Yamaha XSR900 2016-2019 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Yamaha Model: XSR900 Model Codes: XSR900G, XSR900GC Product Name: Yamaha XSR900 2016-2019 Service Repair Workshop Manual Part Number: LIT-11616-29-65 👋 Introduction Market Position Segment: Retro-sport...

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Type: Motorcycle

Vendor:

Sku: 207140

Tags: 2016 2017 2018 2019 Motorcycle Motorcycles XSR900 Yamaha

Product variants

Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XSR900

Model Codes:

XSR900G, XSR900GC

Product Name:

Yamaha XSR900 2016-2019 Service Repair Workshop Manual

Part Number:

LIT-11616-29-65

👋 Introduction

Market Position

Segment:

Retro-sport motorcycle segment, blending modern performance with classic styling.

Target Audience:

Riders seeking a stylish, powerful, and engaging motorcycle with a nod to vintage aesthetics, who are also comfortable with performing their own maintenance.

Competitive Analysis

Key Competitors:

Triumph Bonneville Bobber/T120, Ducati Scrambler, BMW R nineT, Kawasaki Z900RS.

Key Features

Design Philosophy:

Sport Heritage styling, inspired by iconic Yamaha motorcycles of the past, particularly the XS series.

Engine Architecture:

High-torque, cross-plane crankshaft inline-three-cylinder engine, delivering characteristic torque delivery and sound.

Technology Integration:

Modern electronic rider aids such as traction control and ABS, integrated seamlessly into the retro design.

Manual Value Proposition

Empowerment For Owners:

Provides owners with the knowledge to confidently perform maintenance and repairs, reducing reliance on dealerships and saving costs.

Technical Resource:

A comprehensive and authoritative resource for understanding the intricate systems of the XSR900.

📋 Manual Details

Coverage Areas

Years Covered:

2016, 2017, 2018, 2019

Page Count

Page Count:

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine System:

Complete engine overhaul, including disassembly, inspection, assembly, lubrication, and timing procedures.

Fuel System:

Fuel injection system diagnostics, cleaning, servicing of injectors, fuel pump, pressure regulator, and throttle body.

Cooling System:

Radiator, cooling fan, water pump, thermostat, coolant replacement, and leak testing.

Ignition System:

Spark plug inspection and replacement, ignition coil testing, and ECU control diagnostics.

Exhaust System:

Exhaust pipe and muffler inspection, gasket replacement, and emissions control components.

Transmission System:

Clutch operation, gearbox disassembly and assembly, shift drum and fork inspection, and gear oil replacement.

Drivetrain System:

Chain and sprockets inspection, adjustment, and replacement. Rear swingarm and bearing service.

Braking System:

Brake pad and disc inspection/replacement, caliper servicing, brake fluid bleeding and replacement, ABS system diagnostics.

Suspension System:

Front fork (telescopic, upside-down) disassembly, oil change, seal replacement, and spring preload adjustment. Rear shock absorber inspection and adjustment.

Wheel And Tire System:

Wheel bearing inspection and replacement, tire pressure, tread depth, and tire replacement procedures.

Electrical System:

Battery testing and replacement, charging system (stator, rectifier/regulator), starter motor, lighting circuits, and accessory wiring.

Instrumentation And Controls:

Dashboard functionality, switchgear operation, throttle and clutch cable adjustment.

Frame And Bodywork:

Frame inspection, fairing removal/installation, seat servicing, and body panel alignment.

Wiring Diagrams:

Detailed wiring schematics for all electrical components, including color codes and connector pinouts.

Procedures Included

Preventative Maintenance:

Scheduled maintenance tasks, lubrication points, safety checks, and fluid level checks.

Troubleshooting Guides:

Diagnostic procedures for common faults and malfunctions, with step-by-step troubleshooting flows.

Repair Procedures:

Detailed instructions for component removal, replacement, and reassembly for all major systems.

Assembly Disassembly:

Step-by-step guides for taking apart and putting back together various motorcycle sub-assemblies.

Torque Specifications:

Critical torque values for all fasteners and bolts to ensure correct assembly and safety.

Fluid Capacities And Types:

Precise specifications for all necessary fluids, including engine oil, coolant, brake fluid, and gear oil, with their respective capacities.

Special Tool Requirements:

Identification of any specialized tools or equipment required for specific maintenance or repair tasks.

Technical Depth

Diagnostic Capability:

Advanced diagnostic procedures, including ECU fault code interpretation and electrical system testing.

Rebuild Scope:

Comprehensive instructions for complete engine and gearbox rebuilds, including component wear limits.

Electrical Diagnostics:

In-depth analysis of electrical circuits, sensor testing, and actuator diagnostics.

📊 Manual Specifications

File Format

File Format:

JPG (image files, likely organized into a readable sequence or presented within a viewer).

Print Quality

Image Quality:

High-resolution JPG images suitable for viewing on screen and potentially printing individual pages with clarity.

