Yamaha YX600S Bedienungsanleitung

OYAMAHA

LIT-11616-06-16

NOTICE

This manual was

written

the Yamaha

Motor

Company primarily

for

use

Yamaha dealers and

their qualified mechanics.

not

possible

put

an entire mechanic's education

into

one manual,

is assumed

that

persons using this

book

perform maintenance and repairs on Yamaha motor-

cycles have a basic understanding

the mechanical concepts and procedures inherent in motorcycle

repair technology.

Without

such knowledge, attempted repairs

service

this model may render

unfit

use

and/or

unsafe.

Yamaha

Motor

Company, Ltd. is continually striving

improve all models manufactured

Yamaha.

Modifications and significant changes in specifications or procedures will

forwarded

all Authorized

Yamaha dealers and will, where applicable, appear in

future

editions

this manual.

TECHNICAL

PUBLICATIONS

SERVICE

DIVISION

MOTORCYCLE OPERATIONS

YAMAHA

MOTOR

CO., LTD.

HOW

TO USE

THIS

MANUAL

PARTICULARLY

IMPORTANT

INFORMATION

This material is distinguished

the following notation.

NOTE:

WARNING:

A NOTE provides key information

make procedures easier

clearer.

A CAUTION indicates special procedures

that

must

be followed

avoid damage

the motorcycle.

WARNING

indicates special procedures

that

must

be followed

avoid injury

a motorcycle operator or person inspecting

repairing the motorcycle.

MANUAL

FORMAT

All

the procedures in this manual are organized in a sequential, step-by-step format. The informa-

tion has been compiled

provide the mechanic

with

an easy

read, handy reference

that

contains

comprehensive explanations

all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition

a faulty component will precede an arrow symbol and the course

action required will

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.

1:.:~1~1

1~g~1

§ti

@ @

ENG

l\i·I

~Kl

® ®

EARe[

f I

~HASlb®I

0 ®

IELEcl

~pp~'"'

Q])

[8]

(j])

m m 0

@ @ ®

~£.....__

~£.....__ ~£.....__

(2D

ILLUSTRATED

SYMBOLS

(Refer

the illustration)

Illustrated symbols

@ are designed as

thumb

tabs

indicate the chapter's numberand

content.

General information

(2)

Periodic inspection and adjustment

@Engine

@ Cooling system

@ Carburetion

®Chassis

(J)

Electrical

@ Appendices

Illustrated symbols @

@ are used

identify

the specifications appearing in

tlie

text.

® Filling fluid

® Lubricant

@ Tightening

@ Wear limit, clearance

Engine speed

@n,

V,A

Illustrated symbols ®

@ in

the

exploded

diagram indicate grade

lubricant and location

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

..................................................

1-3

FOR

ENGINE SERVICE

..........................................

1-4

FOR

CHASSIS SERVICE

.........................................

1-7

FOR

ELECTRICAL COMPONENTS

................................

1-7

MOTORCYCLE IDENTIFICATION

1-1

GENERAL

INFORMATION

MOTORCYCLE

IDENTIFICAITON

VEHICLE

IDENTIFICATION

NUMBER

The vehicle identification number

stamped

into the right side

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

used

iden-

tify

your motorcycle and may be used

your motorcycle

with

the licensing authority in

your state.

ENGINE

SERIAL

NUMBER

The engine serial number

stamped into the

elevated part

the left rear section

the engine.

Starting

Serial

Number:

VX600S

(Except

for

California)

1UJ-000101

VX600SC

(For

California)

1UL-000101

NOTE:

~~~~~~~~~~~~~-

•The

first three digits

these numbers are

for

model identifications; the remaining digits are

the

unit

production number.

•Designs and specifications are subject

change

without

notice.

IMPORTANT

INFORMATION

IMPORTANT

INFORMATION

300-000

300-003

300-002

ALL

REPLACEMENT

PARTS

Use

only genuine Yamaha parts for

all

replace-

ments. Use oil

and/

or grease recommended

by Yamaha

for

assembly and adjustment.

Other brands may

similar in function and

appearance,

but

inferior in quality.

GASKETS,

OIL

SEALS,

AND

0-RINGS

All gaskets, seals and

0-rings

should

replaced when

engine

overhauled. All

gasket surfaces, oil

seal

lips and 0-rings must

cleaned.

2. Properly oil all mating parts and bearings dur-

ing reassembly. Apply grease

the oil seal

lips.

LOCK

WASHERS/PLATES

AND

COTTER

PINS

All lock washers/Plates G) and cotter pins

must be replaced when they are removed.

Lock tab(s) should

bent along the bolt or

nut

flat(s) after the bolt or

nut

has been

properly tightened.

BEARINGS

AND

OIL

SEALS

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

view.) When

installing oil seal(s), apply a light coating

light-weight lithium base grease

the

seal

lip(s).

Oil

the bearings liberally when installing.

Oil seal

not

use

compressed

air

spin

the

bear-

ings

dry.

This

causes

damage

the

bearing

surfaces.

Bearing

1-2

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

the use

improper tools or improvised

techniques.

FOR

TUNE

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

measure the engine com-

pression.

4. Fuel Level Gauge

P/N.

YM-01312

This gauge is used

measure

the

fuel level in

the

float

chamber.

SPECIAL

TOOLS I

1~~

'"I

Fuel Level Gauge Adapter

P/N.

YM-01329

This tool

needed when measuring the carbu-

retor fuel level together

with

fuel level gauge.

Vacuum Gauge

P/N.

YU-08030

This gauge is needed

for

carburetor synchroni-

zation.

FOR ENGINE SERVICE

Universal Clutch Holder

P/N.

YM-91042

This tool

used

hold the clutch when remov-

ing or installing the clutch boss locknut.

2. Tappet Adjusting Tool

P/N.

YM-01245

This tool

necessary

replace valve adjusting

pads.

Valve Spring Compressor

P/N.

YM-04019

. This tool

needed

remove and install the valve

assemblies.

1-4

1~~~

SPECIAL

TOOLS

F""""'t

][

/if®'@O@

©)~

1-5

4. Valve Guide Remover

P/N.

YM-04064

This

tool

is used

remove

the

valve guides.

Valve Guide Reamer

P/N.

YM-04066

This tool is used

rebore

the

new

valve guide.

6. Valve Guide Installer

P/N.

YM-04065

This

tool

is needed

install

the

valve guides

properly

together

with

valve guide remover.

7. Valve Seat Cutter

Set

P/N.

YM-91043

This

tool

is needed

resurface

the

valve seat.

8. Rotor Puller

.........................

P/N.

YM-01080

................................

P/N.

YM-04052

This

tool

is needed

remove

the

A.C.

Genera-

tor

rotor.

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