Yamaha diversion 900 XJ900S Owner'S Manual Download Page 43

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PERIODIC MAINTENANCE AND MINOR REPAIR

Owner’s tool kit ....................................................6-1

Periodic maintenance and lubrication chart .........6-2

Removing and installing cowlings ........................6-5

Checking the spark plugs ....................................6-7

Engine oil and oil filter cartridge ..........................6-8

Final gear oil ......................................................6-11

Cleaning the air filter element ............................6-13

Adjusting the carburetors ...................................6-15

Adjusting the engine idling speed ......................6-15

Adjusting the throttle cable free play ..................6-16

Adjusting the valve clearance ............................6-16

Tires ...................................................................6-17

Cast wheels .......................................................6-20

Adjusting the clutch lever free play ....................6-20

Adjusting the brake pedal position .....................6-21

Adjusting the rear brake light switch ..................6-21

Checking the front and rear brake pads .............6-22

Checking the brake fluid level ............................6-23

Changing the brake fluid ....................................6-24

Checking and lubricating the cables ..................6-24

Checking and lubricating the throttle grip and

cable ............................................................... 6-24

Checking and lubricating the brake and

shift pedals ...................................................... 6-25

Checking and lubricating the brake and

clutch levers .................................................... 6-25

Checking and lubricating the centerstand and

sidestand ......................................................... 6-25

Lubricating the rear suspension ........................ 6-26

Checking the front fork ...................................... 6-27

Checking the steering ....................................... 6-27

Checking the wheel bearings ............................ 6-28

Battery ............................................................... 6-29

Replacing the fuses .......................................... 6-30

Replacing the headlight bulb ............................. 6-31

Replacing the tail/brake light bulb ..................... 6-32

Replacing a turn signal light bulb ...................... 6-32

Front wheel ....................................................... 6-33

Rear wheel ........................................................ 6-35

Troubleshooting ................................................. 6-37

Troubleshooting chart ........................................ 6-38

E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM

Summary of Contents for diversion 900 XJ900S

Page 1: ...4KM 28199 E7 OWNER S MANUAL XJ900S PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2001 7 0 3 1 CR E ...

Page 2: ...E_5GK_Consumer fm Page 11 Wednesday June 13 2001 1 03 PM ...

Page 3: ... to enjoy all advantages of your XJ900S The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and oth ers from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dea...

Page 4: ...t be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informa...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_4km book Page 2 Tuesday August 28 2001 9 51 AM ...

Page 6: ...MANUAL 2001 by Yamaha Motor Co Ltd 1st edition June 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_4km book Page 3 Tuesday August 28 2001 9 51 AM ...

Page 7: ...MENT AND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 E_4km book Page 1 Tuesday August 28 2001 9 51 AM ...

Page 8: ...E_4km book Page 2 Tuesday August 28 2001 9 51 AM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 E_4km book Page 1 Tuesday August 28 2001 9 51 AM ...

Page 10: ...f even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers Always wear a complete motorcycle suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots motorcycle gloves and a properly fitting helmet Optimum protective wear however shou...

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_4km book Page 1 Tuesday August 28 2001 9 51 AM ...

Page 12: ...1 2 Helmet holder page 3 12 3 Seat lock page 3 11 4 Grab bar 5 Luggage strap holders page 3 15 6 Final gear case page 6 11 7 Shock absorber assembly spring preload adjusting ring page 3 14 8 Shift pedal page 3 8 E_4km book Page 1 Tuesday August 28 2001 9 51 AM ...

Page 13: ...x page 6 30 12 Main fuse page 6 30 13 Seat page 3 11 14 Owner s tool kit page 6 1 15 Air filter element page 6 13 16 Front fork spring preload adjusting bolt page 3 13 17 Engine oil level check window page 6 8 18 Brake pedal page 3 8 E_4km book Page 2 Tuesday August 28 2001 9 51 AM ...

Page 14: ... 3 6 3 Starter choke lever page 3 11 4 Speedometer unit page 3 3 5 Tachometer page 3 4 6 Fuel gauge page 3 5 7 Clock page 3 5 8 Right handlebar switches page 3 7 9 Brake lever page 3 8 10 Throttle grip page 6 16 11 Main switch steering lock page 3 1 E_4km book Page 3 Tuesday August 28 2001 9 51 AM ...

