🏷️ Basic Information

Make:

Yamaha

Model:

XT600

Sub Model:

XT 600 WORK

Product Type:

Workshop Service and Repair Manual

Applicable Model Years:

1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999

Model Code Range:

Specific codes vary by year and market, but generally includes models like 3TB, 4PT, 4SW

👋 Introduction

Target Audience:

Owners of Yamaha XT600 motorcycles (1990-1999), independent repair shops, enthusiast mechanics

Value Proposition:

Provides authoritative, detailed technical information to enable accurate maintenance, repair, and troubleshooting, reducing reliance on expensive dealer services.

Alternatives:

Owner's manuals (less detailed), aftermarket repair guides (may vary in accuracy/completeness), unofficial online forums (unverified information)

Completeness:

Covers all aspects of the motorcycle's operation and maintenance, ensuring no critical procedures are omitted.

Licensing:

No expiry dates or extra fees, indicating a one-time purchase for perpetual access.

Accessibility:

Instant download for use on multiple devices (computer, tablet, smartphone).

📋 Manual Details

Primary Coverage:

Comprehensive repair, servicing, and maintenance for Yamaha XT600 models

Estimated Page Count:

Likely over 500 pages (typical for full service manuals)

Type:

Factory Service Manual / Workshop Manual

Language:

English (typical for factory manuals sold internationally)

Format:

Digital Download (PDF, likely searchable and printable)

📖 Manual Coverage

Engine Mechanical:

Disassembly, assembly, inspection, tuning, piston, rings, cylinder, valve train, camshaft, crankshaft, connecting rods, lubrication system (oil pump, oil cooler), cooling system (air-cooled)

Fuel System:

Carburetor(s) (e.g., Mikuni), fuel pump, fuel tank, fuel lines, fuel filter, air filter

Ignition System:

CDI unit, ignition coils, spark plugs, wiring, timing

Transmission Drivetrain:

Clutch (operation, adjustment, replacement), gearbox (gear ratios, shifting mechanism, inspection), final drive (chain, sprockets, adjustment, lubrication)

Chassis Frame:

Frame inspection, welds, headstock bearings, swingarm, pivot bearings

Suspension Front:

Front fork (disassembly, oil change, seal replacement, spring replacement, damping adjustments, air pressure if applicable)

Suspension Rear:

Rear shock absorber (adjustment, servicing, replacement), linkage system (if applicable)

Braking System:

Front and rear brake systems (disc brakes likely), caliper servicing, master cylinder, brake lines, brake pads, brake fluid type and bleeding procedures, parking brake (if applicable)

Electrical System:

Wiring diagrams, lighting system, battery, charging system (alternator, regulator/rectifier), starter motor, fuses, relays, switches, instrument cluster

Bodywork Fittings:

Fairings, tank, seat, fenders, exhaust system, controls (handlebars, levers, pedals), footpegs

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, tire pressure checks, spark plug service, air filter cleaning/replacement, brake fluid checks/replacement

Troubleshooting:

Diagnostic procedures for common problems, fault finding guides for engine, electrical, and chassis issues

Engine Overhaul:

Complete engine rebuild procedures, including component specifications and tolerances

Carburetor Tuning:

Detailed instructions for cleaning, rebuilding, and adjusting carburetors for optimal performance and emissions

Electrical Diagnosis:

Testing of electrical components, use of multimeters, interpretation of wiring diagrams

Suspension Servicing:

Fork seal replacement, fork oil changes, rear shock absorber service

Brake System Maintenance:

Pad replacement, caliper servicing, bleeding procedures

Chassis Component Replacement:

Wheel bearing replacement, steering head bearing service, swingarm bearing service

Depth:

Full factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts

Diagnostic Capabilities:

Includes troubleshooting charts and diagnostic procedures for identifying and resolving mechanical and electrical faults

Dimensional Data:

Provides critical tolerances, measurements, and specifications for all major components

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable for quick information retrieval

Printability:

Designed for printing individual pages or sections

Quality Assessment:

High-resolution scans, ensuring clarity of diagrams and text

Binding:

N/A (Digital Product)

Paper:

N/A (Digital Product)

⚙️ Engine Specifications

Engine Type:

Four-stroke, SOHC, single-cylinder

Displacement:

