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

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You will have to do without pocket handkerchiefs, and a great many other things, before we reach our journey's end, Bilbo Baggins. You were born to the rolling hills and little rivers of the Shire, but home is now behind you. The world is ahead.

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.

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.









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 ).

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.

thanks for info.
minty smell of the rubber mustn't be a big deal as far as it goes into the hub : )

We have a product Omega 917 for renew seals adding in oil, recomend if you have similar product it works and you dont need alcohol.

I didn't have much luck with the wintergreen oil approach when I was trying to soften the air filter hoses on my old Yamaha. It does soften rubber but it does it in an odd way insofar as it swells up and softens from the edges in. On a tubular structure like an air hose the ends soften and swell more than the middle so they start to curl back on themselves. I tried for a couple of months to find just the right amount of swelling (they slowly contract back if you leave them) but gave up when I found a company in California doing repro hoses.

The odour's nice though if you like your bike smelling like a hospital ward