Yamaha XJ600S Repair Manual 1992-1997

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🏷️ Basic Information Identification Make: Yamaha Model: XJ600S Diversion Production Years Covered: 1992-1997 Codes Chassis Codes: 4BR, 4LX Engine Codes: 4BR 👋 Introduction Market Position Target Audience: Yamaha XJ600S owners,...

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Type: Motorcycle

Vendor:

Sku: 293813

Tags: 1992 1993 1994 1995 1996 1997 Motorcycle Motorcycles Triumph TRW XJ600S Yamaha

Product variants

Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XJ600S Diversion

Production Years Covered:

1992-1997

Codes

Chassis Codes:

4BR, 4LX

Engine Codes:

👋 Introduction

Market Position

Target Audience:

Yamaha XJ600S owners, DIY mechanics, independent repair shops

Value Proposition:

Authoritative guide for maintaining, troubleshooting, and repairing the XJ600S Diversion, saving on dealership costs.

Competitive Analysis

Differentiation:

Offers comprehensive coverage, clear diagrams, and step-by-step instructions, superior to generic online guides.

Key Features

Feature 1:

Detailed electrical diagrams for accurate fault finding.

Feature 2:

Step-by-step procedures with accompanying illustrations.

Feature 3:

Torque specifications for critical fasteners.

Feature 4:

Troubleshooting guides for common issues.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Repair and Service

Secondary Coverage:

Maintenance, Troubleshooting, Reassembly, Wiring Diagrams

Page Count

Estimated Pages:

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, tuning, carburetor service, cooling system, lubrication system

Transmission:

Clutch, gearbox inspection and repair, shift mechanism

Chassis:

Frame, suspension (front forks, rear shock absorber), steering system, wheels, brakes (front and rear)

Electrical:

Ignition system, starting system, charging system, lighting, instruments, wiring diagrams

Fuel System:

Fuel tank, fuel lines, fuel pump, carburetors (VM26SS twin)

Procedures Included

Maintenance:

Oil changes, filter replacement, spark plug service, chain adjustment, lubrication points

Troubleshooting:

Diagnostic flowcharts, common problems and solutions

Repair:

Engine rebuild, carburetor synchronization, brake caliper overhaul, fork seal replacement

Installation:

Component replacement and reassembly procedures

Technical Depth

Depth:

Comprehensive (from basic servicing to complete engine rebuilds and electrical diagnostics)

📊 Manual Specifications

File Format

Compatibility:

Viewable on all devices with PDF reader

Searchability:

Searchable text for quick information retrieval

Print Quality

Resolution:

High-resolution scans for clear diagrams and text

Usability:

Printable pages for workshop use

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, 4-stroke, DOHC

Displacement:

598 cc (36.5 cubic inches)

Bore X Stroke:

62.0 mm x 49.6 mm

Compression Ratio:

10.0:1

Cooling System:

Air-cooled

Performance

Horsepower Est:

57 HP @ 8,500 RPM

Torque Est:

50 Nm @ 7,500 RPM

Fuel System

Carburetor Type:

4 x Mikuni VM26SS constant velocity carburetors

Fuel Capacity:

18 Liters (4.75 US gal)

Ignition

Ignition System:

Digital TCI (Transistor Controlled Ignition)

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 6-speed

Clutch Type:

Wet, multiple disc

Final Drive:

Chain

Features

Gear Ratios:

Detailed in manual (typically 6 ratios including overdrive)

Transmission Fluid Spec:

Yamalube (or equivalent motorcycle-specific 4-stroke engine oil)

📐 Dimensions

Exterior

Overall Length:

2,135 mm (84.1 in)

Overall Width:

755 mm (29.7 in)

Overall Height:

1,160 mm (45.7 in)

Wheelbase:

1,440 mm (56.7 in)

Weights

Dry Weight Est:

187 kg (412 lbs)

Wet Weight Est:

206 kg (454 lbs)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle; subject to manufacturer safety engineering)

Active Features

Braking System:

Front: Dual Disc, Rear: Single Disc

Suspension Front:

Telescopic forks, adjustable preload (on some models)

Suspension Rear:

Monoshock, adjustable preload and rebound damping

Passive Features

Lighting:

Halogen headlamp, LED tail light

Instrumentation:

Tachometer, Speedometer, Fuel Gauge, Warning Lights

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation)

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months

Oil Filter Change Interval:

Every 6,000 km (3,700 miles) or with every oil change

Air Filter Cleaning:

Every 6,000 km (3,700 miles)

Spark Plug Replacement:

Every 12,000 km (7,500 miles)

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or SAE 10W-40 API SG or higher)

Engine Oil Capacity:

3.2 L (3.4 US qt) with filter change

Brake Fluid Type:

DOT 4

Coolant Type:

50% ethylene glycol and water mixture (Yamaha Genuine Coolant recommended)

Known Issues

Issue 1:

Carburetor jet clogging due to fuel degradation over time.

Issue 2:

Potential for fork seal leaks on older models.

Issue 3:

Cam chain tensioner can become noisy; regular inspection recommended.

Issue 4:

Electrical connectors can corrode if not protected from moisture.

📚 Vehicle History

Brand Heritage

Brand Origin:

Yamaha Motor Company, founded in 1955, is a Japanese manufacturer renowned for motorcycles, musical instruments, and marine products.

Model Evolution

Predecessor:

Followed the XJ600 series, offering a more faired and touring-oriented variant.

Features Of Diversion:

Introduced a full fairing for improved aerodynamics and rider comfort, distinguishing it from the naked XJ600.

Production

Manufacturing Location:

Japan

Market Segment:

Sport-Touring / Middleweight Naked

🏆 Awards & Recognition

Recognitions

Historical Reception:

The XJ600S Diversion was generally well-regarded for its reliability, comfortable riding position, and versatile performance for its class and era.

Ratings

Performance Rating:

Good balance of power and handling for commuting and touring.

Certifications

Manufacturing Standards:

Manufactured to Yamaha's high-quality standards for motorcycle production.