Yamaha XJ600 XJ600S 1992-1999 Service Repair Workshop Manual

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Type: Motorcycle

Vendor:

Sku: 57984

Tags: 1992 1993 1994 1995 1996 1997 1998 1999 Marine Motorcycle Sterndrive XJ600 XJ600S Yamaha

Product variants

Description

This manual covers the XJ600 and XJ600S Diversion models, produced from 1992 through 1999. These motorcycles are known for their inline 4-cylinder, liquid-cooled engines, offering a blend of performance and reliability suitable for commuting and touring. The XJ600S Diversion variant features a full fairing, enhancing rider comfort and aerodynamic efficiency. Built with renowned engineering quality, these models have earned a reputation for being dependable and cost-effective, making them a popular choice for riders seeking a capable all-rounder. This comprehensive Service Repair Workshop Manual provides detailed information for the maintenance and repair of your XJ600 / XJ600S. It includes step-by-step instructions, diagnostic procedures, and technical specifications covering all major systems, including the engine, transmission, drivetrain, chassis, suspension, and electrical systems. With clear diagrams, illustrations, and wiring schematics, this manual empowers owners and technicians to perform routine maintenance, complex repairs, and troubleshooting, ensuring the continued optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XJ600 / XJ600S

Model Variant:

Diversion (XJ600S)

Generation

Generation Code:

4BR (common for this period)

Codes

Chassis Code:

XJ600S

Engine Code:

4BR (typically)

👋 Introduction

Market Position

Target Audience:

Owners with basic mechanical skills, independent service professionals, owners wanting to understand repairs better.

Competitive Analysis

Value Proposition:

Provides dealership-level repair and maintenance information, enabling significant cost savings on services.

Key Features

Accuracy:

Vehicle-specific, exact same information used by authorized dealers.

Completeness:

Complete and intact, no missing or corrupt parts/pages.

Usability:

Easy-to-follow, step-by-step instructions with diagrams and illustrations.

📋 Manual Details

Coverage Areas

Years Covered:

1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999

Page Count

Estimated Pages:

Extensive (typical workshop manuals of this era range from 300-600+ pages, not specified in product info)

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Yes (including engine specifications, removal, installation, fuel system, intake, exhaust)

Transmission:

Yes (including transmission overhaul, gears, clutch operation)

Drivetrain:

Yes (drive chain, sprockets)

Chassis Suspension:

Yes (steering system, shocks/suspension components)

Electrical System:

Yes (including wiring diagrams, ignition, charging system, lighting)

Bodywork Cosmetics:

Yes (body work, fairings, general assembly)

Cooling System:

Procedures Included

Maintenance:

Yes (routine maintenance, periodic checks, adjustments)

Troubleshooting:

Yes (advanced troubleshooting sections included)

Repair:

Yes (step-by-step repair instructions)

Diagnostics:

Yes (implied by troubleshooting and technical depth)

Technical Depth

Depth:

Comprehensive (covers all major topics, equivalent to dealership service)

Diagrams Illustrations:

Yes (diagrams, illustrations, wiring schematics)

📊 Manual Specifications

File Format

File Type:

Print Quality

Printability:

Yes (all pages printable)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Compatibility

Operating Systems:

All versions of Windows and Mac

Requirements

Software:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, 4-stroke

Displacement:

598cc (600cc class)

Bore X Stroke:

62.0 mm x 49.6 mm (typical for this engine)

Cooling System:

Liquid-cooled

Valve Train:

DOHC, 4 valves per cylinder

Performance

Horsepower:

Approx. 60-62 HP at 9,000 RPM (depending on market and tune)

Torque:

Approx. 50-52 Nm (37-38 lb-ft) at 7,000 RPM (depending on market and tune)

Fuel System

Fuel Delivery:

Carburetor (likely Mikuni BDST series, 4x34mm)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

17 Liters (approx. 4.5 US gallons)

🔧 Transmission

Standard

Type:

6-speed, constant mesh

Optional

Type:

Features

Clutch:

Wet, multi-plate

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 2130 mm (83.9 in) (XJ600S Diversion)

Width:

Approx. 750 mm (29.5 in) (XJ600S Diversion)

Height:

Approx. 1160 mm (45.7 in) (XJ600S Diversion)

Wheelbase:

Approx. 1440 mm (56.7 in)

Weights

Dry Weight:

Approx. 193 kg (425 lbs)

Wet Weight:

Approx. 214 kg (472 lbs) (fully fueled)

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (Motorcycle safety ratings are typically not standardized in the same way as cars)

Active Features

Braking Front:

Dual Disc Brakes (typically 298mm discs with 2-piston calipers)

Braking Rear:

Single Disc Brake (typically 245mm disc with 1-piston caliper)

Passive Features

Lighting:

Halogen headlight, LED taillight (standard for the era)

💡 Technology Features

Infotainment

Features:

N/A (Basic motorcycle instrumentation typical for the era: speedometer, tachometer, odometer, trip meter, warning lights)

Driver Assistance

Features:

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change:

Every 6,000 km (approx. 3,700 miles) or annually

Air Filter Cleaning:

Every 6,000 km (approx. 3,700 miles)

Spark Plug Replacement:

Every 12,000 km (approx. 7,500 miles)

Valve Clearance Check:

Every 12,000 km (approx. 7,500 miles)

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent SAE 10W-40, API SE, SF, SG, SH, SJ)

Engine Oil Capacity:

3.2 Liters (3.4 US qt) with filter change; 2.9 Liters (3.1 US qt) without filter change

Coolant Type:

Ethylene glycol based coolant (50% mixture with distilled water)

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Common Wear Items:

Regulator/rectifier failure, cam chain wear, carburetor synchronization issues, fork seal leaks.

Maintenance Importance:

Regular maintenance is crucial for the longevity and reliability of the engine and drivetrain components.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Company, Japan

Model Evolution

Predecessor:

XJ600 (Seca II/Radical)

Development:

The XJ600S Diversion was an evolution focusing on improved comfort and touring capability with its full fairing, building upon the naked XJ600.

Production

Production Period:

1991-2003 (for the XJ600/S platform)

🏆 Awards & Recognition

Recognitions

Industry Awards:

Not specifically documented for this model, but known for reliability and value in its class.

Ratings

Owner Satisfaction:

Generally positive for its class, often praised for being a solid all-rounder and dependable commuter.

Certifications

Manufacturing Standards:

Compliant with Yamaha's internal quality control and global automotive standards of the period.