Yamaha XJ900 Service Manual Set, 1984–1986 + 1995 (P/N 4KM-28197-20)

The RK book provides full repair chapters, while the N booklet concentrates on model-specific specifications and chassis work. The Diversion publication supplies its own engine, chassis and electrical procedures.

Scope: The N booklet is not a standalone engine-overhaul manual. The Diversion PDF contains system circuit diagrams, but the separate end-of-book wiring sheet listed in its contents is absent.

PDF Search, Bookmarks and Diagram Detail

Search and navigation: Text search is unavailable in all three PDFs. The RK and N files have section bookmarks; the RK file includes a broken destination. Diversion has no embedded bookmarks, and its opening troubleshooting page appears among the fuel-pump pages at PDF p. 337.

Wiring detail: Small RK and N wiring labels require zooming. Some small labels in the shaded Diversion circuit diagrams remain difficult to read when enlarged.

The ZIP contains three printable English PDFs totaling 604 pages. These counts already include the RK book’s five-page opening photograph/features section, the N booklet’s cover, and the Diversion book’s 15-page front matter plus three further blank or divider pages.

Engine Overhaul, Shaft Drive and Model-Specific Diagnosis

The following selected coverage highlights are not a complete contents list; further topics include fuel-cock inspection and digital-clock checks.

• Engine repair: Engine removal, cylinder-head and valve-guide work, piston and crankshaft inspection, cam-chain service, oil-pump repair and engine reassembly.

• Carburetion: Carburetor disassembly, diaphragm and jet inspection, fuel-level checks, bank alignment and synchronization, with separate specifications for the covered configurations.

• Clutch and shaft drive: Clutch inspection, transmission assembly, middle-gear adjustment, final-drive overhaul, shim selection, drive-shaft inspection and universal-joint checks.

• Brakes and wheels: Master-cylinder and caliper overhaul, hydraulic bleeding, brake-disc inspection, wheel-bearing replacement, tubeless-tire guidance and wheel balancing.

• Suspension and steering: RK air-assisted anti-dive forks, N-specific fork and steering procedures, and Diversion rear-shock, linkage and swingarm service.

• Electrical diagnosis: Starting, charging, T.C.I. ignition, lighting and signal tests, plus Diversion fuel-pump, carburetor-heater and throttle-position-sensor diagnosis.

These publications suit mechanics familiar with internal engine work and precision measurement; the Diversion manual is expressly written for Yamaha dealers and qualified mechanics.

Engine Inspection and Assembly References

The RK engine chapters cover camshafts and caps, valves and seats, cylinders, pistons and rings, connecting rods, crankshaft bearings, starter drive and crankcases. Inspection material includes Plastigauge checks, bearing selection, tightening sequences, lubrication diagrams and assembly-specific torque tables.

Tool references include tappet adjusting tool 90890-01245 and clutch holding tool 90890-04086. The assembly sections explain component orientation and timing relationships alongside the inspection limits.

The RK manual flags carburetor-bank misalignment after separation, valve damage from incorrect camshaft handling, and head/cap/cam damage from uneven cap tightening. The N fork section warns about taper-spindle damage if the inner tube is bottomed during disassembly.

Carburetor and Intake-System Differences

The RK specifications identify Mikuni BS35 carburetors; the N booklet lists BS36 units. The RK carburetor section view identifies the jets, passages and diaphragm arrangement, while its synchronization procedure references YICS shut-off tool 90890-04068 and vacuum gauge 90890-03094.

Diversion uses Mikuni BDSR34 carburetors and adds TPS adjustment, resistance checks and tachometer-based self-diagnosis. Its A.I.S. diagrams accompany reed-valve and air-cut-valve inspection, with separate adjustment material for the air-induction system.

These model-specific tables keep carburetor settings, piston data and electrical test values distinguishable when selecting the relevant procedure.

Final-Drive Diagnosis and Chassis Service

The shaft-drive troubleshooting charts relate rumbling, whining and other symptoms to wheel bearings, gear backlash and driveline components. They support fault isolation before the final-drive assembly is dismantled.

Gear-service material includes positioning calculations, shim and thrust-washer selection, and final-gear lash tool 90890-01230. The RK book also provides dimensioned drawings for press tools and a gear-case holding fixture.

The front-fork/anti-dive exploded view supports the RK suspension procedures. Its anti-dive valve housing is treated as a replacement assembly rather than a rebuildable valve unit; actuating-piston inspection and hydraulic bleeding are covered.

The N booklet supplies its own fork overhaul, steering-bearing inspection, rear-shock preload and headlight procedures. Brake and anti-dive hydraulics, spring-loaded forks and engine removal require stable motorcycle support and the workshop precautions printed in the manuals.

Electrical Tests and Circuit References

The RK material includes a starting-circuit cut-off relay function chart and an A.C. generator/rectifier-regulator schematic. Component tests extend to pickup coils, switches, the self-canceling flasher, fuel sender, oil-level switch, battery and fuses.

Model-specific wiring sheets and cable-routing views accompany the RK and N publications. Diversion adds fuel-pump circuit operation and testing, carburetor-heater relay and thermo-switch checks, and TPS fault tracing.

Selected Valve-Clearance and Compression Data

For the RK/33F engine, the valve-adjustment section specifies an intake clearance of 0.11–0.15 mm with the engine cold and provides pad-selection charts.

Its warm-engine, wide-open-throttle compression test lists a sea-level standard of 981 kPa. These examples illustrate the measurement conditions attached to the manual’s service data.