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Yamaha XJ600 1995-1999 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: Yamaha Model: XJ600 Model Variant: Diversion (Europe), Seca II (North America) Product Type: Workshop Service Manual (WSM) Generation Generation Code: 2nd Generation (4HW/H502E for European models) Codes Chassis Codes: 4BR (European models 1995-1997), 5BW (European models 1998-2000), 4UC (North American models - Seca II) 👋 Introduction Market Position Segment: Middleweight Naked Sportbike / Standard Motorcycle Target Audience: Owners seeking to perform maintenance and repairs themselves, DIY enthusiasts, motorcycle repair shops Competitive Analysis Key Competitors Of The Era: Suzuki GS500, Kawasaki GPZ500S, Honda CB500 Key Features Manual Advantage: Empowers owners to save money on repairs and understand their motorcycle better, providing professional-level repair information. Product Promise: Makes every repair job easy to do with step-by-step instructions, pictures, and wiring diagrams. 📋 Manual Details Coverage Areas Applicable Years: 1995, 1996, 1997, 1998, 1999 Page Count Estimated Page Count: Comprehensive (Exact number not specified, but described as 'in depth') Manual Type Manual Type: Service Repair Manual (SRM) / Workshop Service Manual (WSM) Language Language: English Format File Format: PDF Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader Compatibility Operating Systems: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, tuning, carburetor overhaul, ignition system, cooling system, lubrication system, exhaust system Transmission Systems: Clutch operation and adjustment, gearbox inspection, maintenance, and repair Chassis Systems: Front suspension (forks), rear suspension (monoshock), steering system, wheel and tire maintenance, brake systems (front and rear disc) Electrical Systems: Wiring diagrams, lighting system, charging system, ignition system, starter motor, battery maintenance, instrument cluster troubleshooting Fuel System: Fuel tank, fuel pump, fuel lines, carburetor settings and cleaning Bodywork And Frame: Body panel removal and installation, frame inspection, fairing repairs Procedures Included Maintenance Procedures: Routine maintenance (oil changes, filter replacements, chain adjustment, spark plug replacement), pre-ride inspections Diagnostic Procedures: Troubleshooting guides for common problems, diagnostic charts, fault finding for electrical and mechanical issues Repair Procedures: Step-by-step repair instructions for all major components, including engine rebuilds, suspension overhauls, and brake system servicing Adjustment Procedures: Carburetor synchronization, clutch and throttle cable adjustment, suspension preload adjustment Wiring Diagrams: Complete and detailed wiring diagrams for all electrical systems Technical Depth Depth Of Coverage: Comprehensive, covering routine maintenance to complete engine and chassis rebuilds Detail Level: Step-by-step instructions with illustrations and diagrams for ease of understanding 📊 Manual Specifications File Format File Type: Digital (PDF) Print Quality Printability: Fully printable for workshop use Image Resolution: High-quality for clear viewing of diagrams and images Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, 4-stroke, DOHC Displacement: 599cc Bore X Stroke: 62.0 mm x 49.6 mm Compression Ratio: 10.0:1 Performance Horsepower Peak: Approx. 60 HP (45 kW) at 9,000 rpm (varies slightly by market/tuning) Torque Peak: Approx. 5.3 kgf·m (52 Nm; 38 lb·ft) at 7,000 rpm (varies slightly) Fuel System Fuel Delivery: 4 x Mikuni BS32 carburetors Fuel Type: Unleaded gasoline, 87 octane (minimum) Ignition System Ignition Type: Transistor controlled ignition (TCI) Cooling System Cooling Method: Liquid-cooled Lubrication System Lubrication Type: Wet sump 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Wet, multiple-disc Final Drive: Chain drive 📐 Dimensions Exterior Overall Length: Approx. 2,175 mm (85.6 in) Overall Width: Approx. 770 mm (30.3 in) Overall Height: Approx. 1,175 mm (46.3 in) Wheelbase: Approx. 1,445 mm (56.9 in) Weights Dry Weight: Approx. 186 kg (410 lbs) Wet Weight: Approx. 