Segment:
Middleweight sport touring motorcycle.
Target Audience:
Riders seeking a reliable, comfortable, and versatile motorcycle for commuting, touring, and general sport riding.
Competitors:
Competed against models like the Suzuki GS500E, Honda CB500, and Kawasaki GPZ500S.
Design Philosophy:
Emphasized comfortable ergonomics, smooth power delivery, and practical usability for everyday riding.
Distinctive Features:
The 'S' designation typically indicated the faired version, offering better wind protection compared to the naked XJ 600 N.
Engine:
Detailed coverage of the air-cooled, four-stroke, DOHC, inline-four engine, including disassembly, assembly, inspection, and troubleshooting of all components.
Fuel System:
In-depth information on the carburetor system (likely Mikuni BDST series), including jetting, float adjustments, and diagnostic procedures.
Ignition System:
Coverage of the electronic ignition system, including ignition timing, spark plug specifications, and troubleshooting CDI unit and pickup coil issues.
Transmission And Clutch:
Complete guide to the 6-speed constant mesh gearbox, clutch assembly (wet multi-plate type), and drivetrain maintenance and repair.
Suspension:
Detailed procedures for front telescopic forks (including oil level, viscosity, and fork seal replacement) and rear monoshock suspension system.
Brakes:
Thorough coverage of front and rear braking systems, including hydraulic disc brake components, caliper service, master cylinder overhaul, and brake fluid specifications.
Electrical System:
Comprehensive electrical schematics, wiring diagrams, troubleshooting guides for lighting, starting system, charging system (alternator, regulator/rectifier), and battery maintenance.
Cooling System:
Details on the air-cooling system, oil cooler operation, and related maintenance.
Exhaust System:
Information on exhaust manifold and silencer installation and maintenance.
Frame And Bodywork:
Procedures for frame inspection, fairing removal and installation, seat, and other body component servicing.
Wheels And Tires:
Specifications for wheel bearing maintenance, tire pressures, and wheel removal/installation.
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, chain adjustment, spark plug service, and air filter cleaning/replacement.
Disassembly Reassembly:
Hundreds of photos illustrating complete disassembly and reassembly procedures for major components and systems.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for common issues across all vehicle systems.
Engine Overhaul:
Detailed steps for engine teardown, component inspection (pistons, rings, valves, crankshaft), and reassembly with torque specifications.
Carburetor Tuning:
Guidance on synchronization, idle speed adjustment, and mixture control.
Brake System Service:
Bleeding procedures, pad replacement, caliper and master cylinder servicing.
Electrical Diagnostics:
Wiring diagram interpretation, component testing, and fault finding for electrical systems.
Suspension Rebuild:
Fork oil replacement, seal replacement, and rear shock absorber servicing.
Depth:
Full factory-level repair and maintenance information suitable for professional technicians and advanced DIY enthusiasts.
Engine Type:
Air-cooled, four-stroke, DOHC, inline-four cylinder
Bore X Stroke:
62.0 mm x 49.6 mm
Horsepower Estimate:
Approx. 61 hp @ 8,500 rpm (at crankshaft)
Torque Estimate:
Approx. 52 Nm (38.4 lb-ft) @ 7,000 rpm (at crankshaft)
Carburetor Type:
Four Mikuni BDST36 carburetors
Fuel Tank Capacity:
Approx. 16 liters (4.2 US gallons)
Oil Type:
API SG or higher, SAE 10W-40 recommended (specifics in manual)
Oil Capacity With Filter Change:
Approx. 3.4 liters (specifics in manual)
Oil And Filter Change:
Every 4,000 km or 6 months (refer to manual for specific intervals).
Air Filter Cleaning:
Every 8,000 km (refer to manual for specific intervals).
Spark Plug Replacement:
Every 12,000 km (refer to manual for specific intervals and plug type).
Valve Clearance Check:
Every 16,000 km or 12 months (refer to manual for specific intervals).
Brake Fluid Replacement:
Every 2 years or as needed (refer to manual for specific intervals and fluid type).
Engine Oil:
API SG or higher, SAE 10W-40 recommended.
Brake Fluid:
DOT 4 recommended (refer to manual for exact specification).
Fork Oil:
Yamaha Genuine Fork Oil G-10 or equivalent (refer to manual for viscosity and level).
Potential Issues:
While generally reliable, common older motorcycle issues like carburetor gumming, regulator/rectifier failure, and fork seal leaks can occur. Refer to the manual for diagnosis.
Engine And Chassis:
Detailed torque values for all critical fasteners are provided throughout the manual.
Yamaha Legacy:
Yamaha Motor Company has a rich history in motorcycle manufacturing, known for innovation, performance, and reliability across various genres.
Xj Series:
The XJ series has a long lineage of dependable inline-four motorcycles, often characterized by their smooth power delivery and practicality.
Production Period:
The XJ 600 Diversion was produced from the early 1990s through to the early 2000s, with significant updates during its lifespan.
Manufacturing Location:
Primarily manufactured in Japan.
