1992–2003 Yamaha XJ600S Seca II / Diversion Service Manual with Supplements (P/N LIT-11616-08-22 / 4EA-28197-20)

This Yamaha factory service manual covers the XJ600SD/XJ600SDC, with supplementary service manuals for the XJ600SF/XJ600SFC and XJ600SJ/XJ600SJC. The August 1991 base publication is LIT-11616-08-22 / 4EA-28197-20.

The 346-page PDF contains scanned manual pages without a searchable text layer. Three printed pages are missing from the brake and electrical sections.

• Engine repair: Engine removal, cylinder head inspection, valve and piston service, crankshaft bearing selection, timing-chain work, and engine reassembly.

• Clutch and transmission: Wet-clutch replacement, starter-clutch inspection, gearbox disassembly, and checks of shift forks, guide bars, and the shift cam.

• Maintenance and carburetion: Valve-clearance adjustment, spark plug maintenance, carburetor synchronization, regional carburetor repair procedures, and emission-control and lubrication schedules.

• Brakes and chassis: Wheel-bearing replacement, hydraulic brake inspection and bleeding, front-fork overhaul, steering-head service, and rear shock absorber and swingarm inspection.

• Electrical troubleshooting: Ignition, starting, charging, lighting, and signal-system diagnosis, with circuit diagrams, connector checks, and component test specifications.

• Factory reference data: Component-specific torque tables, fluid capacities, lubrication points, wear limits, adjustment data, and illustrated cable and hose routing.

Written primarily for Yamaha dealers and qualified mechanics, this manual assumes a working understanding of motorcycle repair.

Engine Overhaul, Valve Adjustment, and Transmission Repair

Intake and exhaust shim-selection charts support valve-clearance work, with Yamaha tappet adjusting tool YM-04125 / 90890-04125 identified for pad replacement. Compression testing, crankshaft oil-clearance checks, and bearing color-code selection extend the coverage beyond routine maintenance.

The engine chapter also covers the HY-VO chain, oil pump, and starter drive. Illustrations include the Lubrication Chart, Crankcase Tightening Sequence, and exploded Transmission and Shift Cam/Shift Fork assembly.

Yamaha warns that interchanging main-journal or connecting-rod bearing positions can produce incorrect oil clearance and engine damage.

Regional Carburetors and Supplement Updates

Separate repair sections distinguish Mikuni BDS26 carburetors for USA/California from BDST28 units for Canada/Australia. The latter include thermo-switch and solenoid-valve testing; California-specific evaporative-emission hose routing is also documented.

The SF(C) and SJ(C) supplements revise carburetor identification and setup data. Matching those tables to the motorcycle's model code helps avoid applying the base manual's settings to a revised carburetor assembly.

The SF(C) supplement covers USA, California, Canadian, and Australian configurations. The SJ(C) supplement specifies USA and California models.

Brakes, Front Fork, and Steering

Front-fork procedures cover damper rods, bushings, and seal replacement. The SF(C) supplement revises rear spring specifications; the SJ(C) supplement adds revised fork data and specifies angular steering bearings.

The fork disassembly notes warn that bottoming the inner tube in the outer tube can damage the oil-lock piece.

Rear brake pad replacement is incomplete in this scan: printed page 6-16 is missing between the front-pad procedure and the continuation of rear-pad installation.

Before beginning any diagnostic or maintenance work, always ensure the motorcycle is securely supported on a proper stand and wear appropriate protective gear.

Starting, Charging, and Wiring Diagrams

The Starting Circuit Operation diagram explains the neutral, clutch, and sidestand interlocks. Ignition and charging test charts cover spark-loss and charging faults, including pickup-coil, ignition-coil, and stator checks.

Three full wiring diagrams cover SD(C) USA/California/Canada, SD Australia, and SJ(C). The SJ(C) supplement specifies an SH640 regulator/rectifier, replacing the SH629 specification in the base manual.

The troubleshooting appendix addresses hard starting, poor idle, faulty gear shifting, clutch slipping or dragging, and unstable handling. Printed pages 7-29 and 7-53 are missing from the electric starting and signal-system sections.

Included Documents and PDF Readability

All of the following are already included in the 346-page total:

• Base service manual: 312 pages, including its original cover and two full wiring diagrams.
• SF(C) supplement: 13 pages; first edition, March 1993; LIT-11616-08-87 / 4EA-28197-21.
• SJ(C) supplement: 20 pages; first edition, July 1996; LIT-11616-10-39 / 4EA-28197-22, including its wiring diagram.
• Additional file cover: 1 page.

Chapter bookmarks cover the base manual and both supplements, although two navigation links have incorrect or unavailable targets. Small wire-color codes and connector labels on the full wiring diagrams are best read at increased magnification.