOSE INSPECTION

................................

3-35

AIR BLEEDING

...

.. ..

......

..........

...

3-35

DRIVE CHAIN

SLACK

ADJUSTMENT

....................

...

3-36

DRIVE CHAIN LUBRICATION

...............................

3-38

FRONT FORK INSPECTION .

...

....

...

. .

.....

......

. . . . 3-38

STEERING HEAD

ADJUSTMENT

....

.....

.........

........

3-39

REAR

SHOCK ABSORBER

ADJUSTMENT

.....

...

. .

....

. . 3-40

TIRE INSPECTION

...

.. ..

...

. .

.....

....

. . .

....

3-41

WHEEL INSPECTION

....

. .

.....

...

....

.....

...

3-44

CABLE INSPECTION

AND

LUBRICATION . .

....

......

. . . . .

...

3-44

LEVER

AND

PEDAL LUBRICATION

. .

.......

.....

. . .

. 3-45

SIDESTAND LUBRICATION .

......

...

......

...

. . .

....

. 3-45

SWINGARM

AND

RELAY

ARM

LUBRICATION .

.. ..

. .

....

3-45

ELECTRICAL. . . . .

....

. . . .

...

. .

.... ....

. . . .3-46

BATTERY INSPECTION

...

.....

.. ..

. .

. . . .

...

.......

·3-46

FUSE INSPECTION

....

.. ..

.......

. .

...

3-53

HEADLIGHT

BEAM

ADJUSTMENT

. . .

.....

....

. .

...

.....

3-55

HEADLIGHT BULB REPLACEMENT

.. ..

....

. .

.. ..

. . . .

....

3-55

CHAPTER

ENGINE OVERHAUL

ENGINE

REMOVAL

......

............

....

......

....................

4-1

ENGINE OIL .. .

...........................

............

.. ..

......

4-1

SEAT

AND

FUEL

TANK

................................

..........

4-1

BATTERY LEAD

............

...

.........

. . .

.......................

4-1

CARBURETOR .

......

...

.......

...

........

....

.. .

.........

4-2

CLUTCH CABLE .

.........

. . .

....

.....

...

.......

. .

...

....

4-2

EXHAUST

.........

. .

...

. .

.........

....

.. ..

....

4-2

STARTER MOTOR

..............

........

........................

4-3

HOSE

AND

LEAD

.....

. .

.........

....

.........

. .. ..

..............

4-3

DRIVE CHAIN

........

...

. .

.......

. .

.......

. .. ..

.........

4-4

ENGINE PROTECTOR

....

......

........

....

....................

4-4

ENGINE

REMOVAL

............

....

........

..........

............

4-5

ENGINE

DiSASSEMBLy

..................

......

..........

4-6

CYLINDER

HEAD,

CYLINDER,

CAMSHAFT

AND

PISTON ..

. .

4-6

STARTER IDLE GEAR

AND

CRANKCASE COVER (LEFT)

...

......

.4-9

CLUTCH,

PRIMARY

DRIVE GEAR

AND

BALANCER GEAR

........

4-10

OIL

PUMP

AND

SHIFT LEVER

....

......

..........................

4-12

A.C

MAGNETO

AND

CAM

CHAIN

....

........

.. ..

....

.. ..

....

4-13

CRANKCASE (RIGHT)

......................

......

........

.. ..

....

4-15

SHIFTER

AND

TRANSMiSSiON

....

........

......

....

........

4-16

BALANCER

AND

CRANKSHAFT

..............

........

......

4-17

OIL STRAINER

....

............

....

.........

...

.. ..

..........

....

4-17

ROCKER

ARM

........

..........

....

.. ..

....

......

....

4-18

VALVE

...........

......

. . .

.......

. ..

.....

.. ..

......

INSPECTION

AND

REPAIR

......

............

..................

..4-21

CYLINDER HEAD . .

......

........

.....

........

................

4-21

VALVE

AND

VALVE

GUIDE

.. ..

....

........

....

....................

4-22

VALVE SEAT

....................

...

......

..............

. ..

....

4-23

VALVE SPRING

....

................

....

......

..............

4-27

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

..................

......

....

......................

4-32

PISTON PIN

....

.. .. ..

......

....

............................

4-33

CLUTCH

..........

....

......

...

.....

...

............

4-33

OIL

PUMP

...........

.. .. ..