204 kg (450 lbs) Weight Distribution: Spec not provided, typical for naked bikes of the era Capacities Fuel Tank Capacity: 17 Liters (4.5 US gal) Oil Capacity With Filter: 3.4 Liters (3.6 US qt) 🛡️ Safety Features Ratings Safety Certifications: CE, DOT (where applicable for lighting/reflectors) Active Features Braking System: Dual front disc brakes, single rear disc brake Suspension Features: Adjustable front forks (pre-load), adjustable rear monoshock (pre-load, rebound damping) Passive Features Lighting: Halogen headlamp, LED or incandescent tail/brake lights and turn signals Frame Type: Steel diamond frame 💡 Technology Features Infotainment Instrument Cluster: Analog speedometer and tachometer, fuel gauge, coolant temperature warning light, neutral indicator, oil pressure warning light Driver Assistance ABS Availability: N/A for this model year range Connectivity Connectivity Features: N/A (typical for motorcycles of this era) 🔧 Maintenance Service Intervals Oil And Filter Change: Every 5,000 km (3,000 miles) or 6 months Air Filter Cleaning/Replacement: Every 10,000 km (6,000 miles) Spark Plug Replacement: Every 10,000 - 15,000 km (6,000 - 9,000 miles) Valve Clearance Check: Every 20,000 km (12,000 miles) Fluid Specifications Engine Oil Grade: Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA Coolant Type: Permanent type antifreeze coolant, 50% solution with distilled water Brake Fluid Type: DOT 3 or DOT 4 brake fluid Fork Oil Type And Viscosity: Yamalube Fork Oil (or equivalent) 10W, 450 ml per fork leg Known...
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Tipo: Motorcycle
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Sku: 575340
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Yamaha XJ600 1995-1999 WSM Service Manual Repair
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XJ600
Model Variant:
Diversion (Europe), Seca II (North America)
Product Type:
Workshop Service Manual (WSM)
Generation
Generation Code:
2nd Generation (4HW/H502E for European models)
Codes
Chassis Codes:
4BR (European models 1995-1997), 5BW (European models 1998-2000), 4UC (North American models - Seca II)
👋 Introduction
Market Position
Segment:
Middleweight Naked Sportbike / Standard Motorcycle
Target Audience:
Owners seeking to perform maintenance and repairs themselves, DIY enthusiasts, motorcycle repair shops
Competitive Analysis
Key Competitors Of The Era:
Suzuki GS500, Kawasaki GPZ500S, Honda CB500
Key Features
Manual Advantage:
Empowers owners to save money on repairs and understand their motorcycle better, providing professional-level repair information.
Product Promise:
Makes every repair job easy to do with step-by-step instructions, pictures, and wiring diagrams.
📋 Manual Details
Coverage Areas
Applicable Years:
1995, 1996, 1997, 1998, 1999
Page Count
Estimated Page Count:
Comprehensive (Exact number not specified, but described as 'in depth')
Manual Type
Manual Type:
Service Repair Manual (SRM) / Workshop Service Manual (WSM)
Language
Language:
English
Format
File Format:
PDF
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader
Compatibility
Operating Systems:
All Versions of Windows & Mac
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine disassembly, assembly, tuning, carburetor overhaul, ignition system, cooling system, lubrication system, exhaust system
Transmission Systems:
Clutch operation and adjustment, gearbox inspection, maintenance, and repair
Chassis Systems:
Front suspension (forks), rear suspension (monoshock), steering system, wheel and tire maintenance, brake systems (front and rear disc)
Electrical Systems:
Wiring diagrams, lighting system, charging system, ignition system, starter motor, battery maintenance, instrument cluster troubleshooting
Fuel System:
Fuel tank, fuel pump, fuel lines, carburetor settings and cleaning
Bodywork And Frame:
Body panel removal and installation, frame inspection, fairing repairs
Procedures Included
Maintenance Procedures:
Routine maintenance (oil changes, filter replacements, chain adjustment, spark plug replacement), pre-ride inspections
Diagnostic Procedures:
Troubleshooting guides for common problems, diagnostic charts, fault finding for electrical and mechanical issues
Repair Procedures:
Step-by-step repair instructions for all major components, including engine rebuilds, suspension overhauls, and brake system servicing
Adjustment Procedures:
Carburetor synchronization, clutch and throttle cable adjustment, suspension preload adjustment
