2009 Yamaha XJ6S(Y) / XJ6SA Diversion Factory Service Manual PDF (P/N 36C-28197-E0)

The 2009 Yamaha XJ6S(Y) and XJ6SA Diversion factory service manual, 36C-28197-E0 (first edition, January 2009), covers the 36C1, 36D1, and 36C2 model variants.

Supplied as one English-language, 554-page PDF.

• Engine repair: Engine removal, cylinder-head and valve service, camshaft timing, crankcase separation, wet-clutch repair, and transmission inspection.

• Fuel and air systems: Throttle body synchronization, fuel-pressure testing, injector installation checks, throttle position sensor adjustment, and air induction system inspection.

• Brakes and ABS: Caliper and master-cylinder overhaul, hydraulic brake bleeding, wheel sensor checks, and XJ6SA hydraulic-unit operation tests.

• Chassis service: Front fork leg overhauls, steering head bearing service, swingarm inspection, drive-chain maintenance, and rear shock absorber removal and installation.

• Cooling and lubrication: Radiator-cap testing, thermostat inspection, water-pump repair, oil-cooler service, and engine oil pressure measurement.

• Electrical troubleshooting: FI and ABS fault diagnosis, immobilizer key-code registration, multi-function meter checks, and ignition, starting, charging, lighting, and signaling circuit tests.

Written primarily for Yamaha dealers and their qualified mechanics, this manual assumes an understanding of mechanics and the techniques used to repair these vehicles.

Engine and Transmission Repair

Engine service extends to valve-guide replacement, valve-seat inspection and lapping, piston and ring measurements, and crankshaft bearing selection using the factory color codes. Camshaft procedures include journal-clearance checks, timing-chain tensioner inspection, and valve timing verification.

The clutch section distinguishes the friction-plate types and documents the built-in damper. Six-speed transmission coverage includes shaft disassembly, shift-fork and shift-drum inspection, gear engagement checks, and reassembly.

The camshaft section warns that uneven camshaft-cap tightening can damage the cylinder head, caps, and camshafts.

Fuel System Service

The fuel sections cover pump removal, injector installation and pressure-retention checks, throttle body cleaning, and fast-idle plunger connections. Air induction coverage includes the reed valves, air cut-off valve, and solenoid tests.

Special tools are identified by number, including fuel injector pressure adapter 90890-03210 and fuel pressure adapter 90890-03176. Throttle body service distinguishes air-screw synchronization from the factory settings that must remain undisturbed.

ABS, Brakes and Chassis

The XJ6SA material includes ABS block diagrams, fault-code tables, and hydraulic-unit operation tests 1 and 2 using test coupler adapter 90890-03149. The ABS ECU and hydraulic unit are handled as one assembly, with replacement specified for internal faults. Internal overhaul is not covered.

Wheel-service precautions explain how magnetic tools can damage the ABS wheel sensor rotors. The rear shock absorber section covers inspection and replacement of the gas-charged assembly, not internal overhaul.

Working on high-pressure fuel or ABS systems carries inherent risks. Follow the manual's workshop safety precautions.

Electrical Diagnosis and Model Differences

FI troubleshooting links fault codes to wiring checks, sensor tests, fail-safe operation, and reinstatement methods. Diagnostic monitoring codes cover actuator checks and malfunction history. Immobilizer documentation includes a component-replacement and key-registration requirements table.

Separate XJ6S and XJ6SA wiring schematics show different speed-signal paths: the XJ6S uses a speed sensor, while the XJ6SA uses the rear wheel sensor and ABS ECU. This distinction helps direct speedometer diagnosis to the correct circuit.

The ABS Coupler Location Chart and cable routing diagrams support connector identification and harness work. Electrical test specifications include crankshaft position sensor resistance.

Maintenance, Cooling and Service Data

Periodic maintenance charts give factory service intervals. Exploded-view diagrams accompany removal and disassembly sections, with job charts identifying parts and work order.

Cooling-system procedures cover radiator-cap pressure checks, thermostat testing, and water-pump seal replacement. The Engine Oil Lubrication Chart and cooling system diagrams show the related flow paths.

Torque tables use Nm, m-kgf, and ft-lbs. Reference tables also cover chassis geometry, fluid capacities, clutch friction-plate wear limits, and intake and exhaust valve-clearance specifications.

File Format and Readability

The file contains 550 pages of manual content, front matter, covers, and blank pages, followed by four wiring-diagram sheets: black-and-white and color versions for both XJ6S and XJ6SA. These sheets are already included in the total page count.

Body text and many tables support PDF text search; labels drawn into wiring diagrams are not searchable. Embedded bookmarks cover all nine chapters and major sections. The “RETURN” bookmark links to an external PDF.

Small component numbers, connector markings, and wire-color codes require magnification.