Page 15: ...itches 3 6 Clutch lever 3 7 Shift pedal 3 8 Brake lever 3 8 Brake pedal 3 8 Fuel tank cap 3 9 Fuel 3 9 Fuel tank breather hose for Germany only 3 11 Starter choke lever 3 11 Seat 3 11 Helmet holder 3 12 Storage compartment 3 13 Adjusting the front fork 3 13 Adjusting the shock absorber assembly 3 14 Luggage strap holders 3 15 Sidestand 3 15 Ignition circuit cut off system 3 16 E_4km book Page 1 Tu...

Page 16: ...ed and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EW000016 WARNING Never turn the key to OFF or LOCK while the motorcycle is movi...

Page 17: ...is pushed to the left or right EAU03680 Fuel level warning light This warning light comes on when the fuel level drops below approximately 5 L When this occurs refuel as soon as possible The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Set the engine stop switch to and turn the key to ON 2 Shift the transmission into the neu tral position or pull t...

Page 18: ...al circuit NOTE Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudden acceleration or deceleration but this is not a mal function EAU00096 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter shows the distan...

Page 19: ...isplay the following error code CB 17E Use the table below to identify the faulty electrical circuit CB 18E If the tachometer displays such an er ror code note the circuit specific num ber of r min and then have a Yamaha dealer check the motorcycle EC000004 CAUTION When the tachometer displays an error code the motorcycle should be checked as soon as possible in order to avoid engine damage 1 Tach...

Page 20: ...e gardless of the main switch position To set the clock 1 Push or hold the hour setting but ton H to change the hours 2 Push or hold the minute setting button M to change the minutes NOTE _ To set the clock after the power source has been cut first set the time to 1 00 AM and then set the clock to the correct time _ EAU00109 Anti theft alarm optional This motorcycle can be equipped with an optiona...

Page 21: ...o not use the hazard light for an ex tended length of time otherwise the battery may discharge EAU03889 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When released the switch returns to the cen ter position To cancel the turn signal lights push the switch in after it has re turned to the center position EAU00129 Horn switch Press ...

Page 22: ...tch to crank the engine with the starter EC000005 CAUTION See page 5 1 for starting instruc tions prior to starting the engine EAU00152 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clut...

Page 23: ...ip The brake lever is equipped with a posi tion adjusting nut To adjust the distance between the brake lever and the han dlebar grip turn the adjusting nut while holding the lever pushed away from the handlebar grip Make sure that the mark on the adjusting nut is aligned with the mark on the brake lever EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear b...

Page 24: ... cover NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked EWA00025 WARNING Make sure that the fuel tank cap is properly closed before riding EAU03753 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown EW000130 WARNING _ Do not ove...

Page 25: ...asoline will cause se vere damage to internal engine parts such as the valves and piston rings as well as to the exhaust sys tem _ Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded fuel Use of unleaded fuel will extend spark plug life and reduce ...

Page 26: ...cked and clean it if necessary EAU03839 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke EAU02925 Seat To remove the seat Insert the key into the seat lock turn it counterclockwise and then pull the seat off 1 Fue...

Page 27: ...lmet to the helmet holder 1 Remove the seat See page 3 11 for removal and installation proce dures 2 Attach the helmet to the helmet holder and then securely install the seat EW000030 WARNING Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident To release the helmet from the helmet holder Remove the seat remove the...

Page 28: ... EAU00285 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts EW000035 WARNING _ Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result _ Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre...

Page 29: ...d and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b NOTE _ Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench included in the owner s tool kit to make the ad justment _ 1 Spring preload adjusting ri...

Page 30: ...o excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yamaha dealer service the shock absorber EAU04389 Luggage strap holders There are two luggage strap holders below the rear of the seat EAU00330 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot whil...

Page 31: ...n circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch lever is pulled but the sidestand is still down It cuts the...

Page 32: ...he clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle shou...

Page 33: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_4km book Page 1 Tuesday August 28 2001 9 51 AM ...

Page 34: ...Check vehicle for oil leakage 6 8 Final gear oil Check vehicle for oil leakage 6 11 6 12 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 22 6 23 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system ...

Page 35: ... 6 20 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 25 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 25 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 25 6 26 Chassis fasteners Make sure that all nuts bolts and screws are properly tightene...

Page 36: ...E_4km book Page 3 Tuesday August 28 2001 9 51 AM ...

Page 37: ...S 5 Starting the engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Recommended shift points for Switzerland only 5 4 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 E_4km book Page 1 Tuesday August 28 2001 9 51 AM ...

Page 38: ...tarting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 WARNING _ Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 17 Never ride with the sidestand down _ 1 Turn the key to ON and make sur...

