Yamaha YX600S User manual

OYAMAHA
II
LIT-11616-06-16

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,
so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motor-
cycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle
repair technology. Without such knowledge, attempted repairs 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 OPERATIONS
YAMAHA MOTOR CO., LTD.
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT INFORMATION
This material is distinguished by the following notation.
NOTE:
WARNING:
A NOTE provides key information to make procedures easier or clearer.
A CAUTION indicates special procedures that must be followed to avoid damage
to the motorcycle.
A 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, e.g.,
• 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.

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ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols CD to @ are designed as
thumb tabs to indicate the chapter's numberand
content.
CD General information
(2) Periodic inspection and adjustment
@Engine
@ Cooling system
@ Carburetion
®Chassis
(J) Electrical
@ Appendices
Illustrated symbols @ to @ are used to identify
the specifications appearing in
tlie text.
® Filling fluid
® Lubricant
@ Tightening
@ Wear limit, clearance
@l Engine speed
@n, V,A
Illustrated symbols ® to @ in the exploded
diagram indicate grade of lubricant and location
of lubrication point.
® Apply engine oil
® Apply gear oil
@ Apply molybdenum disulfide oil
® Apply wheel bearing grease
@ Apply lightweight lithium-soap base grease
® Apply molybdenum disulfide grease
@ Apply locking agent (LOCTITE®)

INDEX
GENERAL INFORMATION
PERIODIC INSPECTIONS
AND ADJUSTMENTS
ENGINE OVERHAUL
CARBURETION
CHASSIS
ELECTRICAL
APPENDICES
~
GEN
INFO
ENG
•
~~
,_________
APPX

CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION ................................... 1-1
VEHICLE IDENTIFICATION NUMBER ............................. 1-1
ENGINE SERIAL NUMBER ....................................... 1-1
IMPORTANT INFORMATION ...................................... 1-2
ALL REPLACEMENT PARTS ..................................... 1-2
GASKETS, OIL SEALS, AND 0-RINGS ........................... 1-2
LOCK WASHERS/PLATES AND COTTER PINS ................... 1-2
BEARINGS AND OIL SEALS ..................................... 1-2
SPECIAL TOOLS .................................................. 1-3
FOR TUNE UP .................................................. 1-3
FOR ENGINE SERVICE .......................................... 1-4
FOR CHASSIS SERVICE ......................................... 1-7
FOR ELECTRICAL COMPONENTS ................................ 1-7

I ~~ I ~1 MOTORCYCLE IDENTIFICATION
1-1
GENERAL
INFORMATION
MOTORCYCLE IDENTIFICAITON
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number CD is stamped
into the right side
of the steering head pipe.
Starting Serial Number:
VX600S (Except for California)
JVA 1UJOO*GA000101
VX600SC (For
California)
JVA 1ULOO*GA000101
NOTE:
~~~~~~~~~~~~~-
The vehicle identification number is used to iden-
tify your motorcycle and may be used to register
your motorcycle
with the licensing authority in
your state.
ENGINE SERIAL NUMBER
The engine serial number CD is stamped into the
elevated part of the left rear section of the engine.
Starting Serial Number:
VX600S (Except for California)
1UJ-000101
VX600SC
(For California)
1UL-000101
NOTE:
~~~~~~~~~~~~~-
•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.

IMPORTANT INFORMATION I ~~ I ~1
IMPORTANT INFORMATION
300-000
300-003
300-002
ALL REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all replace-
ments. Use oil and/ or grease recommended
by Yamaha
for assembly and adjustment.
Other brands may be similar in function and
appearance,
but inferior in quality.
GASKETS, OIL SEALS, AND 0-RINGS
1. All gaskets, seals and 0-rings should be
replaced when an engine is overhauled. All
gasket surfaces, oil seal lips and 0-rings must
be cleaned.
2. Properly oil all mating parts and bearings dur-
ing reassembly. Apply grease
to the oil seal
lips.
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/Plates G) and cotter pins
must be replaced when they are removed.
Lock tab(s) should
be bent along the bolt or
nut flat(s) after the bolt or nut has been
properly tightened.
BEARINGS AND OIL SEALS
1. Install the bearing(s) and oil seal(s) with their
manufacturer's marks or numbers facing out-
ward. (In other words, the stamped letters
must be on the side exposed to view.) When
installing oil seal(s), apply a light coating
of
light-weight lithium base grease to the seal
lip(s). Oil the bearings liberally when installing.
CD Oil seal
Do not use compressed air to spin the bear-
ings dry. This causes damage to the bearing
surfaces.
CD Bearing
1-2

I 1~~ I ~1 SPECIAL TOOLS
1-3
SPECIAL TOOLS
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused
by the use of improper tools or improvised
techniques.
FOR TUNE UP
1. Inductive Tachometer
P/N. YU-08036
This tool is needed for detecting engine rpm.
2. Inductive
Timing Light
P/N, YU-08037
This tool is necessary for adjusting timing.
3. Compression Gauge
P/N. YU-33223
This gauge is used to measure the engine com-
pression.
4. Fuel Level Gauge
P/N. YM-01312
This gauge is used to measure the fuel level in
the
float chamber.

SPECIAL TOOLS I 1~~ I '"I
5. Fuel Level Gauge Adapter
P/N. YM-01329
This tool
is needed when measuring the carbu-
retor fuel level together
with fuel level gauge.
6. Vacuum Gauge
P/N. YU-08030
This gauge is needed for carburetor synchroni-
zation.
FOR ENGINE SERVICE
1. Universal Clutch Holder
P/N. YM-91042
This tool
is used to hold the clutch when remov-
ing or installing the clutch boss locknut.
2. Tappet Adjusting Tool
P/N. YM-01245
This tool
is necessary to replace valve adjusting
pads.
3. Valve Spring Compressor
P/N. YM-04019
. This tool is needed to remove and install the valve
assemblies.
1-4

I 1~~~ I ~1 SPECIAL TOOLS
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1-5
4. Valve Guide Remover
P/N. YM-04064
This tool is used to remove the valve guides.
5. Valve Guide Reamer
P/N. YM-04066
This tool is used to rebore the new valve guide.
6. Valve Guide Installer
P/N. YM-04065
This tool is needed to install the valve guides
properly
together with valve guide remover.
7. Valve Seat Cutter
Set
P/N. YM-91043
This tool is needed to resurface the valve seat.
8. Rotor Puller
......................... G)
P/N. YM-01080
Pin ................................ ~
P/N. YM-04052
This tool is needed to remove the A.C. Genera-
tor rotor.