Target Audience:
Yamaha XJ600S Diversion owners, independent motorcycle mechanics, and DIY enthusiasts.
Value Proposition:
Provides in-depth technical knowledge essential for maintaining and repairing the 1992 Yamaha XJ600S, saving on dealership service costs.
Comprehensiveness:
Extensive coverage across all major mechanical and electrical systems.
Diagrams And Illustrations:
Includes detailed exploded views, wiring schematics, and service illustrations.
Primary Coverage:
Service and Repair
Type:
Factory Service Manual
Print Quality:
High-quality, durable paper with clear diagrams and text.
Binding Type:
Stapled or perfect bound for durability in a workshop environment.
Illustrations:
Contains numerous detailed line drawings, diagrams, and charts.
Engine Overhaul:
Complete disassembly, inspection, reassembly, and tuning of the 598cc engine.
Fuel System:
Carburetor adjustment, cleaning, rebuilding, and fuel pump service.
Ignition System:
Ignition timing, spark plug specifications, coil testing, and CDI unit diagnostics.
Transmission And Drivetrain:
Clutch operation, gearbox inspection, gear ratio details, and final drive maintenance.
Suspension System:
Front fork overhaul, rear shock absorber inspection and replacement, and suspension linkage lubrication.
Braking System:
Brake pad replacement, caliper servicing, hydraulic system bleeding, and master cylinder inspection.
Electrical System:
Wiring diagrams, component testing, battery maintenance, lighting system troubleshooting, and starter motor service.
Cooling System:
Radiator, fan, and thermostat inspection and replacement; coolant specifications.
Exhaust System:
Exhaust pipe and muffler inspection and replacement.
Frame And Bodywork:
Chassis inspection, fairing removal and installation, and seat servicing.
Regular Maintenance:
Oil changes, filter replacements, chain adjustment, tire pressure checks, and general lubrication.
Troubleshooting Guides:
Diagnostic flowcharts for common starting, running, and electrical issues.
Rebuild Procedures:
Detailed step-by-step instructions for major component rebuilds (e.g., engine, carburetors).
Special Tool Requirements:
Identification and use of specific tools required for certain repairs.
Diagnostic Capabilities:
Comprehensive diagnostic procedures for identifying the root cause of problems.
Repair Complexity:
Covers from basic rider maintenance to full engine and transmission rebuilds.
Coverage Scope:
Comprehensive workshop manual designed for technicians and advanced enthusiasts.
Engine Type:
Inline-four cylinder, four-stroke
Displacement:
598 cc (36.5 cubic inches)
Bore X Stroke:
62.0 mm x 49.6 mm
Compression Ratio:
10.0:1
Horsepower:
Approximately 60-65 hp @ 8000 rpm (claimed)
Torque:
Approximately 54 Nm @ 7500 rpm (claimed)
Top Speed:
Approximately 190 km/h (118 mph), depending on conditions and rider.
Carburetion:
Four Mikuni constant velocity carburetors (e.g., Mikuni BDSR32)
Fuel Tank Capacity:
18 Liters (4.8 US gal)
Valve Train:
DOHC, 4 valves per cylinder
Valve Actuation:
Mechanical tappets (requiring shims for adjustment).
Cooling Method:
Liquid-cooled
Oil Change Interval:
Every 4,000 km (2,500 miles) or 6 months.
Air Filter Cleaning:
Every 8,000 km (5,000 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Valve Clearance Check:
Every 16,000 km (10,000 miles).
Engine Oil Type:
Yamalube 4 (or equivalent) API SE, SF, SG or higher, SAE 10W-40 or 20W-40.
Engine Oil Capacity:
3.4 Liters (3.6 US qt) without filter change; 3.7 Liters (3.9 US qt) with filter change.
Brake Fluid:
DOT 3 or DOT 4.
Coolant:
Ethylene glycol-based anti-freeze and coolant, mixed 50/50 with distilled water.
Gearbox Oil:
Yamalube Gear Oil (or equivalent) SAE 80W API GL-4.
Gearbox Oil Capacity:
1.7 Liters (1.8 US qt)
Carburetor Synchronization:
Can become out of sync, leading to rough idling or poor throttle response. Manual provides detailed synchronization procedures.
Cam Chain Tensioner:
Some models may experience wear or failure of the automatic cam chain tensioner, resulting in rattling noise. Manual covers inspection and replacement.
Stator Output:
Potential for stator output degradation affecting charging system. Manual details testing procedures.
Yamaha Motorcycles:
Yamaha Motor Company, Ltd., is a Japanese manufacturer of motorcycles, marine products, and other motorized products. Founded in 1955, Yamaha has a long history of innovation and performance in the powersports industry.
Xj Series:
The XJ600S Diversion was part of Yamaha's XJ line, known for its reliable inline-four engines and versatile sporty-touring capabilities.
Production Period:
The XJ600S Diversion was produced from the early 1990s into the early 2000s, with various updates.
