Yamaha XJ600 XJ600N 1995-1999 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Yamaha Model: XJ600 / XJ600N Model Variants: XJ600 (S) Diversion, XJ600N (Naked) Generation Generation Designation: Second Generation (4BR/H) Codes Chassis Codes: 4BR (Diversion), 4HK (Naked) 👋 Introduction Market Position Category: Middleweight Sportbike/Standard Motorcycle Target Audience: Riders seeking a reliable, versatile, and performance-oriented motorcycle for commuting, touring, and spirited riding. Competitive Analysis Key Competitors: Honda CB500/CB500S, Suzuki GS500E/GS500F, Kawasaki GPZ500S/ER-5 Key Features Model Strengths: Smooth inline-four engine, comfortable ergonomics, good balance of performance and usability, durable construction, availability of faired (Diversion) and naked versions. 📋 Manual Details Coverage Areas Model Years Covered: 1995, 1996, 1997, 1998, 1999 Page Count Estimated Page Count: Approximately 400-500 pages (estimated for comprehensive coverage) Manual Type Type: Full Service Repair Manual Language Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Clutch, Drivetrain, Fuel System, Cooling System, Exhaust System Chassis: Frame, Suspension (Front and Rear), Steering, Brakes (Front and Rear), Wheels and Tires Electrical: Ignition System, Lighting System, Charging System, Starting System, Instruments and Controls, Wiring Diagrams, ECU Diagnostics Bodywork: Body Panels, Fairings (Diversion), Seats, Fuel Tank, Stands Procedures Included Maintenance: Regular Inspections, Oil and Filter Changes, Spark Plug Replacement, Chain Adjustment, Brake Pad Replacement, Coolant Flush Repair: Engine Overhaul, Transmission Rebuild, Carburetor Reassembly, Suspension Fork Servicing, Brake Caliper Overhaul, Electrical Component Diagnosis and Replacement Diagnostics: Troubleshooting Guides for Common Problems, Electrical System Diagnostics, Carburetor Tuning and Synchronization Technical Depth Depth: Comprehensive coverage from basic maintenance to complete engine and transmission rebuilds, suitable for both DIY enthusiasts and professional technicians. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Print Quality Printability: Full Printable - All pages can be printed. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Quality: Not Applicable (Digital Download) Software Requirements Reader Software: Adobe PDF Reader Decompression Software: WinRAR (or equivalent) Compatibility Operating Systems: Compatible with all versions of Windows and Mac OS. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Liquid-cooled, DOHC, Inline 4-cylinder Displacement: 598 cc Bore X Stroke: 62.0 mm x 49.6 mm Compression Ratio: 10.0:1 Performance Horsepower: Approximately 57.4 HP (42.8 kW) @ 9000 rpm (Manufacturer Claim) Torque: Approximately 51.5 Nm (5.3 kg-m) @ 7500 rpm (Manufacturer Claim) Fuel System Carburetion: 4 x Mikuni BST30 carburetors Fuel Capacity: 18 Liters (4.8 US gal) Ignition Ignition System: Digital TCI (Transistor Controlled Ignition) Cooling Cooling Method: Liquid-cooled Starter Starting: Electric 🔧 Transmission Standard Type: Constant mesh, 6-speed Optional Optional Gearbox: N/A Features Clutch: Wet, multiple-disc, cable-actuated Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approximately 2110 mm (Diversion), 2090 mm (Naked) Width: Approximately 745 mm (Diversion), 750 mm (Naked) Height: Approximately 1235 mm (Diversion), 1075 mm (Naked) Weights Dry Weight: Approximately 183 kg (Diversion), 177 kg (Naked) Wet Weight: Approximately 206 kg (Diversion), 200 kg (Naked) Weight Distribution: Balanced for agile handling. 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle safety is assessed differently than automobiles) Active Features Braking System Front: Dual 298 mm discs, 2-piston calipers Braking System Rear: 245 mm disc, 2-piston caliper Optional ABS: N/A for this model year range Passive Features Lighting: Halogen Headlight, LED Taillight Mirrors: Adjustable handlebar-mounted mirrors 💡 Technology Features Infotainment Dashboard: Analog speedometer, tachometer, fuel gauge, coolant temperature gauge, odometer, trip meter, and indicator lights. Driver Assistance Assistance Features: N/A (Basic motorcycle technology for its era) Connectivity Connectivity Options: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km or 6 months, whichever comes first. Valve Clearance Check: Every 10,000 km or 12 months. Spark Plug Replacement: Every 10,000 km (refer to manual for specific plug type and gap). Fluid Specifications Engine Oil Type: Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA. Engine Oil Capacity: 3.0 Liters (with filter change). Coolant Type: Ethylene glycol-based antifreeze mixture with demineralized water (50/50 ratio). Brake Fluid Type: DOT 4 Known Issues Common Wear Items: Stator coil failure (common on many Yamahas of this era), carburetor needle wear leading to rich mixtures, chain and sprockets wear, fork seal leaks. Electrical Quirks: Intermittent electrical connections, regulator/rectifier issues. Common Repairs Carburetor Maintenance: Regular cleaning, synchronization, and adjustment are crucial for optimal performance. 📚 Vehicle History Brand Heritage Heritage Focus: Yamaha is known for its sporty motorcycles, reliable engines, and innovative engineering, with a strong racing heritage. Model Evolution Xjseries Lineage: The XJ600 evolved from earlier XJ models, aiming to provide a balance of performance and everyday usability. The XJ600S Diversion introduced a full fairing for improved aerodynamics and touring comfort. Production Manufacturing Location: Japan Production Period: The XJ600 was produced from the mid-1980s through the early 2000s, with this specific generation covering 1995-1999. 🏆 Awards & Recognition Recognitions Historical Acclaim: While specific awards for this exact model year range might not be widely publicized, the XJ600 series was generally well-regarded for its reliability and value proposition in...
