YAMAHA , KTBOOZ(U)" SERVIGE INFORMATIONHANDLING OF ASBESTOS PARTS Wun CERTAIN COMPONENTS USED IN THE CONSTRUCTION OF THIS MACHINE CONTAIN AS- BESTOS. ASBESTOS MAY BE FOUND IN THE FOLLOWING: BRAKE SHOES, BRAKE PADS, GASKETS, CLUTCH PLATES AND HEAT INSULATORS. BREATHING ASBESTOS DUST IS HAZARDOUS TO HEALTH. PLEASE TAKE CARE WHEN WORKING WITH OR SERVICING THE PARTS CONTAINING AS- BESTOS. (1) ALWAYS WORK OUT OF DOORS IN A WELL VENTILATED PLACE. (2) DO NOT DRILL, FILE OR CUT THE COMPONENT UNLESS ESSENTIAL AND THEN USE ONLY LOW SPEED TOOLS EQUIPPED, IF POSSIBLE, WITH DUST EXTRACTORS. IF HIGH SPEED TOOLS ARE USED THEY MUST BE EQUIPPED WITH DUST EXTRAC- TION FACILITY. (3) WHEN POSSIBLE DAMPEN BEFORE CUTTING TO REDUCE POSSIBILITY OF DUST. (4) DAMPEN DUST AND PLACE IT IN A PROPERLY SEALED RECEPTACLE AND DISPOSE OF IT SAFELY. REG-COFOREWORD This Service Information has been prepared to introduce new service and data for the XT600Z(U) ’88. For complete service information procedures it is necessary to use this publication together with the following microfiche service manual. L XT600Z(U) SERVICE MANUAL: 3AJ-ME1 XT600Z(U) ©1987 by Yamaha Motor Co., Ltd. 4st Edition, December 1987 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in JapanNOTICE ‘This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, ‘60 it is assumed that persons using this book to perform maintenance and repairs on Yamaha motor- cycles have @ basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repeirs or service to this model may render it unfit to use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha, ‘Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE GROUP YAMAHA MOTOR CO., LTD. HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation. NOTE: A NOTE provides key information to make procedures easier or clearer. (EAUONE 4 CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle. EGG 4 WARNING indicates special procedures that must be followed to avoid injury to ‘a motorcycle operator or person inspecting or repairing the motorcycle. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, €.9., * Bearings Pitting/Damage- Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying cor- rect disassembly and assembly procedures.ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols @ to @ are designed as ‘thumb tabs to indicate the chapter's number and content, D General information @) Specifications @) Periodic inspection and adjustment Engine 5) Cooling system iustrated symbols () to @ are used to identify the specifications appearing in the text. Filling fluid Lubricant @ Special tool Tightening ‘Wear limit, clearance Engine speed QV, A Illustrated symbols () to @ in the exploded die- ‘gram indicate grade of lubricant and location of lubrication point. Apply engine cil Apply gear oll ‘Apply molybdenum disulfide oll ‘Apply wheel bearing grease ‘Apply lightweight ithium-soap base grease ‘Apply molybdenum disulfide grease Apply locking agent (LOCTITE®)CONTENTS GENERAL INFORMATION : MOTORCYCLE IDENTIFICATION : PERIODIC INSPECTION AND ADJUSTMENT... INTRODUCTION . PERIODIC MAINTENANCE/LUBRICATION INTERVALS EXPLODED DIAGRAMS .. ae VALVE AND ROCKER ARM CAMSHAFT AND CAM CHAIN CRANKSHAFT, PISTON AND BALANCER TRANSMISSION SHIFT CAM AND SHIFT FORK. CRANKCASE ..-..0..5 STARTER DRIVES ... CLUTCH CYLINDER CYLINDER HEAD : OIL PUMP AND OIL DELIVERY LINE CARBURETOR : deel FRONT WHEEL : Setter ied REAR WHEEL FRONT AND REAR BRAKE. FRONT FORK. . STEERING HEAD ......-- REAR SHOCK ABSORBER AND SWINGARM. C.D. MAGNETO 02. eee STARTER MOTOR METER ASSEMBLY . ELECTRICAL COMPONENTS . LUBRICATION DIAGRAM CABLE ROUTING . SPECIFICATIONS ....... GENERAL SPECIFICATIONS . MAINTENANCE SPECIFICATIONS: GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS ....- LUBRICATION POINTS AND LUBRICANT TYPE .. XT600Z(U) WIRING DIAGRAMMOTORCYCLE IDENTIFICATION GENERAL INF . GEN INFO |O™ ORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number (1) is stamped into the tight side of the steering head pipe. Starting Serial Number: XTBOOZ «.-. eee 3AJ-000101 XTBOOZ «2. -3AJ-031101 XTBO0Z ....-- +++ -3AJ-033101 XTOOOZ «eee eeee eee +++ -BDS-000101 XT600ZU see eeeee+-3DE-000101 ENGINE SERIAL NUMBER The engine serial number (@) is stamped into the elevated part of the right rear section of the engine. Starting Serial Number: xTBOOZU. NOTE: XT600Z ++ -3AJ-000101 XT600Z -3AJ-031101 XT600Z -3AJ-033101 xT6OOZ .. -3DS-000101 3DE-000101 The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. ‘Designs and specifications are subject to change without notice,INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. ‘These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information ap- plies to vehicles already in service as well as new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. INSP ADJ PERIODIC MAINTENANCE/LUBRICATION INTERVALS Unit: km (mi ERY lapeaK in ————™ rem REMARKS *Fo00."| 6,000 [12,000 Taeor | (4,000) oF (8,090) oF eee {6 months 2’ months [Valve clearance | Check/Adjust valve cleerance. o 10 |_0 Spark plug | Check/Clean/Replace if necessary. Q ° o Air filter Clean. Replace if necessary. ° o Carburetor Check/ Adjust idle epeed, starter operation o [6 ° Fuel line Check fuel hose for cracks or damage, 0 3 Engine ol Replace (Warm engine before draining). 