Segment:
Dual-sport/Enduro motorcycle
Target Audience:
Adventure riders, off-road enthusiasts, dual-sport touring riders, DIY mechanics
Key Competitors:
Honda XR series, Kawasaki KLR series, Suzuki DR series
Versatility:
Known for its robust nature and ability to handle both on-road commuting and off-road trails.
Completeness:
This manual is critical for maintaining the longevity and performance of the XT600.
Accuracy:
Provides factory-accurate specifications and procedures, essential for correct servicing.
Years Covered:
1984, 1985, 1986, 1987, 1988, 1989
Regions Covered:
Global (assumed for a widely produced model like the XT600)
Estimated Page Count:
Likely between 300-600 pages, typical for comprehensive service manuals of this era.
Type:
Service Repair Workshop Manual
Language:
English (assumed for a global market manual, but confirmation is ideal).
Format:
Digital (PDF is highly probable for modern sales of older manuals).
Engine:
Complete engine overhaul, including disassembly, inspection, assembly, tuning, lubrication, cooling system, and ignition system.
Fuel System:
Carburetor service (cleaning, adjustment, jetting), fuel tank, fuel lines, fuel pump (if applicable).
Transmission:
Gearbox disassembly, inspection, assembly, clutch operation and service, shift mechanism.
Drivetrain:
Chain and sprocket inspection and replacement, rear hub and drive assembly.
Suspension:
Front telescopic forks (oil changes, seal replacement, damping adjustments), rear Monocross suspension (shock absorber service, linkage maintenance).
Brakes:
Front and rear brake system service (hydraulic, drum, or disc depending on variant), caliper overhaul, master cylinder service, brake pad/shoe replacement, bleeding procedures.
Electrical System:
Wiring diagrams, lighting system, charging system (stator, rectifier/regulator), ignition system (CDI, spark plug), starter system (kick-start, electric start if applicable), battery maintenance.
Frame And Bodywork:
Chassis inspection, subframe, swingarm, bearings, body panel removal and installation, seat, fuel tank, handlebars.
Wheels And Tires:
Spoke wheel maintenance, tire pressure, tire inspection and replacement, wheel bearing service.
Maintenance:
Routine checks, lubrication points, air filter cleaning/replacement, spark plug replacement, oil changes, chain adjustment.
Troubleshooting:
Diagnostic charts for common problems, symptom-cause-solution guidance.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation.
Overhaul:
Detailed procedures for complete engine, transmission, and suspension overhauls.
Specifications And Adjustments:
Torque specifications, valve clearances, ignition timing, carburetor settings, suspension sag.
Depth:
Comprehensive. Covers everything from basic owner maintenance to full engine rebuilds and advanced electrical diagnostics.
Diagnostic Capabilities:
Detailed troubleshooting guides and symptom analysis for identifying mechanical and electrical faults.
Special Tools:
Lists recommended special tools for specific repair procedures.
Digital Format:
PDF (Portable Document Format) is the most common and expected format for this type of manual.
Searchability:
Likely text-searchable PDF for quick information retrieval.
Print Readability:
Designed for clear reproduction, with crisp diagrams and legible text when printed.
Binding:
N/A (for digital format). If physical, would typically be perfect-bound or spiral-bound for workshop use.
Paper Quality:
N/A (for digital format). Original manuals often used durable paper stock suitable for workshop environments.
Engine Type:
4-stroke, air-cooled, SOHC, 2-valve
Displacement:
595 cc (for most common variants)
Bore X Stroke:
92.0 mm x 90.1 mm (typical, variations may exist)
Compression Ratio:
8.5:1 or 9.2:1 (depending on specific model year and market)
Starting System:
Kick starter (some later models or variants might have electric start, but the 84-89 is primarily kick-start focused).
Horsepower:
Approximately 33-37 hp at 6,000-6,500 rpm (varies by year and market)
Torque:
Approximately 45-48 Nm at 5,000 rpm (varies by year and market)
Carburetor:
Single Mikuni VM34SS or similar 34mm flat-slide carburetor.
Fuel Capacity:
Typically 13 liters (approx. 3.4 US gallons), including reserve.
