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Yamaha XJ900G 1995-2001 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Yamaha Model: XJ900G Model Nickname: Diversion (in some markets) Generation Generation Code: Not explicitly defined, but refers to the later iteration of the XJ900 series. Codes Chassis Code: 4KM (typical for this generation) 👋 Introduction Market Position Segment: Sport Touring Motorcycle Target Audience: Riders seeking a comfortable, reliable, and capable motorcycle for commuting, touring, and general riding. Competitive Analysis Key Competitors: Honda CB750, Kawasaki GTR1000, Suzuki GSX1100G (air-cooled variants). Key Features Engine Layout: In-line four-cylinder, air-cooled engine. Drivetrain: Shaft drive for low maintenance and smooth power delivery. Suspension Setup: Monoshock rear suspension for improved handling and adjustability. Ergonomics: Comfortable riding position suitable for longer distances. 📋 Manual Details Coverage Areas Years Covered: 1995, 1996, 1997, 1998, 1999, 2000, 2001 Page Count Page Count: 352 Manual Type Manual Type: Workshop Repair Service Manual Language Language: English (assumed, based on product description) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage including disassembly, inspection, assembly, tuning, and troubleshooting of the engine. Fuel System: Carburetor overhaul and adjustment (likely Mikuni CV type), fuel pump, fuel lines, and tank. Ignition System: CDI ignition system components, timing, spark plugs, and troubleshooting. Transmission: Clutch operation, gearbox overhaul, gear selection mechanism, and lubrication. Drivetrain: Shaft drive system maintenance, universal joints, final drive housing, and lubrication. Suspension: Front fork (telescopic) inspection, seal replacement, oil levels, and rear monoshock absorber adjustment and service. Brakes: Front and rear brake systems, caliper overhaul, master cylinders, brake fluid, pad replacement, disc inspection, and bleeding procedures. Electrical System: Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starter motor, lighting, instruments, and switches. Cooling System: Air-cooled engine design, but may cover related components like oil coolers if equipped. Frame And Bodywork: Chassis inspection, fairing removal and installation, seat, fuel tank mounting, and related hardware. Wheels And Tires: Wheel bearing inspection and replacement, tire fitting and pressure recommendations. Procedures Included Preventative Maintenance: Detailed guides for routine servicing, oil changes, filter replacements, and general inspections. Troubleshooting: Systematic diagnostic procedures for common and uncommon problems, symptom analysis. Repair And Overhaul: Step-by-step instructions for complete disassembly, repair, and reassembly of all major components. Component Replacement: Specific guidance on replacing wear items such as brake pads, tires, batteries, and filters. Adjustments: Carburetor synchronization, valve clearance adjustment, chain tension (if applicable, though shaft drive), and brake lever free play. Wiring Diagrams: Complete electrical schematics for troubleshooting and component identification. Technical Depth Depth: Extremely comprehensive, covering everything from basic user maintenance to full engine and gearbox rebuilds. Diagnostics: Detailed diagnostic flowcharts and symptom-based troubleshooting guides for electrical and mechanical issues. Rebuild Specifications: Includes critical tolerance specifications, torque values, and assembly sequences for all major engine and chassis components. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Printability: Printable for offline use and on-the-bench reference. Print Quality Image Resolution: Expected to be high enough for clear viewing of diagrams and illustrations. Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, 4-stroke, DOHC, inline-four cylinder Displacement: 892 cc (892 cubic centimeters) Bore X Stroke: 73.0 mm x 51.5 mm Compression Ratio: 9.5:1 Performance Horsepower: Approximately 80-90 PS (59-66 kW) at 8,000 rpm (varies by market and tuning). Torque: Approximately 75-80 Nm (55-59 lb-ft) at 7,000 rpm (varies by market and tuning). Fuel System Carburetor Type: Likely Mikuni BS32 (Butterfly Spigot) 32mm constant velocity carburetors (4 units). Fuel Capacity: Approximately 21 Liters (5.5 US gallons). Lubrication Oil Capacity: Approximately 3.4 Liters (3.6 US quarts) with filter change. Lubrication Oil Type Specification: Yamaha recommends SAE 20W-40 or SAE 10W-30 API SE, SF, SG, SH or SJ Service Classification. Check manual for specific viscosity based on temperature. 🔧 Transmission Standard Transmission Type: 5-speed manual constant mesh Optional Optional Transmission: N/A Features Drive Type: Shaft drive Clutch Type: Wet, multi-plate 📐 Dimensions Exterior Length: Approximately 2235 mm (88.0 in) Width: Approximately 795 mm (31.3 in) Height: Approximately 1300 mm (51.2 in) Wheelbase: Approximately 1510 mm (59.4 in) Weights Dry Weight: Approximately 220 kg (485 lbs) Wet Weight: Approximately 242 kg (533.5 lbs) Tires Front Tire Size: 120/70-17 Rear Tire Size: 150/80-16 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycles are not typically rated by organizations like NHTSA or Euro NCAP). Active Features Braking System: Dual front disc brakes, single rear disc brake. Suspension Features: Adjustable rear monoshock for optimized handling and load carrying. Passive Features Lighting: Halogen headlamp for improved night visibility. 💡 Technology Features Infotainment Infotainment System: N/A (No integrated infotainment system; typical for motorcycles of this era). Driver Assistance Driver Assistance Features: N/A (Motorcycle-specific; features like ABS were not standard on most XJ900G models). Connectivity Connectivity Features: N/A Instrumentation Instrument Panel: Analog speedometer, tachometer, fuel gauge, coolant temperature gauge (if applicable, likely not for air-cooled),...
