Table Of Contents - Yamaha XT 600 AC Service Manual

Table of Contents

Illustrated Symbols4
Index5
Table Of Contents6
Motorcycle Identification14
General Information14
Vehicle Identification Number14
Engine Serial Number14
Important Information15
Preparation For Removal And Disassembly15
All Replacement Parts16
Gaskets, Oil Seals, And O-Rings16
Lock Washers/Plates And Cotter Pins16
Bearings And Oil Seals16
Circlips17
Special Tools17
For Tune Up17
For Engine Service18
For Chassis Service21
For Electrical Components22
Specifications23
General Specifications25
Maintenance Specifications Engine26
Chassis33
Electrical37
General Torque Specifications39
Definition Of Units39
Lubrication Points And Lubricant Type40
Engine40
Lubrication Diagram42
Cable Routing46
Emission Hose Routing50
Periodic Inspection And Adjustment51
General Maintenance/Lubrication51
Introduction51
Seat, Fuel Tank And Cover Removal52
Seat. Fuel Tank And Cover54
Installation55
Valve Clearance Adjustment56
Valve Clearance Adjurtment58
Cam Chain Adjustment59
Idle Speed Adjustment59
Throttle Cable Free Play Adjustment60
Spark Plug Inspection61
Ignition Timing Check63
Compression Pressure Measurement64
Compression Measurement65
Engine Oil Level Inspection66
Engine Oil Replacement68
Oil Pressure Inspection72
Clutch Adjustment73
Cable Free Play Adjustment73
Engine Oil Tank Strainer Cleaning75
Air Filter Cleaning77
Carburetor Joint Inspection78
Fuel Line Inspection79
Crankcase Ventilation Hose Inspection79
Exhaust System Inspection79
Canister Inspection (Xt600 Eac Only)80
Front Brake Adjustment82
Rear Brake Adjustment82
Brake Fluid Inspection83
Brake Pad Inspection84
Brake Light Switch Adjustment85
Brake Hose Inspection85
Air Bleeding85
Drive Chain Slack Adjustment86
Drive Chain Lubrication88
Front Fork Inspection88
Steering Head Adjustment89
Rear Shock Absorber Adjustment90
Tire Inspection91
Wheel Inspection94
Cable Inspection And Lubrication94
Lever And Pedal Lubrication95
Sidestand Lubrication95
Swingarm And Relay Arm Lubrication95
Battery Inspection96
Charging Method96
Charging Method Using A Variable-Current (Voltage) Type Charger100
Charging Method Using A Constant-Voltage Type Charger101
Charging Method Using A Constant Current Type Charger (Exclusive For Mf Battery)102
Fuse Inspection103
Headlight Beam Adjustment104
Headlight Bulb Replacement105
Engine Overhaul107
Engine Removal107
Engine Oil107
Seat And Fuel Tank107
Battery Lead107
Carburetor108
Clutch Cable108
Exhaust Pipe108
Starter Motor109
Hose And Lead109
Drive Chain110
Engine Protector110
Engine Disassembly112
Cylinder Head, Cylinder, Camshaft And Piston112
Starter Idle Gear And Crankcase Cover (Left)115
Clutch, Primary Drive Gear And Balancer Gear116
Oil Pump And Shift Lever118
A.c. Magneto And Cam Chain119
Crankcase (Right)121
Shifter And Transmission122
Balancer And Crankshaft123
Oil Strainer123
Rocker Arm124
Valve126
Inspection And Repair127
Valve And Valve Guide128
Valve Seat129
Valve Spring133
Camshaft134
Rocker Arm And Rocker Arm Shaft134
Cam Chain And Cam Sprocket135
Cam Chin Guide136
Cylinder And Piston136
Piston Ring138
Piston Pin139
Clutch139
Oil Pump141
Primary Drive141
Oil Pump Clearance141
Transmission And Shifter142
Shift Shaft Stopper Lever143
Starter Drive144
Starter Clutch Operation144
Crankshaft145
Balancer Drive Gear And Balancer Gear145
Crankcase146
Bearing And Oil Seal146
Engine Assembly And Adjustment147
Valve And Rocker Arm147
Crankshaft And Balancer151
Transmission152
Shifter153
Oil Strainer And Oil Pump155
Shift Lever And Oil Pump158
Cam Chain160
Piston And Piston Ring161
Piston, Cylinder, Cylinder Head And Camshaft165
A.c. Magneto171
Balancer Gear And Primary Drive Gear173
Oil Filter And Oil Delivery Line175
Balancer Gear, Primary Drive Gear, Clutch And Oil Filter176
Starter Gear179
Remounting Engine181
Carburetor Sectional View188
Carburetor Removal189
Carburetor Disassembly190
Primary Carburetor191
Carburetor Inspection193
Carburetor Assembly195
Carburetor Installation200
Fuel Level Adjustment201
Front Wheel202
Front Wheel Removal203
Front Wheel Inspection204
Static Wheel Balance Adjustment206
Rear Wheel209
Rear Wheel Removal210
Rear Wheel Inspection211
Rear Wheel Installation212
Front And Rear Brake214
Brake Pad Replacement216
Caliper Disassembly221
Master Cylinder Disassembly224
Caliper Assembly230
Master Cylinder Assembly235
Front Fork240
Front Fork Removal241
Front Fork Disassembly242
Front Fork Assembly245
Front Fork Installation248
Steering Head And Handlebar249
Steering Head And Handlebar Removal250
Steering Head And Handlebar Inspection253
Rear Shock Absorber And Swingarm259
Rear Shock Absorber And Swingarm Removal262
Rear Shock Absorber And Swingarm Inspection265
Side Clearance Adjustment266
Rear Shock Absorber And Swingarm Installation268
Drive Chain And Sprocket272
Drive Chain And Sprocket Removal273
Drive Chain And Sprocket Inspection274
Drive Chain And Sprocket Installation277
Xt600Ea/Eac Circuit Diagram279
Xt600Ea/Eac Wiring Diagram280
Color Code280
Electrical Components281
Checking Of Switches283
Switch Connection As Shown In Manual283
Checking Switch For Terminal Connection283
Checking Of Bulbs286
Kinds Of Bulbs286
Checking Bulb Condition286
Ignition System Circuit Diagram289
Ignition System Troubleshooting291
Electrical Starting System299
Starting Circuit Operation301
Electrical Starting System Troubleshooting302
Starter Motor Does Not Operate302
Charging System Circuit Diagram313
Charging System Troubleshooting315
The Battery Is Not Charged315
Lighting System Circuit Diagram319
Lighting System Troubleshooting321
Lighting System Check324
Signal System Circuit Diagram329
Signal System Troubleshooting331
Signal System Check333
Starting Failure/Hard Starting341
Poor Idle Speed Performance343
Poor Medium And High Speed Performance343
Faulty Gear Shifting344
Hard Shifting344
Change Pedal Does Not Move344
Jump-Out Gear344
Clutch Slipping345
Clutch Dragging345
Faulty Brake346
Front Fork Oil Leakage And Front Fork Malfunction346
Poor Braking Effect346
Oil Leakage346
Instable Handling347
Faulty Signal And Lighting System348
Headlight Dark348
Bulb Burnt Out348
Flasher Does Not Light348
Overheating349
Flasher Winks Slower349
Flasher Winks Quicker349
Horn Is Inoperative349