Fuel Type:
Unleaded gasoline (octane rating as per manual specification).
Oil Type:
API SE, SF or SG, SAE 10W-30 or 20W-40 motorcycle specific oil. (Manual will specify precise grade).
Oil Capacity:
Approximately 1.7 - 1.9 liters (with filter change). (Manual will confirm).
Ignition System:
CDI (Capacitor Discharge Ignition)
Spark Plug Type:
NGK DR8ES-L or equivalent (manual will specify exact type and gap).
Length:
Varies by specific model, typically around 2200 mm.
Width:
Varies by specific model, typically around 800 mm.
Height:
Varies by specific model, typically around 1200 mm.
Wheelbase:
Approximately 1440 mm.
Dry Weight:
Around 150-160 kg (varies by model and equipment).
Wet Weight:
Approximately 170-180 kg (with fluids).
Ground Clearance:
Excellent, typically over 250 mm for off-road capability.
Seat Height:
Approximately 870 mm (can vary with suspension adjustments).
Safety Features Design:
Dual-purpose tires, robust chassis, effective braking system for its class, durable construction.
Braking System:
Front: Disc brake; Rear: Drum brake or Disc brake (depending on variant). Manual will detail service and inspection.
Lighting:
Headlight, taillight, brake light, turn signals (compliance with local regulations may vary).
Frame Type:
Steel diamond frame, known for strength and durability.
Handguards:
Often fitted as standard or common accessory for protection from elements and debris.
Infotainment System:
Not applicable to this model. Focus is on mechanical and electrical functionality.
Driver Assistance Features:
Not applicable. This era of motorcycle predates widespread electronic rider aids.
Connectivity Features:
Not applicable. Primarily analog systems.
Instrument Cluster:
Analog speedometer, tachometer (on some variants), odometer, trip meter, indicator lights (neutral, turn signals, oil pressure, high beam). Manual details calibration and troubleshooting.
Oil Change Interval:
Typically every 3,000-5,000 km or 6-12 months, whichever comes first (manual will specify).
Air Filter Maintenance:
Check/clean every 3,000-6,000 km, replace as needed (manual provides detailed intervals).
Spark Plug Replacement:
Around 10,000-12,000 km (manual will provide exact interval and gap).
Valve Clearance Check:
Typically every 10,000-15,000 km (manual specifies exact intervals and adjustment procedures).
Fork Oil Type:
SAE 10W or 15W fork oil (manual will specify viscosity and capacity).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (manual will confirm).
Carburetor Issues:
Common issues include clogged jets due to fuel varnish, sticky throttle slides, and wear in the float needle seat leading to overfilling. Manual details cleaning and adjustment.
Electrical System Reliability:
Rectifier/regulator failures can occur, leading to charging issues. Wiring connections can corrode over time. Manual aids in diagnosis.
Suspension Wear:
Fork seals can leak, and rear shock absorbers can lose damping over time. Manual provides rebuild instructions.
Kickstart Mechanism:
While robust, the kickstart mechanism can develop wear in the spring or gears. Manual covers inspection and repair.
Yamaha Offroad Legacy:
Yamaha has a rich history in off-road and enduro racing, dating back to the DT series and continuing with the XT line.
Xt600 Predecessors:
Evolved from earlier XT500 and XT550 models, introducing refinements and improved suspension.
Xt600 Tenere Variant:
Many XT600 models from this era were part of the "Tenere" sub-line, featuring larger fuel tanks and fairings for long-distance touring and adventure riding.
Production Period:
The XT600 series was produced for many years, with significant updates throughout its lifespan. This manual covers the initial major iteration.
Manufacturing Location:
Primarily Japan, though specific components might be sourced globally.
Offroad Magazine Reviews:
The XT600 series consistently received positive reviews from off-road and motorcycle publications for its reliability, durability, and off-road prowess in its time.
Owner Satisfaction:
Generally high owner satisfaction due to its robust nature and ease of maintenance, making it a popular choice for long-term ownership.
Emissions Compliance:
Compliance with emissions standards of the late 1980s. Manual might contain specific settings or procedures related to emissions control for different markets.
