Yamaha XT 600 AC Service Manual Download

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Summary of Contents for XT 600 AC

Page 1: ...amaha 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 P...

Page 2: ...on 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 sig...

Page 3: ...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 J the others being indicated by an alphabetical letter...

Page 4: ...gine Carburetion Chassis J Electrical Troubleshooting Illustrated symbols to are used to identify the specifications appearing in the text Filling fluid Lubricant Special tool Tightening j Wear limit...

Page 5: ...INDEX GENERAL INFORMATION GEN INFO SPECIFICATIONS jD SPEC PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL ENG CARBURETION CARB c T0 too CHAS CHASSIS ELECTRICAL TROUBLESHOOTING...

Page 6: ...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 SPECIFICATI...

Page 7: ...L 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...

Page 8: ...5 CHAPTER 4 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 PI PE 4 2 STARTER MOTOR 4 3 HOSE AND LEAD 4 3 DRIVE CHAIN...

Page 9: ...AFT STOPPER LEVER 4 37 STARTER DRIVE 4 38 CRAN KSHAFT 4 39 BALANCER DRIVE GEAR AN D BALANCER GEAR 4 39 CRANKCASE 4 40 BEARING AND OIL SEAL 4 40 ENGINE ASSEMBLY AND ADJUSTMENT 4 41 VALVE 4 42 ROCKER AR...

Page 10: ...T 6 5 INSTALLATION 6 6 REAR WHEEL 6 8 REMOVAL 6 9 INSPECTION 6 10 INSTALLATION 6 11 FRONT AND REAR BRAKE 6 13 BRAKE PAD REPLACEM ENT 6 15 CALIPER DISASSEMBLY 6 20 MASTER CYLINDER DISASSEMBLY 6 23 INSP...

Page 11: ...MANUAL 7 5 CHECKING SWITCH FOR TERMINAL CONNECTION 7 5 CHECKING OF BULBS FOR HEADLIGHT TAIL BRAKE LIGHT FLASHER LIGHT METER LIGHT ETC 7 8 KINDS OF BULBS 7 8 CHECKING BULB CONDITION 7 8 IGNITION SYSTE...

Page 12: ...RFORMANCE 8 3 FAULTY GEAR SHIFTING 8 4 HARD SHIFTING 8 4 CHANGE PEDAL DOES NOT MOVE 8 4 JUMP OUT GEAR 8 4 CLUTCH SLIPPING DRAGGING 8 5 CLUTCH SLIPPING 8 5 CLUTCH DRAGGING 8 5 FAULTY BRAKE 8 6 POOR BRA...

Page 13: ...OVERHEATING 8 9 OVERHEATING 8 9 XT600EA EAC CIRCUIT DIAGRAM J GEN INFO SPEC ENG J CARS c sG t CHAS...

Page 14: ...r is used to identify your motorcycle and may be used to register your motorcycle with the licensing au thority in your state ENGINE SERIAL NUMBER The engine serial number CD is stamped into the eleva...

Page 15: ...IAL TOOL 3 When disassembling the motorcycle keep mated parts together This includes gears cylinders pistons and other mated parts that have been mated through normal wear Mated parts must be reused a...

Page 16: ...embly Apply grease to the oil seal lips LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates CD and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt...

Page 17: ...er special tools are necessary for com plete and accurate tune up and assembly Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques FOR...

Page 18: ...s necessary for adjusting the valve clearance FOR ENGINE SERVICE 1 Universal clutch holder PI N YM 91 042 Q PI N 90890 04086 This tool is used to hold the clutch when remov ing or installing the clutc...

Page 19: ...PI N YM 01227 PI N 90890 01227 This tool is used to rebore the new valve guide 6 Valve guide installer 7 mm 0 28in PI N YM 04017 PI N 90890 0401 7 This tool is needed to install the valve guides prope...

Page 20: ...0 01274 Crankshaft installer bolt PIN 90890 01275 11 Adapter 10 M 14 PI N YM 90069 PI N 90890 04059 This tool is used to install the crankshaft 12 Crank pot spacer PI N YM 91044 P N 90890 04081 Q Spac...

Page 21: ...mating surfaces etc FOR CHASSIS SERVICE 1 T Handle PI N YM 01326 P N 90890 01326 CD Damper rod holder 27 mm 1 06in PI N YM 01388 P N 90890 01388 V This tool is used to loosen and tighten the front fo...

Page 22: ...U 33260 A D PI N 90890 03021 This instrument is necessary for checking the ig nition system components 2 Pocket tester PI N YU 03112 PI N 90890 03112 This instrument is available for checking the elec...

Page 23: ...turer Clutch Type GENERAL SPECIFICATIONS ISPECI p 1 SPECIFICATIONS XT600EA EAC 3UY2 XT600EA 3UY1 XT600EAC JYA3UYEO LA000101 XT600EA JYA3UYCO LA005101 XT600EAC 3UY 000101 XT600EA 3UY 005101 XT600EAC 2...

Page 24: ...Pressure cold tire Maximum load 202 kg 445 Ib Cold tire pressure Front Rear Up to 90 kg 198 Ib load 150 kPa 150 kPa 1 5 kg cm2 21 psi 1 5 kg cm2 21 psi 90 kg 198 Ib Maximum load 150 kPa 200 kPa 1 5 k...

Page 25: ...y 12V 8AH Headlight type Quartz bulb halogen Bulb wattage quantity Headlight 12V 60W 55W 1 pc Tail Brake light 12V 8W 27W 1 pc Flasher light 12V 27W 4 pc Front position light 12V 8W 2 pc Meter light 1...

Page 26: ...ust A head diameter 8 face width C seat width 0 margin thickness A B 2 4 XT600EA EAC 0 03 mm 0 0012 in Lines indicate straightedge measurement 94 97 95 02 mm 3 739 3 741 in 95 1 mm 3 744 in 50 mm 1 97...

Page 27: ...S ISPECI jJ 1 XT600EAjEAC 6 975 6 990 mm 0 274 0 275 in 6 955 6 970 mm 0 273 0 274 in 7 000 7 012 mm 0 275 0 276 in 7 000 7 012 mm 0 275 0 276 in 0 010 0 037 mm 0 0004 0 001 in 0 030 0 057 mm 0 001 0...

Page 28: ...0 02 0 06 mm 0 0008 0 002 in Crankshaft F Crank width A 74 95 75 00 mm 2 950 2 953 in Runout limit C b 0 03 mm 0 0012 in Big end side Clearance 0 0 35 0 65 mm 0 013 0 026 in Small end Free play F Q 0...

Page 29: ...retor 00 Cut away C A 5 5 Pilot air jet size p A J 1 1 0 Pilot jet P J 48 Enricher air jet size E A J 1 1 1 Pilot screw P S Preset Valve seat size V S dl2 5 Sta rter jet G S 76 Fuel level with special...

Page 30: ...gneto Hexagon nut M14 x 1 5 120 12 0 85 Locknut valve clearance adjuster Hexagon nut M6 x 1 0 14 1 4 10 Cam sprocket Flange bolt M7 x 1 0 20 2 0 14 Cam chain tensioner Hexagon socket head bolt M6 x 1...

Page 31: ...plate bearing a Flat head screw M6 x 1 0 7 0 7 5 1 Pressure plate Flange bolt M6 x 1 0 8 0 8 5 8 Clutch boss Hexagon nut M20 x 1 0 90 9 0 65 Primary drive gear Hexagon nut M20 x 1 0 120 12 0 85 Push...

Page 32: ...MAINTENANCE SPECIFICATIONS ISPECI 9 11 Tightening sequence Cylinder head Crankcase Left hand 2 10...

Page 33: ...n Shock absorber travel 71 mm 2 8 in Spring free length 255 mm 10 0 in Fitting length 243 5 mm 9 6 in Spring rate K1 95 N mm 9 5 kg mm 532 ib in Stroke K1 Zero 71 0 mm Zero 2 8 in Optional spring No E...

Page 34: ...pe Single Disc outside diameter 220 mm 8 66 in Disc thickness 5 0 mm 0 20 in Pad thickness 6 0 mm 0 24 in Wear limit 0 8 mm 0 03 in Master cylinder inside diameter 12 7 mm 0 5 in Caliper cylinder insi...

Page 35: ...d frame M10 X 1 25 64 6 4 46 Engine stay upper and engine M10 x 1 25 64 6 4 46 Engine rear and frame M 1Ox 1 25 64 6 4 46 Engine protector and frame M6 x 1 0 10 1 0 7 2 Rear shock absorber Swingarm Pi...

Page 36: ...x 1 0 5 0 5 3 6 License bracket and flap M4 x 0 7 2 0 2 1 4 Rear reflector and stay M5 x O S 4 0 4 2 9 Fuel tank and fuel cock M6 x 1 0 7 0 7 5 1 Fuel tank stay and frame M6 x 1 0 7 0 7 5 1 Helmet hol...

Page 37: ...speed x 1 000 r min Ignitor Unit model Manufacturer TNDF09 NIPPON DENSO Pickup coil resistance 184 276 D at 20 C 68 F color Green White Blue Yellow Ignition coil Model Manufacturer J0268 NIPPON DENSO...

Page 38: ...turer SM 13 MITSUBA Output 0 8 kw Brush overall length 12 mm 0 47 in limit 5 mm 0 20 in Commutator diameter 28 mm 1 10 in limit 27 mm 1 06 in Mica undercut depth 0 7 mm 0 03 in Starter switch Model Ma...

Page 39: ...all for clean dry threads Components should be at room tem perature A Distance across flats B Outside thred diameter DEFINITION OF UNITS A Nut 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm Unit Read Definition...

Page 40: ...0 Valve stem and valve guide Oil seal valve stem end G Rocker arm shaft and rocker arm 0 Cam and bearing camshaft 10 Rotor and rotor housing oil pump 0 Push rod I Primary driven gear and main axle 0 S...

Page 41: ...and thrust cover I iC Pivot shaft swingarm I Bushes rear shock absorber I Bushes relay arm and connecting rod I Bearings relay arm and connecting rod Pivoting points brake pedal and change pedal Bear...

Page 42: ...LUBRICATION DIAGRAM Oil tank 2 Oil strainer oil tank 3 Oil strainer engine 4 Oil pump LUBRICATION DIAGRAM ISPECII ll Al Feed rn J Scavenge 2 20...

