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Yamaha YX600S manuals available for free PDF download: Service Manual
Yamaha YX600S Service Manual (320 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 58.11 MB
Table of Contents
How to Use this Manual
2
Illustrated Symbols
3
Index
4
General Information: Table of Contents
5
Vehicle Identification Number
6
Engine Serial Number
6
All Replacement Parts
7
Gasket, Oil Seals and O-Rings
7
Lock Washers/Plates and Cotter Pins
7
Bearings and Oil Seals
7
Special Tools: for Tune up
8
Special Tools: for Engine Service
9
Special Tools: for Chassis Service
12
Special Tools: for Electrical Components
12
Periodic Inspections and Adjustments: Table of Contents
13
Periodic Inspections and Adjustments
15
Maintenance Intervals Chart
15
Periodic Maintenance Emission Control System
15
General Maintenance/Lubrication
16
Engine: Valve Clearance Adjustment
18
Valve Clearance Measurement Steps
19
Valve Clearance Adjustment Steps
20
Valve Clearence Intake/Exhaust
22
Cam Chain Adjustment
23
Pad Number Verification Steps
23
Carburetor Synchronization
24
Carburetor Adjustment Steps
25
Idle Speed Adjustment
26
Engine Oil Level Inspection
26
Engine Oil Replacement: Without Filter Change
27
Engine Oil Replacement: with Filter Change
28
Clutch Lever Free Play Adjustment
30
Compression Pressure Measurement
30
Compression Pressure Measurement Steps
31
Compression Pressure (with Oil Introduced into Cylinder)
32
Fuel Line Inspection
32
Carburetor Joint Inspection
32
Crankcase Ventilation Pipe Inspection
33
Exhaust System Inspection
33
Air Filter Cleaning
33
Chassis: Fuel Cock Cleaning
34
Front Brake Fluid Inspection
35
Front Brake Pad Inspection
36
Front Brake Lever Free Play Adjustment
36
Rear Brake Pedal Height Adjustment
37
Brake Pedal Free Play Adjustment
37
Rear Brake Lining Inspection
38
Rear Brake Light Switch Adjustment
38
Drive Chain Slack Check/Adjustment
39
Drive Chain Lubrication
40
Cable Inspection and Lubrication
40
Lever and Pedal Lubrication
41
Centerstand and Sidestand Lubrication
41
Front Fork Oil Change
41
Rear Shock Absorber Adjustment
43
Recommended Rear Shock Absorber Settings
43
Steering Head Inspection
43
Steering Head Adjustment
44
Front Wheel Bearing Inspection
44
Rear Wheel Bearing Inspection
45
Tubeless Tires and Aluminium Wheels Inspection
45
Throttle Cable Adjustment
47
Electrical: Ignition Timing Check
47
Spark Plug Inspection
48
Battery Inspection
49
Fuse Inspection
51
Headlight Beam Adjustment
52
Headlight Bulb Replacement
53
Taillight Bulb Replacement
54
Carbretor Air Vent System Inspection (California Only)
54
Engine Overhaul: Table of Contents
56
Engine Overhaul
58
Preparation for Engine Removal
58
Engine Removal: Seat and Fuel Tank
59
Engine Removal: Carburetor
60
Engine Removal: Exhaust Pipes and Mufflers
62
Engine Removal: Drive Chain
62
Engine Removal: Cable and Pipe
63
Engine Removal: Leads
63
Engine Removal: Canister (California Only)
64
Engine Disassembly: Cylinder Head and Camshaft
65
Engine Disassembly: Piston and Intake Side Cam Chain Guide
67
Engine Disassembly: Pickup Coil and Generator
68
Engine Disassembly: Clutch
69
Engine Disassembly: Oil Pump and Shift Shaft
70
Crankcase Disassembly
71
Engine Disassembly: Upper Crankcase
72
Engine Disassembly: Lower Crankcase
73
Inspection and Repair: Cylinder Head
74
Inspection and Repair: Valve, Valve Guide, Valve Seats and Valve Spring
75
Inspection and Repair: Valve Guide Replacement
76
Inspection and Repair: Valve/Valve Seat Assembly Lapping
79
Inspectionand Repair: Relapping Steps
80
Inspection and Repair: Valve Spring Measurement
81
Inspection and Repair: Valve Installation
82
Inspection and Repair: Camshaft
82
Inspection and Repair: Camshaft/Cap Clearance Measurement
83
