Yamaha XJ900 Diversion 1995-2001 Workshop Service Manual
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This manual covers the XJ900 Diversion, a sport-touring motorcycle produced from 1995 to 2001. Known for its smooth inline-four engine, comfortable ergonomics, and practical fairing for wind protection, the XJ900 Diversion offered a blend of performance and touring capability. It was engineered with a commitment to quality and reliability, making it a capable machine for both spirited riding and longer journeys. This first-generation model represents a significant entry in the XJ series, building upon previous iterations to provide a refined riding experience. This comprehensive workshop service manual provides detailed information for the maintenance, repair, and overhaul of your XJ900 Diversion. It covers all major systems, including the engine, fuel system, ignition, electrical components, transmission, brakes, suspension, and chassis. The manual includes step-by-step repair instructions, diagnostic procedures, technical specifications, and routine maintenance schedules. Its purpose is to empower owners and technicians with the knowledge necessary to keep the motorcycle in optimal condition, ensuring its longevity and performance. 🏷️ Basic Information Identification Make: Yamaha Model: XJ900 Diversion Generation Generation Designation: First Generation Codes Internal Model Code: N/A (typically derived from VIN or factory documentation) 👋 Introduction Market Position Category: Sport Touring Motorcycle Competitive Analysis Key Competitors: Honda CBR1000F, Kawasaki ZZR1100, Suzuki GSX1100F Katana (though Diversion offered a more relaxed touring focus) Key Features Distinguishing Features: Smooth inline-four engine, comfortable ergonomics for touring, shaft drive (on many models of this era, though not explicitly stated for this specific manual's coverage, it was a hallmark of the XJ series), practical fairing for wind protection. Manual Value Proposition Owner Benefit: Enables informed DIY maintenance and repairs, saving costs and time compared to dealership visits. Manual Utility Professional Standard: Provides information equivalent to authorized dealer service departments. 📋 Manual Details Coverage Areas Applicable Years: 1995, 1996, 1997, 1998, 1999, 2000, 2001 Page Count Total Pages: 352 Manual Type Type: Workshop Service Manual / Repair Manual Language Primary Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Comprehensive Engine Overhaul, Repair, Tune-ups Fuel System: Carburetor system, fuel delivery, filters Ignition System: Ignition timing, components, troubleshooting Lubrication System: Oil pump, passages, oil change procedures Exhaust System: Muffler, pipes, gasket replacement Electrical System: Wiring diagrams, charging system, lighting, starting system Bodywork: Fairings, panels, seat, fuel tank removal/installation Transmission: Gearbox disassembly and assembly, clutch operation Cooling System: Radiator, hoses, thermostat (if applicable) Suspension: Front forks, rear shock absorber, linkage (if applicable) Brakes: Front and rear brake systems, hydraulic components, pad replacement Wheels And Tires: Tire maintenance, wheel bearing replacement Chassis And Frame: Frame inspection, headstock bearings Procedures Included Maintenance: Routine servicing, lubrication, adjustments Troubleshooting: Diagnostic procedures for common and complex issues Repair: Detailed step-by-step repair instructions for all major components Overhaul: Complete engine and component overhaul procedures Removal Installation: Component removal and installation procedures Assembly Disassembly: Detailed procedures for assembling and disassembling mechanical units Tune Ups: Engine tuning, carburetor synchronization Technical Depth Depth Of Coverage: Comprehensive, covering routine maintenance to complete engine rebuilds User Assumption: Technicians conversant with general automotive/motorcycle practices Special Emphasis: Highlights special aspects of Yamaha XJ900 Diversion and proprietary components 📊 Manual Specifications File Format Format: PDF Print Quality Printable: Yes Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Delivery Method Delivery: Fast and Free Electronic Delivery via Email ⚙️ Engine Specifications Primary Engine Engine Type: Inline Four-Cylinder, 4-stroke Displacement: 892 cc (approximate, based on XJ900 lineage) Bore X Stroke: N/A (Specific to the 1995-2001 model covered by the manual) Compression Ratio: N/A (Specific to the 1995-2001 model covered by the manual) Performance Horsepower: Approx. 98 HP (varies slightly by market and specific tune) Torque: Approx. 78 Nm (58 lb-ft) at ~6,000 RPM Fuel System Carburetion: Mikuni BS36 CV carburetors (typical for this model) Fuel Capacity: Approx. 20 Liters (5.3 US gal) Cooling System Cooling Method: Air-cooled (primary), with oil cooling passages 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Optional Transmission Options: N/A (Standard) Features Drive Type: Shaft Drive (likely, standard on XJ900) Fluid Specifications Transmission Oil Type: Yamalube SAE 10W-30 API SG or higher (typical recommendation, manual will specify exact) 📐 Dimensions Exterior Length: Approx. 2235 mm (88.0 in) Width: Approx. 780 mm (30.7 in) Height: Approx. 1235 mm (48.6 in) Weights Dry Weight: Approx. 225 kg (496 lbs) Wet Weight: Approx. 246 kg (542 lbs) 🛡️ Safety Features Ratings Safety Certifications: N/A (Motorcycle safety is governed by design and operational standards, not typically crash ratings like cars) Active Features Braking System: Dual 298mm discs with 4-piston calipers (front), 267mm disc with 2-piston caliper (rear) - typical for this model. Passive Features Lighting System: Halogen headlight, LED taillight/indicators (depending on specific regional variant) 💡 Technology Features Infotainment Instrument Cluster: Analog speedometer, tachometer, fuel gauge, and warning lights. Driver Assistance Electronic Aids: N/A (This era of motorcycle typically lacked electronic rider aids like ABS or traction...