Page 43: ...Oil pump Oil filter Cam shaft Oil delivery pipe Main axle Drive axle Oil hose LUBRICATION DIAGRAM ISPECI jJ 1 IN Feed ffil Scavenge 2 21 A 1 1_ _ rID _...

Page 44: ...Oil filter Cam shaft Crank pin Main axle Drive axle Drain bolt LUBRICATION DIAGRAM ISPEC ff Al Feed aJ Scavenge A LI_ _ BJ _ __ 3 ____J 4 ___U_i 2 22...

Page 45: ...I Oil pump 2 Oil filter 3 Oil delivery pipe 4 Transmission 5 Oil strainer LUBRICATION DIAGRAM ISPECll fl 6 Feed llil Scavenge A Il _ rID ___ 2 23...

Page 46: ...witch the couper underneath the meter lead and pilot box Align the white tape on the wirehar 4 Clamp the wires at the point ness with the Headlightstay where taping will stop near the 9 Brake hose OJ...

Page 47: ...se Wireharness Ignition coil Cable guide Breather hose guide Rear brake switch lead 2 25 IAl Pass the overflow hose carburetor and air vent hose carburetor bet ween the relayarm and swing arms BJ Fit...

Page 48: ...brake switch Reservoir hose guide Reservoir hose Air vent hose Overflow hose 2 26 181 Pass the vacuum hose through the hole on the flap BJ Clamp the horn lead g Pass the reservoir hose through the re...

Page 49: ...CD Ignitor unit Wireharness Clamp 4 Band 5 Flasher light lead left 6 Flasher light lead right 7 Rectifier Regulator CABLE ROUTING ISPECI Pfl 8 Pass the rear flasher light lead through the guide 2 27...

Page 50: ...oll over valve Carburetor Canister Relay arm Hose to atmosphere Connecting rod J Over flow hose Hose to carburetor Grommet Collar AJ Pass the hose to the right hand side of the relay arm and connectin...

Page 51: ...ain condition 6 Drive chain Adjust and lubricate chain SAE 30W 50W motor oil Every 500 km 300 mil tholoughly rou Yamaha chain and cable r Control and meter Apply chain lube lube or SAE 1OW30 motor 0 0...

Page 52: ...t 2 Remove Side cover left CD Sidecover right NOTE _________________________ When removing the side covers remove the bolt Then pull the front portion of the side cover outward to remove the projectio...

Page 53: ...___________________ When removing the air scoops remove the bolt Then pull the bottom portion of the air scoop outward to remove the projection from the gromm et Then pull the front portion of the air...

Page 54: ...bolt Then pull the projections from the grom mets 5 Turn the fuel cock to OFF 6 Disconnect Fuel hose CD NOTE _________________________ Place a rug on the engine to absorb a spilt fuel AWARNING Gasoli...

Page 55: ...AND COVER 3 5 Except for XT600EAC llil For XT600EAC INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Install Flap Side covers Seat Bolt side cover 7 Nm 0 7 m kg 5 1 ft lb Bolt se...

Page 56: ...stroke When removing the spark plug and tappet covers use caution to prevent an object from falling into the engine AWARNING Securely support the motorcycle so there is no danger of it falling over 1...

Page 57: ...cification Adjust Valve clearance cold Intake O 05 O 1 Omm O 002 O 004 in Exhaust O 12 O 17mm O 005 O 007 in 9 Adjust Valve clearance Adjustment steps Loosen the locknut CD Insert a Feeler Gauge betwe...

Page 58: ...exhaust Spark plug 11 Connect Leads ignition coil Spark plug cap 12 Install Bolts ignition coil bracket Tappet cover exhaust 12 Nm 1 2 m kg 8 7 ft lb Bolt tappet cover intake 10 Nm 1 0 m kg 7 2 ft lb...

Page 59: ...N 90890 03113 3 Check eEngine idle speed Out of specification Adjust Engine idle speed 1 300 1 400 rl min 4 Adjust eEngine idle speed Adjustment steps Turn the throttle stop screw Q in or out until s...

Page 60: ...SEAT FUEL TANK AND COVER section 2 Check Throttle cable free play Out of specification Adjust Throttle cable free play 3 5mm 0 12 0 20 in 3 Adjust Throttle cable free play Adjustment steps Loosen the...

Page 61: ...over fuel tank Fuel tank Refer to the SEAT FUEL TANK AND COVER section 2 Disconnect Spark plug cap 3 Remove Spark plug When removing the spark plug use caution to prevent an object from falling into t...

Page 62: ...park plug gap DPRSEA 9 X24EPR U9 O S 0 9 mm 0 031 0 035 in 8 Tighten Spark plug Before installing a spark plug clean the gasket and plug surfaces Spark plug 18 Nm 1 8 m kg 13 ft lb NOTE ______________...

Page 63: ...ns the oil may spurt out when removing the plug Therefore care should be used when removing 4 Check Ignition timing Checking steps eWarm up the engine and let it at the specified speed Engine speed 1...

Page 64: ...vers Air scoops Cover fuel tank Fuel tank Refer to the SEAT FUEL TANK AND COVER section 2 Check Valve clearance Out of specification Adjust Refer to the VALVE CLEARANCE ADJ USTM ENT section 3 Install...

Page 65: ...re at sea level Standard 1 100 kPa 11 kg cm2 156 psi Minimum 900 kpa 9kg cm2 128 psi Maximum 1 200 kPa 12kg cm2 171 psi If pressure falls below the minimum level 1 Squirt a few drops of oil into the a...

Page 66: ...Ib ENGINE OIL LEVEL INSPECTION Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage AWARNING Never remove the oil tank cap just after high...

Page 67: ...the oil up to the minimum level Recommended oil SAE 20W40 type SE motor oil or SAE 10W30 type SE motor oil 5 Install Oil tank cap 6 Start the engine and warm up until the oil temperature rises to apor...

Page 68: ...C 140 F Engine oil replacement without oil filter 1 Place the motorcycle on a level place 2 Remove Cover fuel tank Refer to the SEAT FUEL TANK AND COVER section 3 Warm up the engine for several minut...

Page 69: ...olt crankcase 9 Fill Bolt oil filter cover 10 Nm 1 0m kg 7 2 ft Ib Drain bolt oil tank 18 Nm 1 8 m kg 13 ft Ib Drain bolt crankcase 30 Nm 3 0 m kg 22 ft Ib Oil tank to frame Oil filter Chamber Recomme...

Page 70: ...FUEL TANK AND COVER section 3 Warm up the engine for several minutes then stop the engine Then place a recep tacle under the drain bolts 4 Remove Oil tank cap Drain bolt CD oil tank e Drain bolt CV c...

Page 71: ...ter cover Drain bolt crankcase Drain bolt oil tank 10 Fill Bolt oil filter cover 10 Nm 1 0 m kg 7 2 ft Ib Drain bolt oil tank 18 Nm 1 8 m kg 13 ft Ib Drain bolt crankcase 30 Nm 3 0 m kg 22 ft Ib Oil t...

Page 72: ...NSPEC TION section Oil pressure Refer to the OIL PRESSURE INSPEC TION section Oil leaks 13 Install Oil tank cap 3 22 Cover OIL PRESSURE INSPECTION 1 Remove Air bleed screw Q 2 Start the engine and kee...

Page 73: ...y is increased Free play is decreased Tighten the locknuts NOTE _________________________ The above procedure provides for maximum cable free play to allow for proper clutch actuating mechanism adjust...

Page 74: ...________ Proper push rod free play is essential to avoid excessive clutch slippage 13 Install Crankcase cover right Union bolt Bolt crankcase cover 10 Nm 1 0 mkg 7 2 ft Ib Union bolt engine oil deliv...

Page 75: ...t section ENGINE OIL TANK STRAINER CLEANING Components are firmly fixed in place Attention should be paid when removing them AWARNING Securely support the motorcycle so there is no danger of it fallin...

Page 76: ...he hose by twisting and pulling down ward 9 Remove Oil strainer CD Gasket 10 Clean Oil strainer Slow out the oil strainer with compressor air 11 Insect Oil hose Gasket oil strainer Gasket drain plug D...

Page 77: ...e cover CD 2 Remove Air filter element CD Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid wear and possible engine damage Additionall...

Page 78: ...r filter case 6 Install Air filter case cover CD as shown 7 Install Side cover right Seat Bolt seat 10Nm 1 Om kg 7 2ft Ib CARBURETOR JOINT INSPECTION 1 Remove Seat Side covers Air scoops Cover fuel ta...

Page 79: ...nstall Air scoop left Side cover left Seat Bolt seat 10Nm 1 Om kg 7 2ft lb CRAN KCASE VENTI LATIOr HOSE INSPECTION 1 Inspect Crankcase ventilation hose CD Crack Damage Replace EXHAUST SYSTEM INSPECTIO...

Page 80: ...or Canister removal 1 Remove Seat Side covers Air scoops Cover fuel tank Fuel tank Refer to the SEAT FUEL TANK AND COVER section 2 Remove Filter case cover right CD Breather hose from crankcase Breath...

Page 81: ...se box J from filter case projection Filter case cover 5 Disconnect Ignitor unit CD 6 Remove Bolts air filter case Joint bands Move airfilter case to the rear of shock absorber as shown so that the ca...

Page 82: ...juster in or out until the speci fied free play is obtained Free play is decreased Free play is increased Tighten the locknut Proper lever free play is essential to avoid excessive brake drag REAR BRA...

Page 83: ...1 Place the motorcycle on a level place NOTE _________________________ Position the motorcycle straight up when i nspecting the brake fluid level When inspecting the front brake fluid level make sure...

Page 84: ...em ical reaction and lead to poor performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in va...

Page 85: ...d the switch body CD with your hand so that it does not rotate and turn the adjusting nut BRAKE HOSE INSPECTION 1 Inspect e Brake hose Crack Damage Replace Refer to the FRONT AND REAR BRAKE section in...

Page 86: ...h Tighten the bleed screw when the lever or pedal limit has been reached then release the lever or pedal I p I Bleed screw 6 Nm 0 6 m kg 4 3 ft Ib i Repeat steps e to h until all of the air bubbles h...

Page 87: ...specified limits Remove the cotter pin CD and loosen the axle nut Loosen the bolt caliper bracket Loosen the bolts swingarm end 3 37 Turn the chain puller CD clockwise or coun terclockwise until the s...

Page 88: ...chain with small rubber O rings between the chain plates Steam cleaning high pressure washes and certain solvents can damage these O rings Use only kerosene to clean the drive chain Wipe it dry and t...

