This manual covers the XJ600 and XJ600S models produced between 1992 and 1999. These motorcycles are powered by a 4-cylinder, 4-stroke, DOHC, air-cooled engine and are recognized as reliable and user-friendly mid-size sport touring motorcycles. The XJ600 series, including the faired 'S' Diversion variant, was engineered for versatility and economy, making it a popular choice for both commuting and touring. Their robust design and straightforward mechanics contribute to their enduring reputation. This comprehensive service repair manual provides detailed information for the maintenance and repair of your XJ600 / XJ600S. It encompasses all major systems, including the engine, fuel system, clutch, transmission, brakes, suspension, steering, and electrical systems. With step-by-step procedures, diagnostic guides, and troubleshooting tips, this manual is an essential resource for owners and technicians alike, empowering them to maintain, repair, and understand the intricacies of these motorcycles. 🏷️ Basic Information Identification Make: Yamaha Model: XJ600 / XJ600S Year: 1992-1999 Engine: 4-cylinder, 4-stroke, DOHC, air-cooled Codes Chassis Code: XJ600 (diversion and naked variants) 👋 Introduction Market Position Market Segment: Mid-size sport touring motorcycle Key Features Manual Value Proposition: Empowers owners to perform maintenance and repairs, saving time and money, provides professional-level knowledge. Manual Usability: Easy to use, no computer skills required beyond basic navigation and printing, clear instructions and diagrams. Manual Benefits: Enhances understanding of vehicle systems, facilitates informed decisions with mechanics, helps identify and resolve issues efficiently. 📋 Manual Details Coverage Areas Coverage Years: 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Models Covered: XJ600, XJ600S (all styles) Page Count Page Count Estimate: Hundreds of pages Manual Type Manual Type: Complete Service Repair Manual Language Language: English Format File Format: PDF Delivery Method: Download 📖 Manual Coverage Systems Covered Engine Systems: Fuel system, Cooling system, Engine top end, Clutch, Engine lubrication system, Crankshaft/Transmission, Engine Removal/Installation Chassis Systems: Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame Electrical Systems: Electrical System, Wiring Diagrams, Engine Management Systems General: General Information, Appendix Procedures Included Repair Procedures: Step-by-step repair procedures for all covered systems, Complete rebuild procedures, Diagnostic and repair procedures Maintenance: Fundamentals of maintaining and repairing, Common fixes, Preventive maintenance tips Diagnostics Troubleshooting: Diagnose engine fault symptoms, Advanced troubleshooting guide, Trace and verify wiring diagrams, Test suspected parts Technical Depth Technical Depth: Comprehensive, covering everything from basic maintenance to complete rebuilds, Information used by professional technicians 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Printable without restriction, allows printing of entire manual or specific pages Binding Type Binding Type: N/A (Digital Download - Printable) Paper Type Paper Type: N/A (Digital Download - Printable) Software Requirements Software Requirements: Adobe PDF Reader Compatibility Operating Systems: All PC based Windows operating systems, Mac ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, 4-stroke Displacement: 598 cc (598 cm³) Bore X Stroke: 62.0 mm x 49.5 mm (typical) Valve Train: DOHC, 4 valves per cylinder Cooling System: Air-cooled Performance Horsepower: Approx. 60-61 HP (depending on market and specific tuning) Torque: Approx. 50-52 Nm (depending on market and specific tuning) Fuel System Carburetion: Multiple carburetors (e.g., 4 x Mikuni BS29 or similar) Fuel Type: Unleaded gasoline 🔧 Transmission Standard Transmission Type: Constant mesh 6-speed Clutch Type: Wet, multiple-disc Features Gear Ratios: Detailed gear ratios are provided within the manual for diagnostic and repair purposes. 📐 Dimensions Weights Dry Weight: Approx. 180-185 kg (depending on model variant) Wet Weight: Approx. 198-203 kg (depending on model variant and fluid levels) 🛡️ Safety Features Active Features Braking System: Front: Disc brake(s) with twin-piston calipers, Rear: Disc brake with single-piston caliper. Suspension Front: Telescopic fork, typically with adjustable pre-load Suspension Rear: Monoshock (or twin shock on earlier models), with adjustable pre-load and rebound damping. 💡 Technology Features Infotainment Dashboard: Analog speedometer, tachometer, fuel gauge, odometer, trip meter, warning lights. Driver Assistance Engine Management: Basic electronic ignition system, carburetor-based fuel delivery. Connectivity Charging System: Alternator with electronic voltage regulator/rectifier. 🔧 Maintenance Service Intervals Oil Change Interval: Recommended every 4,000 - 6,000 km (or as specified in the manual). Spark Plug Replacement: Recommended every 10,000 - 12,000 km (or as specified in the manual). Valve Clearance Check: Recommended at specific mileage intervals (e.g., 10,000 km, 20,000 km) or if engine performance issues are noted. Fluid Specifications Engine Oil Type: Yamaha recommends SAE 20W-40 or 10W-30 API SG or higher motorcycle-specific oil. Consult manual for exact specification. Engine Oil Capacity: Approximately 2.4 - 2.5 liters (with oil filter change). Brake Fluid Type: DOT 3 or DOT 4 brake fluid. Coolant Type: N/A (Air-cooled engine) Final Drive Oil Type: Hypoid gear oil (SAE 80W-90 API GL-4 or GL-5). Known Issues Common Wear Items: Cam chain tensioner, clutch plates, fork seals, carburetor synchronization, rear shock absorber wear. Electrical Gremlins: Corrosion in connectors, faulty regulator/rectifier are potential issues often detailed in troubleshooting sections. 📚 Vehicle History Brand Heritage Manufacturer: Yamaha Motor Company Model Evolution Development Context:...