Inspection and Repair: Cam Chain
83
Inspection and Repair: Cam Sprockets
84
Inspection and Repair: Cam Chain Dampers/Tensioner
84
Inspection and Repair: Cylinder
84
Inspection and Repair: Piston
85
Inspection and Repair: Piston Ring
86
Inspection and Repair: Piston Pin/ Ring Oversize
87
Inspection and Repair: Crankshaft Runout
88
Inspection and Repair: Connecting Rod Bearings/Bearing Clearance
88
Inspection and Repair: Crankshaft Main Bearing Clearance Measurement
89
Inspection and Repair: Crankshaft Main and Connecting Rod Bearing Selection
91
Inspection and Repair: Oil Pump
92
Inspection and Repair: Primary/Starter Drive
93
Inspection and Repair: Electric Starter Clutch
93
Inspection and Repair: Starter Clutch Shaft
94
Inspection and Repair: Clutch
94
Inspection and Repair: Transmission
96
Inspection and Repair: Hy-Vo Chain Guide and Tensioner
97
Inspection and Repair: Relief Valves
97
Inspection and Repair: Crankcase
97
Inspection and Repair: Bearings and Oil Seals
98
Inspection and Repair: Circlips and Washers
98
Engine Assembly and Adjustment: Shifter
99
Engine Assembly and Adjustment: Transmission
100
Engine Assembly and Adjustment: Lower Crankcase
101
Engine Assembly and Adjustment: Starter
103
Engine Assembly and Adjustment: Crankshaft
104
Engine Assembly and Adjustment: Upper Crankcase
105
Engine Assembly and Adjustment: Crankcase Assembly
106
Engine Assembly and Adjustment: Oil Pump
109
Engine Assembly and Adjustment: Shift Shaft
110
Engine Assembly and Adjustment: Clutch
112
Engine Assembly and Adjustment: Generator
115
Engine Assembly and Adjustment: Pickup Coil
116
Engine Assembly and Adjustment: Piston
118
Engine Assembly and Adjustment: Piston and Intake Side Cam Chain Guide
119
Engine Assembly and Adjustment: Cylinder
120
Engine Assembly and Adjustment: Cylinder Head
122
Engine Assembly and Adjustment: Camshaft
124
Engine Assembly and Adjustment: Remounting Engine
130
Carburetion: Table of Contents
135
Carburetor
136
Carburetor: Section View
137
Carburetor: Removal
138
Carburetor: Disassembly
141
Carburetor: Inspection
142
Carburetor: Assembly
143
Carburetor: Installation
144
Carburetor: Adjustment
145
Float Height Adjustment
145
Fuel Level Adjustment
146
Fuel Level Measurement Steps
146
Air Cleaner and Crankcase Ventilation System
148
Chassis: Table of Contents
149
Chassis: Front Wheel
150
Front Wheel: Removal/Inspection
151
Wheel Bearing Replacement Steps
152
Front Wheel: Installation
153
Rear Wheel and Brake
156
Rear Wheel and Brake: Removal
157
Rear Wheel and Brake: Inspection
158
Rear Wheel and Brake: Assembly (Brake Shoe Plate)
159
Rear Wheel and Brake: Installation
160
Front Brake: Brake Caliper
162
Front Brake: Brake Master Cylinder
163
Front Brake: Caliper Pad Replacement
164
Front Brake: Caliper Disassembly
165
Caliper Piston Removal Steps
165
Front Brake: Inspection/Installation
166
Front Brake: Master Cylinder Disassembly
167
Front Brake: Inspection
168
Front Brake: Installation
169
Front Brake: Air Bleeding
170
Air Bleeding Steps
170
Front Fork
172
Front Fork: Removal
173
Front Fork: Disassembly
174
Inner Fork Tube Removal Steps
175
Front Fork: Inspection
175
Front Fork: Reassembly
176
Front Fork: Installation
178
Steering Head
180
Steering Head: Removal
181
Steering Head: Inspection
184
Steering Head: Installation
185
Rear Shock Absorber
188
Rear Shock Absorber: Removal/Inspection/Installation
189
Swingarm
190
Swingarm: Removal
191
Swingarm: Inspection
192
Swingarm: Adjustment
193
Swingarm: Installation
194
Drive Chain and Sprockets: Removal/Inspection
196
Drive Chain and Sprockets: Assembly
197
Electrical: Table of Contents
199
YX600S/SC Circuit Diagram
200
Electrical Components
202
Circuit Diagram: Electrical Starting System
204
Starting Circuit Operation
206
