1986 Yamaha XR600R Manual

The 1986 Yamaha XR600R is a legendary dual-sport motorcycle featuring a 595cc air-cooled four-stroke single-cylinder engine, 5-speed transmission, rugged chassis design, and versatile on/off-road capabilities. This manual covers essential information for proper maintenance, operation, and troubleshooting of this iconic motorcycle. Below are key sections for specifications, maintenance procedures, operation guidelines, and technical data.

1. Specifications 2. Maintenance Schedule 3. Engine Service 4. Chassis Components 5. Electrical System 6. Fuel System 7. Operation Guidelines 8. Troubleshooting 9. Safety Information 10. Warranty & Support

Specifications

Technical specifications for the 1986 Yamaha XR600R motorcycle.

Component	Specification
Engine Type	Air-cooled 4-stroke SOHC single cylinder
Displacement	595cc
Bore x Stroke	97.0 x 80.5mm
Compression Ratio	8.3:1
Carburetor	Keihin 38mm constant velocity
Ignition System	CDI electronic ignition
Transmission	5-speed constant mesh
Final Drive	O-ring chain
Front Suspension	Telescopic fork, 10.6 inches travel
Rear Suspension	Pro-Link single shock, 10.6 inches travel

Maintenance Schedule

Regular maintenance intervals for optimal performance and longevity.

Engine Oil Change: Every 600 miles or 6 months
Oil Filter Replacement: Every 1,200 miles
Air Filter Cleaning: Every 300 miles (more often in dusty conditions)
Spark Plug Replacement: Every 3,000 miles
Valve Clearance Check: Every 3,000 miles
Chain Adjustment: Every 500 miles
Brake Fluid Replacement: Every 2 years

WARNING! Always perform maintenance with engine cool and motorcycle on center stand.

Engine Service

Detailed procedures for engine maintenance and repair.

Oil Change: Drain plug located bottom of crankcase, refill with 1.9 quarts 10W-40 motorcycle oil
Valve Adjustment: Intake 0.004-0.006 in, Exhaust 0.005-0.007 in
Spark Plug: NGK DR8ES-L, gap 0.028-0.031 in
Compression Test: Should read 142-171 psi
Cooling System: Air-cooled design, ensure cooling fins are clean

CAUTION! Use only recommended oil types and torque specifications.

Chassis Components

Frame: Semi-double cradle steel frame
Front Brake: Single 240mm disc with dual-piston caliper
Rear Brake: 220mm disc with single-piston caliper
Front Tire: 3.00-21
Rear Tire: 5.10-18
Wheelbase: 58.3 inches
Seat Height: 37.2 inches
Fuel Capacity: 2.8 gallons
Dry Weight: 295 pounds

Electrical System

Complete electrical system specifications and maintenance procedures.

Battery: 12V 10Ah, maintenance required. Charging System: AC generator, 210W output. Headlight: 60/55W halogen. Tail Light: 21/5W. Fuses: Main 20A, Headlight 10A, Signal 10A.

Testing: Use multimeter for voltage checks. Battery should read 12.6V minimum when fully charged. Charging voltage at 5000 RPM should be 13.5-15.0V.

Fuel System

Carburetor specifications and fuel system maintenance.

Fuel Type: Regular unleaded gasoline (87 octane minimum)
Carburetor Settings: Main jet #152, Pilot jet #62, Needle clip 3rd position
Float Height: 15.5mm
Idle Speed: 1400 ± 100 RPM
Fuel Filter: Clean every 6,000 miles

Tip: Always use fresh fuel and stabilize if storing more than 30 days.

Operation Guidelines

Proper operation procedures for optimal performance and safety.

Starting Procedure: Choke on, no throttle, kick start firmly
Warm-up: Allow 2-3 minutes before riding
Shifting: Clutch fully disengaged, smooth shifts
Break-in Period: Vary RPM, avoid full throttle for first 500 miles
Off-road Operation: Reduce tire pressure for better traction
Storage: Fuel stabilizer, battery maintainer, elevated position

WARNING! Always wear proper protective gear including helmet, gloves, and boots.

Troubleshooting

Common issues and solutions for the XR600R.

Symptom	Possible Cause	Corrective Action
Hard starting	Stale fuel, weak spark, valve adjustment	Fresh fuel, check spark plug, adjust valves
Poor performance	Clogged air filter, carburetor issues	Clean air filter, service carburetor
Overheating	Lean mixture, low oil	Check carburetor settings, oil level
Electrical failure	Battery, stator, regulator	Test charging system components
Oil consumption	Worn rings, valve seals	Compression test, inspect engine

Reset: Disconnect battery for 30 minutes to reset ECU if equipped.

Safety Information

Important safety precautions for operation and maintenance.

CAUTION! Always perform maintenance in well-ventilated area. Use jack stands when working under motorcycle. Hot engine components can cause burns. Wear eye protection when working with batteries or chemicals.

Warranty & Support

Original warranty information and support contacts. Limited 12-month warranty from date of purchase covering defects in materials and workmanship. For technical support, contact Yamaha Motor Corporation at 1-800-962-7926 or visit www.yamaha-motor.com. Replacement parts available through authorized Yamaha dealers.