Positioning:
The Yamaha XJ600 Diversion (or Seca II in some markets) was positioned as a versatile, reliable, and affordable sport-touring motorcycle, offering a blend of performance and comfort for everyday riding and longer journeys. This manual targets owners and independent workshops seeking comprehensive service information.
Competitors 1991:
Competed against bikes like the Honda CB500/CB600 Hornet, Kawasaki GPZ600R, Suzuki GSX600F Katana, and Ducati Monster series.
Vehicle Key Attributes:
Smooth inline-four engine, comfortable riding position, practical for commuting and touring, accessible performance.
Manual Purpose:
To empower owners with the knowledge to perform all necessary maintenance and repairs, ensuring the longevity and optimal performance of their Yamaha XJ600.
Engine:
Complete overhaul, tuning, carburetor synchronization, valve clearance adjustment, ignition system, cooling system (air-cooled)
Transmission:
Clutch inspection and replacement, gearbox disassembly and reassembly, shift mechanism
Brakes:
Hydraulic system inspection, pad replacement, caliper service, fluid bleeding, disc wear
Suspension:
Front fork overhaul (seals, oil), rear shock absorber inspection, linkage lubrication
Electrical System:
Wiring diagrams, component testing (starter, alternator, battery), lighting, ignition coil testing
Fuel System:
Carburetor disassembly, cleaning, jetting, fuel tank inspection, fuel pump operation (if applicable)
Chassis And Frame:
Frame inspection, steering head bearing service, wheel bearing replacement, spoke tensioning (if applicable)
Bodywork And Trim:
Fairing removal and installation, seat, fenders, minor cosmetic repairs
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, chain adjustment and lubrication, spark plug replacement
Troubleshooting:
Diagnostic charts for common performance issues, electrical faults, starting problems
Rebuild Procedures:
Detailed step-by-step instructions for engine, gearbox, and carburetor rebuilds
Adjustment Procedures:
Carburetor synchronization, throttle cable adjustment, clutch cable adjustment
Disassembly And Assembly:
Complete breakdown and reassembly of all major motorcycle components
Diagnostic Capabilities:
Advanced diagnostic flowcharts and troubleshooting for complex issues
Repair Detail Level:
Comprehensive, covering minor repairs to full engine and transmission rebuilds
Technical Diagrams:
Detailed exploded views, wiring schematics, and service diagrams
Digital Format Details:
Typically PDF, often searchable text for efficient information retrieval
Page Quality:
Assumed to be clear and legible, mirroring original factory service manuals. High-resolution for diagrams.
Digital Binding:
N/A (Digital)
Digital Paper Simulation:
N/A (Digital)
Engine Type:
4-stroke, DOHC, inline-four-cylinder
Bore X Stroke:
62.0 mm x 49.6 mm (typical for this generation)
Compression Ratio:
10.0:1 (approximate)
Cooling System:
Air-cooled
Horsepower:
Approximately 60-65 PS (44-48 kW) at 8,500 rpm (claimed)
Torque:
Approximately 5.3 kgf-m (52 Nm) at 7,000 rpm (claimed)
Carburetor Type:
4 x Mikuni BS32 carburetors (or similar)
Fuel Tank Capacity:
18 Liters (approximate)
Safety Certifications:
Meets relevant national and international motorcycle safety standards for its era.
Braking System:
Front: Dual 288mm discs with hydraulic calipers. Rear: Single 245mm disc with hydraulic caliper. ABS was generally not standard on this model in 1991.
Lighting:
Halogen headlamp, LED taillight (common upgrade), standard turn signals.
Frame Construction:
Steel diamond frame for structural integrity.
Instrumentation:
Analog speedometer, tachometer, fuel gauge, odometer, trip meter, and warning lights.
Rider Aids:
Limited by era; primarily focused on robust mechanicals. No electronic rider aids like traction control or ABS typically standard on this model.
Connectivity Features:
N/A (Motorcycle of this era)
Oil Change Interval:
Every 3,000-5,000 km or 6 months, whichever comes first (typical for the era).
Valve Clearance Check:
Every 10,000-15,000 km (or as specified in manual).
Air Filter Maintenance:
Clean every 5,000 km, replace every 15,000-20,000 km.
Chain Maintenance:
Lubricate and adjust every 1,000 km or as needed.
Engine Oil Type:
SAE 20W-40 or 10W-40 motorcycle specific API SG or higher.
Engine Oil Capacity:
Approx. 3.0 Liters (without filter change), 3.2 Liters (with filter change).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Fork Oil Type:
Yamaha Fork Oil (or equivalent SAE 10 or 15 weight suspension fluid).
Coolant Type:
N/A (Air-cooled)
Common Wear Items:
Carburetor jet clogging, fork seal leaks, swingarm pivot bearing wear, aging electrical connectors.
Performance Quirks:
Can exhibit minor carburetor icing in very cold, humid conditions; requires regular chain maintenance for smooth drivetrain operation.
Yamaha Motors History:
Yamaha Motor Company, founded in 1955, has a rich heritage in motorcycle manufacturing, known for innovation, performance, and reliability across various motorcycle segments.
Xj600 Lineage:
The XJ600 series has a lineage dating back to the early 1980s. The 1991 model represents a refinement of the earlier XJ600 Seca, often evolving into the Diversion moniker in later years, emphasizing sport-touring capabilities with improved ergonomics and bodywork.
Production Period:
The XJ600 was produced for many years, with the 1991 model being a key iteration in its development. Production spanned well into the late 1990s and early 2000s in various forms.
Industry Reviews:
Generally received positive reviews for its balance of performance, comfort, and value, making it a popular choice for commuters and intermediate riders.
Reliability Reputation:
Yamaha's reputation for building reliable motorcycles extends to the XJ600, which is known for its robust engine and gearbox when properly maintained.