3 o ot Engine of fiter/ | Replace fiter element and clean oil stainer. ° ° [2 Check operation/fiuid lwakage/See NOTE./ a Adjust if necessary. : 7 e Clutch Check operation/ Adjust # necessary. © 6 ‘Swingarm pot! | Check swingarm assembly for looseness. o Swingarm —_| Clean ond lube,"** eC een Wheels ‘Check balance /damage/runout/spoke tightness. 5 o ; Check bearings assembly for looseness/demege. ; Wheel bearings | Check beatae ser iz ° ae ‘Check bearings assembly for looseness. Moderately Steering beating | repack every 24,000 (16,000) or 28 months.*** | CHECK. oe Front forks Check operation/ollloakege : 6 ° Rear shock ‘on/ol 5 a Rear sho Check operaton/o eakege. a. Drive chain Check and adjust slack/alignment/ clean ube. EVERY 500 (300) Fittings/Fastonors | Check al chassis itings and fasteners. o ° 3 Sidestand switch a : a a 7 7 oe Check operation. Clean or replace if necessery. ; Check specific gravity. [exer Check breather pipe for proper operation. at Hoe 7 Lithium base greasege PERIODIC MAINTENANCE/ [INSP | LUBRICATION INTERVALS [ADJ NOTE: Brake system: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required, 2. We recommended that, on the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years. 3. We recommended that, replace the rake hoses every four years, or if cracked or damaged.4 VALVE AND ROCKER ARM | ENG | @%p EXPLODED DIAGRAMS VALVE AND ROCKER ARM Q Rocker arm #2 © Outor spring Wave washer Valve (intake) Rocker arm shaft (Intake) D Spring seat Rocker arm #1 Rocker arm shaft (Exhaust) Valve retainer Rocker arm #4 © Spring seat Rocker arm #3 @ Ol seal Rocker arm shaft (Exhaust ® Inner spring @ Valve (Exhaust) VALVE SPRING TILT LIMIT: VALVE CLEARANCE (COLD): Inner spring: JA} Intake: 0.07 ~0.12 mm (0.003 ~0.006 in) B| 25° oF 1.7 mm (0.07 in} Exhaust: 0.12~0.17 mm (0.005 ~0.008 in) ‘Outer spring: 2.6° of 1.7 mm (0.07 in} 1 Gane) 4 oo (¢| STEM RUNOUT LIMIT: 10.01. mm (0.0004 in) VALVE SEAT WIDTH: 1.0~1.2 mm (0.04~0.05 in) [Heat CAMSHAFT AND cam cHain_| ENG + CAMSHAFT AND CAM CHAIN @ Camshaft @) Cam sprocket @ Chain guide @) Cam chain ® Chain guide © Gasket @ Chain tensioner a Tas oon clmanance 7 aS ee (0.0008 ~ 0.0021 in) 20 Nim (2.0 m-kg, 14 ftelb)a CRANKSHAFT, PISTON AND BALANCER | ENG CRANKSHAFT, PISTON AND BALANCER @ Piston ring (Top) @) Crank (Left) Boss @) Piston ring (2nd) @® Connecting rod Oil seal Piston ring (Oil) @ Bearing Bearing @ Piston € Crank (Right) €@ Bolancer Piston pin @ Bearing Bearing © Crank pin Balancer drive goar Balancer gear Ja] CRANK wioTH: PISTON RING END GAP: 74,5~7.00 mam (2.950 | RUNOUT LIMIT: 0.03 mm (0.0012 in) SMALL END FREE PLAY: PISTON RING SIDE CLEARANCE ©) “o.8~10 mm (0.031~0.039 in) __| G| Top: 0.04~0.08 mm (0.002~0.003 in) He CRANCE: |_ 2nd 0.03 0.07 mm (0.001 ~0.003 in) | £0,26-~0.78 mn (0.010 ~0.080 in i | Top: 0.30~0.45 mm (0.012~0.018 in) See 0.018 in) in) o | PISTON SIZE: E| 94.915 ~94.965 mm (3.737~3.739 in} BE307SH2-9TC4 USE NEW ONE.a1 transmission | ENG | %p TRANSMISSION @ Drive sprocket Bearing Oil seal Bearing Bearing 2nd pinion gear 2nd wheel gear 5th pinion gear Drive axle @ 34d pinion gear ‘th wheel gear 4th pinion gear 1 Main axle Bearing 3rd wheel geat 4th wheel gear ‘st wheel gear 10 Nm (1.0 mekg, 7.2 ftelb) USE NEW ONE MAIN AXLE RUNOUT LIMIT: 0.08 mm (0.003 in) @~8— SHIFT CAM AND sHiET FoRK | ENG | @%p SHIFT CAM AND SHIFT FORK @ Stopper lever @ Guide bar @ Shitt fork #3 @ ® @® Guide bar D Shift fork #2 QP 10 Nm (1.0 mekg, 7.2 ftelb)9 crankcase | ENG | @%p CRANKCASE D Crankcase (Right) @ Crankcase (Left) Crankease ventilation hose @ Dowel pin ®© Dowel pin Dowel pin Stopper plate Collar [R[iiaurenine Seavence: @~10- starter prives | ENG | Gp STARTER DRIVES Starter motor dive gear (Bearing I) AFTER INSTALLING THE STARTER CLUTCH, Primary starter ile gear @) Starter wheel gear CALK THE BOLT END, AS SHOWN. Bearing @) Starter clutch @ Primary idle gear axle 4 Bearings Secondary starter idle gear) CDI magneto Secondary idle gear axle Ex mCLUTCH D Clutch spring Pressure plato Push rod Ball Friction plete (Type A) Wave plate @ Church plate oe CLUTCH [enc | %p| Friction plate (Type B) Clutch boss Thrust washer iD Clutch housing Push rod Push lover Primary drive gear fk FRICTION PLATE: A CLUTCH SPRING MINIMUM Type Thickness Wear Limit | oe ea 2.94~3.06 mm t = — A | (cme—0.120 im 2.8 mm (0.110 in) CIUTCHIPLATE (2.72~2.88 mm a |C| WARPAGE LIMIT: B (0.107 —0.113 in) 2.6 mm (0.102 in) ‘0.2 mm (0.008 in) 120 Nm (12.0 m-kg, 85 ft-lb) 6, 4 (i @ [p[Use New one] S PUSH ROD RUNOUT LIMIT: 0.2 mm (0.008 in)CYLINDER @ Gasket 2) Cylinder @ O-ring @ Gasket ® Dowel pin © Dowel pin cytinver | ENG | %p [A] TIGHTENING SEQUENCE: 2 Nm (4.2 mekg, 30 ftelb) 22 Nm (2.2 mekg, 16 ft-lb) — ‘BORE SIZE: 194.97 ~ 95.02 mm (3.739~3.741 in) : < 95.1. mm (3.744 in)> B T PISTON-TO-CYLINDER CLEARANCE: | 0,005 ~0.0685 mm (0.002~0.008 in) | cuir 0.1 mm (0,008 inl>-13 cyuinper Heap | ENG | %p CYLINDER HEAD @ cylinder head cover Valve (intake valve) Tappat cover (Intake) Valve {Exhaust valve O-ring Spark plug Dowel pin ® O-ring © Gear unit (Tachometer) @ Tappat