This manual covers the XJ900 Diversion, a sport-touring motorcycle produced from 1995 to 2001. Known for its smooth inline-four engine, comfortable ergonomics, and practical fairing for wind protection, the XJ900 Diversion offered a blend of performance and touring capability. It was engineered with a commitment to quality and reliability, making it a capable machine for both spirited riding and longer journeys. This first-generation model represents a significant entry in the XJ series, building upon previous iterations to provide a refined riding experience.
This comprehensive workshop service manual provides detailed information for the maintenance, repair, and overhaul of your XJ900 Diversion. It covers all major systems, including the engine, fuel system, ignition, electrical components, transmission, brakes, suspension, and chassis. The manual includes step-by-step repair instructions, diagnostic procedures, technical specifications, and routine maintenance schedules. Its purpose is to empower owners and technicians with the knowledge necessary to keep the motorcycle in optimal condition, ensuring its longevity and performance.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XJ900 Diversion
Generation
Generation Designation:
First Generation
Codes
Internal Model Code:
N/A (typically derived from VIN or factory documentation)
👋 Introduction
Market Position
Category:
Sport Touring Motorcycle
Competitive Analysis
Key Competitors:
Honda CBR1000F, Kawasaki ZZR1100, Suzuki GSX1100F Katana (though Diversion offered a more relaxed touring focus)
Key Features
Distinguishing Features:
Smooth inline-four engine, comfortable ergonomics for touring, shaft drive (on many models of this era, though not explicitly stated for this specific manual's coverage, it was a hallmark of the XJ series), practical fairing for wind protection.
Manual Value Proposition
Owner Benefit:
Enables informed DIY maintenance and repairs, saving costs and time compared to dealership visits.
Manual Utility
Professional Standard:
Provides information equivalent to authorized dealer service departments.
