Positioning:
The Yamaha XJ600 was positioned as a versatile middleweight naked and faired sport-touring motorcycle, offering a balance of performance, comfort, and reliability. It appealed to a broad range of riders, from commuters to weekend tourers.
Competitors:
Competed with other 600cc class motorcycles such as the Suzuki GS500/GSF600 Bandit, Kawasaki GPZ500S/ER-5, and Honda CB500/CBF500.
Engine Layout:
Reliable air-cooled, 599cc inline-four engine known for its smooth power delivery.
Chassis Design:
Steel diamond frame providing a stable and predictable ride.
Braking System:
Effective dual front disc brakes and a rear disc brake for confident stopping power.
Ergonomics:
Comfortable riding position suitable for longer journeys, especially the faired 'Diversion' model.
Years Covered:
1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Variants Covered:
All variants of the XJ600S Diversion and XJ600N
Type:
Service and Repair Manual
Format:
Digital Download (PDF)
Engine:
Complete disassembly, assembly, tuning, troubleshooting, and repair of the 599cc air-cooled inline-four engine.
Fuel System:
Carburetor identification, cleaning, synchronization, jetting, and troubleshooting (likely Mikuni CV carbs).
Ignition System:
Ignition timing, spark plug specifications, coil testing, and troubleshooting.
Transmission:
Gearbox operation, clutch service, gearbox disassembly and reassembly, and troubleshooting.
Electrical System:
Wiring diagrams, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instruments, and battery maintenance.
Suspension:
Front fork disassembly, seal replacement, oil levels, rear shock absorber service, and spring preload adjustment.
Brakes:
Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, brake fluid bleeding, and disc inspection.
Cooling System:
N/A (Air-cooled engine)
Exhaust System:
Exhaust pipe and muffler inspection and replacement.
Frame And Bodywork:
Chassis inspection, fairing removal and installation, seat, tank, and mudguard service.
Wheels And Tires:
Wheel bearing service, tire inspection and replacement, and spoke tension adjustment (if applicable).
Maintenance:
Regular servicing, oil changes, filter replacements, spark plug checks, chain adjustment, and lubrication schedules.
Troubleshooting:
Diagnostic procedures for common starting, running, electrical, and performance issues.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation.
Rebuilds:
Engine and gearbox rebuild procedures with detailed torque specifications and clearances.
Adjustments:
Carburetor synchronization, valve clearance adjustment, suspension setup, and chain tension adjustment.
Depth:
Comprehensive: Covers everything from basic owner maintenance to full engine and transmission rebuilds, including electrical diagnostics and troubleshooting.
Engine Type:
599cc, 4-stroke, air-cooled, DOHC, inline-four
Bore X Stroke:
62.0 mm x 49.8 mm
Valve Clearance Intake:
0.06 - 0.11 mm (cold)
Valve Clearance Exhaust:
0.07 - 0.12 mm (cold)
Ignition System Type:
Transistorized ignition (TCI)
Spark Plug Type:
NGK CR9E or Denso U27FER9
Horsepower:
Approx. 60-62 hp @ 9000 rpm
Torque:
Approx. 50 Nm (37 lb-ft) @ 7500 rpm
Carburetor Type:
Four Mikuni CV (Constant Velocity) carburetors
Fuel Tank Capacity:
18 Liters (4.75 US gal)
Recommended Fuel:
Unleaded gasoline, 91 octane or higher
Length:
Approx. 2135 mm (84.1 in) for Diversion model
Width:
Approx. 745 mm (29.3 in) for Diversion model
Height:
Approx. 1210 mm (47.6 in) for Diversion model
Wheelbase:
Approx. 1445 mm (56.9 in)
Dry Weight:
Approx. 188 kg (414.5 lbs)
Wet Weight:
Approx. 207 kg (456.4 lbs) (fully fueled)
Load Capacity:
Refer to manual for specific rider and cargo weight limits.
Crash Safety Ratings:
N/A (Motorcycle safety ratings vary by testing authority and region, not typically standardized like cars).
Braking:
Dual front disc brakes with 2-piston calipers, single rear disc brake with 1-piston caliper.
Lighting:
Halogen headlight, taillight, and turn signals.
Frame Design:
Steel diamond frame contributes to stability.
Instrumentation:
Speedometer, tachometer, fuel gauge, and indicator lights.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months.
Oil Filter Replacement:
At every oil change.
Air Filter Cleaning:
Every 6,000 km (3,700 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or as needed.
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Chain Lubrication:
Every 1,000 km (600 miles) or after riding in rain.
Chain Adjustment:
As needed, typically checked every 6,000 km (3,700 miles).
Engine Oil Type:
Yamalube 4 (or SAE 10W-40 API SG or higher)
Engine Oil Capacity:
3.2 Liters (3.38 US qt) with filter change
Brake Fluid Type:
DOT 3 or DOT 4
Fork Oil Type:
Yamaha Suspension Fluid (or equivalent SAE 10W fork oil)
Fork Oil Capacity:
552 ml (18.6 US fl oz) per fork leg
Common Problems:
Carburetor synchronization drift, potential for clutch slip on high-mileage units, charging system issues (regulator/rectifier), and occasional electrical connector corrosion.
Preventative Maintenance:
Regular cleaning of carburetors, checking electrical connections, and proper chain maintenance can prevent most common issues.
Heritage Summary:
Yamaha Motor Company, a Japanese multinational corporation, has a rich history in motorcycle manufacturing, known for innovation, performance, and reliability since its inception in 1955.
Predecessor:
The XJ600 series evolved from earlier Yamaha middleweights, offering a more modern interpretation of the inline-four engine.
Generation Details:
The 4BR generation (1992-1999) was characterized by the introduction of the faired 'Diversion' model, enhancing its touring capabilities. The naked 'N' variant continued to offer a more minimalist approach.
Production Period:
1991-2003 (global production for the XJ600 line, with the 4BR specific to 1992-1999).
Manufacturing Location:
Japan