cover (Exhaust) @ Cylinder head 10 Nm (1.0 mekg, 7.2 ftelb) 70 Nm (1.0 m-kg, 7.2 ft-lb) 70 Nm (1.0 mekg, 7.2 ft-lb) \ Nm (0.8 m-kg, 6.8 ft-lb) YAMAHA BOND NO. 1215 | 20 Nm (2.0 m-kg, 14 ft-Ib)14 OIL PUMP AND OIL DELiverY LINE | ENG a» OIL PUMP AND OIL DELIVERY LINE @ Oil strainer ® Oil pump & Oil pump gear @ Oil cleaner cover Oil cleaner 6) Oil hose @® Oil hose ‘OlL PUMP: TIP CLEARANCE: 0.12 mm {0.005 in} SIDE CLEARANCE: 0.03 ~0.08 mm (0,001 ~ 0.003 in) 70 Nm (1.0 mekg, 7.2 ft-lb) { / 7 Nm (0.7 mekg, 5.1 ftelb} So 40 Nm (1.0 mskg, 7.2 ft-Ib) pp: -D '5 Nm (0.5 mekg, 3.6 ft+Ib) 4 \, [10m (1.0 moka, 7.2 ftetb) < \ o Qo [to nm 11.0 mekg, 7.2 ft | comemneal [a0 nm (8.0 mekg, 22 ft-1b) |-15— carsuretor [CAR * CARBURETOR Connecting arm ® Jet needlo set SPECIFICATIONS @) Throttle valve to PRIMARY SECONDARY @ Coasting enricher assembly ©) Needle valve sot Me elite ee (pric ten omen PILOT JET) #48 : Main jet JET 5C47—3/5 5X76—3/5 Pilot jet NEEDLE | 5C48—3/5(D)| 6X76—3/5(D} } Plot screw sot PILOT 2 tums out ‘Throttle stop screw set SCREW Float FLOAT | 25.0~27.0 mm (0.98~ 1.06 in) Starter plunger set HEIGHT @ Drain screw FUEL 5.0~7.0 mm (0.20~0.28 in) Main nozzle Throttle valve (D}: For Germany : Main jet evel @ Jet neodle sot [2 Nm (0.2 mekg, 1.4 ft-lb) ‘3.Nm (0.3 mekg, 2.2 ftetb)~16— FRONT WHEEL FRONT WHEEL Wheel axle Collar @) Dust cover @ Oil seat 8) Bearing ® Collar @ Front wheel Bearing Gear unit (Speedometer) CHAS| dO —] [a] TIRE SIZE: 3,00821-4PR RIM SIZE: 1.6021 _| RIM RUNOUT LIMIT: VERTICAL: 2.0 mm (0.08 in) LATERAL: 2,0 mm (0.08 in)-7- REAR WHEEL |CHAS|d%% REAR WHEEL @ Caliper bracket @ Clutch hub Collar Collar Dust cover Driven sprocket Oil seal Boating Bearing @® Bearing ® Collar @ Rear wheel @ Damper @ 19) Oil seal Collar Drive chain @® Wheel axle rc ‘al TIRE SIZE: 4,60818-4PR, 4.00S18-4PR RIM SIZE: MT 2.50% 18 E] USE NEW ONE ~ o 45 Nm (4.5 m-kg, 32 ft-lb) 7 @ DRIVE CHAIN SLACI 30~40 mm 90 Nm (9.0 m-kg, 65 ft-lb) Ke RIM RUNOUT LIMIT: VERTICAL: 2.0 mm (0.08 in} LATERAL: 2.0 mm (0.08 in) o _— sale USE NEW ONE—18— FRONT AND REAR BRAKE |CHAS| dO FRONT AND REAR BRAKE D Master ovinder cap @ Pad spring Rubber seal Piston 3) Master cylinder kit Piston seal @ Master cylinder Brake pad @) Brake hose Brake disc © Brake caliper eo] BRAKE PAD WEAR LIMIT: 0.8 mm (0.03 in) BRAKE DISC WEAR LIMIT: 3.5 mm (0.14 in) fe USE NEW ONE [a] BRAKE FLUID TYPE: DOT #4 (or DOT #3) 2.Nm (0.2 m-kg, 14 ft-lb) NS @ Nm (0.6 m-kg, 4.3 ft-lb) 35 Nm (3.5 mekg, 25 ft-lb) 20 Nm (2.0 mekg, 14 ft-lb) 78 Nm (1.8 mekg, 13 ftelb) USE NEW ONE—19- FRONT AND REAR BRAKE |CHAS| &% D Reservoir tank cap @ Brake pedal Bush @ Brake caliper Diaphragm @ Piston Reservoir tank Piston seal Reservoir hose © Broke pad Master cylinder Pad spring Master cylinder kit ® Brake aise (8) Brake hose BRAKE FLUID TYPE: | > DOT #4 lor DOT #3) @ Nm (0.6 m-kg, 4.3 ftelb) | BRAKE PAD WEAR LIMIT: 18 Nm (1.8 73 fteIb) 0.8 mm (0.03 in} 3.5 mm (0.14 in) LANE —_—_—-—— 36. Nm (3.5 mekg, 25 ft-lb) 20 Nm (2.0 mekg, 14 ft-lb) 4.Nm (0.4 mekg, 2.9 ftelb) ‘27 Nm (2.7 mekg, 19 ft-lb) USE NEW ONE.Front ForK [CHAS| FRONT FORK D Cap bolt 8 Dampor rod Q O-ring Oil lock piece @ Spring seat ( Dust seal @ Fork spring (Small) Retaining clip @ Spring seat Oil seal @® Fork spring (Large) Washer @) Inner fork tube Slide metal ® Guide bush Outer fork tube @ Piston ting Axle holder ® Rebound spring 2) Fork boot ] FORK OIL (EACH): FORK SPRING: CAPACITY: B MINIMUM FREE LENGTH: 593.0 mm (23.3 in) 23 Nm (2.3 mekg, 17 ftelb) A| 817 em’ (18.2 Imp oz, 17.5 US oz) GRADE: FORK OIL 10W or EQUIVALENT @ Nm (0.8 m-kg, 5.8 ftelb)STEERING HEAD @ Handieber holder (Upper) Handlebar holder (Lower! Handle crown Ring nut Cover STEERING HEAD |CHAS SK Bearing (Lower) @) Clamp (Brake hose) Cable holder (Speedometer cable) Headlight stay a21— @© Bearing (Upper) 30 Nm (3.0 mekg, , 22. fret) USE NEW ONE wid é/ [Nm (0.1 mekg, 0.7 ft-lb) * Tighten ring nut mekg, 27 ftelb). one turn. * Retighten it 6 Nm (0.6 m+kg, 4.3 ftelb). ; | / a AGO Nim (1.0 mekg, 7.2 ft-lb) °@ Se2 REAR SHOCK ABSORBER AND swingarm |CHAS RX REAR SHOCK ABSORBER AND SWINGARM Rear shock absorber sssembly ® spring SPRING PRELOAD: _| ‘STANDARD LENGTH: 235 mm (9.3 in) A| MINIMUM LENGTH: 228.5 mm (8.8 in) MAXIMUM LENGTH: |_| 240.5 mm (9.5 in) 59 Nm (5.9 mekg, 43 ft-lb) Go 7 USE NEW ONE 70 Nm (7.0 mekg, 50 ftelb) DAMPING FORCE: [HARD [S.7.0.| SOFT ts [43 [2 1] -OSITION,23 REAR SHOCK ABSORBER AND swincarm |CHAS rcs} Swingarm Relay arm Connecting arm Chain case Chain protector © Chain guide 4 Nm (0.4 m-kg, 2.9 =I | 32 Nm (3.2 mekg, 23 ft-lb) cet=~ c.p.1. maGneto | ELEC C.D.I. MAGNETO Rotor Pickup coil ‘Source coil/ Charging coil PICKUP COIL RESISTANCE: ‘90~ 1300 at 20°C (68°F) {Black/Yellow —Blue/Yellow! 