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

• 1995 Yamaha XJ900S(G) Diversion coverage, with model identification and market-specific specifications for 4KM1, 4KM2, 4PR1, and 4PS1.
• Engine and transmission repair procedures cover engine removal, internal inspection, cam timing, clutch overhaul, and five-speed gearbox assembly.
• Middle Gear Service and shaft-drive repair include backlash measurement, shim selection, final-drive bearing work, and ring-gear positioning.
• Carburetor procedures cover Mikuni BDSR34 disassembly, synchronization, fuel-level adjustment, and throttle position sensor setup.
• Brake and front-fork sections detail caliper and master-cylinder overhaul, hydraulic bleeding, and fork seal and bushing replacement.
• Electrical fault tracing covers ignition, starting interlocks, charging, fuel-pump operation, and carburetor heating, supported by system-specific wiring diagrams and test charts.

This 352-page scanned PDF reproduces Yamaha’s XJ900S(G) ’95 service manual, reference 4KM-28197-20. The covered motorcycle uses an 892cc air-cooled DOHC parallel-four engine and a wet multi-plate clutch.

Scan limitations: Printed pages 7-43 and 7-44 of the Signal System section are missing. Some later sections are stored in reverse page order; the original chapter/page numbers remain visible.

Market-specific identification

The identification data distinguishes the general starting engine number 4KM-000101 from Spain’s 4KM-023101. Separate starting references identify 4PR-000101 for Switzerland and Austria, and 4PS-000101 for Australia and New Zealand.

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 rather than a general overhaul summary.

Valve-adjusting pad selection charts support clearance adjustment and identify the Yamaha 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.

Yamaha specifically warns that uneven cam-cap bolt removal can damage the cylinder head, camshafts, or caps. That caution accompanies the disassembly procedure, where it matters during top-end work.

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 extend to steering-head bearings, swingarm pivots, suspension-linkage bearings, and 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. Fuel-pump testing covers the relay, pump, and wiring; 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 are covered alongside the starting-circuit tests.

Specifications, lubrication, and routing

Factory reference tables provide component-specific tightening torques, fluid capacities, lubricant grades, wear limits, and electrical test specifications. Oil quantities distinguish routine changes, filter replacement, and total capacity rather than treating every fill as the same job.

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.