Category:
Middleweight Naked Sportbike
Target Audience:
Commuters, sport riders, general motorcycle enthusiasts seeking a reliable and versatile machine.
Competitors:
Suzuki GS500, Honda CB500, Kawasaki Zephyr 550/750, Ducati Monster 600/750.
Engine Configuration:
Air-cooled, inline-four cylinder.
Design Philosophy:
Focus on reliability, ease of maintenance, and accessible performance for everyday riding.
Applicable Years:
1995, 1996, 1997, 1998, 1999
Type:
Workshop Service Manual (WSM)
Format:
Digital (likely PDF)
Estimated Pages:
Over 300 pages (typical for WSM)
Engine Mechanical:
Engine disassembly, assembly, inspection, repair of cylinder head, pistons, crankshaft, camshafts, valves, lubrication system, cooling system.
Fuel System:
Carburetor service and adjustment (likely Mikuni CV carbs), fuel pump, fuel lines, fuel tank.
Ignition System:
Ignition coil testing, spark plug specifications, CDI unit, timing adjustments.
Transmission Drivetrain:
Clutch operation, gearbox disassembly and assembly, final drive (chain and sprockets).
Brakes:
Front and rear brake caliper service, master cylinder, brake fluid replacement, bleeding procedures, disc inspection.
Suspension:
Front fork (telescopic) disassembly, oil replacement, seal replacement, rear shock absorber adjustment and replacement.
Electrical System:
Wiring diagrams, starter motor, alternator, battery, lighting system, instrumentation, fuses.
Chassis Frame:
Frame inspection, steering head bearing service, wheel bearing replacement, swingarm service.
Bodywork:
Fairing removal and installation (if applicable to specific sub-models), seat, fuel tank, fenders.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain lubrication and adjustment, brake adjustments.
Troubleshooting:
Diagnostic charts for common problems, symptom-based fault finding.
Major Repairs:
Complete engine overhauls, gearbox rebuilds, suspension component replacement, electrical system diagnostics.
Component Rebuilds:
Carburetor overhaul kits, brake caliper rebuilds, starter motor and alternator servicing.
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers detailed specifications, torque values, and step-by-step instructions for most repair and maintenance tasks.
Type:
DOHC, 4-stroke, air-cooled inline-four
Bore X Stroke:
62.0 mm x 49.6 mm
Horsepower (Approx):
60-65 hp @ 9000 rpm
Torque (Approx):
51 Nm (37.6 lb-ft) @ 7500 rpm
Carburetion:
Four Mikuni CV (Constant Velocity) carburetors, model VM26SS
Fuel Tank Capacity:
15 Liters (3.96 US gallons)
Oil Capacity With Filter:
2.6 Liters (2.75 US quarts)
Recommended Oil Grade:
Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher
Safety Certification:
N/A (Motorcycle safety standards vary by region, but generally meets regulatory requirements for its production era.)
Braking System:
Responsive dual front disc and single rear disc brakes provide effective stopping power.
Chassis Stability:
Steel diamond frame provides a stable platform.
Lighting:
Adequate headlight, taillight, and turn signals for visibility.
Instrument Cluster:
Analog speedometer and tachometer, odometer, trip meter, fuel gauge, warning lights (oil pressure, neutral, high beam, turn signals).
ABS:
Not equipped with ABS as standard.
Charging System:
12V electrical system with alternator and battery for ignition and accessories.
Oil And Filter Change:
Every 6,000 km (3,750 miles) or 6 months, whichever comes first.
Air Filter Inspection:
Every 6,000 km (3,750 miles)
Spark Plug Replacement:
Every 12,000 km (7,500 miles)
Chain Lubrication And Adjustment:
Every 1,000 km (600 miles) or after washing/rain, or when slack exceeds specified limit.
Valve Clearance Check:
Every 24,000 km (15,000 miles)
Brake Fluid Replacement:
Every 2 years or as needed if contaminated.
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher
Transmission Oil Type:
Yamalube Gear Oil SAE 80 API GL-4
Fork Oil Type:
Yamaha Fork Oil G-10 or equivalent SAE 10W
Fork Oil Quantity:
468 ml (15.8 US oz) per fork leg
Common Wear Items:
Clutch wear, carburetor jet clogging, front fork seal leaks, regulator/rectifier failure (though less common than on earlier Yamahas).
Electrical Gremlins:
Occasionally, corroded electrical connectors can cause intermittent issues, particularly with the lighting or ignition systems. Regular inspection and cleaning are advised.
Engine Performance:
Carburetor synchronization can drift over time, affecting smooth running and fuel economy. Regular checks are recommended.
Yamaha Legacy:
Yamaha Motor Company, founded in 1955, has a rich history in motorcycle manufacturing, known for innovation, performance, and reliability across various segments.
Xj600 Predecessors:
The XJ600 series originated in the early 1980s with the XJ600 Seca, evolving into the XJ600S Diversion (faired) and the XJ600N (naked) models.
Production Period:
The XJ600N generation (4BR chassis) was produced from approximately 1991 through 2003, with this manual covering the 1995-1999 update cycle.
Manufacturing Location:
Japan (Primary production)