Page 39: ...arning light does not come on when push ing the start switch or if it does not go off after starting with suf ficient engine oil have a Yamaha dealer check the elec trical circuit If the fuel level warning light re mains on after starting stop the engine and then check the fuel level If necessary refuel as soon as possible and then check the warning light again If the warning light does not come o...

Page 40: ...ion press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it EC000048 CAUTION Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the trans...

Page 41: ...ile shift ing down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traf fic lights or at railroad crossings EAU01128 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1 600 km For this rea son you should read the following ma te...

Page 42: ...ly EC000053 CAUTION _ Keep the engine speed out of the tachometer red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle _ EAU00460 Parking When parking stop the engine and then remove the key from the main switch EW000058 WARNING Since the engine and exhaust system can become very hot park in a place where pedestri ans or...

Page 43: ...the front and rear brake pads 6 22 Checking the brake fluid level 6 23 Changing the brake fluid 6 24 Checking and lubricating the cables 6 24 Checking and lubricating the throttle grip and cable 6 24 Checking and lubricating the brake and shift pedals 6 25 Checking and lubricating the brake and clutch levers 6 25 Checking and lubricating the centerstand and sidestand 6 25 Lubricating the rear susp...

Page 44: ...or cycle maintenance work have a Yamaha dealer do it for you EAU03758 Owner s tool kit The owner s tool kit is located under the seat See page 3 11 for seat re moval and installation procedures The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional t...

Page 45: ... CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust Every 20 000 km 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever wor...

Page 46: ...y tightened 16 Sidestand centerstand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assembly Check operation and shock absorber for oil leakage 20 Rear suspension relay arm and connecting arm pivoting points Check operation Lubricate with lithium soap based grease 21 Carburetors Check starter choke operation Adjust ...

Page 47: ...eplace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged _ 25 Front and rear brake switches Check operation 26 Moving parts and cables Lubricate 27 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1 000 km ANNUAL CHECK 1 1...

Page 48: ...moved and installed EAU03595 Cowling A To remove the cowling 1 Remove the seat See page 3 11 for seat removal and installation procedures 2 Remove the screws and then pull the cowling off as shown NOTE Pull the cowling up then back to re move it To install the cowling 1 Place the cowling in the original position and then install the screws 2 Install the seat 1 Cowling A 2 Cowling B 1 Cowling A 2 S...

Page 49: ...dures 2 Remove the grab bar by removing the bolts 3 Remove the screws and then pull the cowling off as shown To install the cowling 1 Place the cowling in the original position and then install the screws 2 Install the grab bar by installing the bolts 3 Install cowling A 1 Grab bar 2 Cowling B 1 Bolt 2 1 Screw 2 E_4km book Page 6 Tuesday August 28 2001 9 51 AM ...

Page 50: ...l spark plugs installed in the engine should have the same color If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the motorcycle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark...

Page 51: ...il level 1 Place the motorcycle on the cen terstand NOTE _ Make sure that the motorcycle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading _ 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right s...

Page 52: ...t the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE _ Skip steps 4 6 if the oil filter cartridge is not being replaced _ 4 Remove the oil filter cartridge with an oil filter wrench NOTE _ An oil filter wrench is available at a Yamaha dealer _ 1 Engine oil filler cap 1 Engine oil drain bolt 1 Oil filter cartridge 2 Oil filter wrench E_4km book P...

Page 53: ...hemical additives with the oil or use oils of grade CD or higher In addition do not use oils labeled ENERGY CON SERVING II or higher Make sure that no foreign mate rial enters the crankcase _ 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause NOTE _ After the engine is started the e...

Page 54: ...d repair the motorcycle In addition the final gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart EW000066 WARNING _ Make sure that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or wheel _ To check the final gear oil level 1 Place the motorcycle on the cen terstand NOTE _ The final gear oil level ...

Page 55: ... the final gear case 3 Install the final gear oil drain bolt and then tighten it to the specified torque 4 Add the recommended final gear oil to the brim of the filler hole NOTE _ GL4 is a quality rating Hypoid gear oils rated GL5 or GL6 may also be used _ 5 Install and tighten the filler bolt 6 Check the final gear case for oil leakage If oil is leaking check for the cause 1 Final gear oil filler...

Page 56: ...g in unusually wet or dusty areas 1 Remove the seat See page 3 11 for seat removal and installation procedures 2 Turn the fuel cock lever to OFF and then disconnect the fuel hose 3 Remove the fuel tank bolts 4 Disconnect the fuel sender cou pler and then take the fuel tank off 5 Remove the air filter case cover by removing the screws 1 Fuel tank 2 Fuel hose 3 Fuel sender coupler 4 Fuel cock lever ...

