Yamaha XJ600 XJ600S 1992-1999 Service Repair Workshop Manual
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This manual covers the XJ600 and XJ600S Diversion models, produced from 1992 through 1999. These motorcycles are known for their inline 4-cylinder, liquid-cooled engines, offering a blend of performance and reliability suitable for commuting and touring. The XJ600S Diversion variant features a full fairing, enhancing rider comfort and aerodynamic efficiency. Built with renowned engineering quality, these models have earned a reputation for being dependable and cost-effective, making them a popular choice for riders seeking a capable all-rounder. This comprehensive Service Repair Workshop Manual provides detailed information for the maintenance and repair of your XJ600 / XJ600S. It includes step-by-step instructions, diagnostic procedures, and technical specifications covering all major systems, including the engine, transmission, drivetrain, chassis, suspension, and electrical systems. With clear diagrams, illustrations, and wiring schematics, this manual empowers owners and technicians to perform routine maintenance, complex repairs, and troubleshooting, ensuring the continued optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: Yamaha Model: XJ600 / XJ600S Model Variant: Diversion (XJ600S) Generation Generation Code: 4BR (common for this period) Codes Chassis Code: XJ600S Engine Code: 4BR (typically) 👋 Introduction Market Position Target Audience: Owners with basic mechanical skills, independent service professionals, owners wanting to understand repairs better. Competitive Analysis Value Proposition: Provides dealership-level repair and maintenance information, enabling significant cost savings on services. Key Features Accuracy: Vehicle-specific, exact same information used by authorized dealers. Completeness: Complete and intact, no missing or corrupt parts/pages. Usability: Easy-to-follow, step-by-step instructions with diagrams and illustrations. 📋 Manual Details Coverage Areas Years Covered: 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Page Count Estimated Pages: Extensive (typical workshop manuals of this era range from 300-600+ pages, not specified in product info) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Yes (including engine specifications, removal, installation, fuel system, intake, exhaust) Transmission: Yes (including transmission overhaul, gears, clutch operation) Drivetrain: Yes (drive chain, sprockets) Chassis Suspension: Yes (steering system, shocks/suspension components) Electrical System: Yes (including wiring diagrams, ignition, charging system, lighting) Bodywork Cosmetics: Yes (body work, fairings, general assembly) Cooling System: Yes Procedures Included Maintenance: Yes (routine maintenance, periodic checks, adjustments) Troubleshooting: Yes (advanced troubleshooting sections included) Repair: Yes (step-by-step repair instructions) Diagnostics: Yes (implied by troubleshooting and technical depth) Technical Depth Depth: Comprehensive (covers all major topics, equivalent to dealership service) Diagrams Illustrations: Yes (diagrams, illustrations, wiring schematics) 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Yes (all pages printable) Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Compatibility Operating Systems: All versions of Windows and Mac Requirements Software: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, 4-stroke Displacement: 598cc (600cc class) Bore X Stroke: 62.0 mm x 49.6 mm (typical for this engine) Cooling System: Liquid-cooled Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: Approx. 60-62 HP at 9,000 RPM (depending on market and tune) Torque: Approx. 50-52 Nm (37-38 lb-ft) at 7,000 RPM (depending on market and tune) Fuel System Fuel Delivery: Carburetor (likely Mikuni BDST series, 4x34mm) Fuel Type: Unleaded gasoline Fuel Tank Capacity: 17 Liters (approx. 4.5 US gallons) 🔧 Transmission Standard Type: 6-speed, constant mesh Optional Type: N/A Features Clutch: Wet, multi-plate Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 2130 mm (83.9 in) (XJ600S Diversion) Width: Approx. 750 mm (29.5 in) (XJ600S Diversion) Height: Approx. 1160 mm (45.7 in) (XJ600S Diversion) Wheelbase: Approx. 1440 mm (56.7 in) Weights Dry Weight: Approx. 193 kg (425 lbs) Wet Weight: Approx. 214 kg (472 lbs) (fully fueled) 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycle safety ratings are typically not standardized in the same way as cars) Active Features Braking Front: Dual Disc Brakes (typically 298mm discs with 2-piston calipers) Braking Rear: Single Disc Brake (typically 245mm disc with 1-piston caliper) Passive Features Lighting: Halogen headlight, LED taillight (standard for the era) 💡 Technology Features Infotainment Features: N/A (Basic motorcycle instrumentation typical for the era: speedometer, tachometer, odometer, trip meter, warning lights) Driver Assistance Features: N/A Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change: Every 6,000 km (approx. 3,700 miles) or annually Air Filter Cleaning: Every 6,000 km (approx. 3,700 miles) Spark Plug Replacement: Every 12,000 km (approx. 7,500 miles) Valve Clearance Check: Every 12,000 km (approx. 7,500 miles) Fluid Specifications Engine Oil Type: Yamalube 4 (or equivalent SAE 10W-40, API SE, SF, SG, SH, SJ) Engine Oil Capacity: 3.2 Liters (3.4 US qt) with filter change; 2.9 Liters (3.1 US qt) without filter change Coolant Type: Ethylene glycol based coolant (50% mixture with distilled water) Brake Fluid Type: DOT 3 or DOT 4 Known Issues Common Wear Items: Regulator/rectifier failure, cam chain wear, carburetor synchronization issues, fork seal leaks. Maintenance Importance: Regular maintenance is crucial for the longevity and reliability of...
This manual covers the XJ600 and XJ600S Diversion models, produced from 1992 through 1999. These motorcycles are known for their inline 4-cylinder, liquid-cooled engines, offering a blend of performance and reliability suitable for commuting and touring. The XJ600S Diversion variant features a full fairing, enhancing rider comfort and aerodynamic efficiency. Built with renowned engineering quality, these models have earned a reputation for being dependable and cost-effective, making them a popular choice for riders seeking a capable all-rounder.
This comprehensive Service Repair Workshop Manual provides detailed information for the maintenance and repair of your XJ600 / XJ600S. It includes step-by-step instructions, diagnostic procedures, and technical specifications covering all major systems, including the engine, transmission, drivetrain, chassis, suspension, and electrical systems. With clear diagrams, illustrations, and wiring schematics, this manual empowers owners and technicians to perform routine maintenance, complex repairs, and troubleshooting, ensuring the continued optimal performance and longevity of the vehicle.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XJ600 / XJ600S
Model Variant:
Diversion (XJ600S)
Generation
Generation Code:
4BR (common for this period)
Codes
Chassis Code:
XJ600S
Engine Code:
4BR (typically)
👋 Introduction
Market Position
Target Audience:
Owners with basic mechanical skills, independent service professionals, owners wanting to understand repairs better.
Competitive Analysis
Value Proposition:
Provides dealership-level repair and maintenance information, enabling significant cost savings on services.
Key Features
Accuracy:
Vehicle-specific, exact same information used by authorized dealers.
Completeness:
Complete and intact, no missing or corrupt parts/pages.
Usability:
Easy-to-follow, step-by-step instructions with diagrams and illustrations.
📋 Manual Details
Coverage Areas
Years Covered:
1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Page Count
Estimated Pages:
Extensive (typical workshop manuals of this era range from 300-600+ pages, not specified in product info)