90~ 1300 at 20°C (68°F) (Black/Yellow— Green/White) > ‘SOURCE COIL RESISTANCE: | 2400 at 20°C (68°F)—25— STARTER MoTOR | ELEC S STARTER MOTOR D Starter motor lead O-ring Yoke assembly @ Armature coil assembly Brush assembly @© Washer ‘COMMUTATOR UNDER CUT: ‘0.7 mm (0.028 in) _| SOMMUTATOR DIAMETER WEAR LIMIT: 27 mm (1.06 in) Hl BRUSH WEAR LIMIT: 5.0 mm (0.20 in) o26 METER AssemeLy | ELEC} B= METER ASSEMBLY Tachometer ascombly @ “NEUTRAL” indicator tight @) Speedometer assembly rown lead) @ Tachometer cable ficator light @ Speedometer cabio (Yellow and Black tead) © Bulb © "TURN" indicator light © Meter light (Dark green and Chocolate lead) (Blue and Black lead) 7 Nm (0.7 mekg, 6.1 ftelb) ae! le d21 ELECTRICAL components | ELEC] E=3 ELECTRICAL COMPONENTS 3 Wireharness Main switch Ignition coil @) Rectifier/ Regulator Battery © CDI unit Fuse IGNITION COIL: PRIMARY COIL RESISTANCE: 0.15~0.219 at 20°C (68°F) SECONDARY COIL RESISTANCE: 3.8~5.8k2 at 20°C (68°F) BATTERY: CAPACITY: 12V 12AH SPECIFIC GRAVITY: 1.280 7 Nm (0.7 mekg, 5.1 ftelb)~~ ELECTRICAL components _| ELE! D) Rear brake switch Horn 3) Neutral switch g Sidestand switch Flasher rolay © Starter relay @ Starting circuit cut-off relay @® Neutral relay~29— LUBRICATION DIAGRAM SPEC PF LUBRICATION DIAGRAM iit tank Ol strainer il pump A | FEED OIL B | SCAVENGE OIL]—30— LUBRICATION DIAGRAM SPEC PF | it pump SCAVENGE OIL|-31 LUBRICATION DIAGRAM SPEC 99 | Oi cleaner Crank pin Main axle ® Drive axle [Teor | [E[scavence on]—32— LurIcATION Diagram |SPEC| ii cleaner il pump Shift cam @ Ol strainer (5 [leon | SCAVENGE OI]—33— SPEC #9 CABLE ROUTING CABLE ROUTING i Flasher light lead (Right) @ Clamp @ Tachometer cable @ Meter lead @ Flasher light feed (Left) © Speedometer cable © Starter cable ® Headlight lead 9) Clutch switch lead Main switch lead Band Brake hose Throttle cable 2 i) Throttle cable 1 Cable guide Clutch cable Handlebar switch lead (Left) Handlebar switch lead (Right) 9 Stop switch lead @ Fuel hose Wireharness Fuel pumpa cape ROUTING | SPEC Clutch cable Throttle cable 2 Breather hose (Carburetor) Speedometer cable (1) Starter switch ass'y Overflow hose (Carburetor) Brake hose 1D Battery lead Broather hose (Battery) @ Clamp @ Battery lead Oi hose ban Fuse Breather hose (Crankcase) © Throttle cable Battery CDI magneto lead Cable guide Rectifier/ Regulator Starter cable ® Ignition coit @ Flasher relay Wireharness @ Throttle cable 1 B Sidestand switch leadQ Throttle cable 1 @) Throttle cable 2 @ Stop switch lead @ Handlebar switch lead (Right) Cable guide ® Clamo D Main switch lead ® Wireharness —5— caBLE ROUTING | SPEC p @ Tachometer cable Holder—36— caste Routine | SPEC| 9 D Clamp Band Restifier/ Regulator @ Sidestand switch relay @ Wireharness @ Flasher light lead (Left) Flasher light lead (Right) Battery lead 8 Battery lead ©) BatteryGENERAL SPECIFICATIONS ~37— SPEC} © SPECIFICATIONS (Di; For Germany (SF): For Finland (DK): For Denmark (Fy: For France (Ni: For Norway (): For Italy (S): For Sweden {B): For Belgium (GB): For England (GR): For Greece (E): For Spain (CH): For Switzerland (NL: For Holland (P): For Portugal GENERAL SPECIFICATIONS (O}: For Oceania and S. Africa iF Model Model Code Number: xT600Z(U) 3AJ1 (DFHINBYGBNSMGRYP) 3AJ2 (E) 3AJ3 (NLKN)(SF)IDK) 3D81 (CH) 3DEt (0) itt) Engine Starting Number: 3AJ1-000101 3AN2-081101 3AJ3-033101 3D$1-000101 3DE1-000101 Frame Starting Number: Dimensions: Overall Length Overall Width Overall Height Seat Height Wheelbase Minimum Ground Clearance 3AJ1-000101 3AJ2-031101 3AJ3-033101 30$1-000101 3DE1-000101 2,210 mm (87.0 in) 2,290 mm (90.2 in) (D) (S) (DK) (N) 2,340 mm (92.1 in) (SF) 835 mm (32.9 in) 1,340 mm (52.8 in) 890 mm (35.0 in} 1,460 mm (57.5 in) 255 mm (10.0 in} Basic Weight: With Oil and Full Fuel Tank 185 kg (408 Ib) Minimum Turning Radius: 2,300 mm (90.6 in) Engine: Engine Type Cylinder Arrangement Displacement Borex Stroke Compression Ratio Compression Pressure Standard Starting System Air cooled 4-stroke, SOHC Forward inclined single cylinder 595 cm? 9584 mm (3.74x3.31 in) 85:1 1,100 kPa (11 kg/cm? 16 psi) Electric starterGENERAL SPECIFICATIONS SPEC —38— Model xT6002(U) Lubrication System: ‘Type Engine Oil Type Oil Capacity: Periodic Oil Change With Oil Filter Replacement Total Amount Oil Tank Capacity Dry sump SAE 20W40 type SE motor oil or SAE 10W30 type SE motor oil 1.9 L (1.7 Imp at, 2.0 US at) 2.0 L (1.8 Imp at, 2.1 US at) 2.4 L (2.1 Imp at, 2.5 US at) 1.7 L (1.5 Imp at, 1.8 US qt) Fuel Tank Capacity Fuel Reserve Amount Air Filter: Type Wet type element Oil Type Foarn-air-filter oil or SAE 10W30 motor oil Fuel: Type Regular gasoline 23.0 L (5.1 Imp gal, 6.1 US gal) 3.1 L (0.7 Imp gal, 0.8 US gal) Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Carburetor: ‘Type/Quantity Y27PV/1 pe. Manufacturer TEIKE! ‘Spark Plug: Type/Plug Gap DPR7EA-9/0.8~0.9 mm (0,081 ~ 0.036 in) DPR8EA-9/0.8~0.9 mm (0.031 ~0.035 in} Manufacturer NGK Clutch: Type Wet, multiple-dise Transmission: Type Constant mesh 5-speed ' Operation | Left foot operation Spur gear TA/31 (2.387) Chain drive 38/15 (2.633) (CH) 40/15 (2.677) (DMFIUNBNGENSHENMNLMNSFOK) Gear Ratio: ast | 31/12 (2.583) 2nd | 27/17 (1.588) 3rd_| 24/20 11.200) : 4th | 21/22 (0.954) 7 bth | 19/24 (0.792) Chassis: ’ Frame Type Diamond Caster Angle 25° Trail 109 mm (4.29 in) - |GENERAL speciFications | SPEC oF Model XT600Z(U} Tire: Type With tube Size: Front | 3.00821-4PR Rear 4,60S18-4PR 120/80-18-62P (IRC) Manufacturer: Front | BRIDGESTONE (TW25) IRC (GP110) Rear BRIDGESTONE (TW26) IRC (GP110) Tire Pressure (Cold tie): Maximum Load* 180 kg (397 tb) (From | 34 kg {75 1b) (Rear) | 146 