Segment:
Dual-sport motorcycle, dual-purpose, adventure touring.
Target Audience:
Owners and mechanics seeking in-depth technical information for maintenance, repair, and restoration of the Yamaha XT 600 E.
Comparable Models:
Honda Transalp, Kawasaki KLR650, Suzuki DR650. The XT 600 E was known for its rugged simplicity and off-road capability.
Vehicle Appeal:
Reliable single-cylinder engine, robust chassis, long-travel suspension, suitable for both on-road commuting and off-road adventures.
Manual Value Proposition:
Provides factory-level accuracy and detail, crucial for preserving the longevity and performance of this classic dual-sport.
Engine Mechanical:
Complete engine overhaul, disassembly, inspection, and reassembly procedures for the 34kW/46hp 595cc single-cylinder engine.
Fuel System:
Carburetor (likely Mikuni VM series) tuning, cleaning, overhaul, and specifications. Fuel tank, petcock, and fuel line maintenance.
Ignition System:
CDI ignition system, spark plug specifications, timing checks, and component testing.
Exhaust System:
Exhaust pipe and muffler inspection, maintenance, and potential repair.
Transmission And Drivetrain:
Clutch operation and adjustment, gearbox disassembly and assembly, shift mechanism, chain drive maintenance and adjustment, sprocket replacement.
Suspension Front:
Telescopic front forks: seal replacement, oil levels and specifications, spring inspection, general fork maintenance and overhaul.
Suspension Rear:
Monocross rear suspension system: shock absorber inspection, spring preload adjustment, linkage maintenance, and bearing lubrication.
Brakes Front:
Hydraulic disc brake system: caliper overhaul, brake pad replacement, fluid bleeding procedures, master cylinder inspection, and rotor specifications.
Brakes Rear:
Drum brake system: adjustment, shoe replacement, and inspection.
Wheels And Tires:
Spoke wheel maintenance, bearing inspection and replacement, tire pressure specifications, and rim runout checks.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, charging system (alternator/stator), starter motor, switches, and fuses.
Frame And Bodywork:
Frame inspection, handlebar replacement, seat removal, fender mounting, and plastic component care.
Cooling System:
Air-cooled engine; no coolant to cover.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug inspection, chain lubrication and adjustment, brake adjustment, tire pressure checks.
Troubleshooting:
Diagnostic charts and common problems with suggested solutions for engine, electrical, and chassis issues.
Engine Rebuild:
Detailed steps for piston, cylinder, valve, crankshaft, and camshaft overhaul.
Carburetor Overhaul:
Step-by-step instructions for cleaning, replacing jets, floats, and diaphragms.
Suspension Overhaul:
Fork seal replacement, rear shock absorber servicing, and linkage bearing replacement.
Electrical Component Testing:
Stator output testing, CDI unit testing, and starter relay checks.
Brake System Maintenance:
Brake bleeding, pad/shoe replacement, caliper/drum servicing.
Depth:
Comprehensive, covering everything from basic owner maintenance to full engine and chassis rebuilds, including torque specifications and clearances.
Engine Type:
4-stroke, SOHC, Air-cooled, Single-cylinder
Bore X Stroke:
95.0 mm x 81.0 mm
Valvetrain:
SOHC, 2 valves per cylinder
Horsepower:
Approx. 46 HP @ 6500 RPM (for earlier models, may vary slightly)
Torque:
Approx. 50 Nm @ 5000 RPM (for earlier models, may vary slightly)
Carburetion:
Single Mikuni VM34SS carburetor (typical)
Fuel Capacity:
Approx. 13 Liters (3.4 US gal)
Oil Capacity:
Approx. 2.3 Liters (with filter change)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Starter:
Kick starter (standard)
Oil Change Interval:
Recommended every 3,000-5,000 km (1800-3000 miles) or annually. Consult manual for precise interval.
Air Filter Cleaning:
Every 5,000-10,000 km (3000-6000 miles), depending on operating conditions. More frequent if used off-road.
Spark Plug Replacement:
Inspect every 6,000 km (3700 miles), replace as needed or at approx. 12,000 km (7500 miles).
Chain Lubrication Adjustment:
Lubricate every 800-1000 km (500-600 miles) and check/adjust tension at same interval.
Engine Oil:
Yamalube 4 (or equivalent) SAE 20W-40 or 10W-40 motorcycle oil. Check manual for specific viscosity based on temperature.
Fork Oil:
Yamaha Suspension Oil G10 (or equivalent SAE 10W fork oil). Capacity typically around 400-450ml per fork leg.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, fork seals, rear shock absorber bushings, carburetor diaphragm (if applicable), kick-start mechanism wear.
Electrical Quirks:
While generally robust, older wiring harnesses can develop corrosion or worn insulation. Stator output can degrade over time.
Engine Notes:
The 595cc engine is generally very durable but requires regular oil changes and proper valve clearance checks. Cam chain tensioner may require attention.
Yamaha Legacy:
Yamaha has a long and storied history in motorcycle manufacturing, known for innovation and performance across various disciplines, including off-road and dual-sport.
Xt Series:
The XT series represents Yamaha's pioneering efforts in the dual-sport segment, with the XT 500 and XT 600 being foundational models for the genre.
Xt 600E Development:
The XT 600 E (Enduro) model built upon the success of its predecessors, often featuring electric start and updated styling and suspension for the 1990s market.
Production Period:
The XT 600 line was produced from the late 1970s through the early 2000s, with the 'E' variant being prominent in the 1990s.