Binding Type

Binding Type:

Digital (not applicable for physical binding).

Paper Type

Paper Type:

Digital (not applicable for physical paper type).

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 4-valve, inline 3-cylinder

Displacement:

847 cc (51.7 cu. in.)

Bore X Stroke:

74.0 mm x 56.2 mm

Compression Ratio:

11.5 : 1

Ignition System:

TCI (Transistor Controlled Ignition)

Performance

Claimed Horsepower:

Approx. 115 hp @ 10,000 rpm

Claimed Torque:

Approx. 65 ft-lb @ 8,500 rpm

Fuel System

Fuel Delivery:

Mikuni 43mm throttle body x 3 with YCC-T (Yamaha Chip Controlled Throttle)

Fuel Type:

Unleaded gasoline, minimum 91 octane

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40, API SG, SH, SJ, SL, SM, SN or ILSAC GF-3, GF-4, GF-5

Fluid Capacities

Engine Oil Capacity With Filter:

3.70 L (3.91 US qt)

Engine Oil Capacity Without Filter:

3.40 L (3.59 US qt)

Coolant Capacity:

1.80 L (1.90 US qt)

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 6-speed

Features

Clutch Type:

Wet, multiple-disc

Final Drive:

O-ring chain

📐 Dimensions

Exterior

Overall Length:

2,105 mm (82.9 in)

Overall Width:

815 mm (32.1 in)

Overall Height:

1,135 mm (44.7 in)

Seat Height:

815 mm (32.1 in)

Wheelbase:

1,440 mm (56.7 in)

Weights

Wet Weight:

195 kg (430 lbs)

Fuel Tank Capacity:

14 L (3.7 US gal)

🛡️ Safety Features

Active Features

Standard Anti-lock Braking System

Traction Control:

TCS (Traction Control System) with two modes and off

Throttle Control:

YCC-T (Yamaha Chip Controlled Throttle) for precise throttle response

Passive Features

Lighting:

LED headlight and taillight for enhanced visibility

Braking System Specs

Front Brakes:

Dual hydraulic discs, 298mm

Rear Brakes:

Hydraulic disc, 245mm

💡 Technology Features

Infotainment

Instrument Cluster:

Multi-function LCD instrument cluster providing speed, RPM, gear position, fuel level, clock, trip meters, and traction control mode.

Driver Assistance

Traction Control System:

An advanced TCS that detects wheel slip and modulates engine power accordingly, improving safety and grip.

ABS System:

Standard ABS prevents wheel lock-up during braking, enhancing stability and control.

Connectivity

Usb Charging:

Optional accessory available for smartphone charging.

Engine Management

Ycc T:

Yamaha Chip Controlled Throttle provides sophisticated electronic throttle control for seamless power delivery.

Lighting Technology

Led Lighting:

Full LED lighting for headlight, taillight, and turn signals for a modern look and improved visibility.

🔧 Maintenance

Service Intervals

First Service:

1,000 km (600 miles) or 6 months, whichever comes first.

Subsequent Services:

Every 10,000 km (6,000 miles) or 12 months, whichever comes first (for most items), with specific checks at 5,000 km intervals.

Valve Clearance Check:

Every 40,000 km (24,000 miles).

Fluid Specifications

Brake Fluid:

DOT 4

Coolant:

Yamaha Coolant (or equivalent) with anti-rust/anti-freeze properties, mixed 50:50 with distilled water.

Clutch Fluid:

DOT 4 (same as brake fluid)

Known Issues

Throttle Response Smoothness:

Some early models or specific riding conditions may benefit from ECU remapping or fine-tuning for smoother throttle response, particularly at low RPM.

Suspension Tuning:

While adjustable, some riders opt for aftermarket suspension components for enhanced performance and comfort depending on their riding style and weight.

Maintenance Tasks Covered

Oil And Filter Change:

Detailed instructions for engine oil and filter replacement, including correct oil grade and capacity.

Chain Maintenance:

Procedures for cleaning, lubricating, and adjusting the drive chain tension.

Tire Care:

Checking tire pressure, wear, and replacement guidelines.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycles:

Yamaha Motor Company, founded in 1955, has a rich history in motorcycling, known for innovation, performance, and motorsport success across various disciplines.

Model Evolution

Mt09 Platform:

The XSR900 is based on the MT-09 platform, sharing its CP3 engine and chassis, but styled with a retro-futuristic 'Sport Heritage' design.

Xs Inspiration:

The design cues are heavily inspired by iconic Yamaha motorcycles from the 1970s and 1980s, such as the XS650 and XS750.

Production

Introduction Year:

The XSR900 was introduced globally in late 2015 for the 2016 model year.

🏆 Awards & Recognition

Recognitions

Segment Awards:

While specific awards for the 2016-2019 models may vary by region and publication, the XSR900 has consistently received praise for its blend of performance, style, and value within the retro-sport motorcycle segment.