Page 89: ...placing a suitable stand under the engine 3 Check Steering assembly bearings Grasp the bottom of the forks and gently rock the fork assembly back and forth Looseness Adjust steering head 4 Adjust Ste...

Page 90: ...ing shaft 72 Nm 7 2 m kg 52 ft lb Bolt handle crown 23 Nm 2 3 m kg 17 ft lb Install the cover fuel tank REAR SHOCK ABSORBER ADJUSTMENT NOTE _________________________ The spring preload of the rear sho...

Page 91: ...nges 1 mm 0 04 in per turn of the adjuster Never attempt to turn the adjuster beyond the maximum or minimum setting Tighten the locknut Locknut 42 Nm 4 2 mokg 30 ftolb Always tighten the locknut again...

Page 92: ...han listed could cause tire deflation during extreme high speed riding Always use genuine parts or their equivalent for replacement Be sure to install the valve caps securely as these are important to...

Page 93: ...th front and rear 0 8 mm 0 03 in CD Tread depth Side wall Wear indicator AWARNING It is dangerous to ride with a worn out tire When a tire tread begins to show lines replace the tire immediately Patch...

Page 94: ...ING Never attempt even small repairs to the wheel CABLE INSPECTION AND LUBRICATION AWARNING Damaged cable sheath may cause corrosion and interfere with the cable movement An unsafe condition may resul...

Page 95: ...Lubricate pivoting parts of each lever and pedal Recommended lubricant SAE 10W30 motor oil SIDESTAND LUBRICATION Lubricate the sidestand at pivot points Recommended lubricant SAE 10W30 motor oil SWING...

Page 96: ...normal way thus making it im possible for the battery to operate regularly The charging time charging current and charging voltage for the MF battery is differ ent than general type batteries The MF b...

Page 97: ...nk large quantities of water or milk fol low with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydrogen gas therefore you should alway...

Page 98: ...______________ The state of a discharged MF battery can be checked by measuring open circuit voltage the voltage measured with the positive terminals being disconnected Open circuit voltage Charging t...

Page 99: ...y to generate heat at the contact area A weak clip spring may cause sparks Before removing the clips from the battery terminals be sure to turn off the power switch of the charger Change in the open c...

Page 100: ...the charg I ing voltage at 20 25 v Monitor the amperage for 3 5 minutes to check if the stan dard charging current is rea ched lA or more If the current is more than 1 amp adjust the voltage to 16 17...

Page 101: ...n the standard _ 1 1 charging current written on the battery Charge the battery until the battery s charging voltage is 16 volts or more NOTE __________ Set the charging time at 20 hours maximum Check...

Page 102: ...ated NO 1 charging current of the 1 charger is flowing by checking AM P meter Since the charging current is com tant the charging time varies depending on the battery capacity If rated current is not...

Page 103: ...the terminals apply grease light ly to the terminals 7 Install Battery 8 Connect Battery leads NOTE __________________________ Connect the positive lead first and then con nect the negative lead 9 Ins...

Page 104: ...use IS blown replace it 4 Replace eBlown fuse Blown fuse replacement steps Turn off ignition and the circuit Install a new fuse of proper amperage IrD IFuse 20 ampsx1pc Turn on switches to verify oper...

Page 105: ...ster CD clock To right the wise whill turning adjuster beam counterclockwise at the same time Turn the adjuster clock To left the wise whill turning adjuster beam CD counterclockwise at the same time...

Page 106: ...ew CD Secure the new bulb with the bulb holder Avoid touching glass part of bulb Also keep it free from oil otherwise transparency of glass bulb life and illuminous flux will be adversely affected If...

Page 107: ...Shift shaft A C magneto AWARNING Securely support the motorcycle so there is no danger of it falling over ENGINE OIL 1 D ain Engine oil Refer to the ENGINE OIL REPLACEMENT section in the CHAPTER 3 SEA...

Page 108: ...r Refer to the CARBURETOR REMOVAL section in the CHAPTER 5 CLUTCH CABLE 1 Remove Clutch cable CD 2 Disconnect Clutch cable end CD NOTE __________________________ Remove the cable end while pushing it...

Page 109: ...move Oil delivery pipe CD 2 Remove Bolt CD oil hose clamp 3 Disconnect Starter motor lead CD Ground lead 4 Remove Starter motor HOSE AN D LEAD 1 Remove Breather hose CD oil tank Breather hose crankcas...

Page 110: ...so that it does not interfere with engine removal DRIVE CHAIN 1 Remove Change pedal CD Cover drive sprocket 2 Remove Drive sprocket CD NOTE __________________________ Before removing the nut drive sp...

Page 111: ...it falling over 1 Place a suitable stand under the engine 2 Remove Engine stay CD upper 3 Remove Engine stay CD front 4 Remove Bolt CD Pivot shaft Engine assembly NOTE _________________________ The en...

Page 112: ...e cylinder head cylinder camshaft and piston can be maintained by removing the following parts eSeat eSide covers eAir scoops e Cover fuel tank e Fuel tank eCarburetor e Exhaust pipe 1 Remove eSpark p...

Page 113: ...nkcase cover left NOTE _________________________ Fasten safety wire to the cam chain to pre vent it from falling into the crankcase 5 Remove Chain guide CD 6 Remove Cylinder head NOTE ________________...

Page 114: ...____________ Before removing piston pin circlip cover crank case with a clean rag to prevent circlip from fail ing into crankcase cavity 10 Remove Piston pin CD Piston NOTE __________________________...

Page 115: ...EAR AND CRANKCASE COVER LEFT NOTE _________________________ With the engine mounted the starter idle gear and crankcase cover left can be maintained by removing the following parts Starter motor Drive...

Page 116: ...ad holder CD Pickup coil Stator coil CLUTCH PRIMARY DRIVE GEAR AND BALANCER GEAR NOTE _________________________ With the engine mounted the clutch primary drive gear and balancer gear can be maintaine...

Page 117: ...sing Push rod NOTE _________________________ Before loosening the nut jJ clutch boss straighten the lock washer tab Hold the clutch boss to loosen the nut clutch boss by the universal clutch holder Un...

Page 118: ...older Rotor holder PI N YS 01880 PI N 90890 01701 Do not allow the rotor holder to touch the projections on the rotor 4 Remove Push lever CD Spring Plain washer NOTE _________________________ Loosen t...

Page 119: ...clip CD from drive axle Collar Circlip 3 Remove Circlip CD Shift lever Spring Plain washer 4 Remove Stopper lever CD Collar Spring A C MAGNETO AND CAM CHAIN NOTE __________________________ With the en...

Page 120: ...____________ Hold the rotor to loosen the nut rotor by the rotor holder J Rotor holder PIN YS 01880 PIN 90890 01701 Do not allow the special tool to touch the projections on the rotor NOTE ___________...

Page 121: ...90 01135 NOTE __________________________ Fully tighten the tool holding bolts but make sure the tool body is parallel with the case If necessary one screw may be backed out slightly to level tool body...

Page 122: ...mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs take pressure off the push screw realign and start over If the cases do not separate check for a re...

Page 123: ...ating tool Crankcase separating tool PI N YU 01135 A PI N 90890 01135 Fully tighten the tool holding bolts but make sure the tool body is parallel with the case If necessary one screw may be backed ou...

Page 124: ...ing parts Seat Side covers Air scoops Cover fuel tank Fuel tank Cylinder head cover 1 Remove Plug CD 2 Remove Bolt CD rocker arm shaft 3 Remove Rocker arm shaft Rocker arm NOTE _______________________...

Page 125: ...ad cover Cylinder head 1 Check Valve sealing Leakage at valve seat Inspect the valve face valve seat and valve seat width Refer to the INSPECTION AND REPAIR VALVE SEAT section NOTE ___________________...

Page 126: ...alve Oil seal J NOTE __________________________ Identify each part position very carefully so that it can be reinstalled in its original place NOTE _________________________ Compress the valve spring...

Page 127: ...plug threads Valve seat 2 Inspect Cylinder head Scratches Damage Replace 3 Measure Warpage Out of specification Resurface Cylinder head warpage Less than 0 03 mm 0 0012 in 4 Resurface Cylinder head R...

Page 128: ...___ Heat the cylinder head in an oven to 1aao c 212 F to ease guide removal and installation and to maintain correct interference fit Remove the valve guide using the valve guide remover CD Install th...

Page 129: ...limit 0 7 mm 0 028 in 5 Check Valve stem end Mushroom shape or diameter larger than rest of stem Replace Runout Out of specification Replace Stem runout limit 0 01 mm 0 0004 in NOTE Always replace the...

Page 130: ...s the valve through the valve guide and onto the valve seat to make a clear pattern Measure the valve seat width Wherever the valve seat and valve face made contact bluing will have been removed If th...

Page 131: ...e seat is in the middle of the valve face but too narrow Valve seat cutter set Desired result To achieve a uni Use 45 cutter form valve seat width of 1 0 mm O 039 in la Valve seat is too narrow and ri...

Page 132: ...Applya molybdenum disulfide oil to the valve stem 1 nstall the valve into the cylinder head Turn the valve until the valve face and valve seat are evenly polished then clean off all compound NOTE ___...

Page 133: ...at width again If the valve seat width is out of specification reface and lap the valve seat VALVE SPRING 1 Measure Valve spring free length Out of specification Replace I Valve spring free length Inn...

Page 134: ...1 Inspect Cam lobes 0 075 in Pitting Scratches Blue discoloration Replace 2 Measure Cam lobes Out of specification Replace Intake 36 47 36 57 mm 30 06 30 16 mm 1 436 1 440 in 1 183 1 187 in Exhaust 36...

Page 135: ...rm to shaft clearance Arm to shaft clearance Rocker arm inside diameter Rocker arm shaft outside diameter Out of specification Replace as a set Arm to shaft clearance 0 009 0 042 mm 0 0003 0 0020 in C...

Page 136: ...easurement steps IFirst steps I Measure the cylinder bore C with a cylinder bore gauge 304 011 CD 50 mm 1 97 in from the cylinder top 4 30 NOTE _________________________ Measure the cylinder bore C in...

Page 137: ...in Oversize 4 96 0 mm 3 780 in 81f out of the specification replace the piston and piston rings as a set I 3rd steps I Find the piston to cylinder clearance with following formula Piston to cylinder...

Page 138: ...ing in cylinder NOTE __________________________ Insert a ring into cylinder and push it approxi mately 20 mm 0 8 in into cylinder Push ring with piston crown so that ring will be at a right angle to c...