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Yamaha XJ900G 1995-2001 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XJ900G
Model Nickname:
Diversion (in some markets)
Generation
Generation Code:
Not explicitly defined, but refers to the later iteration of the XJ900 series.
Codes
Chassis Code:
4KM (typical for this generation)
👋 Introduction
Market Position
Segment:
Sport Touring Motorcycle
Target Audience:
Riders seeking a comfortable, reliable, and capable motorcycle for commuting, touring, and general riding.
Competitive Analysis
Key Competitors:
Honda CB750, Kawasaki GTR1000, Suzuki GSX1100G (air-cooled variants).
Key Features
Engine Layout:
In-line four-cylinder, air-cooled engine.
Drivetrain:
Shaft drive for low maintenance and smooth power delivery.
Suspension Setup:
Monoshock rear suspension for improved handling and adjustability.
Ergonomics:
Comfortable riding position suitable for longer distances.
📋 Manual Details
Coverage Areas
Years Covered:
1995, 1996, 1997, 1998, 1999, 2000, 2001
Page Count
Page Count:
352
Manual Type
Manual Type:
Workshop Repair Service Manual
Language
Language:
English (assumed, based on product description)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive coverage including disassembly, inspection, assembly, tuning, and troubleshooting of the engine.
Fuel System:
Carburetor overhaul and adjustment (likely Mikuni CV type), fuel pump, fuel lines, and tank.
Ignition System:
CDI ignition system components, timing, spark plugs, and troubleshooting.
Transmission:
Clutch operation, gearbox overhaul, gear selection mechanism, and lubrication.
Drivetrain:
Shaft drive system maintenance, universal joints, final drive housing, and lubrication.
Suspension:
Front fork (telescopic) inspection, seal replacement, oil levels, and rear monoshock absorber adjustment and service.
Brakes:
Front and rear brake systems, caliper overhaul, master cylinders, brake fluid, pad replacement, disc inspection, and bleeding procedures.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starter motor, lighting, instruments, and switches.
Cooling System:
Air-cooled engine design, but may cover related components like oil coolers if equipped.
Frame And Bodywork:
Chassis inspection, fairing removal and installation, seat, fuel tank mounting, and related hardware.
Wheels And Tires:
Wheel bearing inspection and replacement, tire fitting and pressure recommendations.
Procedures Included
Preventative Maintenance:
Detailed guides for routine servicing, oil changes, filter replacements, and general inspections.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, symptom analysis.
Repair And Overhaul:
Step-by-step instructions for complete disassembly, repair, and reassembly of all major components.
Component Replacement:
Specific guidance on replacing wear items such as brake pads, tires, batteries, and filters.
Adjustments:
Carburetor synchronization, valve clearance adjustment, chain tension (if applicable, though shaft drive), and brake lever free play.
Wiring Diagrams:
Complete electrical schematics for troubleshooting and component identification.
Technical Depth
Depth:
Extremely comprehensive, covering everything from basic user maintenance to full engine and gearbox rebuilds.
Diagnostics:
Detailed diagnostic flowcharts and symptom-based troubleshooting guides for electrical and mechanical issues.
Rebuild Specifications:
Includes critical tolerance specifications, torque values, and assembly sequences for all major engine and chassis components.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Likely text-searchable PDF for efficient information retrieval.
Printability:
Printable for offline use and on-the-bench reference.
Print Quality
Image Resolution:
Expected to be high enough for clear viewing of diagrams and illustrations.
