The Yamaha XJ900, produced between 1984 and 1994, is a distinguished sport-touring motorcycle known for its robust engineering and reliable performance. Featuring an air-cooled, 4-stroke, DOHC inline-four engine with an 853 cc displacement, it delivered impressive power and torque suitable for long-distance journeys and spirited riding. Its design, which evolved to include models like the XJ900F and the faired XJ900S Diversion, emphasized comfort, stability, and a smooth shaft drive, solidifying its reputation as a capable and enduring machine.
This comprehensive workshop repair service manual provides essential information for maintaining and repairing the Yamaha XJ900 across its production years. It covers all major systems, including the engine, transmission, fuel, ignition, lubrication, exhaust, and electrical systems, detailing procedures for routine maintenance, tune-ups, assembly, disassembly, and troubleshooting. With clear instructions, special tool identification, and emphasis on safety, this manual is an indispensable resource for professional technicians and knowledgeable owners alike, ensuring the longevity and optimal performance of their XJ900.
Production Years:
1984-1994
Chassis Codes:
XJ900F, XJ900S Diversion (later variants)
Target Audience:
Mechanical technicians familiar with BRP products and general automobile practices, as well as knowledgeable owners aiming for DIY repairs.
Value Proposition:
Provides access to authorized dealer service department level information, enabling professional-quality repairs and maintenance, saving costs compared to dealership labor.
Accuracy And Reliability:
Endeavored to ensure accuracy, providing the most reliable information for effective vehicle maintenance and repair.
Safety Emphasis:
Highlights safety precautions and the importance of using safety equipment and tools like torque wrenches.
Special Tool Identification:
Identifies and illustrates special tools recommended or required for specific adjustments or repairs, often by Yamaha special tool number.
Primary Aim:
To help owners and technicians get the best value from their Yamaha XJ900 by facilitating informed maintenance and repair.
Covered Models:
Yamaha XJ900 (1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994)
Type:
Workshop Repair Service Manual
Engine:
Complete repair and overhaul, including engine disassembly and reassembly.
Transmission:
Complete repair and overhaul, including transmission disassembly and reassembly.
Fuel System:
Detailed coverage of fuel system components, maintenance, and troubleshooting.
Ignition System:
Comprehensive information on the ignition system, including diagnostics and repair.
Lubrication System:
Procedures for lubrication system maintenance and repair.
Exhaust System:
Information related to the exhaust system components and servicing.
Electrical System:
Detailed coverage of the entire electrical system, including wiring diagrams and troubleshooting.
Bodywork:
Procedures for body panel removal, installation, and general body maintenance.
Routine Maintenance:
Instructions for routine maintenance and servicing procedures.
Troubleshooting:
Diagnostic and repair procedures for identifying and resolving common issues.
Assembly Disassembly:
Detailed step-by-step instructions for component and system assembly and disassembly.
Tune Ups:
Procedures for performing comprehensive tune-ups to optimize engine performance.
Removal Installation:
Guidance on the removal and installation of various vehicle components.
Depth:
Comprehensive, suitable for professional technicians, covering routine maintenance to full engine and transmission overhauls.
Binding:
Digital Download (PDF)
Paper Type:
Not Applicable (Digital)
Delivery:
Fast and Free Electronic Delivery via Email
Type:
Air-cooled, 4-stroke, DOHC, inline-four cylinder
Displacement:
853 cc (52.0 cu in)
Bore X Stroke:
67.0 mm x 61.0 mm (approximate for early models)
Compression Ratio:
9.5:1 (typical)
Power Output:
Approx. 80-90 hp (60-67 kW) at 8,500 rpm (varies by year and market)
Torque:
Approx. 72 Nm (53 lb-ft) at 7,500 rpm (varies by year and market)
Carburetion:
Four Mikuni BS32 or similar constant velocity carburetors
Fuel Capacity:
22 Liters (5.8 US gal) (typical)
Oil Capacity With Filter:
Approx. 4.0 Liters (4.2 US qt)
Type:
5-speed, constant mesh
Clutch:
Wet, multiple disc, cable operated
Length:
Approx. 2,200 mm (86.6 in)
Width:
Approx. 750 mm (29.5 in)
Height:
Approx. 1,250 mm (49.2 in)
Dry Weight:
Approx. 230 kg (507 lbs)
Wet Weight:
Approx. 245 kg (540 lbs)
Safety Standards:
Adheres to relevant motorcycle safety standards of its era; specific crash test ratings not applicable in the same manner as cars.
Braking System Front:
Dual disc brakes with twin-piston calipers (e.g., 298mm discs)
Braking System Rear:
Single disc brake with twin-piston caliper (e.g., 267mm disc)
Suspension Front:
Telescopic fork with adjustable air pressure and rebound damping (e.g., 41mm stanchions)
Suspension Rear:
Swingarm with adjustable twin shock absorbers (e.g., Monoshock system in later Diversion models)
Lighting:
Halogen headlight, taillight, turn signals
Instrumentation:
Speedometer, tachometer, fuel gauge, indicator lights
Audio System:
Not equipped with integrated audio system in original factory configuration.
Electronic Aids:
Lacks modern electronic rider aids such as ABS or traction control, as it predates widespread adoption.
Gps Integration:
No integrated GPS or smartphone connectivity from the factory.
Oil Change:
Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first (typical recommendation).
Spark Plug Check:
Every 6,000-10,000 km (3,700-6,000 miles) or annually.
Valve Clearance Check:
Every 12,000-18,000 km (7,500-11,000 miles) or as specified in the manual.
Engine Oil Type:
API SG, SF or SE, SAE 10W-40 or 20W-50 (consult manual for exact specifications based on climate).
Brake Fluid Type:
DOT 3 or DOT 4 (consult manual for specific recommendation).
Coolant Type:
Not applicable (air-cooled engine).
Final Drive Oil:
Yamalube Hypoid Gear Oil or equivalent SAE 85W-90 API GL-4 or GL-5.
Electrical Connections:
Corrosion or loose connections in wiring harness, especially around battery terminals and grounds, can lead to intermittent electrical issues.
Carburetor Sync:
Carburetors may require periodic synchronization for smooth running and optimal performance.
Fork Seals:
Leaking fork seals are a common wear item on older motorcycles.
Charging System:
Stator or rectifier/regulator issues can affect battery charging.
Yamaha Motor Cycles:
Yamaha Motor Company has a rich history in motorcycle manufacturing, known for innovation, performance, and reliability across various classes, from sportbikes to cruisers and touring motorcycles.
Xj900 Development:
The XJ900 was a significant model in Yamaha's lineup, representing a powerful and versatile sport-touring motorcycle. It evolved through various iterations, including the XJ900F and later the XJ900S Diversion, which introduced a full fairing and improved aerodynamics.
Manufacturing Location:
Japan
Market Segment:
Sport-touring
Performance Reviews:
Consistently praised in contemporary reviews for its strong performance, comfortable ergonomics, and suitability for long-distance touring.
Reliability Reputation:
Generally regarded as a reliable and robust motorcycle, particularly well-suited to touring and commuting duties.