Starter Motor Does Not Operate
207
Starter Motor
217
Starter Motor: Removal
218
Starter Motor: Inspection and Repair
219
Starter Motor: Assembly
220
Starter Motor: Installation
222
Circuit Diagram: Ignition System
224
Ignition System: Description/Operation/Pickup Unit
226
Ignition System: Troubleshooting
227
Circuit Diagram: Charging System
236
The Battery Is Not Charged
238
Circuit Diagram: Lighting System
244
Lighting System: Troubleshooting
246
Headlight, Taillight, License Light and Meter Light Do Not Come on
246
Lighting System Test and Checks
251
Headlight And/Or "High Beam" Indicator Light Do Not Come on
251
Meter Light/Taillight/License Light Do Not Come on
252
Circuit Diagram: Signal System
254
Signal System: Troubleshooting
256
Signal System Test and Checks
260
Horn Does Not Work
260
Brake Light Does Not Work
261
"Neutral" Indicator Light Does Not Come on
261
Flasher Lights Do Not Come on
262
"Oil" Indicator Light Does Not Come on
262
Oil Level Switch Test
263
Circuit Diagram: Carburetor Air Vent System (California Only)
264
Carburetor Air Vent System: Description/Operation
266
Carburetor Air Vent System: Troubleshooting
267
The Air Vent Control Valve Does Not Operate (the Engine Loses Power)
267
Appendices: Table of Contents
273
General Specification
274
Maintenance Specifications: Engine
277
Maintenance Specifications: Lubrication Chart
282
Crankcase Tightening Sequence: Upper/Lower Case
282
Maintenance Specifications: Chassis
285
Maintenance Specifications: Electrical
288
General Torque Specifications
290
Definition of Units
291
Conversion Tables
291
Lubrication Diagram
292
Cable Routing
294
Cable Routing (California Only)
299
YX600S/SC Wiring Diagram
300
YX600U/UC: How to Use this Manual
302
YX600U/UC: Illustrated Symbols
303
YX600U/UC: Vehicle Identification Number
304
YX600U/UC: Engine Serial Number
304
YX600U/UC: General Specifications
305
YX600U/UC Wiring Diagram
306
YX600W/WC: How to Use this Manual
308
YX600W/WC: Illustrated Symbols
309
YX600W/WC: Vehicle Identification Number
310
YX600W/WC: Engine Serial Number
310
YX600W/WC: General Specifications
311
YX600W/WC: Maintenance Specifications (Electrical)
312
YX600W/WC: Maintenance Specifications (Tightening Torque Chart)
313
YX600W/WC Circuit Diagram
315
YX600W/WC Ignition System: Circuit Diagram
317
YX600W/WC Digital Ignition Control System Description/Operation
319
Yamaha YX600S Service Manual (319 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 30.62 MB
Table of Contents
Chapter 1 General Information
5
Table of Contents
5
Motorcycle Identification
6
Vehicle Identification Number
6
Engine Serial Number
6
Important Information
7
All Replacement Parts
7
Gaskets, Oil Seals, and 0-Rings
7
Lock Washers/Plates and Cotter Pins
7
Bearings and Oil Seals
7
Special Tools
8
For Tune up
8
For Engine Service
9
For Chassis Service
12
For Electrical Components
12
Chapter 2 Periodic Inspections and Adjustments
13
Introduction
15
Maintenance Intervals Chart
15
Periodic Maintenance Emission Control System
15
General Maintenance/Lubrication
16
Engine
18
Valve Clearance Adjustment
18
Cam Chain Adjustment
23
Carburetor Synchronization
24
Idle Speed Adjustment
26
Engine Oil Level Inspection
26
Engine Oil Replacement
27
Clutch Lever Free Play Adjustment
30
Compression Pressure Measurement
30
Fuel Line Inspection
32
Carburetor Joint Inspection
32
Crankcase Ventilation Pipe Inspection
33
Exhaust System Inspection
33
Air Filter Cleaning
33
Chassis
34
Fuel Cock Cleaning
34
Front Brake Fluid Inspection
35
Front Brake Pad Inspection
36
Front Brake Lever Free Play Adjustment
36
Rear Brake Pedal Height Adjustment
37
BRAKE PEDAL FREE PLAY Adjustitilent
37
Rear Brake Lining Inspection
38
Rear Brake Light Switch Adjustment
38
Drive Chain Slack Check
