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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...
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Type: Motorcycle
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Sku: 57670
Collecties: ALL Marine

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Yamaha XJ600 XJ600N 1995-1999 Full Service Repair Manual
🏷️ 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 the middleweight sport-touring segment.
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