Model Years Covered:
1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Chassis Codes:
XT600K, XT600E, XT600Z (Tenere variants may have slight variations, confirm with specific model year details within manual)
Market Segment:
Dual-sport, Enduro, Adventure Motorcycle
Key Competitors:
Honda XR series, Kawasaki KLR series, Suzuki DR series.
Model Philosophy:
Robust, air-cooled, single-cylinder engine designed for reliability, versatility, and ease of maintenance in a wide range of conditions, from street commuting to off-road exploration.
Systems Covered:
Engine, Fuel System, Ignition System, Transmission, Clutch, Drivetrain, Suspension (Front & Rear), Brakes (Front & Rear), Wheels & Tires, Frame, Electrical System, Lighting, Controls, Bodywork, Cooling System, Exhaust System, Troubleshooting, Specifications
Estimated Page Count:
700+
Type:
Workshop Service Repair Manual
Format:
Digital Download (PDF)
Engine Mechanical:
Detailed breakdown and assembly of all engine components including cylinder head, piston, crankshaft, connecting rods, valves, camshafts, and timing. Torque specifications for all fasteners.
Fuel System:
Carburetor overhaul, tuning, and adjustment. Fuel pump operation (if applicable to specific variants), fuel lines, and fuel filter replacement.
Ignition System:
CDI unit testing and replacement, spark plug selection and gap, ignition coil testing, stator and pickup coil testing.
Transmission Drivetrain:
Gearbox disassembly, inspection, and reassembly. Clutch operation, adjustment, and replacement. Final drive chain and sprockets maintenance and replacement procedures.
Suspension Steering:
Front fork service, including oil changes, seal replacement, and spring inspection. Rear shock absorber inspection, adjustment (preload), and replacement. Steering head bearing maintenance.
Brakes:
Front and rear brake system service, including caliper overhaul, pad replacement, brake fluid bleeding, master cylinder inspection, and disc inspection.
Electrical System:
Wiring diagrams for all circuits, battery maintenance, charging system (alternator/stator), starter motor testing, fuse box layout, and lighting system troubleshooting.
Maintenance Tasks:
Routine oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement, brake system checks, tire pressure checks, and general lubrication points.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon issues, including starting problems, engine misfires, electrical faults, and performance issues.
Repair Procedures:
Step-by-step instructions for engine rebuilds, transmission repairs, suspension overhauls, brake caliper rebuilds, and electrical component replacement.
Adjustment Procedures:
Carburetor synchronization and idle speed adjustment, clutch cable adjustment, brake lever adjustment, and suspension preload adjustment.
Depth:
Comprehensive, covering everything from basic rider maintenance to complete engine and chassis overhauls. Suitable for both amateur and professional mechanics.
Quality:
High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Text Search:
Searchable text within PDF for quick information retrieval.
Diagrams And Photos:
Includes detailed exploded diagrams, schematics, and sometimes photographic sequences for complex procedures.
Engine Type:
4-stroke, SOHC, 2-valve (some later variants may feature 4 valves depending on specific model designation)
Displacement:
595 cc (595 cubic centimeters)
Bore X Stroke:
92.0 mm x 84.0 mm (typical, confirm specific year)
Compression Ratio:
Typically around 8.5:1 to 9.7:1, depending on model year and specific engine tuning.
Horsepower:
Approx. 40-45 HP at 6,000-6,500 RPM (varies by year and tuning)
Torque:
Approx. 48-50 Nm (35-37 lb-ft) at 4,000-5,000 RPM (varies by year and tuning)
Carburetion:
Mikuni VM34 or similar (single carburetor, constant velocity type is common). Some later models might have different carburetor configurations or fuel injection in specific international markets, but the manual primarily covers carbureted versions.
Fuel Type:
Unleaded gasoline (Octane rating as specified in manual, typically 87 or higher).
Cooling Method:
Air-cooled
Oil Type:
Yamalube 4 (or equivalent SAE 10W-40 or 20W-40 motorcycle oil, API SG or higher). Confirm specific viscosity and API rating in manual.
