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General| Displacement | 598 cc |
|---|---|
| Transmission | 6-speed |
| Final Drive | Chain |
| Front Suspension | Telescopic fork |
| Seat Height | 790 mm (31.1 inches) |
| Bore x Stroke | 58.5 mm x 55.7 mm |
| Ignition System | TCI (Transistor Controlled Ignition) |
| Front Brakes | Dual discs |
| Rear Brakes | Single disc |
| Rear Tire | 130/70-17 |
Traces Yamaha's history from musical instruments to motorcycles, highlighting early models.
Details the founding and growth of Yamaha Motor Company, including global expansion.
Discusses Yamaha's innovations and popular two-stroke models in the 1960s and 70s.
Covers Yamaha's move into four-stroke engines and popular models like XS and XJ series.
Introduces the XJ600S Diversion and XJ600N models, tracing their lineage.
Expresses thanks to parties who provided assistance for the manual.
Explains the manual's purpose, how to use it, and disclaimers.
Warns about potential asbestos in certain motorcycle parts and necessary precautions.
Provides safety precautions regarding petrol and fire hazards during maintenance.
Details hazards of toxic fumes and necessary ventilation during work.
Lists safety precautions related to the motorcycle battery and potential hazards.
Outlines safety measures when working with electrical systems and tools.
Explains the importance and location of frame and engine numbers for parts and security.
Provides guidance on how to ensure correct part identification when purchasing.
Step-by-step guide to checking the engine oil level, including correct oil type and viscosity.
Instructions for checking front and rear brake fluid levels and identifying potential issues.
Outlines checks for suspension operation, steering smoothness, and final drive condition.
Covers checks for lighting, signalling, safety features, and fuel.
Details correct tyre pressures, care, tread depth, and inspection for damage.
Provides technical specifications for engine, cycle parts, and other components.
Details chain slack adjustment, lubrication, and sprocket inspection.
Details the procedure for changing the engine and transmission oil and filter.
Explains how to synchronize carburetors using vacuum readings for smooth engine operation.
Covers checks and adjustments for the front and rear brake levers, pedals, and system.
Guides on checking clutch cable freeplay and ensuring proper clutch operation.
Provides guidance on lubricating controls, cables, and pivot points for smooth operation.
Outlines checks for front and rear suspension components for safety and performance.
Covers inspection of wheels for damage and tyre condition, including tread depth.
Details periodic checks of the exhaust system for leaks and loose fasteners.
Emphasizes the importance of periodically checking all fasteners for proper tightness.
Guides on checking the fuel tank, tap, lines, and filter for leaks or damage.
Instructions for inspecting the crankcase breather system for blockages or damage.
Describes how to test the sidestand switch for proper operation.
Explains how to check for and adjust play in the steering head bearings.
Details the check procedure for the evaporative emission control system on specific models.
Provides instructions for changing the brake fluid, emphasizing cleanliness.
Guides on dismantling, inspecting, and rebuilding brake calipers and master cylinders.
Recommends periodic cleaning and repacking of steering head bearings.
Outlines lubrication procedures for swingarm and rear suspension pivot points.
Explains the process for checking and adjusting valve clearances when the engine is cool.
Advises on periodic checks of battery leads for security and corrosion.
Describes how to perform a compression test to assess engine condition.
Details the procedure for replacing fork oil, including differences between models.
Provides detailed specifications for engine, clutch, and transmission components.
Offers an overview of the engine, transmission, and general service information.
Discusses factors indicating the need for engine overhaul and general considerations.
Provides a step-by-step guide for removing and installing the engine assembly.
Outlines initial steps and precautions for engine disassembly and reassembly.
Details the procedure for removing and installing the valve cover.
Guides on the removal and installation of the camshaft chain tensioner.
Covers the process of removing, inspecting, and installing camshafts and lifters.
Details how to inspect camshaft bearing surfaces, lobes, and oil clearances.
Provides instructions for reassembling camshafts, ensuring correct timing and alignment.
Describes how to handle valve lifters and shims during disassembly.
Step-by-step guide for removing and installing the cylinder head.
Explains the process for servicing valves, valve seats, and guides.
Guides on inspecting valves, seats, guides, and cylinder head for wear or damage.
Provides instructions for lapping valves and reassembling the cylinder head components.
Covers the removal, inspection, and installation of the cylinder block.
Provides a guide for removing, inspecting, and installing pistons and rings.
Details how to inspect pistons for wear, damage, and check clearances.
Explains the process of installing new piston rings and pistons correctly.
Guides on checking piston ring end gaps and correct installation on pistons.
Details removal, inspection, and installation of the oil pan and relief valves.
Covers the removal, inspection, and installation of the oil pump assembly.
Guides on inspecting the oil pump body and rotors for wear or damage.
