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
F""""'t
~ [~ ~ ][ ][ l
/if®'@O@
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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.

SPECIAL TOOLS I 1~~~ I ~1
9. Piston Ring Compressor
P/N. YM-04047
This tool is used when installing the piston into
the cylinder.
10. Piston Base
P/N. YM-01067
Use 4 of these to hold the pistons during cylinder
installation.
11. Piston Pin Puller
P/N. YU-01304
This tool is used to remove the piston pin.
12. Rotor Holding Tool
P/N. YM-04043
This tool is used to hold the A.C. Generator ro-
tor during removal and installation.
13. Plastigage® Set "Green"
P/N. YU-33210
This gauge is needed to measure the clearance
for the connecting rod bearing.
1-6

I ~~~ I ~1 SPECIAL TOOLS
1-7
FOR CHASSIS SERVICE
1. T-Handle ........................... CD
P/N. YM-01326
Front Fork Cylinder Holder ............ (2)
P/N. YM-33298
This tool is used to loosen and tighten the front
fork cylinder holding bolt.
2. Front Fork Seal Driver (Weight) ....... CD
P/N. YM-33963
Adapter ............................ (2)
P/N. YM-08010
These tools are used when installing the fork seal.
3. Ring Nut Wrench
PIN. YU-33975
This tool is used to loosen and tighten the steer-
ing ring nut.
FOR ELECTRICAL COMPONENTS
1. Electro Tester
P/N. YU-33260
This instrument is necessary for checking the ig-
nition system components.
2. Pocket Tester
P/N. YU-03112
This instrument is invaluable for checking the elec-
trical system.

CHAPTER 2
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION .................................................. . 2-1
MAINTENANCE INTERVALS CHART .............................. 2-1
PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM ......... 2-1
GENERAL MAINTENANCE/LUBRICATION ......................... 2-2
ENGINE .......................................................... .2-4
VALVE CLEARANCE
ADJUSTMENT .............................. 2-4
CAM CHAIN
ADJUSTMENT .................................... 2-9
CARBURETOR SYNCHRONIZATION ............................. 2-10
IDLE SPEED
ADJUSTMENT .................................... 2-12
ENGINE OIL LEVEL INSPECTION ................................ 2-12
ENGINE OIL REPLACEMENT .................................... 2-13
CLUTCH LEVER FREE PLAY ADJUSTMENT ..................... 2-16
COMPRESSION PRESSURE MEASUREMENT ..................... 2-16
FUEL LINE INSPECTION ........................................ 2-18
CARBURETOR JOINT INSPECTION .............................. 2-18
CRANKCASE VENTILATION
PIPE INSPECTION ................... 2-19
EXHAUST SYSTEM INSPECTION ............................... 2-19
AIR FILTER CLEANING ......................................... 2-20
CHASSIS ........................................................ 2-20
FUEL COCK CLEANING
........................................ 2-20
. FRONT BRAKE FLUID INSPECTION
............................. 2-21
FRONT BRAKE PAD INSPECTION .............................. 2-22
FRONT BRAKE LEVER FREE PLAY ADJUSTMENT ............... 2-22
REAR BRAKE PEDAL HEIGHT ADJUSTMENT ................... 2-23
BRAKE PEDAL
FREE PLAY ADJUSTitilENT ...................... 2-23
REAR BRAKE LINING INSPECTION ............................. 2-24
REAR BRAKE LIGHT SWITCH ADJUSTMENT ................... 2-24
DRIVE CHAIN SLACK CHECK .................................. 2-25
DRIVE CHAIN SLACK ADJUSTMENT ........................... 2-25
DRIVE CHAIN LUBRICATION ................................... 2-26
CABLE INSPECTION
AND LUBRICATION ........................ 2-26
LEVER AND PEDAL LUBRICATION ............................. 2-27
CENTERSTAND
AND SIDESTAND LUBRICATION ................ 2-27
FRONT FORK OIL CHANGE .................................... 2-27
REAR SHOCK ABSORBER ADJUSTMENT ....................... 2-29
STEERING HEAD INSPECTION .................................. 2-29
STEERING HEAD ADJUSTMENT ................................ 2-30
FRONT WHEEL BEARING INSPECTION
.......................... 2-30
REAR WHEEL BEARING INSPECTION ........................... 2-31
TUBELESS TIRES AND ALUMINUM WHEELS INSPECTION ....... 2-31
THROTTLE CABLE ADJUSTMENT .............................. 2-33

