1986 Yamaha SRX600S / SRX600SC Service Manual (P/N LIT-11616-05-49)

This Yamaha factory service manual covers the 1986 SRX600S (2EF) and California SRX600SC (2EG). Publication P/N LIT-11616-05-49, first edition, April 1986, carries the additional cover code 2EF-28197-10.

• Engine overhaul: Engine removal and reinstallation, crankcase separation, cylinder-head repair, crankshaft inspection, and balancer assembly.

• Clutch and transmission: Wet-clutch disassembly, friction-plate inspection, kick starter service, shift-fork checks, and transmission assembly.

• Carburetion: Primary and secondary carburetor teardown, coasting-enricher inspection, float-height and fuel-level adjustment, and secondary-carburetor synchronization.

• Chassis and brakes: Fork overhaul, steering-head bearing service, swingarm inspection, wheel-bearing replacement, and caliper and master-cylinder repair with hydraulic bleeding.

• Electrical diagnosis: Ignition, charging, lighting, and signal-system troubleshooting, including neutral/sidestand control circuits and self-canceling turn signals.

• Factory references: Exploded assembly drawings, carburetor sectional views, lubrication diagrams, cable-routing layouts, wiring diagrams, and component torque and wear tables.

Written primarily for Yamaha dealers and qualified mechanics, this manual assumes a working knowledge of motorcycle maintenance and repair.

Single-Cylinder Engine Repair and Lubrication

The engine-overhaul chapter covers rocker-arm and camshaft inspection, valve-guide replacement, valve-seat cutting and lapping, cylinder-sleeve replacement, and piston and ring checks. Crankshaft work includes reassembly checks and oil-passage alignment, with separate inspection criteria for the oil pump and transmission gears.

Assembly references: The crankshaft/balancer, clutch, and transmission drawings identify component positions and assembly marks. The special-tool section lists the crankcase separator YU-01135, crankshaft installing set YU-90050, and universal clutch holder YM-91042.

Dry-sump service: Oil-tank strainer cleaning, filter replacement, and oil-flow inspection accompany diagrams distinguishing feed oil from scavenge oil. The oil-pressure inspection section warns that continued running without oil flow can seize the engine.

Carburetor Setup and California Emissions Equipment

Primary and secondary carburetor service is separated, with inspection coverage for the starter plunger, vacuum piston, and coasting enricher. Adjustment sections distinguish float height, running fuel level, primary throttle full-open position, and secondary synchronization.

California-specific material includes fuel-tank breather-hose inspection, the canister and rollover-valve hose layout, and canister removal and installation. Periodic inspection pages also cover compression diagnosis, idle-speed adjustment, and throttle-cable free play.

The decompression device is kick-synchronous. Its cable adjustment is linked to valve-clearance maintenance, rather than treated as an independent manual decompression control.

Fork, Steering and Brake Service

Fork overhaul includes damper-rod removal and replacement of the slide bush, guide bush, oil seal, and dust seal. The disassembly cautions explain how excessive force or bottoming the inner tube can damage seals, bushings, or the oil lock piece.

Steering-head bearing inspection and adjustment, drive-chain service, and brake-fluid checks are included. Brake coverage extends to front and rear calipers and master cylinders, hydraulic bleeding, and disc inspection, with warnings about the loss of braking performance caused by trapped air.

Rear-shock work covers removal, inspection, installation, and preload adjustment. Leaking or damaged units are replaced as assemblies; the manual warns against opening the pressurized nitrogen cylinder.

Tracing Ignition and Charging Faults

No-spark troubleshooting separates spark-plug and cap faults, switch continuity, ignition-coil resistance, and CDI-magneto source and pickup-coil tests. The ignition-control explanation connects neutral and sidestand switch operation with spark availability, helping distinguish an interlock fault from an ignition-component fault before replacement.

The electrical chapter also covers charging-voltage tests, rectifier/regulator fault isolation, lighting circuits, and switch-continuity charts. Separate circuit diagrams accompany the ignition, charging, lighting, and signal systems.

Examples of Piston, Valve-Guide and Drain-Plug Specifications

Engine inspection data lists piston-to-cylinder clearance of 0.045–0.065 mm (0.0018–0.0026 in). The intake valve’s standard stem-to-guide clearance is 0.010–0.037 mm, distinct from the separate valve-lash adjustment.

The oil-change section specifies 30 Nm (22 ft-lb) for both the crankcase and oil-tank drain plugs.

PDF Bookmarks, Wiring Detail and Page Count

Search and diagram access: Embedded bookmarks provide chapter and section navigation, but PDF text search is unavailable. Small wiring labels require zooming. The legacy “Back to Index” bookmark refers to a separate index file that is not included.

The download contains one printable English PDF with 238 pages, including five front-matter pages and two chapter divider pages. The specifications appendix, lubrication and cable-routing diagrams, and final wiring diagram are included in that total.