Provides steps for reassembling and installing the oil pump, including priming.
Details the procedure for removing, inspecting, and installing the clutch assembly.
Guides on inspecting clutch components like splines, plates, springs, and housing.
Covers the reassembly and installation of the clutch components.
Provides instructions for removing, installing, and adjusting the clutch cable.
Guides on removing, installing, and adjusting the shift pedal and linkage.
Details the removal, inspection, and installation of the external shift mechanism.
Outlines the procedure for separating crankcase halves for access to internal components.
Provides critical steps and precautions for reassembling the crankcase halves.
Covers cleaning and inspecting crankcase components and checking for damage.
Discusses the importance of examining old bearings to diagnose engine condition.
Guides on checking crankshaft endplay and removing/inspecting main bearings.
Explains how to select the correct main bearing size based on clearance measurements.
Details the installation of main bearings and connecting rod assemblies.
Guides on checking connecting rod bearing clearances and selecting appropriate bearings.
Covers the removal, inspection, and installation of starter chain, camshaft chain, and guides.
Outlines inspection of chains for binding, damage, and proper tension.
Details inspection of the starter chain tensioner for wear and proper function.
Guides on checking chain guides for wear, damage, or distortion.
Provides procedures for removing and installing transmission shafts and related components.
Covers disassembly, inspection, and reassembly of the mainshaft and its gears.
Details disassembly, inspection, and reassembly of the driveshaft components.
Guides on removing, inspecting, and installing the shift cam and forks.
Covers removal, inspection, and installation of the starter clutch assembly.
Details the removal and installation of the oil cooler assembly for specific models.
Provides instructions for the initial startup procedure after engine work.
Outlines the recommended break-in procedure for rebuilt engines and new parts.
Provides specifications for the fuel tank and carburetor types used on the models.
Details fuel grade, capacity, and reserve capacity for the fuel tank.
Lists the types of carburetors fitted to US and UK models.
Provides detailed jet sizes for US and UK carburetor models.
Details float height and fuel level adjustments for US and UK carburetor models.
Lists torque specifications for exhaust pipe and carburetor heater system components.
Provides an overview of the fuel system, carburetors, and exhaust system.
Guides on removing and installing the fuel tank and tap, including safety warnings.
Recommends professional cleaning and repair of the fuel tank due to safety risks.
Explains the importance and methods for adjusting idle fuel/air mixture for emissions.
Discusses common carburetor problems and when a major overhaul might be needed.
Details the procedure for removing and installing the carburetor assembly.
Covers removal and installation of intake manifolds, noting O-ring replacement.
Provides a detailed guide for disassembling, cleaning, and inspecting carburetors.
Explains how to check and adjust float height and fuel level in carburetors.
Guides on removing, installing, and adjusting the throttle cable and grip.
Details the removal and installation of the choke cable, including routing and adjustment.
Covers the removal and installation of the air cleaner housing and related components.
Provides instructions for removing and installing the exhaust system, noting hot components.
Guides on removing and installing the fuel pump, including testing procedures.
Details testing procedures for the carburetor heater system components.
Provides specifications for general ignition parameters, ignition coil, spark plugs, and pickup coil.
Overviews the transistorized ignition system and its components.
Outlines basic checks for the ignition system to identify potential faults.
Details how to visually check and measure the resistance of ignition coils.
Guides on checking pickup coil resistance and procedures for removal/installation.
Explains how to identify a faulty igniter, recommending dealer testing.
Covers the function and setup of the throttle position sensor on specific models.
Provides specifications for front forks, rear suspension, and final drive components.
Lists specifications for front fork spring length, oil capacity, and levels.
Details specifications for rear spring free length and swingarm endplay limits.
Provides chain size and link count, plus freeplay and lubricant information.
Offers an overview of the frame, front forks, rear suspension, and final drive systems.
Guides on inspecting the frame for damage, cracks, or wear.
Covers maintenance of the side and centre stands, including pivot bolts and springs.
Details the procedure for removing and installing handlebars, including trim caps and grips.
Step-by-step guide for removing and installing the front forks.
Guides on cleaning and inspecting fork components like tubes, bushings, and seals for wear.
Provides instructions for reassembling fork components, ensuring proper alignment and lubrication.
Covers the removal, inspection, and replacement of steering head bearings and races.
Details how to clean, inspect, and measure steering head bearings, races, and stem.
Provides steps for installing steering head bearings, races, and related components.
Guides on removing, inspecting, and installing the rear shock absorber.
Outlines how to check swingarm bearings for play, dryness, or deterioration.
Details the procedure for removing and installing the swingarm and related parts.
Covers the inspection and replacement of swingarm bearings if they are worn or dry.
Provides instructions for removing, cleaning, and installing the drive chain.