ELECTRICAL ..................................................... 2-33
IGNITION TIMING CHECK ...................................... 2-33
SPARK PLUG INSPECTION ..................................... 2-34
BATTERY INSPECTION
......................................... 2-35
FUSE INSPECTION ............................................. 2-37
HEADLIGHT BEAM ADJUSTMENT .............................. 2-38
HEADLIGHT BULB REPLACEMENT .............................. 2-39
TAILLIGHT BULB REPLACEMENT ............................... 2-40
CARBURETOR AIR VENT SYSTEM INSPECTION
(CALIFORNIA ONLY)
........................................... 2-40

l
lANDSJP1~1_1_N_T_R_o_o_u_cT_1_o_N_1 ______________________ _
. .
~ . MAINTENANCE INTERVALS CHART
PERIODIC INSPECTIONS AND ADJUSTMENTS
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.
MAINTENANCE INTERVALS CHART
Proper periodic maintenance is important. Especially important are the maintenance services related
to emissions controls. These controls not only function to ensure cleaner air but are also vital to proper
engine operation and maximum performance. In the
following maintenance tables, the services relat-
ed to emissions control are grouped separately.
PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM
Initial Odometer readings
**1 **2 **3
No. Item Remarks 1,000 km 7,000 km 13,000 km 19,000 km 25,000 km 31,000 km
or or or
or or or
1 month 7 months 13 months 19 months
25 months 31 months
(600 mi) (4,400 mi) (8,200 mi) (12,000 mi) (15,800 mi) (19,600 mi)
1* Cam chain
Adjust chain tension.
*O 0 0 0 0 0
Valve Check and adjust valve
2*
clearance clearance
when engine is 0
cold.
Check condition.
Adjust
Spark gap and clean. Replace at
3*
13,000 km (or 13 months) 0 Replace 0 Replace 0
plug and thereafter every
12,000 km (or 12 months).
Crankcase Check ventilation hose
4*
ventilation for cracks or damage. 0 0 0 0 0
system Replace if necessary.
Check fuel hose and vacum
5*
Fuel line pipe for cracks or damage. 0 0 0 0 0
Replace if necessary.
Exhaust Check
for leakage. Retigh-
6*
ten if necessary. Replace 0 0 0 0 0
system gasket(s)
if necessary.
Carbure-
7*
tor syn-
Adjust synchronization of
*O
0 0 0 0 0
chroni- carburetors.
zation Check and adjust engine
8*
Idle speed idle speed. Adjust cable 0 0 0 0 0
free play.
* It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
NOTE: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
For father odometer reading, repeat the above maintenance at the period established; **1: Every 6,000
km (3,800 mi), **2: Every 12,000 km (7,600 mi), and **3: Every 30,000 km (19,000 mi) intervals.
2-1

1~g~1~1
MAINTENANCE INTERVALS CHART _ -~ _
GENERAL MAINTENANCE/LUBRICATION
Initial Odometer readings
' **1
**2
**3
No. Item Remarks Type 1,000 km 7,000 km 13,000 km 19,000 km 25,000 km 31,000 km
or or or
or
or or
1 month 7 months
13 months 19 months 25 months
31 months
(600mi) (4,400 mi)
(8,200 mi) {12,000 mil (15,800
mi) (19,600 mil
*1) Yamalube
4-cycle oil or
SAE 20W40
Warm-up type
"SE"
1 Engine oil engine before motor oil 0 0 0 0 0 0
draining *2) SAE
10W30 type
"SE" motor
oil
2 Oil filter Replace. -0 0 0
Clean with
3* Air filter compressed -0 0 0 0 0
air. Replace
fl
\I
if necessary.
Adjust free
play. Replace
Brake ·pads
if neces-
4* sary. (Front) -0 0 0 0 0 0
system Replace shoes
if necessary.
(Rear)
5* Clutch Adjust free -0 0 0 0 0 0
play.
Check chain
condition. SAE
6 Drive chain Adjust and 30W-50W Every
500 km (300 mi)
lubricate
motor oil.
chain
thoroughly. Yamaha chain
Control Apply chain and cable
7 and meter lube lube or SAE 0 0 0 0 0 0
cable thoroughtly. 10W30
motor
oil.
Check bear-
ing assembly Midium
Rear arm
for looseness. weight wheel
8*
pivot Moderately bearing Repack
bearing repack every
24,000 km grease.
(15,200 mi).
Brake/ Yamaha chain
Clutch Apply chain and cable
9 lube or SAE 0 0 0 0 0
lever pivot lube lightly. 10W30
motor
shaft oil.
Brake Yamaha chain
Lubricate. and cable
10
pedal and
Apply chain lube or SAE 0 0 0 0 0
change
pedal shaft lube lightly. 10W30
motor
oil.
Check opera- Yamaha chain
Center/ tion and and cable
11* Side stand lubricate. lube or SAE 0 0 0 0 0
pivots
Apply chain 10W30
motor
lube lightly. oil.
2-2