Page 139: ...in 3 Measure to Piston pin to piston clearance Out of specification Replace piston Piston pin to piston clearance Bore size piston pin Outside diameter piston pin Piston pin to piston clearance 0 004...

Page 140: ...cause erratic operation 4 Measure Friction plate thickness Out of specification Replace as a set Thickness Wear limit Type A 2 94 3 06 mm 2 8mm 2 pes 0 116 O 120in 0 11 in Type 8 2 72 2 88 mm 2 6mrn...

Page 141: ...rotor V Side clearance between outer rotor and pump housing Ouf of specifications Replace oil pump Oil pump clearance Tip clearance Side clearance 2 Inspect 0 12 mm 0 005 in 0 03 0 08 mm 0 001 0 003...

Page 142: ...ove CD Shift cam segment Wear Damage Replace 3 Check Shift fork movement Unsmooth operation Replace shift fork and or guide bar 4 Inspect Guide bar Roll the guide bar on a flat surface Bends Replace A...

Page 143: ...lace Transmission gear reassembling points Press the 2nd wheel gear in the drive axle CD as shown 60 0 mm 2 36 in Press the 2nd pinion gear and 5th pinion gear in the main axle 90 5 mm 3 56 in 8 Inspe...

Page 144: ...he starter clutch and the wheel gear should be engaged If not the starter clutch is faulty Replacf It When turning the starter wheel gear r Junter clockwise ill the starter wheel W dr should turn free...

Page 145: ...Replace big end bear ing crank pin and or connecting rod Small end free play 0 8 mm 0 031 in Side clearance Out of specification Replace connecting rod Big end side clearance 0 35 0 65 mm O 014 0 026...

Page 146: ...Check Match marks CD If they are not aligned Align match marks as shown CRANKCASE 1 Inspect Crank halves Bearing seat Damage Replace BEARING AND OIL SEAL 1 Inspect Bearing Roughness Pitting Damage Rep...

Page 147: ...ring 2 5 or 1 9 mm 0 075 in 1 10 Nm 11 0 m kg 7 2 7 14 Nm 1 4 m kg 10 ft lb 6 STEM RUNOUT LIMIT 0 01 mm 0 0004 in VALVE SEAT WIDTH 1 0 1 2 mm 10 04 0 05 in 9 Outer spring 10 Valve intake 11 Valve reta...

Page 148: ...nstall Oil seal CD Valve Valve retainer Inner spring Outer spring Valve retainer NOTE __________________________ Install the inner and outer springs with wider gapped coils facing upwards as shown J L...

Page 149: ...ROCKER ARM 1 Lubricate eEngine oil to the rocker arm shaft 2 Install Rocker arm Rocker arm shaft Bolt CD rocker arm shaft 10 Nm 1 0 mokg 7 2 fto b NOTE _________________________ Numeral is stamped on...

Page 150: ...nk left 3 Connecting rod 4 Bearing Bearing Bearing J Balancer Bearing CRANK WIDTH A 74 95 75 00 mm 2 950 2 953 in RUNOUT LIMIT B 0 03 mm 0 0012 in C SMALL END FREE PLAY 0 8 mm 0 031 in BIG END SIDE CL...

Page 151: ...N YM 91044 PIN 90890 04081 Spacer PIN 90890 01016 NOTE __________________________ Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other O...

Page 152: ...l gear Drive axle 5th wheel gear j 3rd wheel gear 4th wheel gear 1st wheel gear B6305NRX1C3 16 Bearing Bearing 2nd pinion gear 5th pinion gear 3rd pinion gear 4th pinion gear Main axle Bearing MAIN AX...

Page 153: ...JUSTMENT IENGI I SHIFTER CD Stopper lever Guide bar Shift fork 3 Shift fork 1 m Shift cam 6 Guide bar 7 Shift fork 2 1 m Shift shaft 1 Shift shaft 2 Oil seal j Shift lever 11 1 m SD12 22 6 110 Nm 1 0...

Page 154: ...ift cam Guide bar NOTE _________________________ Each shift fork is identified by a number cast on its side All the numbers should face the left side 3 Install Shift shaft 1 CD Shift shaft 2 NOTE ____...

Page 155: ...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...

Page 156: ...plate Crankcase left Crankcase ventilation hose Dowel pin Dowel pin Dowel pin Stopper plate Collar A TIGHTENING SEQUENCE 7 Nm 0 7 m kg 5 1 ft lb 10Nm 1 0m kg 7 2ft lb 20 Nm 2 0 m kg 14 ft lb t t I SE...

Page 157: ...ealant quick gasket PIN ACC 11 001 01 Yamaha Bond No 1215 PIN 90890 85505 2 Install Dowel pin 3 Fit the left crankcase onto the right case Tap lightly on the case with a soft hammer NOTE _____________...

Page 158: ...ft lb 5 Apply 4 stroke engine oil to the crank pin bearing and oil delivery hole 6 Check Crankshaft and transmission operation Unsmooth operation Repair SHIFT LEVER AND OIL PUMP 1 Install Spring CD Co...

Page 159: ...ft 3 Install Circlip CD to drive axle Collar Circlip 4 Apply 4 stroke engine oil to the oil passages in the crankcase Apply a liberal amount of 4 stroke engine oil to the oil pump passages in the cran...

Page 160: ...ENGINE ASSEMBLY AND ADJUSTMENT ENG CAM CHAIN 1 Install Cam chain CD Chain guide 4 54...

Page 161: ...Piston pin clip PISTON SIZE A 94 915 94 965 mm 3 737 3 739 in D USE NEW ONE 4 55 PISTON RING END GAP Top O 30 O 45mm O 012 O 018in B 2nd O 30 O 45mm O 012 O 018in Oil O 20 O 70mm O 008 O 028in PISTON...

Page 162: ...sket Dowel pin Dowel pin A TIGHTENING SEQUENCE 42 Nm 4 2 m kg 30 ft lb 22 Nm 2 2 m kg 16 ft lb I 3 4 56 BORE SIZE 94 97 95 02mm 3 739 3 741 in B LIMIT 95 1 mm 3 744 in PISTON TO CYLINDER CLEARANCE C 0...

Page 163: ...R HEAD Cylinder head cover Tappet cover intake O ring Tappet cover exhaust O ring Blind cap Cylinder head Valve guide intake valve 9 Valve guide exhaust valve 10 Spark plug 11 Dowel pin 10 Nm 1 0 m kg...

Page 164: ...AM CHAIN CD Camshaft l Cam sprocket Chain guide Cam chain Chain guide Gasket J Chain tensioner SHAFT TO CAP CLEARANCE A 0 020 0 054 mm 0 0008 0 0021 in CAMSHAFT RUNOUT LIMIT 0 03 mm 0 0012 in 3 J 4 58...

Page 165: ...___ The arrow on the piston must point to the front of the engine Before installing the piston pin clip cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip and...

Page 166: ...fore installing the cylinder apply a liberal coat ing of 4 stroke engine oil to the piston rings CD Top ring bl Oil ring Lower rail Oil ring Upper rail 2nd ring 6 Install Cylinder CD NOTE ____________...

Page 167: ...owest num bered one f Bolt CD and 29 Nm 2 9 m kg 21 ft lb Nut and 22 Nm 2 2 m kg 16 ft lb Bolt j 10 Nm 1 0 m kg 7 2 ft lb 9 Install Chain guide Camshaft Cam sprocket Installing steps Install the camsh...

Page 168: ...ile pushing the cam chain damper be sure cam sprocket timing marks align with the cylinder head upper surface elf marks are aligned tighten the cam sprocket bolts Bolt cam sprocket 20 Nm 2 0 mokg 14 f...

Page 169: ...tension rod Install the tensioner with a new gasket into the cylinder Bolt tensioner body 10 Nm 1 0 mokg 7 2 ftolb AWARNING Always use a new gasket Install the spring washer and tensioner cap bolt Te...

Page 170: ...D exhaust Tappet cover intake Spark plug Tappet cover exhaust 12 Nm 1 2 m kg 8 7 ft lb Bolt tappet cover intake 10 Nm 1 0 m kg 7 2 ft Ib Spark plug 18 Nm 1 8 m kg 13 ft Ib NOTE _______________________...

Page 171: ...kup coil 3 Stator coil PICKUP COIL RESISTANCE A 184 276Q at 20 C 68 F Green White Blue Yellow 17 Nm 0 7 m kg 5 1 ft lb 1 120Nm 12mokg 85ftolb 17 Nm 0 7 m kg 5 1 ft lb 1 a B 4 65 3 30 Nm 3 0 mokg 22 ft...

Page 172: ...the woodruff key is properly seated in the keyway of the crankshaft Apply a light coating of lithium soap base grease to the tapered portion of the crankshaft end 2 Tighten Nut rotor Nut rotor 120 Nm...

Page 173: ...1 BALANCER GEAR AND PRIMARY DRIVE GEAR Key Balancer gear Plate Lock washer Nut Plate washer Key A USE NEW ONE I60 Nm 6 0 mokg 43 ft lb I 5 10 A USE NEW ONE Plate Balancer drive gear Plate Primary dri...

Page 174: ...es 0 116 0 120 in B 2 72 2 88 mm 6pes 0 107 0 113 in Friction plate type B Clutch boss Thrust washer jJ Clutch housing Push rod Push lever J Primary drive gear Wear limit 2 8 mm 0 110 in 2 6 mm 0 102...

Page 175: ...L FILTER AND OIL DELIVERY LINE CD Oil filter Oil filter cover Oil hose Oil hose Oil delivery pipe Oil drain bolt 10 Nm 1 0 m kg 7 2 ft lb 15 Nm 0 5 m kg 3 6 ft lb I 10 Nm 1 0 m kg 7 2 ft lb r 18Nm 1 8...

Page 176: ...g 43 ft lb Nut primary drive gear 120 Nm 12 0 m kg 85 ft lb NOTE __________________________ When installing the drive gear align the punched mark on the drive gear with the punched mark on the balance...

Page 177: ...B j Clutch plate Friction plate type A Wave plate Ball jJ Pressure plate Clutch spring Bolt pressure plate Nut clutch boss 90 Nm 9 0 m kg 65 ft lb Bolt pressure plate 8 Nm 0 8 m kg 5 8 ft lb NOTE ___...

Page 178: ...placed on the inside of the second friction plate Friction Plate Type A Type 8 Quantity 2 pes 6 pes Inside 116 mm 113 mm Diameter 0 14 67 in 14 45 in NOTE _________________________ Align the punched...