ka (322 tb) Cold Tire Pressure Front. Rear i 150 kPa 150 kPa Up to 90 kg (198 Ib} loadt (1.5 kg/em?, 21 psi) | (1.5 kg/cm?, 21 ps iz 150 kPa. 180 kPa 90 kg (198 Te) ~ Maximum load (1.5 kg/om?, 21 psi) | (1.8 kg/cm?, 26 psi) aa 100 kPa 100 kPa ee (1.0 kg/em®, 14 psi) | (1.0 kg/om?, 14 psi) oo 150 kPa. 150 kPa. Het sae ee (1.5 kg/om?, 21 pei) | (1.5 kg/m’, 21 psil i Load Is total weight of cargo, rider, passenger, and accessories. Brake: Front Brake Type Front Brake Operation Rear Brake Type Rear Brake Operation Single disc brake Right hand operation Single disc brake Right foot operation Headlight Type ‘Suspension: Front Telescopic fork Rear ‘Swingarm (New Monocross) ‘Shock Absorber Front Coil—~ Air spring/Oil damper Rear Coil—Gas spring/Oil damper ‘Wheel Travel: Front 255 mm (10.0 in) Rear 225 mm (8.9 in} Electrical: Ignition System col Generator System A.C. magneto generator Battery Type GM12Az Battery Capacity 12, 12AH Quartz bulb (Halogen) (OUBUSNENFNGRIP)(GBYO) Bulb type (IDKNSFY(NLICHYN)~40— GENERAL SPECIFICATIONS/ MAINTENANCE SPECIFICATIONS SPEC “TURN" indicator Light Model xT600ZIU) _| Bulb Wattage (Quantity): Headlight 12V 6OW/SBW (1 pc.) (DMEMBNSIFMGRMP) 12V 55W (1 pc.) | 12v 35W/35W (2 pes.) (1(DKNGBMO)(SFINL] | 12V 6OW/55W (1 pe.) (CHIN) Tail/ Brake Light 12V BW/21W (1 po.) Flasher Light | 12V 21W (4 pes.) Auxiliary Light 12V 4W (1 pc.) (DMENBSMFMGRMP)SFNNLICH)IN) 12V 4W (2 pes.) (IMDK) 12V 3.4W (2 pes.) (GB) (0) Meter Light 12V 3.4W (2 pes.) “NEUTRAL indicator Light 12V 3.4W (1 po.) “HIGH BEAM" indicator Light 12V 3.4W (1 pe.) 12V 3.4W (1 pe.) MAINTENANCE SPECIFICATIONS ENGINE [ Model XT6O0Z(U) a Cylinder Head: * Warp Limit 0.03 mm (0.0012 in} * Lines indicate straightedge measurement. S Cylinder: Bore Size 94.97 ~95.02 mm (3.739 ~3.741 in) <95.1 mm (3.744 in) > Measuring Point @ 40 mm (1.6 in} Le Camshaft: Drive Method Chain drive (Left) Camshaft Outside Diameter 22.967 ~ 22.980 mm (0.904 ~ 0,905 in) ‘Shaft-to-cap Clearance 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) ‘Cam Dimensions Intake “A” | 36.52 ~ 36.62 mm (1.438 ~ 1.442 in) i “Be 30.01 ~30.11 mm (1.181 ~1.185 in) “Cc a | 6.51 mm {0.256 in) 36.70 ~ 36.80 mm (1.445 ~ 1.449 in) Exhaust A’ [Camshaft Runout Limit 30,07 ~30.17 mm (1.184 ~ 1.188 in} 6,63 mm (0.261 in} 0.03 mm (0.0012 in)a MAINTENANCE SPECIFICATION | SPEC Model xT600Z(U) Cam Chain: Cam Chain Type Number of Links Cam Chain Adjustment Method Rocker Arm/Rocker Arm Shaft: Rocker Arm Inside Diameter Shaft Outside Diameter Anm-to-shaft Clearance 75 — 010 126 Links Automatic 42.000 ~ 12.018 mm (0.472 ~0.473 in) 11.976 ~ 11.991 mm (0.471 ~0.472 in) 0.009 ~ 0,042 mm {0.0003 ~0.002 in) Valve, Valve Seat, Valve Guide: Valve Clearance (Cold): Intake 0.07 ~0.12 mm (0.003 ~ 0.005 in) Exhaust, 0.12~0.17 mm (0.005 ~ 0.007 in) Valve Dimensions: Intake Exhaust “IN” Head Diameter 36.9~37.1 mm 31,9~32.1 mm } (1.45~1.46 in) {1,25 ~1.26 in) “B" Face Width 2,26 mm pee (0.09 in) “C" Seat Width 1.0~1.2 mm on {0.04-0.08 in) "D" Margin Thickness: 1.0—1.4 mm 0.8~1.2 mm (0.04 ~ 0.06 in} {0.03 ~ 0.05 in) a t . 7 4 ou. "K ¢°° Stem Outside Diameter: Intake 6.975 ~6.990 mm (0.274 ~0,275 in) Exhaust 6.955 ~ 6.970 mm (0.273~0.274 in} Guide Inside Diameter: Intake 7.000 ~7.012 mm {0.275~0.276 in) Exhaust 7,000 ~7.012 mm (0.275 ~ 0.276 in) ‘Stem-to-guide Clearance: Intake | 0.010~0.037 mm {0.0004 ~ 0.001 in) Exhaust 0.030~0.057 mm (0.001 ~ 0.002 in) ‘Stem Runout Limit Valve Seat Width: Intake Exhaust 0.01 mm {0.0004 in) 1.0~1.2 mm (0.04 ~0.08 1.0~1.2 mm (0.04~0.05 in)42 MAINTENANCE spEciFication | SPEC| 9 a [_ Model XT600ZIU) Valve Spring: Inner Spring Outer Spring Free Length: ] a Intake 40.1 mm (1.58 in) | 43.8 mm (1.72 in) Exhaust 40.1 mm (1.58 in} | 43.8 mm (1.72 in) Set Length (Valve Closed): Intake 22.7 mm (0.89 34.2 mm (1.35 in) Exhaust 22.7 mmm (0.89 in) | 34.2 mm (1.35 in) Direction of winding (Top View) | Clockwise Counterclockwise Tilt Limit: C ° Intake 2.5°/1.7 mm (0.07 in) - Exhaust 2.5°/1.7 mm (0.07 in} - Piston: Piston Size “D" 94.915 ~94.965 mm (3.737 ~3.739 in) Measureing Point “H” 5,0 mm (0.20 in) Over Size 2nd Over Size 4th 95.5 mm (3.760 in} 96.0 mm (3.780 in) Piston Off-set 2.0 mm {0.08 in) Piston Off-set Direction Intake side Piston-to-cylinder Clearance 0.045 ~ 0.065 mm (0.002 ~ 0.003 in) <0.1 mm (0.004 in) > Piston Ring: ‘Type: Top Ring Barrel 2nd Ring Plain Dimensions (B xT): Top Ring .2. mm (0.047 in) £8 mm (0.150 in) 2nd Ring 1.2 mm (0.047 in} 3.8 mm (0.150 in) Oil Ring 2.6 mm (0.098 in) ae 3.4 mm {0.134 in} End Gap (Installed): - Top Ring 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 2nd Ring 0.30~0.45 mm (0.012~ 0.018 in) Oil Ring | 0.20~0.70 mm (0.008 ~ 0.028 in)3 MAINTENANCE SPECIFICATION | SPEC p Model xT600Z(U) Side Clearance (Installed): Top Ring 0,04~0.08 mm {0.002~0,003 in} 2nd Ring 0.03~ 0.07 mm (0.001 ~0.003 in) Crankshaft: Crank Width “A” 74,95 ~75.00 mm (2,950~ 2.953 in} Runout Limit “C" 0.03 mm (0.0012 in} Big End Side 0.25 ~0.75 mm (0.010 ~ 0.080 in) Clearance “D" ‘Small End 0.8~1.0 mm (0.031 ~0,089 in} Free Play "F” j Balancer: Drive Method Spur gear Clutch: Friction Plate: Thickness 2.72 ~2.88 mm (0.107~0.113 in) ‘Quantity 6 pes. Wear