🏷️ Basic Information

Make:

Yamaha

Model:

XT600

Model Designation:

XT 600

Chassis Codes:

Likely 3TB, 4PT (depending on specific market and minor variations)

Engine Codes:

Likely 3TB or 4PT variant of the 4-valve, SOHC, air-cooled single-cylinder engine

👋 Introduction

Market Segment:

Dual-sport motorcycle, popular for adventure touring, commuting, and off-road riding.

Key Competitors:

Honda XR series, Kawasaki KLR series, Suzuki DR series of the same era.

Notable Features:

Robust air-cooled engine, reliable chassis, long-travel suspension, dual-purpose capability.

Manual Value Proposition:

Essential resource for maintaining, troubleshooting, and repairing the Yamaha XT600, ensuring longevity and optimal performance.

📋 Manual Details

Applicable Years:

1990, 1991, 1992, 1993, 1994, 1995, 1996

Similar Year Coverage:

Likely covers models with minor variations in these years and potentially very close preceding/succeeding years

Estimated Page Count:

400-600 pages (typical for a comprehensive service manual of this era)

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

Digital (PDF assumed for online sales, often printable)

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, assembly, inspection, overhaul, valve clearance adjustment, piston/cylinder work, crankshaft, connecting rod, timing system.

Fuel System:

Carburetor (likely Mikuni VM series) disassembly, cleaning, adjustment, jetting, fuel pump, fuel tank, fuel lines, fuel filter.

Ignition System:

CDI ignition system, spark plug, ignition coil, stator, pick-up coil, wiring diagrams.

Cooling System:

Air-cooled engine, no coolant system details typically.

Exhaust System:

Exhaust pipe, muffler, mounting, gasket replacement.

Transmission Drivetrain:

Clutch operation, disassembly, inspection, assembly, gearbox internal inspection and repair, drive chain maintenance.

Suspension Front:

Telescopic fork disassembly, oil change, seal replacement, spring inspection, adjustment.

Brakes Front:

Hydraulic disc brake system, caliper disassembly, pad replacement, fluid flush and bleeding, master cylinder service.

Electrical System:

Wiring diagrams, lighting system, starter motor, battery, charging system (alternator/stator), fuses, relays, switches.

Frame Chassis:

Frame inspection, headstock bearing service, general chassis component inspection.

Wheels Tires:

Wheel bearing service, spoke tensioning, tire replacement, wheel balancing.

Bodywork:

Fender removal/installation, seat, tank cover, side panels, handle bar replacement.

Suspension Rear:

Monocross rear suspension, shock absorber overhaul, linkage inspection and lubrication, swingarm bearing service.

Brakes Rear:

Drum brake system (often), brake shoe inspection, adjustment, replacement, cable maintenance.

Routine Maintenance:

Oil changes, filter replacement, chain adjustment, spark plug check, air filter cleaning, brake adjustments.

Troubleshooting:

Diagnostic charts and procedures for common problems related to starting, running, electrical issues.

Engine Rebuild:

Complete engine overhaul procedures, including piston, ring, valve, and bearing replacement.

Suspension Overhaul:

Front fork seal replacement, rear shock absorber rebuild (if applicable or seal replacement).

Brake System Service:

Hydraulic brake fluid flush, caliper service, brake pad replacement.

Carburetor Tuning:

Carburetor cleaning, adjustment, jetting for different conditions.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, testing components.

Specifications And Data:

Torque values, clearances, fluid capacities, electrical resistance values, part numbers.

Depth Of Coverage:

Comprehensive. Covers routine maintenance through complete engine and chassis rebuilds. Suitable for home mechanics and professional technicians.

📊 Manual Specifications

Digital File Format:

PDF (Portable Document Format)

Print Quality Notes:

High-resolution scans for clear text and diagrams. Optimized for printing.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

4-stroke, air-cooled, SOHC, 4-valve

Displacement:

595 cc (approx. 36.3 cubic inches)

Bore X Stroke:

97.0 mm x 80.6 mm (typical for this engine variant)

Compression Ratio:

9.5:1 (typical, subject to minor variation)

Horsepower:

Approx. 45-48 HP at 6,500 RPM (estimate based on era and displacement)

Torque:

Approx. 50 Nm (37 ft-lb) at 5,000 RPM (estimate)

Carburetor:

Single Mikuni VM34SS (or similar VM series) or twin carbs depending on specific model variant/market. Manual will detail specific type.

Fuel Type:

Unleaded gasoline

Fuel Capacity:

Approx. 13 Liters (3.4 US gallons)

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

📐 Dimensions

Overall Length:

Approx. 2,200 mm (86.6 in)

Overall Width:

Approx. 830 mm (32.7 in)

Overall Height:

Approx. 1,230 mm (48.4 in)

Seat Height:

Approx. 865 mm (34.1 in)

Ground Clearance:

Approx. 270 mm (10.6 in)

Dry Weight:

Approx. 158 kg (348.3 lbs)

Wet Weight:

Approx. 175 kg (385.8 lbs) (estimated, with fluids)

Wheelbase:

Approx. 1,475 mm (58.1 in)

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycles are not typically rated by organizations like NHTSA or Euro NCAP)

Braking System:

Front: Hydraulic disc; Rear: Drum (typically, check specific model)

Lighting:

Headlight, tail light, brake light, turn signals.

💡 Technology Features

Infotainment System:

N/A (Basic motorcycle of its era, no digital infotainment).

Driver Assistance Features:

N/A

Connectivity Features:

N/A

Instrumentation:

Analog speedometer, tachometer, odometer, trip meter, indicator lights (neutral, oil pressure, turn signals, high beam).

🔧 Maintenance

Oil Change Interval:

Typically every 3,000 - 5,000 km (1,800 - 3,100 miles) or every 6 months. Manual will specify exact interval.

Valve Clearance Check:

Typically every 10,000 - 15,000 km (6,200 - 9,300 miles). Manual will provide exact interval and procedure.

Chain Maintenance:

Lubrication and tension check every 500-1,000 km (300-600 miles).

Engine Oil Type:

Yamaha recommends Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher. Manual will specify viscosity and API classification.

Engine Oil Capacity:

Approx. 2.3 Liters (2.4 US qt) without filter change, 2.5 Liters (2.6 US qt) with filter change. Manual will confirm.

Fork Oil Type:

Yamaha Suspension Oil (or equivalent) SAE 10W. Manual will specify exact type and quantity per fork leg.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify exact type.

Common Wear Items:

Clutch plates, fork seals, swingarm bearings, carburetor internal parts, starter motor brushes.

Potential Faults:

Carburetor gumming if left unused, some electrical connections can corrode, kick-start mechanism wear on high-mileage units.

📚 Vehicle History

Yamaha Heritage:

Yamaha Motor Company, founded in 1955, has a rich history in motorcycle manufacturing, known for innovation, performance, and reliability across various racing disciplines and street bikes.

Xt600 Lineage:

The XT600 line is a continuation of Yamaha's highly successful XT series, which pioneered the dual-sport category. This 90-96 generation represents a refinement of earlier models, incorporating updates for performance and reliability.

Production Period:

The XT600 was produced for an extended period, with significant updates occurring throughout its lifespan. The 1990-1996 models represent a distinct phase in its development.