Smooth inline-four engine, comfortable ergonomics, good balance of performance and usability, durable construction, availability of faired (Diversion) and naked versions.
📋 Manual Details
Coverage Areas
Model Years Covered:
1995, 1996, 1997, 1998, 1999
Page Count
Estimated Page Count:
Approximately 400-500 pages (estimated for comprehensive coverage)
Manual Type
Type:
Full Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission, Clutch, Drivetrain, Fuel System, Cooling System, Exhaust System
Chassis:
Frame, Suspension (Front and Rear), Steering, Brakes (Front and Rear), Wheels and Tires
Troubleshooting Guides for Common Problems, Electrical System Diagnostics, Carburetor Tuning and Synchronization
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to complete engine and transmission rebuilds, suitable for both DIY enthusiasts and professional technicians.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Print Quality
Printability:
Full Printable - All pages can be printed.
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Quality:
Not Applicable (Digital Download)
Software Requirements
Reader Software:
Adobe PDF Reader
Decompression Software:
WinRAR (or equivalent)
Compatibility
Operating Systems:
Compatible with all versions of Windows and Mac OS.
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, Liquid-cooled, DOHC, Inline 4-cylinder
Displacement:
598 cc
Bore X Stroke:
62.0 mm x 49.6 mm
Compression Ratio:
10.0:1
Performance
Horsepower:
Approximately 57.4 HP (42.8 kW) @ 9000 rpm (Manufacturer Claim)
Torque:
Approximately 51.5 Nm (5.3 kg-m) @ 7500 rpm (Manufacturer Claim)
Fuel System
Carburetion:
4 x Mikuni BST30 carburetors
Fuel Capacity:
18 Liters (4.8 US gal)
Ignition
Ignition System:
Digital TCI (Transistor Controlled Ignition)
Cooling
Cooling Method:
Liquid-cooled
Starter
Starting:
Electric
🔧 Transmission
Standard
Type:
Constant mesh, 6-speed
Optional
Optional Gearbox:
N/A
Features
Clutch:
Wet, multiple-disc, cable-actuated
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approximately 2110 mm (Diversion), 2090 mm (Naked)
Width:
Approximately 745 mm (Diversion), 750 mm (Naked)
Height:
Approximately 1235 mm (Diversion), 1075 mm (Naked)
Weights
Dry Weight:
Approximately 183 kg (Diversion), 177 kg (Naked)
Wet Weight:
Approximately 206 kg (Diversion), 200 kg (Naked)
Weight Distribution:
Balanced for agile handling.
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle safety is assessed differently than automobiles)
Active Features
Braking System Front:
Dual 298 mm discs, 2-piston calipers
Braking System Rear:
245 mm disc, 2-piston caliper
Optional ABS:
N/A for this model year range
Passive Features
Lighting:
Halogen Headlight, LED Taillight
Mirrors:
Adjustable handlebar-mounted mirrors
💡 Technology Features
Infotainment
Dashboard:
Analog speedometer, tachometer, fuel gauge, coolant temperature gauge, odometer, trip meter, and indicator lights.
Driver Assistance
Assistance Features:
N/A (Basic motorcycle technology for its era)
Connectivity
Connectivity Options:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km or 6 months, whichever comes first.
Valve Clearance Check:
Every 10,000 km or 12 months.
Spark Plug Replacement:
Every 10,000 km (refer to manual for specific plug type and gap).
Fluid Specifications
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA.
Engine Oil Capacity:
3.0 Liters (with filter change).
Coolant Type:
Ethylene glycol-based antifreeze mixture with demineralized water (50/50 ratio).
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
Stator coil failure (common on many Yamahas of this era), carburetor needle wear leading to rich mixtures, chain and sprockets wear, fork seal leaks.
Regular cleaning, synchronization, and adjustment are crucial for optimal performance.
📚 Vehicle History
Brand Heritage
Heritage Focus:
Yamaha is known for its sporty motorcycles, reliable engines, and innovative engineering, with a strong racing heritage.
Model Evolution
Xjseries Lineage:
The XJ600 evolved from earlier XJ models, aiming to provide a balance of performance and everyday usability. The XJ600S Diversion introduced a full fairing for improved aerodynamics and touring comfort.
Production
Manufacturing Location:
Japan
Production Period:
The XJ600 was produced from the mid-1980s through the early 2000s, with this specific generation covering 1995-1999.
🏆 Awards & Recognition
Recognitions
Historical Acclaim:
While specific awards for this exact model year range might not be widely publicized, the XJ600 series was generally well-regarded for its reliability and value proposition in the middleweight sport-touring segment.
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