Page 179: ...ENGINE ASSEMBLY AND ADJUSTMENT 1 ENG 1 1 STARTER GEAR CD Starter gear Starter idle gear 1 Starter idle gear 2 Starter wheel gear Starter one way 10 Nm 1 0 m kg 7 2 ft lb 120 Nm 12 0 mokg 85 ftolb 4 73...

Page 180: ...coil CD Pickup coil Lead holder Screws stator and pickup coil 7 Nm 0 7 m kg 5 1 ft lb Use LOCTITE Screw lead holder 7 Nm 0 7 m kg 5 1 ft lb 2 Install Shaft CD Searing Starter idle gear 2 3 Install Do...

Page 181: ...tarter idle gear Bolts starter idle gear cover 10 Nm 1 0 mokg 7 2 ftolb REMOUNTING ENGINE When remounting the engine reverse the EN GINE REMOVAL procedure Note the following points AWARNING Securely s...

Page 182: ...t 85 Nm 8 5 m kg 61 ft lb 2 Install Engine protector CD Bolt engine protector 10 Nm 1 0 m kg 7 2 ft lb 3 Connect Magneto lead 4 Install Spark plug lead CD 5 Install Drive sprocketCD Drive chain Nut dr...

Page 183: ...Bolt footrest 45 Nm 4 5 m kg 32ft lb 7 Adjust Drive chain slack 30 40 mm 1 18 1 57 in Refer to the DRIVE CHAIN SLACK AD JUSTMENT section in the CHAPTER 3 8 Install Oil hose CD inlet Oil hose outlet Bo...

Page 184: ...engine oil to the cam shaft upper side and into the oil filter room Apply a liberal amount of 4 stroke engine oil to the oil passage in the crankcase or the engine may be damaged Oil quantity Cam sha...

Page 185: ...Adjust Clutch cable f ree play Free play rA l 2 3 mm 0 08 0 12 in Refer to the CLUTCH ADJUSTMENT section in the CHAPTER 3 18 lnstall Carburetor Screw clamp 2 Nm 0 2 m kg 1 4 ftolb Refer to the CARBURE...

Page 186: ...tall Fuel tank Never start the engine when the oil is drained 23 Apply Engine oil Oil quantity 3 3 L 2 9 Imp qt 3 5 US qt Refer to the ENGINE OIL REPLACE MENT section in the CHAPTER 3 24 Check Engine...

Page 187: ...ndary Main nozzle Secondary Piston valve Jet needle set Secondary 2 Nm 0 2 m kg 1 4 ft lb 9 Nm 0 9 mokg 6 5 ftolb 3 Nm 0 3 m kg 2 2 ft lb CARBURETOR ICARBI I CARBURETION SPECIFICATIONS Model XT600EA X...

Page 188: ...e Primary Valve seat Needle valve Main nozzle Primary Main jet Primary Jet needle Secondary J Main nozzle Secondary Main jet Secondary 5 2 CARBURETOR ICARBI I AJ Primary carburetor ill Secondary carbu...

Page 189: ...aphragm Coasting enricher Starter plunger Throttle stop screw Pilot screw 1 Remove Seat Side covers Air scoops Cover fuel tank Fuel tank Refer to the SEAT FUEL TANK AND COVER section in the CHAPTER 3...

Page 190: ...ter case CD Air filter case from projection _ Carburetor joint from carburetor by mov ing air filter case to the rear 6 Remove Carburetor DISASSEMBLY 1 Remove Stay plate CD front Stay plate rear 2 Sep...

Page 191: ...oat pin Float NOTE _________________________ Remove the float pin in the arrow direction 2 Remove Needle valve Valve seat CD Main jet Main nozzle Pilot jet O ring 3 Remove Throttle stop screw CD Stqrt...

Page 192: ...move Top cover CD Gasket Screw connecting arm 6 Remove Throttle lever CD Collar Cable holder 7 Remove Throttle shaft CD Spring 8 Remove Connecting arm CD Jet needle Throttle valve Secondary carburetor...

Page 193: ..._____________ Use a petroleum based solvent for cleaning Blow out all passages and jets with compressed air 2 Inspect Valve seat CD Needle valve Wear Contamination Replace O ring Damage Replace NOTE _...

Page 194: ...eJet needle secondary Bends Wear Replace 6 Inspect eThrottle valve CD primary ePiston valve secondary WearI Damage Replace 7 Check eFree movement Stick Replace Insert the throttle valve and piston val...

Page 195: ...rocedures Note the following points Before reassembling wash the all parts with a clean gasoline Secondary carburetor 1 Install Jet needle CD Piston valve NOTE _________________________ Match the tab...

Page 196: ...he illustrated position 2 Install Throttle valve 3 Install Spring Throttle shaft NOTE __________________________ Set the spring as shown 4 Install Screw connecting arm NOTE __________________________...

Page 197: ...hrottle lever nut Screw cable holder CD 3 Nm 0 3 m kg 2 2 ft Ib 6 Install Top cover CD Screw top cover 2 Nm 0 2 m kg 1 4 ft lb 7 Install Diaphragm CD coasting enricher NOTE _________________________ M...

Page 198: ...27 0 mm 0 98 1 06 in Measurement and adjustment steps Hold the carburetor in an upside down po sition Measure the distance from the mating sur face of the float chamber gasket removed to the top of th...

Page 199: ...Stay plate rear Screw stay plate 3 Nm 0 3 m kg 2 2 ft lb 15 Adjust Secondary carburetor synchronization Adjustment steps Raise the primary throttle valve CD to a height of 7 0 mm 0 28 in as indicated...

Page 200: ...Install e Carburetor joint to carburetor by moving air filter case forward eAir filter case on to projection CD e Bolts air filter case Bolt air filter case 10Nm 1 0 mokg 7 2 ft lb Screw clamp 2Nm 0...

Page 201: ...evel Gauge CD to the float chamber nozzle Fuel level gauge PI N YM 01312 A PI N 90890 01312 4 Loosen the drain screw and warm up the engine for several minutes 5 Measure Fuel level Out of specificatio...

Page 202: ...Oil seal Bearing Collar Front wheel Bearing Gear unit speedometer 10 Damper rubber 158 Nm 5 8 mokg 42 ftolb I 19 Nm 0 9 mokg 6 5 ftolb I 6 1 7 A TIRE SIZE 90 90 21 54S B RIM SIZE 1 85 x 21 RIM RUNOUT...

Page 203: ...eel by placing a suitable stand under the engine 3 Remove Speedometer cable CD Disc cover 4 Loosen Nut CD axle holder 5 Remove Wheel axle Front wheel NOTE _________________________ Do not depress the...

Page 204: ...TION section in the CHAPTER 3 4 Check Spoke s Bend Damage Replace Loose spoke s Retighten Turn the wheel and tap the spokes with a screw driver NOTE _________________________ A tight spoke will emit a...

Page 205: ...damper rubber should be installed with the 3TB mark CD outside_ 8 Inspect Wheel bearings CD Bearings allow play in the wheel hub or wheel turns roughly Replace Oil seals Wear Damage Replace Oil seal...

Page 206: ...rim wheel balancer should be adjusted Adjust the wheel balance with brake disk installed 1 Remove Balancing weight 2 Set the wheelan a suitable stand 3 Find Heavy spot Procedure a Spin the wheel and w...

Page 207: ...0 up Check that t he heavy spot is at rest there If not try another weight until the wheel is balanced 5 Check Wheel balance Checking steps Turn the wheel so that it comes to each point as shown Check...

Page 208: ...th the locating slot on the gear unit assembly 4 Tighten Wheel axle CD Nut axle holder Wheel axle 58 Nm 5 8 mokg 42 ft lb Nut axle holder 9 Nm 0 9 mokg 6 5 ftolb NOTE __________________________ The ax...

Page 209: ...EBE L R EA R W H E E L lcHASI 1 2 USE NEW ONE D DRIVE CHAIN SLACK 30 40 mm 1 18 1 57 i 6 8 A TIRE SIZE 120 90 17 64S B RIM SIZE MT 2 50 X 17 RIM RUNOUT LIMIT C VERTICAL 2 0 mm 0 08 in LATERAL 2 0 mm 0...

Page 210: ...liper protector 4 Remove Bolt CD brake caliper Bolt caliper bracket NOTE _________________________ Do not depress the brake pedal when the wheel is off the motorcycle as tlie brake pads will be forced...

Page 211: ...SPE CTION section 2 Inspect Tire Wheel Damper rubber Refer to the FRONT WHEEL INSPE CTION section 3 Inspect Spoke s Refer to the FRONT WHEEL INSPE CTION section 4 Measure Wheel runout Refer to the FRO...

Page 212: ...on the left side and the R mark on the right side 3 Adjust Drive chain slack Drive chain slack 30 40 mm 1 18 1 57 in Refer to the DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 4 Tighten Axle...

Page 213: ...after torque tighten ing If the axle nut groove is not aligned with the wheel shaft cotter pin hole align groove to hole by tightening up on the axle nut 5 Install Cotter pin NOTE ___________________...

Page 214: ...AKE FLUID TYPE A If DOT 4 is not available DOT 3 can be used B BRAKE PAD WEAR LIMIT 1 0 mm 0 04 in C BRAKE DISC WEAR LIMIT 4 0 mm 0 16 in I D 1 USE NEW ONE I I Piston 9 Piston seal 10 Dust seal II Bra...

Page 215: ...E PAD WEAR LIMIT 0 8 mm 0 03 in C BRAKE DISC WEAR LIMIT 4 5 mm 0 18 in FRONT AND REAR BRAKE ICHASI I Brake caliper Piston Piston seal Dust boot Ring dust boot 15 Shim 1 Brake pads 1 Pad springs 1 Moun...

Page 216: ...w brake fluid to contact painted sur faces or plastic parts otherwise damage may occur Disconnect any hydraulic connection other wise the entire system must be disassem bly drained cleaned and then pr...

Page 217: ...Replace the pads as a set if either is found to be worn to the wear limit Wear limit 1 0 mm 0 04 in 4 Lubricate Guide pins CD r d lithium soap base grease 5 Install Caliper bracket CD to caliper body...

Page 218: ...new and brake pad assembly new NOTE _________________________ The longer tangs of the pad spring must point in the outside direction 7 Install Retaining bolts 8 Install Bolts caliper body CD 9 Tighten...