📋 Manual Details
Coverage Areas
Applicable Years:
1995, 1996, 1997, 1998, 1999, 2000, 2001
Page Count
Total Pages:
352
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Primary Language:
English
Format
Digital Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive Engine Overhaul, Repair, Tune-ups
Fuel System:
Carburetor system, fuel delivery, filters
Ignition System:
Ignition timing, components, troubleshooting
Lubrication System:
Oil pump, passages, oil change procedures
Exhaust System:
Muffler, pipes, gasket replacement
Electrical System:
Wiring diagrams, charging system, lighting, starting system
Bodywork:
Fairings, panels, seat, fuel tank removal/installation
Transmission:
Gearbox disassembly and assembly, clutch operation
Cooling System:
Radiator, hoses, thermostat (if applicable)
Suspension:
Front forks, rear shock absorber, linkage (if applicable)
Brakes:
Front and rear brake systems, hydraulic components, pad replacement
Wheels And Tires:
Tire maintenance, wheel bearing replacement
Chassis And Frame:
Frame inspection, headstock bearings
Procedures Included
Maintenance:
Routine servicing, lubrication, adjustments
Troubleshooting:
Diagnostic procedures for common and complex issues
Repair:
Detailed step-by-step repair instructions for all major components
Overhaul:
Complete engine and component overhaul procedures
Removal Installation:
Component removal and installation procedures
Assembly Disassembly:
Detailed procedures for assembling and disassembling mechanical units
Tune Ups:
Engine tuning, carburetor synchronization
Technical Depth
Depth Of Coverage:
Comprehensive, covering routine maintenance to complete engine rebuilds
User Assumption:
Technicians conversant with general automotive/motorcycle practices
Special Emphasis:
Highlights special aspects of Yamaha XJ900 Diversion and proprietary components
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printable:
Yes
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Delivery Method
Delivery:
Fast and Free Electronic Delivery via Email
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline Four-Cylinder, 4-stroke
Displacement:
892 cc (approximate, based on XJ900 lineage)
Bore X Stroke:
N/A (Specific to the 1995-2001 model covered by the manual)
Compression Ratio:
N/A (Specific to the 1995-2001 model covered by the manual)
Performance
Horsepower:
Approx. 98 HP (varies slightly by market and specific tune)
Torque:
Approx. 78 Nm (58 lb-ft) at ~6,000 RPM
Fuel System
Carburetion:
Mikuni BS36 CV carburetors (typical for this model)
Fuel Capacity:
Approx. 20 Liters (5.3 US gal)
Cooling System
Cooling Method:
Air-cooled (primary), with oil cooling passages
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Optional
Transmission Options:
N/A (Standard)
Features
Drive Type:
Shaft Drive (likely, standard on XJ900)
Fluid Specifications
Transmission Oil Type:
Yamalube SAE 10W-30 API SG or higher (typical recommendation, manual will specify exact)
📐 Dimensions
Exterior
Length:
Approx. 2235 mm (88.0 in)
Width:
Approx. 780 mm (30.7 in)
Height:
Approx. 1235 mm (48.6 in)
Weights
Dry Weight:
Approx. 225 kg (496 lbs)
Wet Weight:
Approx. 246 kg (542 lbs)
🛡️ Safety Features
Ratings
Safety Certifications:
N/A (Motorcycle safety is governed by design and operational standards, not typically crash ratings like cars)
Active Features
Braking System:
Dual 298mm discs with 4-piston calipers (front), 267mm disc with 2-piston caliper (rear) - typical for this model.
Passive Features
Lighting System:
Halogen headlight, LED taillight/indicators (depending on specific regional variant)
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer, tachometer, fuel gauge, and warning lights.
Driver Assistance
Electronic Aids:
N/A (This era of motorcycle typically lacked electronic rider aids like ABS or traction control).
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 4,000 km (2,500 miles) or annually, whichever comes first (typical, manual will confirm).
Spark Plug Replacement:
Every 12,000 km (7,500 miles) (typical, manual will confirm).
Valve Clearance Check:
Every 24,000 km (15,000 miles) (typical, manual will confirm).
Fluid Specifications
Engine Oil Capacity:
Approx. 3.3 Liters (3.5 US qt) with filter change (typical, manual will confirm).
Coolant Type:
N/A (Air-cooled engine, but check manual for any specific fluid requirements).
Brake Fluid Type:
DOT 3 or DOT 4 Brake Fluid (manual will specify exact)
Known Issues
Common Wear Items:
Cam chain tensioner, rectifier/regulator, fork seals, carburetor O-rings (common for motorcycles of this age and type).
Maintenance Importance:
Regular maintenance, especially of the fuel and ignition systems, is crucial for optimal performance and longevity.
Special Tools
Tool Requirement:
Manual may reference specific Yamaha special tools for precise adjustments and repairs, such as torque wrenches, specialized pullers, or diagnostic tools.
📚 Vehicle History
Brand Heritage
Manufacturer Focus:
Yamaha Motor Company is renowned for its performance motorcycles, musical instruments, and marine products. In motorcycles, they have a strong history in racing and innovation.
Model Evolution
Xj Series Lineage:
The XJ900 Diversion evolved from earlier XJ models, aiming to blend the performance of the larger displacement bikes with a more comfortable, faired touring package. It was a successor to the XJ900F.
Production
Production Period:
1995-2001 for the specific generation covered by this manual.
🏆 Awards & Recognition
Recognitions
Industry Awards:
N/A (Specific model awards are not readily available for this generation, but Yamaha's overall reputation is strong).
Ratings
Owner Satisfaction:
Generally regarded as a reliable and comfortable sport-touring machine by its owners.