Page 57: ...ION Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the pistons and or cylinders may become excessively worn 9 Install the air filter case cover by installing the screws 10 Connect the fuel sender coupler and then install the fuel tank by in stalling the bolts 11 Connect the fu...

Page 58: ...2 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Start the engine and warm it up for several minutes at 1 000 2 000 r min while occasionally rev ving it to 4 000 5 000 r min NOTE The engine is warm when it quickly re sponds to the throttle 2 Check the engin...

Page 59: ...if necessary have a Yamaha dealer adjust it EAU00637 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart a Throttle cable free play E_4km book Page 16 Tuesday Aug...

Page 60: ...ecautions in mind NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider passenger cargo and accesso ries does not exceed the speci fied maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Securely pack the heaviest items close to the cen...

Page 61: ... country Always comply with the local regulations EW000079 WARNING Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the motorcycle with excessively worn tires decreases riding sta bility and can lead to loss of control The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional kno...

Page 62: ... specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approximately 100 km after installing a new tire The tires must be warmed up before a high speed run Always adj...

Page 63: ... The clutch lever free play should mea sure 10 15 mm as shown Periodically check the clutch lever free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch lever 2 To increase the clutch lever free play turn the adjusting bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b 3 If the specified clutch lever free play could be obt...

Page 64: ...c system will diminish the braking performance which may result in loss of control and an accident _ EAU00713 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear b...

Page 65: ...chart Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake If a brake pad has worn to the point that the wear indicator grooves have almost disappeared have a Yamaha dealer replace the brake pads as a set 1 Brake pad wear indicator groove 3 Front 1 Brake pad wear indicator groove Rear E_4km book Page 22 Tuesday A...

Page 66: ...li ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in ...

Page 67: ...the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it EW000112 WARNING Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent u...

Page 68: ...e lever pivots should be lu bricated if necessary EAU03371 Checking and lubricating the centerstand and sidestand The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary EW000114 WARNING If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re p...

Page 69: ...ting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease E_4km book Page 26 Tuesday August 28 2001 9 51 AM ...

Page 70: ...ion 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be c...

Page 71: ...aha dealer check or repair the steering EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings E_4km book Page 28 Tuesday August 28 2001 9 51 AM ...

Page 72: ...pt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the bat...

Page 73: ...d the fuse box which contains the fuses for the individual cir cuits are located behind cowling B See page 6 6 for cowling removal and installation procedures If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Fuse box 2 Main fuse 1 Headlight fuse 2 Ignition f...

Page 74: ...e electrical system EAU04136 Replacing the headlight bulb This motorcycle is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Disconnect the headlight coupler and then remove the bulb cover 2 Unhook the headlight bulb holder and then remove the defective bulb EW000119 WARNING _ Headlight bulbs get very hot There fore keep flammable products away from a ...

Page 75: ...ove the tail brake light lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws EC000108 CAUTION _ Do not overtighten the screws oth erwise the lens may break _ EAU03497 Replacing a turn signal light bulb 1 Remove t...

Page 76: ...he front wheel 3 Remove the brake hose holders by removing the bolts 4 Remove the brake calipers by re moving the bolts ECA00047 CAUTION Do not pull the brake lever after the brake caliper has been removed otherwise the brake pads will be forced shut 5 Loosen the front wheel axle pinch bolt then the wheel axle 6 Pull the wheel axle out and then remove the wheel 1 Speedometer cable 1 Bolt 3 2 Brake...

Page 77: ...ace between the brake pads before install ing the brake calipers onto the brake discs _ 5 Install the brake hose holders by installing the bolts 6 Take the motorcycle off the cen terstand so that the front wheel is on the ground 7 Tighten the wheel axle then the front wheel axle pinch bolt and the brake caliper bolts to the specified torques 8 Connect the speedometer cable 9 Push down hard on the ...

Page 78: ...n the cen terstand 3 Remove the brake caliper by re moving the bolts 4 Disconnect the brake torque rod from the brake caliper bracket by removing the cotter pin the nut and the bolt 5 While supporting the rear wheel pull the wheel axle out 6 Remove the brake caliper bracket and spacer 7 Pull the wheel to the right to sepa rate it from the final gear case and then remove it 1 Rear wheel axle pinch ...