Page 219: ...clockwise 2 Remove Brake pads CD Shim Pad springs NOTE __________________________ Replace the spring if the pad replacement is required Replace the pads as a set if either is found to be worn to the...

Page 220: ...ew Caliper bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the pad shim new to the piston side brake pad Install the pad springs new and brake pads new NOTE __________________________ Be sure to position...

Page 221: ...efer to AIR BLEEDING section in the CHAPTER 3 CALIPER DISASSEMBLY NOTE __________________________ Before disassembling the front brake caliper or rear brake caliper drain the brake system of its brake...

Page 222: ...the standing brake fluid 4 Remove Caliper bracket CD Piston Dust seal Piston seal Remove steps Blow compressed air into the tube joint open ing to force out the piston from the caliper body AWARNING...

Page 223: ...the caliper to catch the standing brake fluid 4 Remove Piston CD Ring dust boot Dust boot Piston seal NOTE __________________________ Remove the piston and then the ring dust boot and dust boot Remova...

Page 224: ...rain the brake system of the brake fluid AWARNING Securely support the motorcycle so there is no danger of it falling over 6 23 Front Brake 1 Remove Protecter right CD 2 Remove Brake lever CD Return s...

Page 225: ...______ Place a container under the master cylinder to catch the standing brake fluid Rear Brake 1 Remove Seat Side cover right Refer to the SEAT FUEL TANK AND COVER section in the CHAPTER 3 2 Remove C...

Page 226: ...phragm NOTE _________________________ Place the container under the reservoir tank to catch the standing brake fluid 9 Disconnect Reservoir tank hose J from reservoir tank INSPECTION AND REPAIR Recomm...

Page 227: ...t Damage Replace Rubber boots Cracks Wear Damage Replace Oil delivery passage caliper body Blowout with compressed air AWARNING Replace the piston seal and dust boot when ever a caliper is disassemble...

Page 228: ...ragm rear Wear Damage Replace Reservoir tank Cracks Damage Replace AJ Front ill Rear 6 Inspect Brake hoses CD Reservoir hose Cracks Wear Damage Replace AJ Front ill Rear 7 Measure Brake pad thickness...

Page 229: ...lace Refer to the FRONT WHEEL INSPECTION section A Front ill Rear 9 Measure Brake disc deflection Out of specification Inspect wheel runout If wheel runout is in good condition replace the brake disc...

Page 230: ...caliper is disassembled Front Brake 1 Install Piston seals CD Dust seals Pistons V 1 tj __________ Always was new piston seal and dust seal 2 Install Caliper bracket CD to the caliper body Pad spring...

Page 231: ...r washers 5 Fill Brake fluid Recommended Brake Fluid If DOT 4 is not available DOT 3 can be used CAUTION Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediate...

Page 232: ...R 3 8 Install Diaphragm CD Master cylinder cap Screws Screw master cylinder cap 2 Nm 0 2 m kg 1 4 ft Ib Rear Brake 1 Install Pistion seal CD Piston Rubber boot Ring dust boot NOTE ____________________...

Page 233: ...tector Retaining bolt 23 Nm 2 3 m kg 17 ft Ib NOTE _________________________ Place the rubber boot securely in the groove of guide pin when installing the caliper body 5 Install Copper washers CD Brak...

Page 234: ...uids may result in a harmful chem ical reaction and lead to poor performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of...

Page 235: ...sed Rear Brake DOT 4 Replace the master cylinder kit whenever a caliper is disassembled Front Brake 1 Install Master cylinder kit CD Circlip Dust boot 2 Install Master cylinder NOTE __________________...

Page 236: ...d If DOT 4 is not available DOT 3 can be used CAUTION Brake fluid may erobe painted surfaces or plastic parts Always clean up spilled fluid immediately AWARNING Use only the designated quality brake f...

Page 237: ...cap Screws Screw master cylinder cap 2 Nm 0 2 m kg 1 4 ft Ib Rear Brake 1 Install Reservoir tank CD temporarily 2 Connect Reservoir tank hose to reservoir tank 3 Install e Master cylinder kit CD Adju...

Page 238: ...2 Always use new copper washers 5 Install Master cylinder Q Bolt master cylinder Bolt master cylinder 20 Nm 2 0 m kg 14 ft Ib 6 Tighten Union bolt Union bolt 26 Nm 2 6 m kg 19 ft lb 7 Connect Reservo...

Page 239: ...mful chemi cal reaction and lead to poor performace Be careful that water does not enter the master cylinder whem refilling Water will significantly lower the boiling point of the fluid and may result...

Page 240: ...rk tube Damper rod Oil lock pieces FORK OIL EACH CAPACITY A 538 em3 18 9 Imp OZ 18 1 US oz GRADE FORK OIL 10W OR EQUIVALENT FRONT FORK ICHASI I FORK SPRING B MINIMUM FREE LENGTH 468 4 mm 18 4 in 23 Nm...

Page 241: ...lace 2 Elevate the front wheel by placing a suitable stand under the engine 3 Remove Front wheel Refer to the FRONT WHEEL RE MOVAL section 4 Remove for left hand front fork Band CD speedometer cable H...

Page 242: ...e Snap ring CD NOTE __________________________ Use a thin screwdriver and be careful not to scratch the inner fork tube 5 Remove Bolt CD damper rod Washer NOTE _________________________ Hold the dampe...

Page 243: ...he outer tube by forcefully but carefully withdrawing the inner fork tube Ilili0AO tb lfri________ Excessive force will damage the oil seal and or the bushes Damaged oil seal and bushing must be repla...

Page 244: ...ork tube as this may dangerously weaken the tube 2 Measure Fork spring free length Out of specification Replace Fork spring free length 478 0 mm 18 8 in Minimum free length 468 4 mm 18 4 in 3 Inspect...

Page 245: ...reassembly be sure to use fol lowing new parts Guide bush Oil seal Dust seal Make sure all components are clean before reassembly 1 Install Damper rod CD Allow the damper rod to slide slowly down the...

Page 246: ...amper rod 62 Nm 6 2 m kg 45 ft Ib LOCTITE 5 Install Slide metal CD Use the fork seal driver weight and adapter Inner fork tube Outer fork tube Fork seal driver weight YM 33963 90890 01367 Adapter 41 m...

Page 247: ...V NOTE _________________________ Fit the snap ring CV correctly in the groove in the outer tube 8 Fill Front fork Each fork 538 cm3 18 9 Imp OZ 18 1 US oz Fork Oil 10W or equivalent After filling slow...

Page 248: ...end in such a way that it is flush with the top of the handle crown 2 Tighten Nut Q lower bracket Cap bolt Pinch bolt handlebar crown Nut lower bracket 23 Nm 2 3 m kg 17 ft Ib Cap bolt 30 Nm 3 0 m kg...

Page 249: ...eedometer cable Cable holder speedometer cable Headlight stay Ring nut 20 Nm 2 0 m kg 14 tt lb J4J j 6 1 I _ L 1 172 Nm 7 2 m kg 52 ft lb I 13 0 N m 3 0 m k g 22 ft I b I 6 IBlusENEwo i 7 f 9 1 12 3 N...

Page 250: ...tand under the engine 3 Remove Front wheel Refer to the FRONT WHEEL REMOVAL section Front forks Refer to the FRONT FORK REMOVAL section 4 Remove Bolts CD front fender Front fender Washer 5 Remove Scre...

Page 251: ...itch coupler Main switch coupler Brake switch coupler Clutch switch coupler 9 Remove Speedometer cable CD 10 Remove Headlight stay CD Meter assernbly 11 Remove Protecter right Brake lever Mirror right...

Page 252: ...utch cable 16 Remove eClutch cable 17 Remove eBands CD Handlebar switch left Clutch switch 18 Remove Handlebar CD eThrottle holder assembly 19 Remove Steering shaft bolt CD Handlebar crown Ring nut Be...

Page 253: ...1 Wash the bearings with a solvent 2 Inspect eBearing CD e Bearing race Pitting Damage Replace as a set Bearing race replacement steps Remove the bearing races using a long rod CD and hammer as shown...

Page 254: ...cement steps Remove the handlebar grip and lever holder Install the lever holder to a new handlebar Apply a light coat of an adhesive for rubber on the leh handlebar end Install the handlebar grip NOT...

Page 255: ...wrench Ring nut wrench PI N YU 33975 PI N 90890 01403 NOTE __________________________ Set the torque wrench to the ring nut wrench so that they form a right angle Ring nut initial tightening 38 Nm 3 8...

Page 256: ..._________________ The upper handlebar holder should be installed with the punched mark CD forward A Forward 0 IlgN First tighten the bolts on the front side of the handlebar holder and then tighten th...

Page 257: ...the lower bolt Bolts master cylinder bracket 7 Nm 0 7 m kg 5 1 ft olb 10 Install Meter assembly CD Headlight stay Bolt meter assembly 7 Nm 0 7 m kg 5 1 ft olb Bolt headlight stay 7 Nm 0 7 mokg 5 1 ft...

Page 258: ...on in the CHAPTER 2 15 Install Headlight lens unit Cowling Bolt headlight upper 16 Nm 1 6 mokg 12 ftolb Bolt headlight lower 7 Nm 0 7 mokg 5 1 ft lb Bolt cowling 7 Nm 0 7 mokg 5 1 ft lb 16 Install Fro...

Page 259: ...GARM ICHASIAI REAR SHOCK ABSORBER AND SWINGARM CD Rear shock absorber assembly Spring SPRING PRELOAD STANDARD FITTING LENGTH 243 5 mm 9 6 in A MINIMUM LENGTH 4 1 237 5 mm 9 4 in t MAXIMUM LENG H J 248...

Page 260: ...REAR SHOCK ABSORBER AND SWINGARM ICHASIAI Swingarm Relay arm Connection rod Chain case Chain protector Chain guide 6 59 17 Nm 0 7 m kg 5 1 ft lb 1 32 Nm 3 2 m kg 23 ft b...

Page 261: ...s may cause the unit to explode due to excessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance Take care not to scratch the conta...

Page 262: ...on a level place 2 Remove Seat Side covers Air scoops Cover fuel tank Fuel tank Refer to the SEAT FUEL TANK AND COVER section in the CHAPTER 3 3 Elevate the rear wheel by placing a suitable stand und...

Page 263: ...9 Remove Rubber cover CD Washer from rear shock absorber 10 Remove Bolt CD connecting rod 11 Remove Bolt CD hose clamp 12 Check Swingarm free play Inspection steps eCheck the tightening torque of the...

