Vehicle Segment:
Mid-size naked sportbike / sport-tourer.
Key Competitors:
Honda CB500/CB600 (Hornet), Kawasaki GPZ500S/ZZR600, Suzuki GS500E/GSF600 Bandit.
Engine Layout:
Inline-four cylinder, air-cooled.
Frame Type:
Steel diamond frame.
Styling:
The 'Diversion' model featured a half-fairing and dual headlights, offering a more comfortable sport-touring profile. The 'Seca II' was a US-market variant with a distinctive single-sided swingarm and a more aggressive, faired design.
Years Covered:
1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Estimated Page Count:
Likely 200-350 pages (typical for comprehensive factory-level manuals)
Manual Type:
Repair Service Manual
Language:
English (primary, based on product description)
Delivery Format:
Digital Download (PDF)
Engine System:
Complete overhaul, tuning, diagnostics, lubrication, cooling, fuel delivery (carburetor system), ignition system, exhaust system.
Transmission System:
Clutch operation, gear shifting mechanisms, gearbox disassembly and reassembly, lubrication, troubleshooting.
Chassis And Suspension:
Front fork (telescopic), rear suspension (monoshock), steering system, swingarm, wheel bearing service, linkage maintenance.
Brakes System:
Hydraulic front and rear brake systems, caliper maintenance, master cylinder overhaul, brake fluid specifications and bleeding procedures, disc and pad replacement.
Electrical System:
Wiring diagrams, lighting system, ignition system components, charging system (stator, regulator/rectifier), starter system, battery maintenance, fuses, relays, diagnostic procedures for electrical faults.
Fuel System:
Carburetor identification and specifications (Mikuni CV), synchronization, jetting, float bowl service, fuel pump (if applicable), fuel filter replacement.
Cooling System:
Air-cooled engine operation, cooling fin cleaning, oil cooler system (if applicable), oil type and capacity.
Body And Frame:
Fairing removal and installation, seat, fuel tank, body panel repairs, frame inspection, mounting points.
Routine Maintenance:
Oil changes, filter replacements (oil, air), spark plug service, chain adjustment and lubrication, brake adjustments, fluid level checks.
Diagnostic Procedures:
Troubleshooting common issues, fault finding for engine performance, electrical problems, braking anomalies.
Disassembly And Reassembly:
Step-by-step guides for major component removal and installation, including engine, gearbox, suspension, and electrical components.
Technical Specifications:
Torque values for all fasteners, engine clearances, valve timings, electrical resistance values, tire pressures, fluid capacities.
Special Tool Requirements:
Identification of specific tools needed for certain maintenance and repair tasks.
Depth Of Coverage:
Comprehensive. Covers basic to advanced repairs, including full engine rebuilds, carburetor tuning, and electrical system diagnostics.
Engine Type:
Four-stroke, DOHC, inline-four cylinder, air-cooled.
Displacement:
598 cc (cubic centimeters)
Bore X Stroke:
60.0 mm x 54.0 mm
Compression Ratio:
10.5:1
Horsepower Peak:
Approx. 60-65 HP (at crankshaft) depending on specific market tuning.
Torque Peak:
Approx. 50-55 Nm (at crankshaft) depending on specific market tuning.
Fuel Delivery:
Four Mikuni CV (Constant Velocity) carburetors, model likely BST32.
Fuel Type:
Unleaded gasoline, minimum octane rating 91 (RON+MON)/2.
Ignition Type:
Digital TCI (Transistor Controlled Ignition) with dual spark plugs per cylinder.
Oil Type:
Yamalube 4 (or equivalent SAE 10W-40 or 20W-40 API SE, SF, SG, SH, SJ or JASO MA)
Oil Capacity With Filter:
Approx. 3.2 Liters (3.4 US qt)
Cooling Method:
Air-cooled.
Gearbox Type:
Constant mesh, 6-speed sequential.
Clutch Type:
Wet, multiple-disc, manual operation.
Final Drive:
O-ring sealed chain drive.
Gear Ratios:
Specific ratios are detailed within the manual for each gear. (e.g., 1st: 2.785, 2nd: 1.944, 3rd: 1.555, 4th: 1.333, 5th: 1.150, 6th: 1.038 - typical values, confirm in manual).
Length Overall:
Approx. 2150 mm (84.6 in) for Diversion, 2115 mm (83.3 in) for Seca II.
Width Overall:
Approx. 750 mm (29.5 in) for Diversion, 770 mm (30.3 in) for Seca II.
Height Overall:
Approx. 1200 mm (47.2 in) for Diversion, 1160 mm (45.7 in) for Seca II.
Wheelbase:
Approx. 1445 mm (56.9 in).
Dry Weight:
Approx. 177 kg (390 lbs) for Diversion, 182 kg (401 lbs) for Seca II.
Wet Weight:
Approx. 198 kg (436 lbs) for Diversion, 203 kg (448 lbs) for Seca II (with fluids).
Fuel Tank Capacity:
18 Liters (4.8 US gal).
Front Wheel Size:
17M/C x MT3.50.
Rear Wheel Size:
17M/C x MT4.50 (Diversion) or MT5.00 (Seca II).
Wheel Bolt Pattern:
5 x 114.3 mm (4.5 inch PCD) - standard for many Japanese motorcycles of this era.
Infotainment System:
N/A (Basic motorcycle technology of its era, no electronic infotainment systems).
Rider Aids:
No electronic rider aids such as traction control or ride modes were available.
Connectivity Features:
N/A (Analog instrument cluster, no connectivity options).
Dashboard Features:
Analog speedometer, tachometer, fuel gauge, odometer, trip meter, indicator lights (neutral, oil pressure, high beam, turn signals).
Oil Change Interval:
Every 5,000 km (3,000 miles) or annually, whichever comes first.
Oil Filter Replacement Interval:
Every 10,000 km (6,000 miles) or annually.
Spark Plug Replacement:
Every 10,000 km (6,000 miles).
Valve Clearance Check:
Every 20,000 km (12,000 miles).
Air Filter Cleaning Or Replacement:
Inspect every 5,000 km (3,000 miles), clean/replace as needed. Replacement typically every 20,000 km (12,000 miles).
Brake Fluid Type:
DOT 3 or DOT 4 (as per manual recommendation, typically DOT 3 is acceptable).
Coolant Type:
N/A (Air-cooled engine).
Fork Oil Type:
Yamaha Fork Oil G-10 (or equivalent SAE 10W).
Fork Oil Quantity:
Approx. 432 ml (14.6 US oz) per fork leg.
Carburetor Issues:
Carburetor synchronization drift over time, leading to rough idling and uneven power delivery. Diaphragm wear can also occur.
Electrical Connections:
Corrosion in electrical connectors, particularly around the regulator/rectifier, can lead to charging system problems.
Suspension Wear:
Fork seals can leak over time, and rear shock absorber damping may degrade, requiring rebuild or replacement.
Stator Failure:
The stator can fail, impacting the charging system's ability to recharge the battery.
Manufacturer:
Yamaha Motor Company, Ltd. is a Japanese manufacturer of motorcycles, marine products, and other motorized products.
Development:
The XJ600 line built upon Yamaha's experience with inline-four engines, aiming to provide a balanced package of performance, comfort, and reliability. The Diversion variant was particularly popular in Europe for its blend of sportiness and practicality.
Variants:
Key variants include the XJ600S Diversion (half-faired) and the XJ600N (naked) in many markets. The US-market XJ600 Seca II (41X, 4LX) offered different styling and a single-sided swingarm.
Production Period:
1992-1999. This manual covers the entire primary production run of the XJ600 model.
