Yamaha XT500E / XT600E 1990 Service Manual

This English-language PDF reproduces Yamaha’s XT500E/XT600E Service Manual, 1st Edition, January 1990, for the model and market variants listed above.

PDF Search, Diagram Detail, and Page Count

Text access and diagram detail: Text search is limited to the added title page; the manual pages are not searchable. There are no embedded PDF bookmarks. Small wiring labels require zooming, and the starting-system circuit diagram has a dark, mottled background that makes some codes harder to read.

The ZIP contains one printable, 369-page PDF, including one added title page, one repeated special-tools page, and 15 blank or nearly blank divider and back pages.

Engine Overhaul, Carburetor Setup, and Electrical Fault Tracing

The following selected coverage highlights outline the main workshop areas rather than reproduce the complete contents. Other topics include seat and fuel-tank removal and side-cover installation.

• Engine repair: Engine removal, disassembly, inspection, repair, and reassembly, including the cylinder head, valve train, piston, cylinder, cam chain, crankshaft, balancer, and oil pump.

• Clutch and transmission: Clutch inspection and assembly, primary-drive service, starter-drive checks, transmission and shifter inspection, and A.C. magneto removal and installation.

• Carburetor service: Primary and secondary carburetor disassembly, diaphragm and jet inspection, reassembly, synchronization, fuel-level adjustment, throttle-cable setup, and market-specific jetting data.

• Wheels and brakes: Wheel-bearing replacement, static wheel balancing, brake-pad replacement, caliper and master-cylinder overhaul, disc inspection, and hydraulic bleeding.

• Steering and suspension: Front-fork teardown and assembly, steering-head and handlebar service, rear-shock removal, swingarm and relay-linkage inspection, and side-clearance adjustment.

• Electrical diagnosis: Digital TCI ignition testing, starter-circuit checks, starter-motor repair, charging tests, lighting and signal diagnosis, switch and bulb checks, and wiring diagrams.

• Workshop reference: Maintenance schedules, special-tool part numbers, component torque tables, lubrication and cable-routing drawings, capacities, wear limits, clearances, and electrical test specifications.

Yamaha wrote this manual primarily for its dealers and qualified mechanics, assuming a working understanding of motorcycle mechanical systems and repair procedures.

Model Identification and Scheduled Service

The specification tables distinguish XT500E and XT600E components and market-dependent settings. Matching the full model code and the separate vehicle, frame, and engine starting-number entries helps select the applicable specifications, carburetor settings, electrical data, and replacement parts.

Engine maintenance: Procedures cover valve-clearance adjustment, spark-plug inspection, ignition-timing checks, compression measurement, engine-oil level and pressure checks, and clutch adjustment. The cam-chain tensioner is automatic and adjustment-free; ignition timing is checked rather than adjusted.

Oil-tank strainer and air-filter cleaning are covered alongside carburetor-joint, fuel-line, crankcase-breather, and exhaust inspection.

Chassis and electrical maintenance: The schedule includes brake-fluid, pad, hose, and brake-light-switch checks; drive-chain adjustment and lubrication; and tire, wheel, cable, control, and sidestand service. Swingarm and relay-arm lubrication, sealed MF-battery checks and charging charts, fuse inspection, headlight aiming, and bulb replacement are also included.

Internal Engine Repair and Reassembly

Step-by-step overhaul procedures extend from engine removal and strip-down through inspection, repair, reassembly, and remounting. Cylinder-head work includes valve-guide replacement, valve-seat refacing and lapping, and camshaft, rocker-arm, and rocker-shaft inspection.

Piston and ring measurements, cylinder inspection, oil-pump clearances, clutch-plate checks, transmission gears and shift forks, starter drive, crankshaft, bearings, and oil seals receive component-specific attention.

Assembly instructions address valve timing, crankshaft and balancer installation, transmission and shifter setup, oil-pump lubrication, clutch-stack arrangement, primary-drive and starter-idle gears, and A.C. magneto installation. The engine chapter identifies selected top-end and clutch work that can be performed with the engine installed.

Factory cautions address crankcase mating-face damage from forced separation or blows to gasket surfaces, and bearing-surface damage from spinning cleaned bearings dry with compressed air.

Carburetor Synchronization and Fuel-Level Checks

The carburetor sectional view identifies the primary and secondary circuits. Inspection covers the needle valve and seat, starter plunger, coasting-enricher and piston-valve diaphragms, jet needles, throttle and piston valves, float, jets, and nozzles.

Assembly includes secondary-carburetor synchronization and float-height checks. The specification tables keep model and market jetting differences separate, rather than treating every Y26PV assembly as the same setup.

Brake, Fork, and Rear-Suspension Work

Wheel procedures include hubs, bearings, seals, spokes, damper rubbers, and the speedometer drive. Brake coverage distinguishes front and rear calipers, master cylinders, hoses, pads, discs, and approved fluid requirements, with installation checks after repair.

Front-fork instructions cover damper rods, seals, bushings, springs, and oil-level setting. Excessive force during fork separation can damage seals or bushings, while bottoming the tubes during separation can damage the oil-lock piece.

Rear-suspension coverage includes shock removal and replacement, spring-preload adjustment, swingarm and relay-linkage service, and shim-based side-clearance adjustment. Drive-chain and sprocket sections include wear inspection and replacement procedures.

Brake work requires stable support, clean hydraulic components, and the specified fluid for the circuit being serviced. The rear shock absorber is gas charged and must not be opened, heated, or physically damaged.

Electrical Tests, Diagrams, and Workshop Tools

The ignition and starting sections combine component tests with circuit operation and fault-tracing charts. Checks cover pickup and ignition coils, starter relays and cut-off circuits, starter-motor brushes and commutator, charging output, stator resistance, regulator/rectifier diagnosis, and lighting and signal circuits.

Illustrations include the ignition-system circuit diagram, starting-system circuit and operating diagrams, charging- and lighting-system diagrams, and the final two-page wiring diagram. Lubrication feed/scavenge drawings and four cable-routing pages show hose, cable, and harness arrangements.

Chapter 8 provides probable-cause charts for hard starting, poor idle and higher-speed performance, shifting faults, clutch slip or drag, weak braking, fork leakage, unstable handling, lighting and flasher faults, horn failure, and overheating.

Engine tools: Identified equipment includes crankcase separator YU-01135-A / 90890-01135, valve-spring compressor YM-04019 / 90890-04019, and rotor puller YU-33270 / 90890-01362.

Fork and electrical tools: The manual lists T-handle YM-01326 and damper-rod holder YM-01388 for fork work, plus pocket tester YU-03112 / 90890-03112 for electrical checks.

Selected Valve, Fuel-Level, and Fork Settings

For both models, the valve-adjustment section specifies cold clearances of 0.05–0.10 mm at the intake and 0.12–0.17 mm at the exhaust.

The carburetor fuel-level check specifies 6.0–8.0 mm below the carburetor body edge, with the carburetor vertical and the engine warmed.

The fork-assembly section gives an oil level of 155 mm below the top of the inner tube, measured with the fork fully compressed and the spring removed.