Segment:
Dual-Sport / Trail Motorcycle
Target Audience:
Owners and mechanics of Yamaha XT500 and XT600 motorcycles seeking detailed repair and maintenance guidance.
Rivals:
Competed with models like Honda XL series, Kawasaki KLR series, Suzuki DR series during their respective production eras.
Legacy:
The XT500 pioneered the dual-sport market with its robust single-cylinder engine and off-road capability. The XT600 evolved this lineage with more modern features and improved performance.
Manual Value:
Essential for maintaining the longevity and performance of these classic Yamaha machines, providing factory-accurate procedures.
Engine:
Comprehensive coverage including disassembly, inspection, assembly, and troubleshooting of the XT600 and XT500 engines.
Fuel System:
Detailed instructions on carburetor (Mikuni VM type common) service, adjustment, fuel tank, and fuel line maintenance.
Ignition System:
Information on CDI (Capacitor Discharge Ignition) system, spark plugs, coils, and troubleshooting.
Transmission:
In-depth coverage of the gearbox, clutch assembly (wet multi-plate), shift mechanism, and lubrication.
Suspension Front:
Service and adjustment procedures for telescopic front forks, including oil changes and seal replacement.
Suspension Rear:
Maintenance and repair of the monoshock rear suspension system (often a rising rate linkage on later XT600 models) and swingarm bearings.
Brakes Front:
Disc brake system service, including caliper overhaul, pad replacement, fluid flush, and master cylinder maintenance.
Brakes Rear:
Drum brake service and adjustment, including shoe replacement and linkage maintenance.
Electrical System:
Wiring diagrams, component testing, charging system (alternator/stator, regulator/rectifier), lighting, and starter motor service.
Frame And Bodywork:
Body panel removal and installation, frame inspection, seat, and tank maintenance.
Routine Maintenance:
Covers routine checks such as oil changes, filter replacement, chain adjustment, brake checks, tire pressure, and lubrication points.
Troubleshooting:
Diagnostic guides and common problem identification for various systems, aiding in efficient repair.
Engine Rebuild:
Step-by-step instructions for complete engine teardown, overhaul, and reassembly, including piston, cylinder, and valve train work.
Carburetor Tuning:
Detailed guidance on carburetor cleaning, reassembly, jetting, and synchronization for optimal performance.
Suspension Overhaul:
Instructions for replacing fork seals, bushings, and rear shock components.
Electrical Diagnostics:
Methods for testing circuits, components like the stator, CDI unit, and rectifier, and troubleshooting common electrical faults.
Depth Level:
Comprehensive; suitable for both home mechanics and professional technicians. Covers everything from basic adjustments to complete engine and chassis overhauls.
Type:
Four-stroke, SOHC, air-cooled, single-cylinder
Displacement:
499 cc (30.4 cu in)
Bore X Stroke:
87.0 mm x 84.0 mm
Compression Ratio:
Approx. 8.0:1
Fuel System Xt500:
Single Mikuni VM34SS carburetor
Type:
Four-stroke, SOHC, 2-valve, air-cooled, single-cylinder
Displacement:
595 cc (36.3 cu in) - (Note: Various sub-models and updates exist within XT600 family with minor displacement variations)
Bore X Stroke:
Approx. 97.0 mm x 80.0 mm (varies by specific XT600 model)
Compression Ratio:
Approx. 8.5:1 to 9.5:1 (varies by specific XT600 model)
Fuel System Xt600:
Typically single Mikuni carburetor (e.g., VM36SS or BST33 CV type on later models)
Horsepower Xt500:
Approx. 24-30 HP @ 5500-6000 RPM (varies by market and tuning)
Torque Xt500:
Approx. 30-35 Nm @ 4500-5000 RPM (varies by market and tuning)
Horsepower Xt600:
Approx. 30-45 HP @ 6000-6500 RPM (varies by specific model and market)
Torque Xt600:
Approx. 40-50 Nm @ 4500-5500 RPM (varies by specific model and market)
Carburetor Type:
Mikuni (specific model varies by year/sub-model)
Engine Oil Capacity:
Approx. 2.0-2.5 Liters (including filter, check specific model for exact amount)
Oil Change Interval:
Every 3,000 - 5,000 km (or 6 months), refer to specific manual section.
Air Filter Cleaning:
Every 3,000 - 6,000 km, depending on operating conditions (dusty environments require more frequent checks).
Spark Plug Replacement:
Every 10,000 - 15,000 km.
Chain Maintenance:
Lubrication and adjustment every 1,000 km or as needed (visual inspection).
Valve Clearance Check:
Every 10,000 - 20,000 km, or as specified for the model.
Engine Oil Specification:
API SG or higher, SAE 20W-40 motorcycle-specific oil recommended. Check manual for exact grade and API classification.
Fork Oil Specification:
Yamaha Fork Oil 10W or equivalent (refer to manual for exact viscosity and quantity per fork leg).
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid (typically for front disc brake).
Xt500 Common Wear:
Kickstarter mechanism wear, clutch basket wear, timing chain tensioner issues, carburetor jetting sensitivity.
Xt600 Common Wear:
Automatic decompression mechanism issues (if equipped), carburetor float needle wear, rear shock absorber degradation over time, oil leaks from the output shaft seal.
Electrical Issues:
Stator failure, regulator/rectifier issues leading to charging problems, corrosion in connectors.
Yamaha Motorcycles:
Yamaha Motor Corporation has a long and successful history in motorcycle design and manufacturing, known for innovation and reliability.
Xt500 Introduction:
Introduced in 1976, the XT500 was a groundbreaking dual-sport motorcycle, celebrated for its torquey 499cc engine and off-road prowess, becoming an instant classic.
Xt600 Introduction:
The XT600 lineage began in the early 1980s (around 1983-1984), evolving the concept with advancements like monoshock rear suspension and sometimes electric starting on later models (XT600E).
Production Period Xt500:
Approximately 1976-1981
Production Period Xt600:
Approximately 1983-2003 (across various iterations like XT600, XT600E, XT600K)
