Segment:
Mid-size naked and faired sport-touring motorcycle.
Competitors:
Honda CB500, Kawasaki ER-5, Suzuki GS500, Triumph Bonneville (earlier models)
Features:
Reliable inline-four engine, comfortable riding position (especially the naked 'N' version), good balance of performance and economy, practical for daily commuting and light touring.
Audience:
Owners looking for comprehensive DIY maintenance and repair guidance, mechanics working on the XJ600 series.
Primary Coverage:
Full Service, Repair, Maintenance, Troubleshooting, Rebuild, Restoration
Estimated Page Count:
300+
Type:
Full Service & Repair Manual
Format:
Digital (likely PDF)
Engine Systems:
Top-end, bottom-end, lubrication, cooling, ignition, fuel delivery, emissions control
Drivetrain:
Clutch, gearbox, final drive (chain and sprockets)
Suspension:
Front forks (including oil change and seal replacement), rear shock absorber, swingarm, linkages
Brakes:
Front and rear hydraulic brake systems, master cylinders, calipers, brake lines, fluid replacement
Electrical System:
Wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), ignition system, lighting, instrumentation, fuses, relays
Chassis And Bodywork:
Frame inspection, body panels, seat, fuel tank, handlebars, levers, footpegs, exhaust system
Maintenance Procedures:
Oil changes, filter replacement, spark plug replacement, air filter cleaning/replacement, chain adjustment and lubrication, brake bleeding, coolant flush, tire pressure checks
Repair Procedures:
Engine disassembly and reassembly, carburetor synchronization and overhaul, fork seal replacement, wheel bearing replacement, clutch assembly repair, transmission gear replacement
Troubleshooting:
Diagnostic flowcharts for common issues, fault finding for starting, running, and electrical problems
Depth:
Comprehensive: Covers everything from routine maintenance to complete engine rebuilds and electrical system diagnostics.
File Type:
PDF (typically, for digital manuals)
Quality:
High-resolution scans of original factory manuals, ensuring clear diagrams and text.
Binding:
N/A (for digital format). If printed, likely spiral-bound or perfect-bound for ease of use.
Paper:
N/A (for digital format). Original manuals often printed on durable, glossy paper.
Engine Type:
Inline Four-cylinder, 4-stroke, DOHC, 2 valves per cylinder
Displacement:
599 cc (599cm³)
Bore X Stroke:
62.0 mm x 49.6 mm
Compression Ratio:
10.0:1
Horsepower:
Approx. 60-62 HP (44-46 kW) @ 9000 RPM (depending on market and specific tune)
Torque:
Approx. 52 Nm (38 lb-ft) @ 7500 RPM
Carburetor Type:
Four constant velocity (CV) carburetors, Mikuni BDS32 or similar
Fuel Capacity:
17 Liters (4.5 US gal)
Oil Capacity With Filter Change:
Approx. 2.4 Liters
Cooling System:
Air-cooled
Length:
Approx. 2140 mm (Diversion), 2060 mm (Naked)
Width:
Approx. 750 mm (Diversion), 750 mm (Naked)
Height:
Approx. 1220 mm (Diversion), 1060 mm (Naked)
Wheelbase:
Approx. 1445 mm
Dry Weight:
Approx. 186 kg (Diversion), 171 kg (Naked)
Wet Weight:
Approx. 205 kg (Diversion), 190 kg (Naked)
Max Load:
Approx. 190 kg (rider + passenger + luggage)
Safety Features:
Dual front disc brakes, single rear disc brake, robust frame construction.
Braking System:
Front: Dual 298mm discs with 2-piston calipers. Rear: Single 245mm disc with 2-piston caliper.
Lighting:
Halogen headlight, LED taillight (typical).
Oil Change Interval:
Every 5,000-6,000 km or annually.
Air Filter Cleaning:
Every 6,000 km.
Spark Plug Replacement:
Every 10,000-12,000 km.
Valve Clearance Check:
Every 12,000-15,000 km.
Engine Oil Type:
Yamaha recommends Yamalube 4 (10W-40) or equivalent API SG or higher, JASO MA certified.
Coolant Type:
Yamaha All Weather Coolant or equivalent ethylene glycol-based antifreeze, 50% mixture with distilled water.
Common Problems:
Carburetor synchronization drift, starter clutch wear (less common), potential fork seal leaks, exhaust header pipe corrosion.
Maintenance Tips:
Regular carb cleaning and synchronization is key for smooth running. Check chain tension and lubrication frequently. Inspect exhaust headers for rust and consider a ceramic coating for longevity.
Heritage:
Yamaha's long-standing reputation for reliable, well-engineered motorcycles.
Predecessor:
XJ600 Seca II (4LX chassis) - featured a 4-valve head and different styling.
Successor:
FZ6 Fazer/FZ6 S2 (98 HP variant) - introduced a liquid-cooled engine based on the YZF-R6.
Production Years:
1991-2003 (XJ600 Diversion/Naked series)
Manufacturing Location:
Japan