l
lANDSJPl91_~~~~~~~~~
. . ~ . MAINTENANCE INTERVALS CHART
Initial
No. Item Remarks Type 1,000 km
or
1 month
(600 mO
Front fork Check opera- Yamaha Fork
12* tion and Oil 10WT or
oil leakage. equivalent
Check bear-
ings assembly Medium
Steering
for looseness. weight wheel
13* Moderately
bearing repack every bearing
24,000 km grease.
(15,000 mil.
Check bear- Medium
14* Wheel ings
for
weightwheel
bearings smooth bearing
rotation. grease
Check specific
gravity and
15
Battery breather pipe -
for proper
operation.
16*
A.C. Replace gener-
Generator ator brushes. -
Check and
17* Sidestand clean
or
0
switch replace
if
-
necessary.
*1)
If ambient temperature does not go below 5°C (41°F).
*2)
If ambient temperature does not go below 15°C (59°F).
Odometer readings
**1
**2
**3
7,000 km 13,000 km 19,000 km 25,000 km
or
or
or or
7 months
13 months 19 months 25 months
(4,400 mO
(8,200 mi)
(12,000 mO
(15,800 mi)
0 0 0 0
0 0 0 Repack
0 0 0 0
0 0 0 0
0 0
0 0 0 0
* It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
NOTE:
31,000 km
or
31 months
(19,600 mO
0
0
0
0
0
For father odometer reading, repeat the above maintenance atthe period established, ** 1: Every 6,000
km (3,800 mi), **2: Every 12,000 km (7,600 mi) and **3: Every 24,000 km (15,200 mi) intervals.
2-3

I
IANDSJP I~ I
VALVE CLEARANCE ADJUSTMENT ~
~~~~~~~~~~~~~~~~~~~~~~~~~~~-
ENGINE
VALVE CLEARANCE ADJUSTMENT
NOTE: ~~~~~~~~~~~~~
•Valve clearance mustbe measured and adjusted
when the engine
is cool to the touch.
•Measure and adjust valve clearance when piston
is at TDC on compression stroke.
1. Remove:
•Seat
2. Turn the fuel cock to "ON" position.
3. Remove:
•Cover G)
4. Disconnect:
•Fuel pipe G)
•Vacuum pipe ~
•Fuel tank breather pipe @
5. Remove:
•Fuel tank
2-4

EX
IN
2-5
6. Remove:
•Spark plugs
•Horn CD
7. Remove:
•Cylinder head cover
8. Remove:
•Crankcase cover
9. Measure:
•Valve clearance
Valve clearance measurement steps:
•Turn the crankshaft counterclockwise.
•Align the "T" mark CD on the timing plate
with the pickup coil mark ( (2) or @) when
the piston is at Top Dead Center (T.D.C.) on
compression stroke.
NOTE: ~~~~~~~~~~~~-
•Compression T.D.C. can be found when the
cam lobes are apart from each other, as
shown.
•Measure the valve clearance by aligning the
"T" mark with the upper pickup coil mark (2)
for the # 1 and #4 cylinders and with the
lower pickup coil mark @for the #2 and #3
cylinders.

I
IANDSJP I~· 1
VALVE CLEARANCE ADJUSTMENT ~
~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
• Front
303-000
•Measure the valve clearance using feeler
gauge@.
Out of specification-Adjust valve clearance.
Intake Valve (Cold):
0.11 -0.15 mm (0.004-0.006 in)
Exhaust Valve (Cold):
0.16-0.20 mm (0.006-0.008 in)
NOTE: ~~~~~~~~~~~~
•Record the measured amount if the clearance
is incorrect.
•Measure valve clearance in sequence.
Measuring Sequence:
#1-#2-#4-#3
10. Adjust:
•Valve clearance
Valve clearance adjustment steps:
•Position the valve lifter slots (intake and ex-
haust) opposite each other.
•Turn the camshaft until the lobe fully
depresses the valve lifter and opens the valve.
•Attach the Tappet Adjusting Tool CD
(YM-01245) onto the cylinder head.
NOTE: ~~~~~~~~~~~~-
Make sure that the tool contacts the lifter ®
only, and not the pad ~-
•Carefully rotate the camshaft so thatthe pads
can be removed.
To avoid cam touching the
adjusting tool, turn cams as shown.
Intake: Carefully rotate CLOCKWISE.
Exhaust:
Carefully rotate COUNTER-
CLOCKWISE.
2-6