Binding Type
Binding Type:
N/A (Digital PDF Download)
Paper Type
Paper Type:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, DOHC, inline-four cylinder
Displacement:
892 cc (892 cubic centimeters)
Bore X Stroke:
73.0 mm x 51.5 mm
Compression Ratio:
9.5:1
Performance
Horsepower:
Approximately 80-90 PS (59-66 kW) at 8,000 rpm (varies by market and tuning).
Torque:
Approximately 75-80 Nm (55-59 lb-ft) at 7,000 rpm (varies by market and tuning).
Fuel System
Carburetor Type:
Likely Mikuni BS32 (Butterfly Spigot) 32mm constant velocity carburetors (4 units).
Fuel Capacity:
Approximately 21 Liters (5.5 US gallons).
Lubrication
Oil Capacity:
Approximately 3.4 Liters (3.6 US quarts) with filter change.
Lubrication
Oil Type Specification:
Yamaha recommends SAE 20W-40 or SAE 10W-30 API SE, SF, SG, SH or SJ Service Classification. Check manual for specific viscosity based on temperature.
🔧 Transmission
Standard
Transmission Type:
5-speed manual constant mesh
Optional
Optional Transmission:
N/A
Features
Drive Type:
Shaft drive
Clutch Type:
Wet, multi-plate
📐 Dimensions
Exterior
Length:
Approximately 2235 mm (88.0 in)
Width:
Approximately 795 mm (31.3 in)
Height:
Approximately 1300 mm (51.2 in)
Wheelbase:
Approximately 1510 mm (59.4 in)
Weights
Dry Weight:
Approximately 220 kg (485 lbs)
Wet Weight:
Approximately 242 kg (533.5 lbs)
Tires
Front Tire Size:
120/70-17
Rear Tire Size:
150/80-16
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles are not typically rated by organizations like NHTSA or Euro NCAP).
Active Features
Braking System:
Dual front disc brakes, single rear disc brake.
Suspension Features:
Adjustable rear monoshock for optimized handling and load carrying.
Passive Features
Lighting:
Halogen headlamp for improved night visibility.
💡 Technology Features
Infotainment
Infotainment System:
N/A (No integrated infotainment system; typical for motorcycles of this era).
Driver Assistance
Driver Assistance Features:
N/A (Motorcycle-specific; features like ABS were not standard on most XJ900G models).
Connectivity
Connectivity Features:
N/A
Instrumentation
Instrument Panel:
Analog speedometer, tachometer, fuel gauge, coolant temperature gauge (if applicable, likely not for air-cooled), and warning lights.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Recommended every 4,000-6,000 km (2,500-3,700 miles) or annually, whichever comes first. Consult manual for exact intervals.
Valve Clearance Interval:
Typically every 12,000-16,000 km (7,500-10,000 miles). Manual is essential for exact figures.
Spark Plug Replacement:
Recommended at 12,000-16,000 km (7,500-10,000 miles) or based on wear inspection.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific recommendation).
Final Drive Oil Type:
Hypoid gear oil, SAE 80W-90 API GL-5.
Fork Oil Type:
Yamaha Suspension Oil (or equivalent SAE 10W fork oil is common).
Known Issues
Common Wear Items:
Fork seals, clutch plates (with high mileage), carburetor diaphragm wear, and exhaust system corrosion.
Potential Electrical Issues:
Age-related deterioration of wiring insulation, stator or regulator/rectifier failure can occur on older units.
Common Maintenance Tasks
Carburetor Cleaning And Sync:
Essential for smooth running, especially after storage or if issues arise.
Shaft Drive Maintenance:
Regularly check and change the final drive oil as per the manual's schedule.
📚 Vehicle History
Brand Heritage
Brand History Focus:
Yamaha's long-standing reputation for building reliable and performance-oriented motorcycles.
Model Evolution
Xjn Series Context:
The XJ900G is part of Yamaha's long-running XJ series, known for its transverse four-cylinder engines and shaft drive, evolving from earlier models like the XJ650 and XJ750.
Generation Characteristics:
This generation (1995-2001) often featured updated styling, including the 'Diversion' fairing in many markets, enhancing its sport-touring capabilities.
Production
Manufacturing Location:
Japan (primarily)
🏆 Awards & Recognition
Recognitions
Market Reception:
Generally well-regarded for its reliability, comfort, and shaft drive convenience, particularly for touring and commuting.
Ratings
Consumer Ratings:
Praised by owners for its robust engine and low maintenance requirements compared to chain-driven bikes.
Certifications
Emissions Standards:
Built to meet the emissions standards of its respective production years and target markets.
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