Yamaha XT600 XT 500 Repair Service Manual

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🏷️ Basic Information Identification Make: Yamaha Model: XT600 / XT500 Vehicle Type: Dual-Sport Motorcycle 👋 Introduction Market Position Segment: Dual-Sport / Trail Motorcycle Target Audience: Owners and mechanics of Yamaha...

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类型: Motorcycle

斯库: 476764

标签: Motorcycle Motorcycles XT 500 XT Models XT600 Yamaha

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Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XT600 / XT500

Vehicle Type:

Dual-Sport Motorcycle

👋 Introduction

Market Position

Segment:

Dual-Sport / Trail Motorcycle

Target Audience:

Owners and mechanics of Yamaha XT500 and XT600 motorcycles seeking detailed repair and maintenance guidance.

Competitive Analysis

Rivals:

Competed with models like Honda XL series, Kawasaki KLR series, Suzuki DR series during their respective production eras.

Key Features

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.

📋 Manual Details

Coverage

Page Count:

Manual Type:

Repair Service Manual

Language:

English

Format

Format:

Downloadable Digital File (PDF)

📖 Manual Coverage

Systems

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.

Procedures

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.

Technical Depth

Depth Level:

Comprehensive; suitable for both home mechanics and professional technicians. Covers everything from basic adjustments to complete engine and chassis overhauls.

📊 Manual Specifications

File Details

File Format Quality:

Digital PDF, typically high-resolution scans of original factory documentation, often with searchable text layers.

Physical Properties

Print Quality:

N/A (Digital Download) - Implied high quality from source material.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine Xt500

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

Ignition Xt500:

Primary Engine Xt600

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)

Ignition Xt600:

Performance

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)

Fuel System

Carburetor Type:

Mikuni (specific model varies by year/sub-model)

Oil Capacity

Engine Oil Capacity:

Approx. 2.0-2.5 Liters (including filter, check specific model for exact amount)

🔧 Transmission

Gearbox

Type:

5-speed manual constant mesh

Clutch

Type:

Wet multi-plate

Final Drive

Type:

Chain drive

Oil Type

Transmission Oil Recommendation:

Yamalube 4 (or equivalent SAE 20W-40 API SG classification)

📐 Dimensions

General

Wheelbase:

Approx. 1400-1460 mm (varies by model/year)

Seat Height:

Approx. 860-900 mm (varies by model/year)

Weights

Dry Weight:

Approx. 130-150 kg (varies by model/year)

Wet Weight:

Approx. 145-165 kg (varies by model/year)

🛡️ Safety Features

Features

Braking System:

Front: Disc brake; Rear: Drum brake (later XT600 models may feature rear disc).

Lighting:

Headlight, taillight, brake lights, turn signals (as per market regulations).

💡 Technology Features

Infotainment

Features:

N/A - These motorcycles are from an era where electronic rider aids and complex infotainment systems were not present. Focus is on mechanical and electrical function.

🔧 Maintenance

Service Intervals

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.

Fluid Specifications

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).

Known Issues

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.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycles:

Yamaha Motor Corporation has a long and successful history in motorcycle design and manufacturing, known for innovation and reliability.

Model Evolution

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

Production Period Xt500:

Approximately 1976-1981

Production Period Xt600:

Approximately 1983-2003 (across various iterations like XT600, XT600E, XT600K)

🏆 Awards & Recognition

Recognitions

Xt500 Legacy:

Widely recognized as a pioneering and influential dual-sport motorcycle that defined a segment and remains highly sought after by enthusiasts.

Xt600 Reputation:

Known for its robust construction and versatility, the XT600 is respected for its reliability and capability in various riding conditions.