Page 79: ...re is enough space between the brake pads before install ing the brake caliper onto the brake disc _ 4 Connect the brake torque rod to the brake caliper bracket by in stalling the bolt and the nut 5 Install the axle nut and then slight ly tighten it 6 Take the motorcycle off the cen terstand so that the rear wheel is on the ground 7 Tighten the rear wheel axle pinch bolt the axle nut the brake cal...

Page 80: ... poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may ...

Page 81: ...nition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over q...

Page 82: ...E_4km book Page 39 Tuesday August 28 2001 9 51 AM ...

Page 83: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_4km book Page 1 Tuesday August 28 2001 9 51 AM ...

Page 84: ...well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION Avoid using strong acidic wheel cleaners especially on...

Page 85: ...nd shield is scratched use a quali ty plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After ridi...

Page 86: ...painted surfaces 7 Let the motorcycle dry completely before storing or covering it EWA00031 WARNING Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braking performance and cor ne...

Page 87: ...event fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bo...

Page 88: ... every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C or more than 30 C For more information on storing the battery ...

Page 89: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 E_4km book Page 1 Tuesday August 28 2001 9 51 AM ...

Page 90: ...Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter cartridge replacement 3 2 L With oil filter cartridge replacement 3 4 L Total amount dry engine 4 4 L 20 10 0 10 20 30 40 50 C SAE 10W 30 SAE 15W 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 CAUTION Be sure to use motor oils that do not contain anti f...

Page 91: ...et multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 672 Secondary reduction system Shaft drive Secondary reduction ratio 1 278 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 188 2nd 1 500 3rd 1 154 4th 0 933 5th 0 813 Chassis Frame type Double cradle Caster angle 27 Trail 121 mm Tire Front Type Tubeless tire Size 120 70 17 58V 12...

Page 92: ...go and accessories Wheels Front Type Cast wheel Size 17 MT 3 00 17 M C MT 3 00 Rear Type Cast wheel Size 17 MT 4 00 17 M C MT 4 00 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm link suspension Spring shock absorber Front Coil spring oil damper Rear Coil spring gas oil da...

Page 93: ...l light 12 V 21 W 4 Meter lighting 12 V 3 4 W 4 Neutral indicator light 12 V 3 4 W 1 High beam indicator light 12 V 3 4 W 1 Oil level warning light 12 V 3 4 W 1 Turn signal indicator light 12 V 3 4 W 2 Fuel level warning light 12 V 3 4 W 1 Fuses Main fuse 30 A Signaling system fuse 20 A Headlight fuse 15 A Hazard fuse 10 A Ignition fuse 10 A Clock fuse 10 A E_4km book Page 4 Tuesday August 28 2001...

Page 94: ...IMPERIAL SYSTEM Metric unit Conversion factor Imperial unit Torque m kgf m kgf cm kgf cm kgf 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous ...

Page 95: ...CONSUMER INFORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 E_4km book Page 1 Tuesday August 28 2001 9 51 AM ...

Page 96: ...01E EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space provided NOTE The vehicle identification number is used to identify y...

Page 97: ...e frame under the seat See page 3 11 for seat removal and installation procedures Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label E_4km book Page 2 Tuesday August 28 2001 9 51 AM ...

Page 98: ... Fuel gauge 3 5 Fuel level warning light 3 2 Fuel tank breather hose Germany only 3 11 Fuel tank cap 3 9 Fuses replacing 6 30 H Handlebar switches 3 6 Hazard switch 3 6 Headlight bulb replacing 6 31 Helmet holder 3 12 High beam indicator light 3 3 Horn switch 3 6 I Identification numbers 9 1 Idling speed adjusting 6 15 Ignition circuit cut off system 3 16 Indicator and warning lights 3 2 K Key ide...

Page 99: ...le checking and lubricating 6 24 Tires 6 17 Tool kit 6 1 Troubleshooting 6 37 Troubleshooting chart 6 38 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 32 Turn signal switch 3 6 V Valve clearance adjusting 6 16 Vehicle identification number 9 1 W Wheel bearings checking 6 28 Wheel front 6 33 Installing 6 34 Removing 6 33 Wheel rear 6 35 Installing 6 36 Removing 6 35 Wheels 6 2...

Page 100: ...E_5GK_Consumer fm Page 11 Wednesday June 13 2001 1 03 PM ...

Page 101: ...E_5GK_Consumer fm Page 11 Wednesday June 13 2001 1 03 PM ...

Page 102: ...4KM 28199 E7 OWNER S MANUAL XJ900S PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2001 7 0 3 1 CR E ...

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Yamaha diversion 900 XJ900S, Owner'S Manual

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