Limit 2.6 mm (0.102 in) Friction Plate: Thickness: 2.94~3.06 mm (0.116~0.120 in) Quantity 2 pes. Wear Limit 2.8 mm (0.110 in) Clutch Plate: Thickness 1.2 mm (0,047 in) Quantity 7 pcs. Warp Limit 0.2 mm (0.008 in) Clutch Spring: Free Length 34.6 mm (1.362 in) ‘Quantity 5 pes. Minimum Free Length 32.6 mr (1.283 in) Clutch Housing: Thrust Clearance 0.070~0.071 mm (0.003 in} Clutch Release Method Inner push, cam push Transmission: Main Axle Runout Limit 0,08 mm (0.003 in) Drive Axle Runout Limit 0.08 min (0.003 in) Shifter: Type Cam drum and guide bar44 MAINTENANCE SPECIFICATION | SPEC Pp [ Model xT600Z(U) Carburetor: Except for Germany For Germany 1.D. Mark 3AJ 10 3AJ 00 Main Jet (MJ) Primary Carburetor #155 #165 Secondary Carburetor #125 « Main Air Jet (MAJ) Primary Carburetor $1.0 + Secondary Carburetor O12 . Jet Needle (J.N.) Primary Carburetor | 8C47—3/5 5C48—3/5 Secondary Carburetor 8X76—3/5 BX76—-3/5 Needle Jet iN) 92.6 . Cutaway (CA) 55 + Pilot Outlet (P.0.) 408 . Pilot Jot (PJ) #48 . Bypass 1 61.0 . Pilot Screw 16/8 tums out | - Valve Seat Size (V.s.) 62.5 « Starter Jet (G.s.) #80 - Fuel Level (FL) 5.0-7.0 mm a (0.20~0.28 in) Float Height (FH) 2.0~27.0 mm os (0.98~ 1.06 in) Engine Idle Speed 1,250~ 1,350 r/min + ; Lubrication System: ii Filter: Type Paper type Oil Pump: Type Trochoid type Tip Clearance 0.12 mm (0.006 in) Side Clearance 0.03 ~0.08 mm (0.001 ~0.003 in) Bypass Valve Setting Pressure 80~ 120 kPa (0.8~1.2 kg/om?, 11~17 psi) Relief Valve Operating Pressure 80~ 120 kPa (0.8~1.2 kg/cm’, 11~17 psi) Oil Pressure 13 kPa (0.13 kg/em?, 1.8 psi at 1,300 r/min Pressure Checking Location Oil cleaner chamber |45 MAINTENANCE SPECIFICATION | SPEC Model XT600Z(U) Tightening torque: Thread #t Tightening torque Rane oe rt Part to be tightened | wead size Nm |mekg] tte Cylinder head | Flange bolt M8 x 1,25 29 29 21 Stud bolt ) M10x 1.25 20 2.0 14 Hexagon socket head bolt M6 x1.0 10 1.0 72 Stud bolt MB x 1.0 7 | 07) 54 | Spark plug M12x 1,25 18 18 13 Cylinder head cover Hexagon socket head bolt M6 x1.0 10 1.0 7.2 Tappet cover {Intake} Hexagon socket head bolt M6 x1.0 10 10 | 7.2 Tappet cover (Exhaust! M32x 1.5 12 1.2 8.7 Gear unit (Tachometer) Hexagon socket head bolt M6 x1.0 10 1.0 7.2 Flat head screw M6 x1.0 | 7 07 51 Cylinder Cap nut M8 xX 1.25 22 2.2 16 Nut M10x 1.25 42 42 30 ‘Hexagon nut M10 1,25 42 42 30 Hexagon socket head bolt M6 x1.0 10 1.0 72 Balancer gear Hexagon nut M16 x 1.0 60 6.0 4B Rotor (A.C. magneto) Hexagon nut Miaxt5 120 | 120 | 95 | Locknut (Valve clearance adjuster) | | Hexagon nut | M6 x1.0 14 1.4 10, Cam sprocket Flange bolt | M7 x1.0 20 2.0 14 Cam chain tensioner } Hexagon socket head bolt M6 x1.0 10 1.0 72 Blind plug M16x 1.0 20 2.0 4 Flange bolt M6 x10 8 | 08 | 68 Rocker arm shaft Hexagon socket head bolt M6 «1.0 10 1.0 72 il pump Hexagon socket head bolt M6 x1.0 10 | 1.0 | 72 Oil strainer Panhead screw M6 x1.0 7 0.7 5.1 Drain plug (crankcase) M14x 1.5, 30 3.0 22 Oil cleaner cover Hexagon socket head bolt M6 x 1.0 10, 1.0 7.2 Screw MB x0.8 5 0.5 3.6MAINTENANCE SPECIFICATION | SPEC PF Model XT6OOZ(U) Part to be tightened Thread size peas Lidia Remarks See Nm_| mekg | ftelb Oil hose Hexagon socket head bolt M6 x1.0 | 10 | 72 Union nut Mi6x1.5 50 | 5.0 | 36 Dolivery pipe | Union bolt M8 x1.25 8 | 18 13 Carburetor joint Bolt M6 x1.0 10 1.0 72 Clamp (Carburetor joint) Screw Ma x07 2| 02] 14 Ait filter case Flange bolt M6 x1.0 10 1.0 72 Exhaust pipe Flange nut M6 x1.0 10 1.0 72 Exhaust pipe protector Bind head screw M6 x1.0 7 07 5.1 Muffler protector Bind head screw M6 x10 7 07 5.1 A Band (Exhaust pipe and muffler! Flange bolt we x12 | 2} 20) 4) & Muffler Flange bott ms x125 | 40 | 40 | 29 Crankease | Hexagon socket head bolt M6 x1.0 10 1.0 72 Stud bolt M10x 1.25 20 2.0 14 Clamp (C.D.. magneto lead) Panhead screw M6 x10 7 07 51 Crankcase cover (Right) Hexagon socket head bolt Me x10 | 10) 10) 72 Crankcase cover (Left) Hexagon socket head bolt M6 x 1.0 10 1.0 7.2 ‘Stopper plate (Bearing) Flat head screw M6 x1.0 7 0.7 5.1 A Ratchet wheel guide Hexagon bolt M6 x10 10 1.0 7.2 Pressure plate Flange bolt M6 x1.0 8 08 58 Clutch boss 7 Hexagon nut 20x1.0 | 90 | 90 | 66 Primary drive gear Hexagon nut M20x 1.0 120 | 12.0 85 Push lever Panhead screw M8 x1.0 12 1.2 87 Push rod Hexagan nut M6 x1.0 8 08 5.8 Drive sprocket Hexagon nut Mix 1.0 10 | 11.0 | 80MAINTENANCE SPECIFICATION —47~ spec] OF Model XT6OOZ(U) Tightening torque j Part to be tightened ‘Thread size — Remarks Nm | mekg| ftelb ‘Stopper plate (Oil seal) Hexagon bolt M6 x1.0 10 1.0 7.2 ‘Stopper lever Bolt M6 x 1.0 10 1.0 7.2 Change pedal Hexagon bolt M6 x1.0 10 1.0 72 Stator coil Panhead screw Me x1.0 7\o7\51| & Pickup coil Panhead screw M6 x1.0 7 07 5.1 A Neutral switch M10x 1.25 20 | 2.0 14 Starter motor M6 x10 10 1.0 72 Flange bolt Tightening sequence: Cylinder head CrankeaseMAINTENANCE SPECIFICATION [spec PF CHASSIS [ Mode! xTe00z(U) Steering System: Bearing Type Taper roller bearing Front Suspension: Front Fork Travel Fork Spring Free Length Spring Rate/ Stroke (K1) (K2) Optional Spring il Capacity il Level Oil Grade Enclosed Air Pressure: Standard Minimum ~ Maximum 255 mm (10.0 in} 603 mm {23.7 in} <593 mm (23.3 