Oil Capacity:
Approx. 2.5 - 3.0 liters (with filter change) - consult manual for exact capacity.
Length:
Varies by model year and whether it's a 'K' or 'Z' (Tenere) variant, generally around 2100-2250 mm.
Width:
Varies, typically around 800-900 mm.
Height:
Varies, typically around 1200-1400 mm (including windscreen on Z models).
Wheelbase:
Approx. 1400-1460 mm.
Dry Weight:
Approx. 145-165 kg (varies significantly by model year and equipment like fairings/larger tanks).
Wet Weight:
Approx. 165-185 kg (including fluids).
Fuel Capacity:
Approx. 13 liters (standard tank), Tenere models often had larger tanks (e.g., 18-20 liters).
Tire Size Front:
Typically 90/90-21 or 3.00-21.
Tire Size Rear:
Typically 110/80-18 or 120/80-18.
Wheel Type:
Spoked wheels with tube-type tires.
Wheel Bolt Pattern:
N/A (Hub-mounted wheels)
Safety Certification:
Meets relevant national and international motorcycle safety standards for its production era.
Braking System:
Front: Disc brake. Rear: Disc brake (some early models may have drum rear). Specific caliper and master cylinder details in manual.
Lighting:
Halogen headlight, taillight, brake light, turn signals.
Frame Construction:
Steel semi-double cradle frame for rigidity and durability.
Ergonomics:
Designed for an upright riding position suitable for both on-road and off-road use.
Features:
Basic motorcycle instrumentation: speedometer, odometer, tachometer (on some models), neutral indicator, high beam indicator, turn signal indicators. No advanced infotainment systems.
Features:
None. This is a mechanical motorcycle from an era before electronic rider aids.
Features:
None. No provision for smartphone integration or data connectivity.
Oil Change Interval:
Every 4,000 km (2,500 miles) or 6 months, whichever comes first (typical, consult manual for exact recommendation).
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or as needed based on inspection. Specific plug types and gap settings (e.g., NGK DPR8EA-9, gap 0.7-0.8 mm) detailed in manual.
Air Filter Cleaning:
Every 6,000 km (3,700 miles) or annually. Inspect more frequently in dusty conditions.
Valve Clearance Check:
Every 12,000 km (7,500 miles) or as per manual's recommendation. Specific clearance values for intake and exhaust valves are critical and found in the manual.
Fork Oil Type:
Yamalube Fork Oil (or equivalent SAE 10W). Specific volume and level for front forks are detailed in the manual.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (ensure it's fresh and properly sealed).
Common Wear Items:
Clutch plates, valve guides, kickstart mechanism wear, carburetor diaphragm degradation (in some models), stator coil failure, and fork seal leaks are common areas to inspect.
Carburetor Tuning:
Maintaining correct carburetor jetting and float bowl levels is crucial for optimal performance and can be a point of frequent adjustment or cleaning.
Electrical Connections:
Corrosion in electrical connectors, especially in older bikes exposed to elements, can lead to intermittent faults.
Yamaha Legacy:
Yamaha has a long and storied history in motorcycle manufacturing, known for innovation, performance, and reliability across various disciplines, from road racing to off-road championships.
Xt Series Development:
The XT 600 line evolved from earlier Yamaha dual-sport models, building upon the success of the XT500. It was a significant player in the growing dual-purpose motorcycle market, offering a balance of off-road capability and street usability.
Key Variants:
The XT600K typically refers to the standard model with the more conventional fuel tank and seat. The XT600Z (Tenere) featured larger fuel tanks, more extensive fairings, and often improved suspension for long-distance touring and adventure riding. The XT600E typically denotes electric start versions.
Production Period:
The XT600 was produced for a considerable period, with this manual covering the extensive range from its introduction in 1983 through to 2003, representing several generations of design updates and refinements.
Model Reputation:
The XT600 is widely respected for its reliability, simplicity, and go-anywhere capability, making it a popular choice for adventure riding, commuting, and as a base for custom builds. It has earned a reputation as a workhorse.
Industry Impact:
Contributed significantly to the dual-sport segment's growth, establishing Yamaha as a major player in this market niche.