Page 264: ...check the inner collar bearing washer and thrust cover Side play at end of swingarm Limit 1 0 mm 0 04 in eCheck the swingarm vertical movement ill by moving it up and down If vertical movement is tig...

Page 265: ...od relay arm Connecting rod Thrust cover J relay arm Collar relay arm Rubber cap Nut relay arm swingarm Relay arm Thrust cover relay arm Collar relay arm Thrust cover swingarm Collar swingarm INSPECTI...

Page 266: ...amage Replace Bearing Pitting Damage Replace 5 Inspect Chain guide CD Chain protector roller Chain protector Wear Damage Replace NOTE _________________________ When replacing the bearing and bush of s...

Page 267: ...pcs 3 Measure Pivot width 4 Measure Washer thickness Out of specification Replace Washer thickness 1 90 2 00 mm 0 075 0 079 in 5 Calculate Swingarm side clearance Out of specification Adjust side cle...

Page 268: ...8 22 in 1 9 mm 0 075 in Side clearance 63 6 74 9 x 2 208 8 1 9 x 2 0 8 mm 0 03 in Then install the one shim Shim thickness 6 0 3 mm 0 012 in INSTALLATION Reverse the REMOVAL procedure Note the follow...

Page 269: ...9 Nm 5 9 m kg 43 ft Ib Nut relay arm connecting rod 32 Nm 3 2 m kg 23 ft Ib Bolt chain protector 7 Nm 0 7 m kg 5 1 ft lb 3 Tighten Nut CD pivot shaft Nut CD pivot shaft 85 Nm 8 5 m kg 61 ft Ib 4 Tight...

Page 270: ...over NOTE __________________________ Bend the ends of the cotter pin AWARNING Always use a new cotter pin 8 Tighten Screw Q chain case Screw Q chain case 4 Nm 0 4 m kg 2 9 ft Ib 9 Install Rear wheel R...

Page 271: ...2 ft Ib Bolt caliper bracket 45 Nm 4 5 m kg 32 ft Ib Bolt brake caliper 35 Nm 3 5 m kg 25 ft Ib Refer to the REAR WHEEL INSTALLA TION section in the CHAPTER 6 12 Install Cotter pin NOTE _____________...

Page 272: ...I DRIVE CHAIN AND SPROCKET Clutch hub 2 Collar 3 Driven sprocket 4 Bearing Oil seal 6 Collar 7 Drive chain 8 Drive sprocket DR1VE CHAIN SLACK A 30 40 mm 1 18 1 57in B6203RS 162 Nm 6 2 mokg 45 ftolb 1...

Page 273: ...ver drive sprocket 3 Remove Drive sprocket CD NOTE __________________________ Before removing the nut drive sprocket straighten the lock washer tab Loosen the nut drive sprocket while apply ing the re...

Page 274: ...ake the chain tense by finger 1a link length is a measurement between the insides of the CD and lJ rollers as shown Two or three different 1a link lengths should be measured 2 Clean Drive chain Place...

Page 275: ...t SAE 30 50 motor oil 5 Inspect Drive chain Stiff Clean and lublicate or replace 6 Inspect Drive sprocket Driven sprocket More than 1 4 teeth CD wear Replace sprocket Bent teeth Replace sprocket Corre...

Page 276: ...ve the oil seals CD using a flat head screw driver NOTE _________________________ Place a rag on the outer edge to prevent damage Remove the bearing using a general bear ing puller Install the new bea...

Page 277: ...Nut pivot shaft 85 Nm 8 5 m kg 61 ft Ib Nut frame connecting rod 32 Nm 3 2 m kg 23 ft Ib 2 Install Rear wheel Refer to the REAR WHEEL INSTALLA TION section 3 Install Drive sprocket Nut drive sprocket...

Page 278: ...nut 90 Nm 9 0 m kg 65 ft lb Bolt swingarm end 3 Nm 0 3 m kg 2 2 ft lb Bolt caliper bracket 45 Nm 4 5 m kg 32 ft lb Bolt brake caliper 35 Nm 3 5 m kg 25 ft lb Refer to the REAR WHEEL INSTALLATION secti...

Page 279: ...XT600EA EAC CIRCUIT DIAGRAM CD R Br L ON OFF LOCK P 0 0 T B r RNJ RNJ RO WQ c L1Y W fl GNJ W B 4 R W Gy I OFF RUN 0 0 RNJ 0 fnj J _J iW B I r nO j t B Y O r B W 1 t I ___ Sb 1 r B W L Gy Br Br Br Br...

Page 280: ...left Front flasher position light left Horn COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green L Blue 0 Orange P Pink R Red Sb Sky blue W White HORN switch Front brake switch Rear brake sw...

Page 281: ...gnition coil Rectifier Regulator Battery Ignitor unit 7 Fuse Diode 9 Starter relay 10 Starting circuite cut off relay 7 3 IGNITION COIL PRIMARY COIL RESISTANCE 3 4 4 S Q at 20 C SS F SECONDARY COIL RE...

Page 282: ...Rear brake switch 2 Horn 3 Neutral switch 4 Sidestand switch 5 Flasher relay 7 Nm 0 7 m kg 5 1 ft lb 2 20 Nm 2 0 m kg 14 ft lb ELECTRICAL COMPONENTS IELECI iii I 5 7 4...

Page 283: ...top line indicates the colors of leads connected with the terminals in the switch component Q D indicates the terminals between which there is a continuity of electricity i e a closed circuit at the r...

Page 284: ...color combination for continuity a closed cir cuit In this example the continuity is as follows R and Br and L W and L R are continu ous with the ON switch position B and B W is continuous with the OF...

Page 285: ...n and there must be no continuity the tester indicating 00 at OFF LOCK or P There is something wrong between R and Br if there is no continuity at the ON position or if the re is some continuity eithe...

Page 286: ..._________________________ Bulbs of the and type uses a bulb holder Remove the bulb holder before removing the bulb itself Most of the bulb holders for this type can be removed by turning them coun ter...

Page 287: ...onnecting the tester lead to the CD terminal and the tester lead to the terminal Then check the continuity between the CD and terminals by connect ing the tester lead still to the CD terminal and the...

Page 288: ...CHECKING OF BULBS IElECIIiiiI 7 10...

Page 289: ...I IGNITION SYSTEM CIRCUIT DIAGRAM CD R Br L ON OFF LOCK P 0 fO 1 7 B r R W R W OFF RUN 0 0 R w Gy R W 0 BMI B r l Y o J t B Y o__B W 1 t t Sb B W Br Br __ L Br h ON G Y L Gy Br p Br W P B Ch D9 l Ch...

Page 290: ...circuit in the circuit diagram NOTE ___________________________________________________________ For the color codes see page 7 2 Main switch Pickup coil Ignitor Ignition coil Spark plug Clutch switch...

Page 291: ...eat 2 Side cover left and right 3 Air scoop left and right 4 Cover fuel tank 5 Fuel tank 6 Cowling headlight Use the following special tools in this troubleshooting Dynamic spark tester 1 Fuse PI N YM...

Page 292: ...1 0 035 in CORRECT 4 Ignition spark gap Disconnect the spark plug cap from spark plug Connect the dynamic spark tester CD as shown Spark plug cap Spark plug Turn the main switch to ON Check the igniti...

Page 293: ...N 6 Ignition coil resistance Disconnect the ignition coil leads Orange and Black from the wire harness Connect the pocket tester Q x 1 to the ignition coil Tester lead EEl terminal Tester lead e termi...

Page 294: ...8 terminal n BOTH MEET SPECIFICATIONS 7 Main switch Disconnect the main switch coupler from the wire harness Connect the pocket tester Qxl to the main switch term inal Check the switch component for t...

Page 295: ...ECKING OF SWITCHES section CORRECT 9 Sidestand switch Disconnect the sidestand switch coupler from the wire harness Connect the pocket tester Q x 1 to the sidestand switch terminal Check the switch co...

Page 296: ...CHECKING OF SWITCHES section CORRECT 11 Clutch switch Disconnect the clutch switch coupler from the wire harness Connect the pocket tester Qx1 to the clutch switch lead Check the switch component for...

Page 297: ...terminal Tester lead Green White termi nal I I n Check the pickup coil for specified resistance Pickup coil resistance 184 276 Q at 20 C 68 F Blue Yellow Green White OUT OF SPECIFICATION i Pickup coi...

Page 298: ...IGNITION SYSTEM IHEel iii I 7 20...

Page 299: ...ING SYSTEM IElECI iii I ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM CD R Br L ON OFF LOCK P 1 Br RO WO LN W E GIW W B Gv J B c nO j B Y o BIW r RIW RIW OFF RUN 0 f O I R W 1 1 __ _Sb f l BIW L Gy Br Br...

Page 300: ...cuit in the circuit diagram NOTE _____________________________________________________________ For the color codes see page 7 2 Main switch Clutch switch Diode Neutral switch Sidestand switch START sw...

Page 301: ...h is closed The starting circuit cut off relay prevents the starter from operating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so current...

Page 302: ...Side cover left and right 3 Air scoop left and right 4 Cover fuel tank 5 Fuel tank 6 Cowling headlight Use the following special tool in this troubleshooting Pocket tester PI N YU 03112 PI N 90890 031...

Page 303: ...ing the jumper lead CD as shown Battery terminal Red White terminal Frame Blue White terminal Check the starter motor operation OPERATIVE 7 25 AWARNING A wire for the jumper lead must have the equival...

Page 304: ...he CHECKING OF SWITCHES section CORRECT 6 ENGINE STOP switch Disconnect the handlebar switch right lead coupler from the wire harness Connect the pocket tester Qx1 to the engine stop switch terminal C...

Page 305: ...y between Black CD and Black Refer to the CHECKING OF SWITCHES section B B CORRECT 8 Neutral switch Disconnect the neutral switch coupler from the wire harness Connect the pocket tester Q x 1 to the n...

Page 306: ...cuit cut off relay relay assembly Connect the pocket tester DC20V to the starting circuit cut off relay coupler termi nals Battery terminal Red White CD terminal Battery terminal Sky blue terminal Tes...

Page 307: ...ar switch terminal Check the START switch component for the continuity between Blue White CD and Black Refer to the CHECKING OF SWITCHES section L W B Free CORRECT 12 Wiring connection Check the entir...