Approximately 595cc (may vary slightly by specific model variant)

Bore X Stroke:

Typically around 95.0 mm x 81.4 mm

Cooling System:

Air-cooled

Compression Ratio:

Around 9.5:1 (may vary)

Lubrication System:

Wet sump

Horsepower Output:

Approx. 40-45 PS (29-33 kW) at ~6500 rpm (varies by year/market/tuning)

Torque Output:

Approx. 46-50 Nm (34-37 lb-ft) at ~5000 rpm (varies by year/market/tuning)

Carburetion:

Likely single Mikuni VM34SS or similar (may vary by market, e.g., dual carburetors on some models)

Fuel Type:

Unleaded gasoline, Octane rating as specified by Yamaha (typically 91 RON or higher)

🔧 Transmission

Transmission Type:

Constant mesh, 5-speed

Primary Drive:

Gears

Final Drive:

Chain drive

Clutch Type:

Wet, multi-disc

Gear Ratios:

Specific ratios are detailed within the manual and vary by model year.

📐 Dimensions

Length:

Approx. 2230 mm (varies by specific XT600 model)

Width:

Approx. 830 mm (varies)

Height:

Approx. 1250 mm (varies)

Wheelbase:

Approx. 1460 mm (varies)

Dry Weight:

Approx. 155-165 kg (varies by model variant, e.g., kick-start vs. electric start)

Gross Vehicle Weight Rating:

Information typically found in the manual, related to maximum load capacity.

🛡️ Safety Features

Safety Standards:

Adherence to relevant motorcycle safety regulations of the era (e.g., emissions, lighting).

Braking System:

Dual hydraulic disc brakes front and rear (typical for later models). Earlier models might have a drum rear brake. Manual details servicing for all configurations.

Lighting:

Headlight, taillight, brake light, turn signals

Frame Construction:

Steel semi-double cradle frame, designed for durability and handling.

💡 Technology Features

Infotainment Features:

N/A (Primarily mechanical and basic electrical systems)

Assistance Features:

N/A (No electronic rider aids typical for this era of motorcycle)

Instrument Cluster:

Analog speedometer, tachometer (if equipped), odometer, trip meter, neutral indicator, turn signal indicators, high beam indicator.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-5,000 km or annually. Manual provides exact schedule.

Spark Plug Service Interval:

Recommended check/replacement around 6,000-10,000 km. Manual details specific types and gaps.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions. Replacement interval varies.

Chain Lubrication Adjustment:

Recommended every 500-1000 km, or after riding in wet conditions.

Engine Oil Type:

Yamalube or equivalent SAE 10W-40 or 10W-50 API SE, SF, SG or higher quality motorcycle oil.

Engine Oil Capacity:

Approximately 2.0-2.5 liters (with filter change). Manual provides precise capacity.

Brake Fluid Type:

DOT 4 or DOT 5.1 (ensure manual confirmation for specific model year).

Fork Oil Type:

Yamaha KSA or equivalent SAE 10W fork oil. Manual specifies exact type and quantity.

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, fork seals, wheel bearings, swingarm bushings due to age and use.

Potential Engine Concerns:

Valve guide wear, carburetor issues (e.g., stuck floats, clogged jets), starter motor wear (on electric start models).

Electrical Quirks:

Corrosion on connectors, regulator/rectifier failure (common in older bikes), issues with kickstand switch.

📚 Vehicle History

Heritage Statement:

Yamaha has a long history of producing robust and capable dual-sport motorcycles known for their reliability and off-road prowess.

Xt Lineage:

The XT600 is part of Yamaha's legendary XT line, which began in the late 1970s. This model represents an evolution of the popular XT500, incorporating technological advancements for improved performance and user experience.

Key Updates 90S:

Models from the 1990-1999 period saw refinements, including potential upgrades to suspension, braking systems (e.g., introduction of dual front discs on some variants), and minor engine tuning changes. Electric start was introduced on some models during this era.

Production Period:

The XT600 was produced for many years, with the 1990-1999 range representing the later iterations of this model before its evolution into other platforms.

🏆 Awards & Recognition

Model Acclaim:

While specific awards for the 1990-1999 XT600 variants are not widely publicized, the XT series is renowned for its durability, versatility, and off-road capability, earning it a strong reputation among adventure and dual-sport riders.