Target Audience:
Mechanical technicians familiar with service procedures and knowledgeable motorcycle owners seeking to perform their own maintenance and repairs.
Value Proposition:
Provides comprehensive, dealer-level information to enable owners to maintain and repair their XJ600, potentially saving significant costs compared to professional shop labor.
Accuracy:
Claims to provide the most reliable information, aiming for accuracy comparable to authorized dealer service departments.
Completeness:
Stated to contain all necessary instructions for any repair the Yamaha XJ600 may require.
Emphasis On Safety:
Highlights the importance of using safety equipment and observing safety precautions, including the use of a torque wrench.
Symbols Notation:
Utilizes specific wording and symbols (WARNING, CAUTION, NOTE) to highlight critical information.
Years Covered:
1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992
Geographic Applicability:
Assumed global, but the reference to 'BRP products' in the description is unusual for a Yamaha motorcycle manual and might indicate a specific regional or third-party publication's origin.
Type:
Workshop Repair Service Manual
Primary Language:
English
Delivery Method:
Electronic Delivery via Email
Quality Description:
As a PDF download, print quality depends on the user's printer and settings. Content is expected to be clear and legible.
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Engine Mechanical:
Engine overhaul, disassembly, and assembly procedures.
Fuel System:
Carburetor tuning, cleaning, and overhaul; fuel pump and lines.
Ignition System:
Ignition timing, spark plugs, coils, and electronic control unit (ECU) if applicable.
Lubrication System:
Oil pump, oil filter, oil passages, and oil change procedures.
Exhaust System:
Exhaust pipe and muffler inspection and replacement.
Electrical System:
Wiring diagrams, lighting, charging system (alternator, rectifier/regulator), starter motor, battery, and fuses.
Transmission Drivetrain:
Gearbox removal, disassembly, assembly, and adjustments.
Chassis Suspension:
Front fork (telescopic), rear suspension (mono-shock or twin-shock depending on specific XJ600 variant), swingarm, and steering head bearings.
Braking System:
Front and rear brake systems (disc or drum), caliper service, master cylinder overhaul, and bleeding procedures.
Wheels Tires:
Wheel bearing inspection and replacement, tire mounting and balancing.
Bodywork Frame:
Body panel removal, installation, and frame inspection.
Routine Maintenance:
Tune-ups, oil changes, filter replacements, chain adjustment, brake fluid checks, and general servicing.
Diagnostic Procedures:
Troubleshooting guides for common issues, symptom-based diagnostics.
Repair Overhaul:
Detailed step-by-step instructions for component removal, repair, and reinstallation.
Troubleshooting Guides:
Specific sections dedicated to diagnosing and rectifying common problems.
Component Specific Instructions:
Instructions for proprietary components manufactured by Yamaha or its suppliers.
Depth:
Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers basic maintenance to full engine and transmission rebuilds.
Diagnostic Focus:
Emphasizes diagnostic and repair procedures when trouble occurs.
Special Tool References:
References specific Yamaha special tools required for certain adjustments or repairs, often with part numbers and illustrations.
Engine Type:
Air-cooled, 4-stroke, DOHC, inline-four cylinder (based on common XJ600 configurations of the era).
Displacement:
Typically 598cc for the XJ600 Seca II / Diversion models of this period. Exact displacement can vary slightly by specific sub-model or market.
Bore X Stroke:
Likely around 62.0 mm x 49.2 mm (typical for 598cc inline-four).
Horsepower Estimate:
Around 58-60 HP at the crankshaft (typical for 600cc Japanese inline-fours of the 1980s/early 1990s).
Torque Estimate:
Approximately 50-53 Nm (37-39 lb-ft) at the crankshaft.
Carburetors:
Likely features multiple Mikuni constant-velocity (CV) carburetors (e.g., 4 x Mikuni BS29 or similar).
Fuel Delivery:
Gravity feed from the fuel tank, potentially with an electric fuel pump for reserve or specific models.
Oil Type Recommendation:
The manual would specify SAE 10W-40 or 20W-40 motorcycle-specific oil meeting JASO MA standards. Exact viscosity may vary with ambient temperature.
Oil Capacity:
Typically around 2.5 - 3.0 liters (including oil filter change).
Transmission Type:
Constant mesh, 6-speed manual transmission.
Optional Transmissions:
N/A (Manual transmission only for this model).
Clutch Type:
Wet, multiple-disc clutch.
Final Drive:
Chain drive.
Transmission Oil Type:
The manual would specify a gear oil or motorcycle transmission fluid, often SAE 80 or 85W-90.
Length:
Approx. 2,170 mm (varies slightly by sub-model/fairing).
Width:
Approx. 770 mm (varies slightly).
Height:
Approx. 1,245 mm (varies slightly).
Dry Weight:
Approximately 180-190 kg.
Wet Weight:
Approximately 195-205 kg (with all fluids).
Fuel Capacity:
Around 16-18 Liters.
Safety Certification:
Not directly applicable to a repair manual. However, the manual would detail safety procedures for operation and maintenance adhering to manufacturer safety standards.
Braking System Features:
Dual front disc brakes, rear disc brake (or drum on some early variants). Manual covers inspection, pad replacement, fluid changes, and bleeding.
Frame Construction:
Steel diamond frame designed for stability and rider control.
Lighting System:
Headlight, taillight, brake lights, and turn signals. Manual covers bulb replacement and circuit diagnostics.
Oil Change Interval:
Typically every 4,000 - 6,000 km (2,500 - 3,700 miles) or annually, whichever comes first. The manual will provide precise intervals.
Chain Lubrication Adjustment:
Lubrication recommended every 500-1000 km, adjustment as needed to maintain specified slack (e.g., 20-30mm).
Valve Clearance Check:
Typically at 12,000 km or 24,000 km intervals. The manual will specify the exact interval and adjustment procedure.
Brake Fluid Type:
DOT 4 or DOT 5.1 brake fluid is typically recommended for Yamaha motorcycles of this era. The manual will confirm the specific type.
Coolant Type:
N/A (Air-cooled engine).
Common Wear Items:
Potential issues include carburetor synchronization, aging fuel lines, worn brake pads and discs, chain and sprockets wear, and fork seal leaks.
Electrical Gremlins:
Older wiring harnesses can sometimes develop issues; manual provides diagnostic help.
Yamaha Motorcycle Legacy:
Yamaha has a long history of producing innovative and reliable motorcycles across various categories, known for performance and engineering.
Xj600 Lineage:
The XJ600 series was part of Yamaha's mid-size, versatile motorcycle offerings, often bridging the gap between commuter bikes and sportbikes, with variants like the Seca II and Diversion.
Production Period:
1984-1992 is the specific range covered by this manual. The XJ600 model line continued with further iterations.
Manufacturing Location:
Typically manufactured in Japan.
Historical Reception:
The XJ600 series was generally well-received for its balance of performance, reliability, and value, making it a popular choice for commuting and general sport-touring.
Industry Reviews:
Contemporary reviews often highlighted its smooth four-cylinder engine, comfortable riding position, and competent handling.
Manual Certification:
Not applicable. This is a third-party or factory service manual.
