Yamaha XT500E / XT600E 1990 Service Manual (1st Edition)

• Factory coverage: 369 PDF pages reproducing Yamaha's 1st Edition, January 1990 service manual for the XT500E and XT600E, with model codes 3WS1, 3TB1, 3TB2, 3UW1, and 3UX1 and A, E, D, and CH market identifiers.
• Engine repair depth: Covers engine removal, full disassembly, inspection, repair, reassembly, and adjustment of the cylinder head, valve train, piston and cylinder, cam chain, crankshaft, balancer, oil pump, clutch, starter drive, five-speed transmission, shifter, and A.C. magneto.
• Carburetion work: Details the Teikei Y26PV primary/secondary carburetor through sectional views, removal, disassembly, inspection, assembly, installation, fuel-level adjustment, throttle-cable setup, idle adjustment, and variant-specific jetting data.
• Chassis procedures: Includes wheel and bearing service, static wheel balancing, brake pad replacement, caliper and master-cylinder overhaul, brake bleeding, front-fork teardown, steering-head service, rear shock and swingarm work, side-clearance adjustment, and drive-chain and sprocket repair.
• Electrical diagnosis: Provides digital TCI ignition testing, starting-circuit operation, starter-motor inspection, charging checks, lighting and signal fault tracing, switch and bulb tests, system circuit diagrams, and the full two-page wiring diagram.
• Workshop reference data: Supplies periodic maintenance schedules, special-tool part numbers, component-specific torque tables, lubrication and cable-routing drawings, capacities, wear limits, clearances, adjustment specifications, electrical test values, and system fault-isolation charts.

Model and Serial Identification

The identification pages are more specific than a simple “1990 XT500E/XT600E” label. The XT500E is listed as 3WS1 (A). XT600E coverage is divided among 3TB1, 3TB2 (E), 3UW1 (D), and 3UX1 (CH). Frame starting numbers are 3WS-000101, 3TB-000101, 3UW-000101, and 3UX-000101; the engine table adds the E-market 3TB-020101 starting point. That distinction matters when selecting specifications, carburetor settings, electrical data, or replacement parts. Match the code and starting number on the motorcycle rather than applying this edition to later, unlisted variants.

Scheduled Service and Engine Overhaul

The periodic inspection chapter covers valve-clearance and cam-chain adjustment, idle and throttle-cable setup, spark-plug and ignition-timing checks, compression measurement, oil-level and oil-pressure inspection, clutch adjustment, oil-tank strainer and air-filter cleaning, and fuel, breather, and exhaust inspection. Chassis maintenance includes brake-fluid, pad, hose, and light-switch checks; hydraulic bleeding; drive-chain adjustment and lubrication; steering-head, fork, shock, tire, wheel, cable, control, sidestand, swingarm, and relay-arm service. Battery, fuse, headlight-aim, and bulb procedures are covered separately.

Engine coverage goes well beyond routine maintenance. The manual follows removal and strip-down through the cylinder head, cylinder, camshaft, piston, starter idle gear, crankcase covers, clutch and primary drive, balancer, oil pump, shift mechanism, magneto, transmission, crankshaft, rocker arms, and valves. Inspection and repair sections address valve guides and seats, cam and rocker components, piston and rings, clutch plates, oil-pump clearances, transmission gears and shift forks, starter drive, crankshaft, bearings, and oil seals. Reassembly includes valve timing, crankshaft and balancer installation, transmission and shifter setup, oil-pump priming and installation, clutch-stack arrangement, magneto installation, and engine remounting.

Carburetor, Chassis, and Brake Repair

The carburetion chapter uses a sectional view to identify the primary and secondary circuits before covering removal, internal inspection, reassembly, installation, and fuel-level adjustment. Specification tables keep XT500E and XT600E jetting and market variations separate instead of treating the Y26PV assembly as one universal setup.

Chassis repair sections cover both wheels, hubs, bearings, seals, spokes, speedometer drive, brake discs, calipers, master cylinders, hoses, pads, front fork, steering head, handlebar, rear shock, swingarm, relay linkage, drive chain, and sprockets. Factory procedures include static wheel-balance adjustment, fork seal and bushing service, brake-system bleeding, swingarm side-clearance adjustment, and final installation checks. The brake information also distinguishes the approved front- and rear-circuit fluid requirements.

Electrical Testing, Diagrams, and Fault Isolation

Useful drawings include the XT500E/600E circuit diagram, ignition-system circuit diagram, electrical starting-system circuit and operating diagram, charging-system circuit diagram, lighting-system circuit diagram, and final two-page XT500E/600E wiring diagram. The specification chapter adds engine lubrication feed/scavenge diagrams and four cable-routing pages for the handlebar, frame, battery/relay area, brake hoses, and rear lighting harness.

Test procedures cover switch continuity, bulb condition, ignition spark, pickup and ignition-coil checks, starter relay and cut-off circuit operation, starter-motor brushes and commutator, charging output, regulator/rectifier checks, and lighting and signal diagnosis. Chapter 8 adds fault trees for hard starting, poor idle or high-speed performance, shifting faults, clutch slip or drag, weak braking, fork leakage, unstable handling, lighting and flasher faults, horn failure, and overheating.

Selected factory tools are identified by number, including the YU-01135-A / 90890-01135 crankcase separator, YM-04019 / 90890-04019 valve-spring compressor, YU-33270 / 90890-01362 rotor puller, YM-01326 and YM-01388 front-fork holding tools, and YU-03112 / 90890-03112 pocket tester.

A few repair cautions are especially worth noting. Forcing the crankcase halves apart or striking the gasket surfaces can damage the mating faces. Excessive force during front-fork separation can damage the oil seal, bushings, or oil-lock piece. Cleaned bearings must not be spun dry with compressed air because the bearing surfaces can be damaged.

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.