The 1983-1989 Yamaha XT600, TT600 off-road bike repair manual by Clymer, covers the following dual-purpose motorcycle models:
Book Excerpt: Yamaha XT600 1984-1989, TT600 1983-1986 Repair Manual
- Yamaha XT600, 1984-1989
- Yamaha TT600, 1983-1986
A tune-up consists of a series of inspections, adjustments and parts replacements to compensate for normal wear and deterioration of engine components. Regular tune-ups are especially important to a dual-purpose motorcycle.
INTERNAL SHIFT MECHANISM
Since proper engine operation depends upon a number of interrelated system functions, a tune-up consisting of only one or 2 corrections will seldom give lasting results.
For improved power, performance and operating economy, a thorough and systematic procedure of analysis and correction is necessary.
The following paragraphs discuss each facet of a proper tune-up ? which should be performed in the order given. Unless otherwise specified, the engine should be completely cool before starting any tune-up procedure.
NOTE: It is a good idea to start the engine after each one of the tune-up procedures is completed and make sure it runs okay.
If for some reason, the procedure was not done correctly or a faulty new part(s) was installed, you can then concentrate on that specific procedure and part(s) and correct the problem.
If you wait until all the procedures are competed and then the bike runs worse or does not start at all, then you have to narrow it down to which one of the procedures or parts is causing the problem.
A TUNE-UP CONSISTS OF THE FOLLOWING:
- Valve clearance check and adjustment.
- Engine compression check.
- Ignition system inspection.
- Carburetor check and adjustment.
To perform a tune-up on your Yamaha, you will need the following tools and equipment:
- Spark plug wrench.
- Ratchet and assorted sockets.
- Allen wrenches.
- Flat feeler gauge.
- Compression gauge.
- Spark plug feeler gauge and gap adjusting tool.
- Ignition timing light.
Remove and install the transmission and internal shift mechanism as described under Crankcase Disassembly and Crankcase assembly in Chapter Five.
SHIFT FORK INSPECTION
Refer to Figure 47 for this procedure.
- Inspect each shift fork (Figure 48) for signs of wear or cracking.
- Examine the shift forks at the points where they contact the slider gear (A, Figure 49). This surface should be smooth with no signs of wear or damage.
- Make sure the forks slide smoothly on their respective shafts (Figure 50).
- Make sure the shafts are not bent. This can be checked by removing the shift forks from the shaft and rolling the shaft on a piece of plate glass (Figure 51).
Any clicking noise detected indicates that the shaft is bent and should be replaced.
Subject: 1983, 1984, 1985, 1986, 1987, 1988, 1989 Yamaha XT600, TT600 service, maintenance, repair. ISBN-10: 0892875461 | ISBN-13: 9780892875467 | Clymer M416