1995-2001 Yamaha XJ900S(G) Diversion Service Manual

Diagnostic procedures and component service for Yamaha XJ900S(G) Diversion: engine, carburetor, chassis, electrical. Includes part number J4T0581.

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Document Details

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Document Number / Seller:
25786 / Donna White
File Size:
113.04 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Jun 26, 2025

Models Covered & Key Technical Specifications

Applied Workshop Operator's Manual: Motorcycle Yamaha XJ900S(G) Diversion repair manual, 1994-2001 models Blueprint-Vault

Engine-Identifier: XJ900S(G) (4KM) // Product-Line: Motorcycle / Yamaha Logic // System-Identifier: Repair manual. Assessment-Element Rating Validation-Data
Motorcycle Identification 4KM1 JVA4KMS0*SA023101
Frame Serial Number 4KM-000101 4PR-000101
Engine Serial Number 4KM-000101 4PS-000101
Overall Length 2,230 mm 2,230 mm
Overall Width 725 mm 725 mm
Overall Height 1,300 mm 1,300 mm

Technical content addresses:

Engine Removal Procedures

Carburetor Specifications

Chassis Systems Overview

Electrical Component Identification

Ignition System Schematics

Torque specifications are documented for drive axle components to ensure proper rotational loosening prevention.

  • Approved Tightening Data: 97/58 (1.672) specifies the primary reduction gear ratio.
  • Baseline Fill Levels: For optimal operation, 3.2 L indicates the total engine oil capacity.
  • Primary Tolerance Values: Coil resistance is 1.87 ~ 2.53 Ω at 20°C, defining the minimum acceptable resistance.
  • General Amperage Specs: The starter motor requires 100 A for its rated output.
  • Essential Feed Speed: The rear suspension travel requires 177 mm for full excursion.
  • Operational Bolt Torques: The front brake caliper mount bolts require 35 Nm for secure installation.

Professional Workshop Service Manual & Technical Specifications

Applied Workshop Operator's Manual: Motorcycle Yamaha XJ900S(G) Diversion repair manual, 1994-2001 models Blueprint-Vault

System-Identifier: XJ900S(G) (4KM) // Product-Line: Motorcycle / Yamaha Logic // System-Identifier: Repair manual. Assessment-Element Rating Validation-Data
Motorcycle Identification 4KM1 JVA4KMS0*SA023101
Frame Serial Number 4KM-000101 4PR-000101
Engine Serial Number 4KM-000101 4PS-000101
Overall Length 2,230 mm 2,230 mm
Overall Width 725 mm 725 mm
Overall Height 1,300 mm 1,300 mm

Technical content addresses:

Engine Removal Procedures

Procedures for removing the engine assembly are clearly outlined, detailing the sequence for disconnecting components.

Carburetor Specifications

This section provides detailed specifications for the carburetor system, including jet sizes and idle speed adjustments.

Chassis Systems Overview

Information on the motorcycle's chassis, including front and rear suspension, steering, and braking systems, is documented.

Electrical Component Identification

This part of the manual covers the identification and function of various electrical components, such as the ignition system and lighting.

Ignition System Schematics

Detailed schematics and troubleshooting information for the ignition system are included to aid in diagnostics. Torque specifications are documented for drive axle components to ensure proper rotational loosening prevention.

  • Approved Tightening Data: 97/58 (1.672) specifies the primary reduction gear ratio.
  • Baseline Fill Levels: For optimal operation, 3.2 L indicates the total engine oil capacity.
  • Primary Tolerance Values: Coil resistance is 1.87 ~ 2.53 Ω at 20°C, defining the minimum acceptable resistance.
  • General Amperage Specs: The starter motor requires 100 A for its rated output.
  • Essential Feed Speed: The rear suspension travel requires 177 mm for full excursion.
  • Operational Bolt Torques: The front brake caliper mount bolts require 35 Nm for secure installation.

FAQ

What **essential** testing parameters are used for the ignition system? keyboard_arrow_down

Ignition timing is checked using a timing light and inductive tachometer, with engine speed set at 950 - 1,050 r/min for verification.

Check the **correct** diagnostic procedures for the clutch. keyboard_arrow_down

Clutch operation is verified by checking for smooth engagement and disengagement; clutch free play should be between 3-5 mm at the lever.

What does the **documented** fluid capacity requirements specify for the final gear? keyboard_arrow_down

0.2 L is the total final gear oil capacity, with periodic changes recommended at intervals.

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Reviews (3)

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I received the download link quickly and the manual is very detailed. Perfect for both beginners and experienced mechanics!
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New
This manual is a lifesaver for anyone working on the XJ900S. The layout is clear and easy to follow, making repairs a breeze!
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Rated 5 out of 5 stars