Yamaha XJ900S(G) Diversion 1995–2001 Service Manual (P/N 4KM-28197-20)

Yamaha’s XJ900S(G) ’95 service manual, P/N 4KM-28197-20, covers XJ900S Diversion maintenance, diagnosis, and repair, with market-specific identification and specifications for Spain, Switzerland, Austria, Australia, and New Zealand.

PDF Reading and Page Order

Text search and diagram detail: The PDF has no searchable text or embedded bookmarks. Small wiring labels require zooming, and some remain faint or difficult to distinguish. Printed Signal System pages 7-43 and 7-44 are missing. Some later sections are stored in reverse page order; the original chapter/page numbers remain visible.

Supplied as one printable English-language, 352-page PDF, including the cover, 13 introductory and contents pages, and three unnumbered blank pages.

Engine Overhaul, Shaft Drive, and Electrical Fault Tracing

The following selected coverage highlights outline the main workshop areas. Further topics include compression-pressure diagnosis and maintenance-free battery inspection and charging charts.

• Engine and transmission: Step-by-step procedures for engine removal, internal inspection, cam timing, wet multi-plate clutch overhaul, and gearbox assembly.

• Middle gear and shaft drive: Backlash measurement, shim selection, universal-joint service, final-drive bearing work, and ring-gear positioning.

• Carburetor service: Mikuni BDSR34 disassembly, synchronization, fuel-level adjustment, and throttle position sensor inspection and setup.

• Brakes and front forks: Caliper and master-cylinder overhaul, hydraulic bleeding, and fork seal and bushing replacement.

• Steering and rear suspension: Steering-head bearing service, swingarm and linkage inspection, and rear-shock removal and replacement.

• Electrical diagnosis: Ignition, starting-interlock, charging, fuel-pump, and carburetor-heater fault tracing with system-specific circuit diagrams and test charts.

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

Market-Specific Specifications

The Swiss/Austrian specifications list 4PR00 carburetors and a J4T052 T.C.I. unit, rather than the standard 4KM00 carburetor identification and J4T051 unit. Separate ignition-advance data accompanies that configuration, helping match the reference information to the motorcycle’s market specification.

Top-End and Bottom-End Repair

The engine section distinguishes work possible with the engine in the frame from jobs requiring removal. Cylinder and piston service, valve-guide replacement, and valve-seat refacing and lapping receive dedicated treatment.

Valve-adjusting pad selection charts support clearance adjustment and identify Yamaha’s tappet adjusting tool, 90890-04125. Bottom-end inspection covers Plastigauge clearance checks and color-coded main-journal and crankpin bearing selection.

Transmission inspection extends to shift forks, guide bars, gear engagement, and shaft runout. Lubrication-system repair includes oil-pump inspection, relief-valve checks, and oil-jet passage inspection.

Yamaha specifically warns that uneven cam-cap bolt removal can damage the cylinder head, camshafts, or caps. That caution accompanies the disassembly procedure.

Shaft-Drive Setup and Chassis Work

Final-drive setup procedures cover gear positioning after replacement of the gear case, ring-gear bearing housing, or bearings. The middle-gear section identifies backlash tool 90890-04080 and explains shim calculations from component markings. Final-drive coverage also includes ring-gear thrust-clearance measurement and thrust-washer selection.

The manual warns that overtightening the middle-gear bearing housing during backlash setup can leave insufficient clearance and damage the gears.

Chassis procedures include static wheel balancing. Rear-shock coverage is removal, inspection, and replacement, not internal rebuilding of the sealed nitrogen-charged unit.

Carburetion and Electrical Diagnosis

Carburetor inspection addresses vacuum diaphragms, starter plungers, jets, and needle valves. The A.I.S. (Air Induction System) section adds reed-valve and air-cut-valve checks, dedicated A.I.S. diagrams, and exhaust CO adjustment using test equipment.

The Fuel Pump System and Carburetor Heater System circuit diagrams support separate diagnostic charts. Pump testing distinguishes relay, pump, and wiring checks; heater diagnosis includes thermoswitch checks through heating and cooling cycles.

TPS self-diagnosis uses tachometer display patterns, with separate sensor inspection and adjustment procedures. Starter-motor disassembly and component inspection accompany the starting-circuit tests. Charging-system diagnosis separates stator, rotor, brush, and regulator-related checks.

Factory Reference Tables and Routing Drawings

Component-specific tables provide tightening torques, lubricant grades, wear limits, fluid capacities, and electrical test specifications.

Lubrication Diagrams trace oil distribution through the engine and transmission. Cable Routing drawings identify harness, hose, and control-cable paths, including sensor leads and connections around the fuel tank and carburetor assembly.

Working on motorcycle braking systems and engine internals involves inherent risks. These specifications reflect the factory baselines, but any hands-on maintenance should always follow the complete teardown steps, safety protocols, and tool requirements outlined within the manual itself.

Selected Valve-Clearance and Final-Drive Specifications

The valve-adjustment section specifies cold clearances of 0.11–0.15 mm for intake valves and 0.16–0.20 mm for exhaust valves, alongside the adjusting-pad selection charts.

Final-drive inspection specifies ring-gear thrust clearance of 0.1–0.2 mm, with a Plastigauge measurement procedure and a thrust-washer selection chart.