in)> 2.25 N/mm (0.225 kg/mm, 12.6 Ib/in}/ Zero ~ 76.0 mm (Zero ~3.0 in} 4,6 N/mm (0.46 kg/mm, 2.3 Ib/in)/ 76.0~255 mm (3.0~10.0 in) No 517 cm? (18.2 Imp 02, 17.5 US oz) 120 mm (4.72 in) From top of inner tube fully compressed without spring Fork oil 10W or equivalent Zero kPa (Zero kg/cm’, Zero psi Zero ~ 100 kPa (Zero~1.0 kg/cm’, Zero~ 14 psi) Rear Suspension: Shock Absorber Travel Spring Free Length Fitting Length Spring Rate/Stroke Optional Spring Enclosed Gas Pressure 74 mm (2.9 in} 244.5 mm (9.6 in) 235 mm (9.3 in) 90 N/mm (9.0 kg/mm, 504 tb/in)/ Zero ~65.0 mm (0,0~2.6 in} No 1,500 kPa (15 kg/om?, 213 psi) ‘Swingarm: Free Play Limit Side Clearance Front Wheel: Type Rim Size Rim Material Rim Runout Limit: Vertical Lateral 4.0 mm (0.039 in) at swingarm end Move swingarm end side to side. 0.3 mm (0.012 in} at swingarm pivot ‘Spoke wheel 1.6021 Aluminum 2.0 mm (0.079 in) _| 2.0 mm (0.079 in)MAINTENANCE SPECIFICATION [sPec a Disc Outside Diameter Disc Thickness Pad Thickness Master Cylinder Inside Diameter Caliper Cylinder Inside Diameter Brake Fluid Type Model XT600Z(U) Rear Wheel: Type Spoke whee! Rim Size MT2.50 x 18 Rim Material Aluminum Rim Runout Limit: Vertical 2.0 mm (0.079 in) Lateral 2.0 mm (0.078 in) Drive Chain: “Type/Manufacturer DID 520V6/DAIDO Number of Links 104 Chain Siack 30~40 mm (1.18~ 1.57 in) Front Dise Brake: Type Single 267 mm (10.5 in) 4.0 mm (0.16 in) 6.8 mm (0.27 in) <0.8 mm {0.03 in} > 12.7 mm (0.5 in) 38.1. mm (1.5 in) DOT No. 4 or DOT No. 3 Rear Dise Brake: Type Disc Outside Diameter Thickness Ped Thickness Master Cylinder inside Diameter Caliper Cylinder Inside Diameter Brake Fluid Type Brake Lever and Pedal: Brake Lever Free Play Brake Pedal Posi Clutch Lever and Throttle Grip: Clutch Lever Free Play Throttle Cable Free Play Single 220 mm [8.66 in) 5.0 mm (0.20 in) | 6.0 mm (0.24 in) | <0.8 mm (0.03 in)> | 12.7 mm (0.6 in) 34.9 mm (1.37 in} DOT No. 4 or DOT No. 3 2.0~5.0 mm (0.08 ~0.20 in) At end of brake lever. 5.0~ 10.0 mm (0.20~0.40 in) Below top of footrest. 2.0~3.0 mm (0.08~0.12 in) At pivot of clutch lever. 2.0~5.0 mm (0.08~0.20 in) At grip fiange.—50— MAINTENANCE speciricaTion |SPEC| 9 Model XT600Z(U) Tightening torque: | Tightening torque Part to be tightened Thread size Remarks Nm | mekg | ftelb Front fork/ Handlebar: iz Handle crown and inner tube me xt.2s | 23 | 23| 7 Handle crown and steering shaft miaxt.2s | 7 | 7.7) 56 Handlebar me x1.25 | 20 | 20| 14 Steering shaft and ring nut M25 1.0 6 | 06| 43 | Refer to “NOTE” Clamp (Front brake hose) we x15 | 10 | 10) 72 Master cylinder cap (Front brake) M4 X0.7 2| 02| 14 Cowling stay and frame me xt0 | 23 | 23| 17 Cowling stay and cowling Me x10 7 | o7| 51 Meter mounting bolt MB x1.0 7| 07) 61 Horn and frame Me x10 7} 07) 5.1 Main switch and handle crown M6 x1.0 7, 07/51) & Handlebar holder mioxt26 | 7 | 07) 64 Cable holder (Speedometer cable) M5 x08 1] 01 | 07 Cowling and fust tank M5 x08 4} o4| 29 Windscreen and cowling M5 x08 1] o1| 07 Engine mount: | Engine stay (Front) and frame ioxi25 | 64 | 64 | 46 Engine stay (Front) and engine miox125 | 64 | 64} 46 Engine stay (Upper) and frame miox125 | 64 | 64) 46 Engine stay (Upper) and engine mioxt25 | 64 | 64 | 46 Engine (Rear) and frame miox1.25 | 64 | 64) 46 Engine protector and frame me x10 | 10 | 10] 7.2 Rear shock absorber/ Swingarm: ; Pivot shaft maxis | 85 | 85 | 6t Swingarm and relay arm mi2x125 | 69 | 59| 43 Relay arm and connecting rod iox125 | 32) 32) 2 Connecting rod and frame miox125 | 32 | 32) 23 Rear shock absorber and frame mraxi25 | 69 | 59 | 43 Chain tensioner me xi25 | 23) 23) 17 Chain case and swingarm Me x1.0 4| o4| 29 Chain protector and swingarm | Me x10 7 | 07 | 51 Chain guide and swingarm MB x1.0 7) 07) 52) Bott (at swingarm end) MB x1.0 3 | 03|22| - Front wheel/ Rear wheel: Front wheel axle and nut miaxi.e | 140 | 11.0} 80 Rear wheel axle and nut miex1.5 | 90 | 9.0] 65 Front axle holder M6 X1.0 g | o8| 58 Brake caliper (Front) and front fork miox1.25 | 36 | 35) 25 Brake caliper (Rear) and bracket mioxt25 | 35 | 35 | 2 Bracket end swingarm M10 1.25 5 | 32 45 | 4.61 SPEC] PF MAINTENANCE SPECIFICATION Model XT6O0ZIU) | Tightening toraue | a Part to be tightened Tread size aT nan | omens Footrest/Pedal/ Stand: Sidestand and frame m10x1.25 | 40 | 40 | 29 Rear brake switch and frame Me x1.0 4 | 04 | 29 Footrest (For rider) and frame mi0xi.25 | 45 | 45 | 32 Footrest (For passenger) and frame ms x1.25 | 20 | 20 | 14 ‘Master cylinder (Rear brake) and frame Mg x1.25 | 20 | 20 | 14 Reservoir tank (Rear brake) and frame Me x1.0 4 | 04 | 29 Tank/Seat/Cover/ Fender: License bracket Me x1.0 5 | 05 | 36 Rear reflector M5 x08 4 | 04 | 29 Oil tank and oil hose M6 x1.0 0 | 1.0 | 7.2 Drain bolt (Oil tank) mg xi.25 | 18 | 18 | 13 Special bolt (Oil tank) m12x1.25 | 20 | 20 | 14 Helmet holder and frame M6 x1.0 4 | 04 | 29 Seat and frame Me x1.0 10 | 10 | 7.2 Front fender and lower bracket Me x1.0 7 | 07 | 51 Rear fender M6 x1.0 7 | 07 | 54 Battery box and frame M6 x1.0 7 | 07 | 54 Fuel tank stay and frame M6 x1.0 7107 | 54 Fuel tank and frame Me x1.0 7 | 07 | 6.4 Fuel pump and frame MB x0.8 5 | 05 | 36 Fuel pump and clamp Me x1.0 7 | 07 | 54 Oil tank and