Guides on checking sprockets for wear and replacement procedures.
Details how to check and replace the rear wheel coupling and rubber dampers.
Explains how to adjust rear spring preload for different riding conditions.
Provides specifications for brake fluid, pad thickness, disc thickness, and wheel runout limits.
Lists brake fluid type, pad thickness, and disc thickness specifications.
Details wheel runout limits and tyre pressure/tread depth information.
Lists torque specifications for various brake and wheel components.
Offers general information and safety precautions related to brake system components.
Provides step-by-step instructions for replacing front and rear brake pads.
Details the procedure for removing the front caliper and accessing brake pads.
Guides on removing the rear caliper and accessing brake pads, including safety warnings.
Covers the removal, overhaul, and installation of brake calipers, with safety warnings.
Details how to inspect brake discs for wear, runout, and damage, and their removal/installation.
Guides on removing, overhauling, and installing the front brake master cylinder.
Provides instructions for removing, overhauling, and installing the rear brake master cylinder.
Details inspection of brake hoses for leaks and procedures for replacement.
Explains the process of bleeding the brake system to remove air bubbles.
Guides on inspecting wheels for damage, cracks, and checking wheel alignment.
Describes methods for checking wheel alignment using strings or straight edges.
Step-by-step instructions for removing and installing the front wheel.
Guides on removing and installing the rear wheel, including chain and sprocket adjustments.
Details the inspection and maintenance of wheel bearings, including cleaning and lubrication.
Covers the removal, inspection, and installation of front wheel bearings and related parts.
Guides on inspecting and replacing the rear coupling bearing.
Details the inspection and replacement of rear wheel bearings.
Provides general information on tyres, fitting new tyres, and tyre options.
Offers an overview of fairings and body parts, noting repair limitations.
Provides instructions for removing and installing the motorcycle seat.
Guides on removing and installing the tail cover, grab bars, and side covers.
Details the removal and installation of the optional lower fairing (belly pan).
Covers the removal and installation of the upper fairing and related components.
Provides specifications for battery, fuses, and starter motor components.
Lists battery type and capacity specifications.
Details fuse ratings for various electrical circuits.
Provides specifications for starter commutator diameter and brush length.
Offers general information about the electrical system and troubleshooting tips.
Outlines general procedures and warnings for diagnosing electrical faults.
Advises on periodic battery checks and precautions against damage.
Details methods for charging the battery using external sources and voltage checks.
Guides on checking fuses for continuity or visual inspection and replacement.
Covers checks for headlight, tail light, brake light, and instrument cluster lights.
Provides instructions for replacing headlight and parking light bulbs.
Details how to check and adjust headlight aim vertically and horizontally.
Guides on replacing turn signal and tail light bulbs.
Outlines checks for the turn signal circuit, including battery voltage and bulb condition.
Covers checking and replacing front and rear brake light switches.
Details procedures for removing, disassembling, and installing the instrument cluster.
Guides on removing and installing the speedometer cable from the drive unit.
Provides instructions for replacing instrument illumination and warning light bulbs.
Details the removal, check, and installation of the oil level sender.
Guides on checking and replacing the ignition main switch, with safety precautions.
Outlines general checks for handlebar switches, focusing on contacts and wiring.
Details the removal and installation of handlebar switch assemblies.
Guides on checking the neutral switch operation and replacement procedures.
Covers checking the horn for operation and replacing it if necessary.
Details testing and replacement procedures for starter relays and the starter cut-off relay.
Provides instructions for removing and installing the starter motor.
Guides on disassembling, inspecting, and reassembling the starter motor.
Offers general information and precautions for testing the charging system.
Details how to test the stator coil resistance to check for defects.
Guides on removing and installing the alternator and stator coil.
Covers removal and installation of the regulator/rectifier unit.
Describes the relay assembly and diode, referencing wiring diagrams for details.
Explains how to locate, test, and replace the diode for proper function.
Presents the wiring diagram for specific UK and US XJ600S models.
Displays the wiring diagram for the XJ600N UK model from 1995.
Presents the wiring diagram for 1997 onwards UK XJ600S models.
Shows the wiring diagram for 1996 UK models of both XJ600S and XJ600N.
Displays the wiring diagram for 1997 onwards UK models of both XJ600S and XJ600N.
Provides dimensional data such as wheelbase, overall length, width, and height.
Highlights a section with useful tools and workshop tips for performing tasks.
Refers to a section dedicated to diagnosing and resolving common faults.
Lists recommended chemicals and lubricants for motorcycle maintenance.
Lists possible causes and checks for an engine that won't start or starts with difficulty.
Outlines potential causes for poor engine performance at low speeds.
Details common causes for lack of power or poor running at high speeds.
Lists potential causes for engine overheating, including oil issues and carbon buildup.
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