Looking for 1984 Yamaha XT 600 service manual
 

Hello Yamaha Tech team!

I recently picked up 1984 Yamaha XT600. The bike is in pretty rough condition. I am currently looking for OEM service manual. I have had no luck so far.

I would be grateful if there is there is anyone out on Horizons unlimited who can help me out.



Thank you

There is one listed on eBay in the USA at the moment:

https://www.ebay.co.uk/itm/Yamaha-XT...4AAOSw08pazSZJ

post some pictures of the bike including close ups to understand the condition

some months ago there was a guy here that was trying to save a totally worthless xt, he gave up after investing quite a lot of money and time in it

In another forum i am active, there is also a similar situation with a dr600 that's just not worth saving, guy is insisting and gets frustrated when discovering new problems every week


Sometimes even a free bike is not worth fixing, better keep it for spares

1984 xt600
 

@ Turboguzzi: I will share the pictures on this forum shortly. I understand the bike is in fairly rough condition. I will be stripping this XT600 all the way to the frame and restoring it. There will not be any room for errors.

ok, understand that you are full of enthusiasm but we seen a few cases like that here where restoration projects ended in tears once the expenses started to add up.



dont know where you are, but a decent xt600 in europe can be found for 1500 euro, it's really easy to spend more than that trying to fix a bike in bad condition, not to mention the agro of dealing with fu#$%d up parts.


all my restorations/builds took at least 200-300 hours, just so you know whats waiting for you :)



but if you are looking for a winter project and cost is no object, go for it.

I totally understand that this is going to be a big project restoring this Xt600. I picked this XT for CAD 400$. A decent XT can go for $2800 to $3000 CAD easily.

ok, looks salvageable.... good luck


does it have documents? that mx rear fender hasnt seen a number plate in ages.... :)

Unfortunately the bike does not have papers but, I am in the process of obtaining one. I found the Yamaha XT 600 1990 And xt550j service manual. I have looked hard everywhere including deep web and so far no luck. Looks like I will continue to build this bike by referring these two manuals. If anyone out there can find one 1984 XT or TT 600 manual please ping me.

Based on the one I had (1984 43F from Italy, I may be able to help with a couple of bits of info.



Model is 43F.



If the carb rubbers are original, they are shot.


I never found a manual either.



FYI, power for the ignition comes from two extra coils on the stator. It doesn't need a battery to run.



Good luck with it. It can be a cracking bike with slightly less weight and slightly more power than the XT600E.

Would something like this be of use to you? If it needs to go to a UK address then drop me a line and I will receive it and send it on to you.

https://www.ebay.co.uk/itm/Yamaha-XT600Z-Assembly-Manual-1986/284053570303?hash=item4222e982ff:g:HR0AAOSwN5pfkVE Z

There is also a downloadable copy of the Care and Maintenance book available here:

https://www.voteforselfdetermination.co.za/yamaha_xt_600_service_repair_manual.pdf

He`s not logged on in five months & only did this one post, id say he couldnt get the title & sold it on as parts.

Mezo.

1984 Xt600 build
 

I got way too busy over the summer riding and working on this project plus there was no way to get notified.

I got the title and restored the bike 80% so far . I realized I overlooked the front forks and they are slightly bent. I am having trouble during the cold
start but I will get there soon.

Work performed:

Rebuilt the engine completely
Replaced worn out bearings, rebored to 3rd stage, changed the shifter forks, lapped the valves The rest of the engine was in good condition.

Attachment 26403

Attachment 26404

Attachment 26405

Attachment 26406

Sand blasted and painted the frame
Steering neck bearings replaced
Swing arm bearings replaced with new seals
Linkage bearings cleaned and packed
Wheel bearings replaced and trued the rim
New chain and sprocket
Cushion rubber softened with wintergreen oil and alcohol combo
Front and rear brakes replaced
Straightened axle (I should have realized and looked at forks but was hoping for the best)

I think I should count what was not done on this bike. I definitely went over board on this project

Currently, the front end assembly is on the bench . I will
have to straighten the right fork inner tube and possibly the lower triple tree

I ended up purchasing the soft copy of 1984 xt600 service manual. I am happy to send it to anyone in need.

nice to read about this much of progress.
and wishing a good luck with remaining 20% (hopefully, it will not happen like that 80/20 rule :wink3:).

if there will be some need in the future to replace rubber cushions in the hub of the rear wheel, i could recommend you polyurethane - i'm running it for >3 years / >40K kms already and so far no stiffening/compression.
i've made them from circular red polyurethane rod (somehow average hardness), cut into sectors of appropriate size.

meanwhile, still became curious about your method of softening rubber - could you share the proportions with alcohol and whether some other factors involved like temperature or special timings?

Thanks, good to know about the Polyurethane rod. I will consider that in the future.

I used 80% wintergreen oil and 20% ethyl alcohol .

I tested one cushion rubber at first, checked every hour for 4 hours. Once I confirmed the rubber is safe and would not disintegrate into pieces . I submerged all the cushion rubbers overnight. I kept it at room temperature.

Day 2 I verified whether all the cushion rubbers were soft and continued to soak the hard ones for longer . The wintergreen oil does leave behind minty or balm smell on the rubber but it works.