...

.........

.......

.. ..

..........

4-35

PRIMARY

DRiVE

..........................

......

..............

4-35

TRANSMISSION

AND

SHIFTER

....

........

....

....................

4-36

SHIFT

SHAFT

STOPPER LEVER

..............

....................

4-37

STARTER DRIVE

....

.. ..

..........

.. ..

..........................

4-38

CRANKSHAFT

......

........

....

................................

4-39

BALANCER DRIVE GEAR

D BALANCER GEAR

....

......

4-39

CRANKCASE

......................

....

............................

4-40

BEARING

AND

OIL SEAL

.. ..

......

.. ..

....

....................

4-40

ENGINE

ASSEMBLY

AND

ADJUSTMENT

........................

4-41

VALVE

................

.. .. ..

................

.. ..

.................

4-42

ROCKER

ARM

....

.. .. ..

....

........

..........................

4-43

CRANKSHAFT

AND

BALANCER

......

........

....

..............

4-45

TRANSMISSION

AND

SHIFTER

....

......

....

................

4-48

OIL

STRAINER

..............

....

......

.. .. ..

..............

.....

.4-51

CRANKCASE

.....

...

..........

....

........

....

..........

4-51

I----~

GEN

INFO

SPEC

1-----

INSP

ADJ

1----....;;

ENG

CARB

SHIFT

LEVER

AND

OIL

PUMP

........

......

................

4-52

CHAS

CAM

CHAIN

.........

. .

.....

......

.......

....

...........

.....

...

4-54

:1.~~O~~g~~~~D~~

~.~~I.~~~~

~~~~.

~~~~~~.F.~:::::::::

::~~~

Iii

BALANCER GEAR,

PRIMARY

DRIVE GEAR,

CLUTCH

AND

OIL FILTER

............

....

........

..............

4-70

STARTER IDLE GEAR

AND

CRANKCASE COVER (LEFT)

..........

4-74

REMOUNTING ENGINE

.. ..

....

......

....

.. ..

..................

4-75

ELEC

~---.

TRBL

SHTG

CHAPTER

CARBURETION

CARBURETOR .. .

....

...

. .

............

....

...........

. .

...

5-1

SECTIONAL VIEW

.........

..............

....

...

. . .

.........

5-2

REMOVAL ...

...

......

................

...

.......

. .

...

. . 5-3

DISASSEMBLY

...

.....

..........

....

......

...

.......

5-4

INSPECTION . .

...

............

....

.........

...

....

...

5-7

ASSEMBLY

...

. . .

.............

...

. .

......

5-9

INSTALLATION ......

..........

....

.........

, . . .

...

. .5-

FUEL

LEVEL

ADJUSTMENT.

...

.........

. .

.......

. .

......

·5-15

CHAPTER

CHASSIS

FRONT

WHEEL.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

REMOVAL.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

INSPECTION.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

STATIC

WHEEL

BALANC

ADJUSTMENT.

. . . . . . . . . . . . . . . . . .

6-5

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9

INSPECTION

...............

........

.................

6-10

INSTALLATION . .

....

...

. .

.......

...

.....

....

...

. 6-

FRONT

AND

REAR BRAKE

...

.............

........

....

. . 6-

BRAKE PAD REPLACEMENT

....

...

.....

....

...

....

. . . 6-

CALIPER DISASSEMBLY

..........

. .

.......

...

....

. . . . 6-

MASTER CYLINDER DISASSEMB

.......

.................

6-23

INSPECTION

AND

REPAIR

........

.....

........

...

.....

CALIPER

ASSEMBL

Y .

...........

. . .

................

6-29

MASTER CYLINDER ASSE

.................

.......

FRONT FORK .. . . .

..........

...

.......

....

...

. .

...

. . 6-39

REMOVAL

.........................

...

..........

...

DISASSEMBL

...

.....

...

.......

... ...

INSPECTION .

.....

................................

...

6-43

ASSEMBLY

. . . .

...

......

................

........

6-44

INSTALLATION

............

.........

...

......

STEERING HEAD

AND

HAND

LEBAR .

...

......

...

......

REMOVAL

........

...

......................

....

...

. . . 6-

INSPECTION

...................

. . .

......

.....

6-52

INST

ALLATION

. .

....

...........

...

. .

.....

...

.....

Questo manuale è adatto per i seguenti modelli

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