Wiring Diagrams:
Complete and detailed wiring diagrams for all electrical systems
Technical Depth
Depth Of Coverage:
Comprehensive, covering routine maintenance to complete engine and chassis rebuilds
Detail Level:
Step-by-step instructions with illustrations and diagrams for ease of understanding
📊 Manual Specifications
File Format
File Type:
Digital (PDF)
Print Quality
Printability:
Fully printable for workshop use
Image Resolution:
High-quality for clear viewing of diagrams and images
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, 4-stroke, DOHC
Displacement:
599cc
Bore X Stroke:
62.0 mm x 49.6 mm
Compression Ratio:
10.0:1
Performance
Horsepower Peak:
Approx. 60 HP (45 kW) at 9,000 rpm (varies slightly by market/tuning)
Torque Peak:
Approx. 5.3 kgf·m (52 Nm; 38 lb·ft) at 7,000 rpm (varies slightly)
Fuel System
Fuel Delivery:
4 x Mikuni BS32 carburetors
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
Ignition System
Ignition Type:
Transistor controlled ignition (TCI)
Cooling System
Cooling Method:
Liquid-cooled
Lubrication System
Lubrication Type:
Wet sump
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Features
Clutch Type:
Wet, multiple-disc
Final Drive:
Chain drive
📐 Dimensions
Exterior
Overall Length:
Approx. 2,175 mm (85.6 in)
Overall Width:
Approx. 770 mm (30.3 in)
Overall Height:
Approx. 1,175 mm (46.3 in)
Wheelbase:
Approx. 1,445 mm (56.9 in)
Weights
Dry Weight:
Approx. 186 kg (410 lbs)
Wet Weight:
Approx. 204 kg (450 lbs)
Weight Distribution:
Spec not provided, typical for naked bikes of the era
Capacities
Fuel Tank Capacity:
17 Liters (4.5 US gal)
Oil Capacity With Filter:
3.4 Liters (3.6 US qt)
🛡️ Safety Features
Ratings
Safety Certifications:
CE, DOT (where applicable for lighting/reflectors)
Active Features
Braking System:
Dual front disc brakes, single rear disc brake
Suspension Features:
Adjustable front forks (pre-load), adjustable rear monoshock (pre-load, rebound damping)
Passive Features
Lighting:
Halogen headlamp, LED or incandescent tail/brake lights and turn signals
Frame Type:
Steel diamond frame
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer and tachometer, fuel gauge, coolant temperature warning light, neutral indicator, oil pressure warning light
Driver Assistance
ABS Availability:
N/A for this model year range
Connectivity
Connectivity Features:
N/A (typical for motorcycles of this era)
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 5,000 km (3,000 miles) or 6 months
Air Filter Cleaning/Replacement:
Every 10,000 km (6,000 miles)
Spark Plug Replacement:
Every 10,000 - 15,000 km (6,000 - 9,000 miles)
Valve Clearance Check:
Every 20,000 km (12,000 miles)
Fluid Specifications
Engine Oil Grade:
Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA
Coolant Type:
Permanent type antifreeze coolant, 50% solution with distilled water
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Fork Oil Type And Viscosity:
Yamalube Fork Oil (or equivalent) 10W, 450 ml per fork leg
Known Issues
Common Wear Items:
Carburetor diaphragm cracking, rear shock absorber wear, swingarm bearings, headlight bulbs
Potential Electrical Issues:
Stator/regulator issues (less common than some models but possible), aging wiring connectors
Engine Performance Notes:
Carburetor synchronization is critical for smooth operation and consistent performance.
📚 Vehicle History
Brand Heritage
Brand Focus:
Yamaha's reputation for reliable inline-four engines and sporting motorcycles
Model Evolution
Predecessor:
Yamaha XJ600 (pre-1991 models, air-cooled)
Key Changes For This Generation:
Introduction of liquid cooling, updated chassis, revised bodywork (Diversion fairing introduced in Europe).
Production
Production Period:
Mid-1990s to early 2000s (specific end date varies by market, largely replaced by the FZ6 series)
Manufacturing Locations:
Japan
🏆 Awards & Recognition
Recognitions
Industry Accolades:
Generally well-regarded for reliability and ease of use in its class, though not typically associated with major awards.
Ratings
Reliability Reputation:
Good, considered a dependable mid-weight sportbike for its time.
Certifications
Emissions Compliance:
Compliant with regional emissions standards for its production years.
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