39
Drive Chain Slack Adjustment
39
Drive Chain Lubrication
40
Cable Inspection and Lubrication
40
Lever and Pedal Lubrication
41
Centerstand and Sidestand Lubrication
41
Front Fork Oil Change
42
Rear Shock Absorber Adjustment
43
Steering Head Inspection
43
Steering Head Adjustment
44
Front Wheel Bearing Inspection
44
Rear Wheel Bearing Inspection
45
Tubeless Tires and Aluminum Wheels Inspection
45
Throttle Cable Adjustment
47
Electrical
47
Ignition Timing Check
47
Spark Plug Inspection
48
Battery Inspection
49
Fuse Inspection
51
Headlight Beam Adjustment
52
Headlight Bulb Replacement
53
Carburetor Air Vent System Inspection (California Only)
54
Chapter 3 Engine Overhaul
56
Taillight Bulb Replacement
54
Engine Removal
58
Preparation for Removal
58
Seat and Fuel Tank
59
Carburetor
60
Exhaust Pipes and Mufflers
62
Drive Chain
62
Cable and Pipe
63
Leads
63
Canister (California Only)
64
Engine Removal
64
Engine Disassembly
65
Cylinder Head and Camshaft
65
Piston and Intake Side Cam Chain Guide
67
Pickup Coil and Generator
68
Clutch
69
Oil Pump and Shift Shaft
70
Crankcase Disassembly
71
Upper Crankcase
72
Lower Crankcase
73
Inspection and Repair
74
Cylinder Head
74
Valve, Valve Guide, Valve Seats and Valve Spring
75
Camshaft, Cam Chain and Cam Sprocket
82
Cylinder
84
Piston, Piston Ring and Piston Pin
85
Crankshaft and Connecting Rod
88
Oil Pump
92
Primary Drive
93
Starter Drives
93
Clutch
94
Hy-Vo Chain Guide and Tensioner
97
Relief Valves
97
Crankcase
97
Bearings and Oil Seals
98
Circlips and Washers
98
Lower Crankcase
101
Upper Crankcase
105
Crankcase Assembly
106
Oil Pump and Shift Shaft
111
Clutch
112
Pickup Coil and Generator
117
Piston and Intake Side Cam Chain Guide
119
Cylinder
120
Cylinder Head
122
Camshaft
124
Remounting Engine
130
Chapter 4 Carburetion
135
Carburetor
136
Section View
137
Removal
138
Disassembly
141
Inspection
142
Assembly
143
Installation
144
Adjustment
145
Air Cleaner and Crankcase Ventilation System
148
Chapter 5 Chassis
149
Front Wheel
150
Inspection
151
Removal
151
Installation
153
Rear Wheel and Brake
156
Removal
157
Inspection
158
Assembly (Brake Shoe Plate)
159
Installation
160
Front Brake
162
Caliper Pad Replacement
164
Caliper Disassembly
165
Inspection
166
Installation
166
Master Cylinder Disassembly
167
Inspection
168
Installation
169
Air Bleeding
170
Front Fork
172
Removal
173
Disassembly
174
Inspection
175
Reassembly
176
Installation
178
Steering Head
180
Removal
181
Inspection
184
Installation
185
Rear Shock Absorber
188
Removal
189
Inspection
189
Installation
189
Swingarm
190
Removal
191
Inspection
192
Adjustment
193
Installation
194
Drive Chain and Sprockets
196
Removal
196
Inspection
196
Assembly
197
Chapter 6 Electrical
199
Electrical Components
202
Electrical Starting System
204
Circuit Diagram
204
Starting Circuit Operation
206
Troubleshooting
207
Starter Motor
217
Ignition System
224
Circuit Diagram
224
Description
226
Operation
226
Pickup Unit
226
Troubleshooting
227
Charging System
236
Circuit Diagram
236
Troubleshooting
238
Lighting System
244
Circuit Diagram
244
Troubleshooting
246
Lighting System Test and Checks
251
Signal System
254
Circuit Diagram
254
Troubleshooting
256
Signal System Test and Checks
260
Oil Level Switch Test
263
Carburetor Air Vent System
264
Circuit Diagram
264
Description
266
Operation
266
Troubleshooting
267
Chapter 7 Appendices
273
General Specifications
274
Specifications
274
Maintenance Specifications
279
General Torque Specifications
290
Conversion Tables
291
Definition of Units
291
Lubrication Diagram
292
Cable Routing
294
Yx600S/Yx600Sc Wiring Diagram
300
Yamaha YX600S Service Manual (317 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 27.05 MB
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