Page 308: ...tor 4 O ring 4 ELECTRICAL STARTING SYSTEM IElECI iii I BRUSH LENGTH LIMIT A 5 mm 0 20 in COMMUTATOR WEAR LIMIT B 27 mm 1 06 in C MICA UNDERCUT 0 7 mm 0 027 in ARMATURE COIL RESiSTANCE D oQ at 20 C 68...

Page 309: ...L section in the CHAPTER 4 Disassembly 1 Remove Circlip CD Drive gear 2 Remove Bolts CD Shim Washer Shim Brush Armature Yoke j Inspection and Repair 1 Inspect Commutator Dirty Clean it with 600 grit s...

Page 310: ...utator 4 Inspect eArmature coil insulation continuity Defects s Replace starter motor Armature coil inspecting steps eConnect the Pocket Tester for continuity check CD and insulation check eMeasure th...

Page 311: ...ollowing points 1 Install eBrush seat NOTE __________________________ Align the projection CD on the brush seat with the slot on the housing 2 Install eYoke CD eHousing cover NOTE ____________________...

Page 312: ...iii I 7 34 Installation 1 Install Starter motor NOTE _________________________ Apply a lightly grease to the O ring CD Bolt starter motor 10 Nm 1 0 m kg 7 2 ft Ib Refer to the ENGINE OVERHAUL ENGINE I...

Page 313: ...R Br L ON 10fO 0 OFF LOCK P 10f 1 L Br I R W R W OFF RUN 0 ro CHARGING SYSTEM IElEel iii I t R W Gy J J 4 j I B Y B W It l 1 Sb f l B W L Gy Br Br I t I HI LO Y Br h ON G Y L Br Br o p Br W P B Ch 0...

Page 314: ...Aforementioned circuit diagram shows charging circuit in the circuit diagram NOTE _____________________________________________________________ For the color codes see page 7 2 Rectifier regulator A...

Page 315: ...is troubleshooting Inductive tachometer 1 Fuse PIN YU OS036 A PIN 90S90 03113 Remove the fuse Connect the pocket tester Q x 1 to the fuse Check the fuse for continuity Refer to the FUSE INSPECTION sec...

Page 316: ...charging voltage Charging voltage 14 0V at 5 000 r min NOTE Use a full charged battery 4 Stator coil resistance OUT OF SPECIFICATION CHARGING SYSTEM IELEel iiiI MEETS SPECIFICATION I ICharging circuit...

Page 317: ...0 78n at 20 C S8 F CHARGING SYSTEM IELEeIiii I OUT OF SPECIFICATION 1 Stator coil is faulty replace it n BOTH RESISTANCES MEET SPECIFICATIONS 5 Wiring connection Check the entire charging system for...

Page 318: ...CHARGING SYSTEM IHEel iiiii I 7 40...

Page 319: ...Br ON OFF LOCK P 10I I Br L 0 L RIW RIW OFF RUN 0 1 0 R LIGHTING SYSTEM IHEel iii I RO WO LIY W Gffl W B r Rffl L iJ j Gy I __ _ _ B Y o_Bffl R C 4_ Sb Bffl Br Br _ J I HI LO Y L ON G Y L Gy Br p P B...

Page 320: ...it diagram shows lighting circuit NOTE _____________________________________________________________ For color codes see page 7 2 CD Main switch Tail brake light LIGHTS dimmer switch Meter light Headl...

Page 321: ...headlight 4 Headlight lens unit 5 Tail cover Use the following special tool in this troubleshooting Pocket tester P N YU 03112 P N 90890 03112 1 Fuse Remove the fuse Connect the pocket tester Q x 1 to...

Page 322: ...switch Disconnect the handlebar switch left cou ple from the wireharness Connect the pocket tester Q x 1 to the handlebar switch left terminal Check the switch component for the conti nuity between Br...

Page 323: ...__IElECI iii 1 5 Wiring connection Check the entire lighting system for con nections Refer to the WIRING DIAGRAM section CORRECT Check condition of each circuit for lighting system Refer to LIGHTING...

Page 324: ...ester DC20V to the headlight and HIGH BEAM indicator light couplers Head light Tester lead Green CD or Yellow lead Tester lead Black lead HIGH BEAM indicator light A B Tester lead Yellow lead Tester l...

Page 325: ...r continu ity Refer to the CHECKING OF BULBS sec tion CONTINUITY 2 Voltage Connect the pocket tester DC20V to the bulb socket coupler Tester lead Blue CD terminal Tester lead Black terminal DI B L DC2...

Page 326: ...ulb socket connector Tester lead Blue CD terminal Tester lead Black terminal eTurn the main switch to ON Check for voltage 1 2V on the Blue lead at the bulb socket connector n MEETS LIGHTING SYSTEM IE...

Page 327: ...ctor Tester lead Blue CD terminal Tester lead Black terminal B B LJ D 0 II DC20V I o Turn the main switch to ON Check for voltage 12V on the Blue lead at the bulb socket connector n MEETS LIGHTING SYS...

Page 328: ...LIGHTING SYSTEM IHEel iii I 7 50...

Page 329: ...K P 10I I B r L ro L L R W R W OFF RUN 0 f R SIGNAL SYSTEM IELEel iiiI Rtl WO y E iJR y BIW I 0 I 1 R I B Y o_BIW t R I I T r Sb 1 B w L Sb Gy Br Br HI LO y b B B J J iQ 8r h X ON GIY L Br P PIB B L N...

Page 330: ...s see page 7 2 Main switch Ignitor NEUTRAL indicator light Neutral switch REV indicator light Flasher relay TU RN switch TURN indicator light 1 Front flasher position light r ight j Rear flasher light...

Page 331: ...t 5 Tail cover 3 Cowling headlight Use the following special tool in this troubleshooting Pocket tester P N YU 03112 P N 90890 03112 1 Fuse Remove the fuse Connect the pocket tester Q x 1 to the fuse...

Page 332: ...etween Red CD and Brown 2 Refer to the CHECKING OF SWITCHES section CORRECT 4 Wiring connection Check the entire signal system for connec tions Refer to the WIRING DIAGRAM section CORRECT Check condit...

Page 333: ...efer to the CHECKING OF SWITCHES section CORRECT 2 Voltage Connect the pocket tester DC20V to the horn lead Tester lead Brown CD lead Tester lead Frame ground Turn the main switch to ON Check for volt...

Page 334: ...SOUNDED eConnect the pocket tester DC20V to the horn at the Pink terminal Tester lead Pink CD lead Tester lead Frame ground eTurn the main switch to ON eCheck for voltage 1 2V on the Pink lead at the...

Page 335: ...t the pocket tester Q x 1 to the brake switch terminal Check the switch component for the conti nuity between Green Yellow CD and Brown or Black and Black Refer to the CHECKING OF SWITCHES section ON...

Page 336: ...t connector is faulty repair SPECIFICATION 12V IThis circuit is good I 3 Flasher light and or TURN indicator light do not blink 1 Bulb and bulb socket Check the bulb and bulb socket for continu ity Re...

Page 337: ...ound Turn the main switch to ON Check for voltage 12V on the Brown lead at the flasher relay terminal n MEETS SIGNAL SYSTEM IELECIIiiiI INCORRECT i TURN switch is faulty replace handlebar switch left...

Page 338: ...e Brown White lead at the flasher relay terminal n MEETS SPECIFICATION 12V 5 Voltage Connect the handlebar switch left coupler to the wireharness Connect the pocket tester DC20V to the bulb socket con...

Page 339: ...BULBS sec tion CONTINUITY 2 Neutral switch Disconnect the neutral switch lead from the wireharness Connect the pocket tester Q x 1 to the neutral switch leads Check the switch component for the conti...

Page 340: ...Wiring circuit from main switch to bulb socket connector is faulty repair 4 Neutral switch lead Disconnect the neutral switch lead and bulb socket connector from the wireharness Connect the pocket te...

Page 341: ...arts STARTING FAILURE HARD STARTING FUEL SYSTEM PROBABLE CAUSE Fuel tank l Empty Clogged fuel filter Clogged fuel tank cap air passage Deteriorated fuel or fuel containing water or foreign material Fu...

Page 342: ...Faulty sidestand switch Faulty clutch switch Starter motor Faulty starter motor l_Faulty starter relay Faulty circuit cut off relay relay unit Faulty starter clutch COMPRESSION SYSTEM PROBABLE CAUSE...

Page 343: ...agneto Faulty ignition coil Valve train Improperly adjusted valve clearance POOR MEDIUM AND HIGH SPEED PERFORMANCE POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING FAILURE HARD STARTING FUEL S...

Page 344: ...plate Swollen friction plate Broken clutch boss Engine oil r High oil level L Improper quality high viscosity Deterioration CHANGE PEDAL DOES NOT MOVE PROBABLE CAUSE Shift shaft Bent shift shaft Shift...

Page 345: ...BLE CAUSE Clutch Improperly adjusted clutch cable Loose clutch spring Fatigued clutch spring Worn friction plate Worn clutch plate L Incorrectly assembled clutch Engine oil Low oil level L Improper qu...

Page 346: ...Improper brake fluid level FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION OIL LEAKAGE PROBABLE CAUSE L r Bent damaged or rusty inner tube Damaged or cracked outer tube Damaged oil seal lip Imprope...

Page 347: ...Front forks rL Uneven oil levels on both sides Broken spring Twisted front forks Tires L Uneven tire pressures on both sides I ncorrect tire pressure Unevenly worn tires Wheels l Incorrect wheel bala...

Page 348: ...switch Bulb life expired PROBABLE CAUSE L _ _ _ _ _ _ _ _ _ _ _ _ _ Improper bulb Faulty battery Faulty rectifier regulator Improperly grounded Faulty main and or LIGHTS switch Bulb life expired FLASH...

Page 349: ...LE CAUSE L _ _ _ _ _ _ _ _ _ _ _ _ _ Faulty battery Faulty main and or HORN switch Improperly adjusted horn Faulty horn Broken wireharnes OVERHEATING OVERHEATING PROBABLE CAUSE Ignition system Lr Impr...

Page 350: ...ght 8 8 r H I 0 D 0 J 1 I N S T I UW ry t 1 r Starter Flasher LIGHT HORN position light Irightl START switch Ne tral St rter relay switch motor relay dimmer sWitch ENGINE STOP Front flasher position l...

Page 351: ...YAIVIAHA MOTOR CO LTD IWATA JAPAN PRINTED IN U S A...

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Yamaha XT 600 AC, Service Manual

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