frame Mg x1.25 | 10 | 1.0 | 72 Oil cooler and frame me xt0 | 7 | 07 | 51 CDI unit and mud guad M6 x10 | 4 | 04 | 29 License bracket and taillight Me x1.0 7 | 07 | 51 Regulator and battery box we x0 | 7 | 07 | 61 Regulator and battery box wi6x1.25 | 3 | 3.5 | 25 Regulator and battery box mi2x1.25 | 24 | 24 | 17 a NOTE: 1. First, tighten the ring nut approximately 38 Nm (3.8 m-kg, 27 ftelb) by using the torque wrench, then loosen the ring nut one turn, 2. Retighten the ring nut to specification.MAINTENANCE SPECIFICATION SPEC al ELECTRICAL Modet Voltage: Ignition System: Ignition Timing (B.T..C.) Advanced Timing (B.T.D.C.) Advancer Type 40° XT6OOZ(U) 12 12° at 1,200 r/min 36° at 6,000 r/min Electrical Type 36° 20° 25° 18° 10° Ignition Timing (B8.T.0.C.) 5° oe 1 234567 8 9 10 Engine Speed (x 10" r/min} C.D.L: Magneto Model/Manufacturor Pickup Coil Resistance (Color) Source Coil Resistance {Color} C.D.1, Unit Model/ Manufacturer VCD92/NIPPON DENSO 92~ 1380 at 20°C (68°F) {Blue/ Yellow—Black/ Yellow) | 92~ 1389 at 20°C (68°F) (Green/White—Black/Yellow) | 112~ 1320 at 20°C (68°F) (Brown—Red) QAB52-50/NIPPON DENSO Ignition Coil: Model/Manufacturer Minimum Spark Gap Primary Coil Resistance Secondary Coil Resistance J0138-50/NIPPON DENSO 6.0 mm (0.24 inl 0.15~0.219 at 20°C (68°F) 3.8~5.8 kO at 20°C (68°F)53 MAINTENANCE SPECIFICATION | SPEC p 0 Charging Coil Resistance (Color) 123 4 Engine speed Modo! XT600Z(U) Spark Plug Cap: Type Resin type Resistance 8~12k0 at 20°C (68°F) Charging System: Type A.C. magneto generator Model/ Manufacturer \VCD92/NIPPONDENSO Output 14V 12A at 5,000 r/min z 38 6 667 8 (10 r/min) 0,7~1.19 at 20°C (68°F) (W—W) Voltage Regulator/ Rectifier: Model/Manufacturer Voltage Regulator: Type No Load Regulated Voltage Rectifi Capacity Withstand Voltage Batter Specific Gravity ‘SH569/SHINDENGEN ‘Semi conductor-short circuit type 14.3~15.3V 25A 240 1.280 Starter Motor: Model/ Manufacturer SM13/MITSUBA Amperage R Output O.8kW Brush Overall Length 12 mm (0.47 in} <5 mm (0.20 in)> Brush Spring Pressure 680~920 g (24.0~32.4 oz) <520 g (13.6 o2)> Commutator Dia. 28 mm (1.10 in) ~ <27 mm (1.06 in)> Mica Underout __| 97 mm (0.028 in} Starter Switch: Model/ Manufacturer 126-22011-D000/HONDA LOCK 100A,MAINTENANCE spEciFications | SPEC) OJ Model xT600ZIU} Horn: Type Plane type ‘Quantity 1 pe. Model/Manutfacturer YF-12/ NIKKO Maximum Amperage 2.5A Flasher Relay: Type Condenser type Model/ Manufacturer | FZ249SD/NIPPON DENSO FJ245EF/NIPPON DENSO.....(D) Self Cancelling Device No Flasher Frequency 75~95 cycles/min Wattage (21 x2+3.4W Circuit Breaker: Type Fuse Amperage for Individual 2005 GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS [spec pF GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners Gensral tran with standard I.S.0. pitch threads. Torque specifi- A B speeifications cations for special components or assemblies are (nus) | (Bol) EP mekg | ftelb included in the applicable sections of this book. [79mm | emm | 6 | 06 | 43 _| To avoid warpage, tighten multi-fastener assern- wis blies in a crisscross fashion, in progressive stages, tae |e Until full torque is reached. Unless otherwise a) specified, torque specifications call for clean, dry See threads. Components should be at room tem- fMRI | _ perature. Ay Distance across flats B: Outside thred diameter DEFINITION OF UNITS Unit Read Measure mm millimeter Length cm centimeter_ Length kg kilogram ___ {a0 Weight N Newton 1 kg xm/soo” Force Nm Newton meter Nxm Torque ‘ mekg Meter kilogram mxkg Torque Pa Pascal Nim? Pressure | N/mm Newton per millimeter _| N/mm Spring rate t Liter cm’ Cubic centimeter iz Volurae or capacity r/min Rotation per minute a Engine speed _ a—56~ LUBRICATION POINTS AND LUBRICANT TYPE | SPEC SF | LUBRICATION POINTS AND LUBRICANT TYPE ENGINE Lubrication Points (Part name) Lubricant Type Oil seal lips (Al) Bearing retainer Crank Pin Piston and piston ring Boss (Balancer drive gear) Piston pin Valve stem and valve guide Oil seal (Valve stem end) Rocker arm shaft and rocker arm Cam and bearing (Camshaft) | Rotor and rotor housing (Oil pump} | Push rod Primary driven gear and main axle [ Stiding gear (Transmission) Free movernent gear (Transmission) Shift fork and guide bar Shift cam and bearing (Shift cam) Shift shaft Crankcase mating surfaces Yamaha Bond No. 1215 Mating surfaces (Cylinder head and cylinder head cover) Yamaha Bond No. 121557 LUBRICATION POINTS AND LUBRICANT TvPE_ | SPEC CHASSIS Lubrication Points (Part name) Lubricant Type Gear unit (Speedometer) aie Oil seal lips (Al) fae _ sis Wheel axle (Front wheel and rear wheel) — ail Sey Rear wheel hub and clutch hub ae a Bush (Swingarm) and thrust cover _ sale Pivot shaft (Swingarm) aise Bushes (Rear shock absorber) ie | Bushes (Relay arm and connecting rod} aS Boarings (Relay arm and connecting rod) Se Pivoting points (Brake pedal and change pedal) Fie Bearings (Steering head) a ; _ sie | Right handlebar end aise Z Pivoting points (Brake lever and clutch lever] sie Clutch cable end False Pivoting point (Sidestand) sas: Bushes (Chain tensioner) te é sae Grease nipple (Swingatm) a <“e Grease nipple (Relay arm) alae Grease nipple (Connecting arm) ails