🏷️ Basic Information Identification Make: Yamaha Model: XJ600 XJ600S Diversion Year: 1997 Codes Chassis Code: 4BR (Diversion) 👋 Introduction Market Position Target Audience: Professional technicians and experienced DIY mechanics. Key Features Instructional Format: Numbered instructions, bold figure numbers, detailed illustrations, drawings, photos, and enlarged insets. Information Presentation: Notes, cautions, and warnings highlight critical information; detailed sub-steps enhance clarity. Navigation: Numbered table of contents for fast information retrieval. 📋 Manual Details Coverage Areas General Coverage: Full Service Repair Page Count Estimated Page Count: Refer to specific manual for exact count; typically 300-600 pages for a comprehensive service manual. Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, lubrication, cooling, fuel delivery, ignition, exhaust, engine management, tuning. Transmission Systems: Clutch operation, gearbox internal inspection and repair, shift mechanism. Chassis Systems: Frame inspection, suspension (front forks and rear shock absorber), steering, wheels, brakes (front and rear), final drive. Electrical Systems: Wiring diagrams, lighting, instrumentation, starting system, charging system, ignition system, diagnostic codes. Fuel System Details: Detailed carburetor service, including disassembly, cleaning, reassembly, jetting information, and synchronization procedures. Brake System Details: Inspection, replacement of pads and discs, caliper overhaul, master cylinder service, bleeding procedures. Procedures Included Maintenance Procedures: Routine servicing, oil changes, filter replacements, chain adjustment, brake fluid flush, coolant replacement, spark plug replacement. Repair Procedures: Component-level diagnostics and repair, engine rebuilds, carburetor tuning and rebuild, suspension component replacement, electrical fault finding. Troubleshooting: Systematic diagnosis of common and uncommon issues, fault code interpretation, diagnostic flowcharts. Engine Tuning: Carburetor tuning, ignition timing checks (though CDI is typically fixed timing, verification of system operation). Technical Depth Depth Of Coverage: Comprehensive, from basic maintenance to complete engine and chassis rebuilds, including detailed diagnostic procedures and wiring diagrams. Engine Rebuild Level: Covers full engine teardown, component measurement, piston/ring replacement, valve service, crankshaft and connecting rod inspection. 📊 Manual Specifications File Format Printability: Full Printable Searchability: Likely searchable text within the PDF, allowing for quick information retrieval. Binding Type Binding Type: Digital (PDF download) Paper Type Paper Type: N/A (Digital) Requirements Software Requirements: Adobe PDF Reader, WinRAR Operating System Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Inline Four-Cylinder, DOHC, 4-stroke Displacement: 599cc (598cc actual) Bore X Stroke: 62.0 mm x 49.6 mm Performance Horsepower: Approx. 59-61 PS (44-45 kW) @ 9,000 rpm (dependent on market and tuning) Torque: Approx. 52 Nm (38.4 lb-ft) @ 7,500 rpm Fuel System Fuel Delivery: Four Mikuni CV (Constant Velocity) Carburetors, likely 34mm (e.g., Mikuni BST34) Fuel Type: Unleaded Gasoline (91+ octane recommended) Ignition Ignition System: Digital CDI (Capacitor Discharge Ignition) Lubrication Oil Type: Yamaha recommends 10W-40 API SE, SF or SG classification motorcycle oil. Refer to manual for precise specification. Oil Capacity: Approx. 3.1 liters (3.3 US qt) with filter change. Refer to manual for precise capacity. Cooling Cooling System: Liquid Cooled Coolant Type: Ethylene glycol-based antifreeze (50/50 mix with distilled water). Refer to manual for specific YAMALUBE coolant recommendation. 🔧 Transmission Standard Transmission Type: 6-Speed, Constant Mesh Clutch Type: Wet, Multi-disc Features Gear Ratios: Specific gear ratios will be detailed in the manual, crucial for understanding performance characteristics. Final Drive: O-ring sealed chain drive 📐 Dimensions Exterior Length: Approx. 2,155 mm (84.8 in) for XJ600S Diversion Width: Approx. 750 mm (29.5 in) for XJ600S Diversion Height: Approx. 1,230 mm (48.4 in) for XJ600S Diversion Weights Dry Weight: Approx. 196 kg (432 lbs) Wet Weight: Approx. 217 kg (478 lbs) 🛡️ Safety Features Active Features Brakes Front: Dual Hydraulic Disc, likely 298mm diameter, twin-piston calipers Brakes Rear: Hydraulic Disc, likely 245mm diameter, single-piston caliper Suspension Front: Telescopic forks, non-adjustable or preload adjustable. Likely 41mm stanchion diameter. Suspension Rear: Monoshock, adjustable preload. Swingarm with linkage system. Passive Features Lighting: Halogen Headlight, LED or incandescent taillight and turn signals. Manual will detail bulb types and wattages. 💡 Technology Features Infotainment Infotainment System: N/A - Motorcycle of this era typically lacks advanced infotainment systems. Features include analog instrumentation. Driver Assistance Rider Aids: N/A - No electronic rider aids such as ABS or traction control were standard on this model. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-6,000 km (2,000-4,000 miles) or 6 months. Refer to manual for specific mileage/time interval and oil quality requirements. Spark Plug Replacement: Recommended every 10,000-15,000 km (6,000-9,000 miles). Manual will specify exact plug type and gap. Air Filter Cleaning Replacement: Inspect every 5,000-10,000 km (3,000-6,000 miles), clean or replace as needed. More frequent cleaning may be required in dusty conditions. Chain Lubrication Adjustment: Lubricate every 500-1,000 km (300-600 miles) and adjust slack as needed. Manual will specify correct chain slack. Fluid Specifications Brake Fluid Type: DOT 4 recommended. Refer to manual for exact specification. Coolant Type: 50/50 mix of ethylene glycol...