![Yamaha XJ900S (G) (1995) [10/352] Engine overhaul](/img/pdf.png)
Yamaha XJ900S (G) (1995) [10/352] Engine overhaul
![Yamaha XJ900S (G) (1995) [10/352] Engine overhaul](/views2/1121394/page10/bga.png)
Содержание
- Service manual 1
- Xj900s g 1
- Notice 3
- Particulary important information 3
- How to use this manual 4
- Ber and content 5
- Diagram indicate grade of lubricant and 5
- Identify the specifications appearing in the 5
- Illustrated symbols 5
- Illustrated symbols to 9 are designed as 5
- Illustrated symbols to are used to 5
- Illustrated symbols to in the exploded 5
- Location of lubrication point 5
- Refer to the illustration 5
- Thumb tabs to indicate the chapter s num 5
- Adjustment 7
- Carburetion 7
- Chassis 7
- Electrical 7
- Engine overhaul 7
- General information 7
- Periodic inspection and 7
- Specifications 7
- Troubleshooting 7
- Chapter 1 8
- Chapter 2 8
- Contents 8
- General information 8
- Specifications 8
- And adjustment 9
- Chapter 3 9
- Periodic inspection 9
- Trbl k 9
- Chapter 4 10
- Engine overhaul 10
- Carburetion 12
- Chapter 5 12
- Chapter 6 12
- Chassis 12
- Chapter 7 13
- Electrical 13
- Chapter 8 14
- Troubleshooting 14
- General information 16
- Motorcycle identification 16
- Important information 17
- Important information 18
- J j ____________________ 18
- Are provided 19
- Bly using the correct special tool will help 19
- Complete and accurate tune up and assem 19
- For tune up 19
- Improper tools or improvised techniques 19
- Prevent damage caused by the use of 19
- Refer to the list provided to avoid errors 19
- Special tool differ by country so two types 19
- Special tools 19
- Special tools gen 19
- The proper special tools are necessary for 19
- The shape and part number used for the 19
- When placing an order 19
- For engine service 20
- Special tools gen 20
- For chassis service 21
- Special tools 21
- Components 22
- For electrical 22
- Special tools gen 22
- General specifications 24
- General specifications spec o 24
- Specifications 24
- General specifications spec 25
- General specifications spec 26
- Maintenance specifications 27
- Maintenance specifications spec ü 27
- Maintenance specifications spe 28
- Maintenance specifications spec 0 29
- Maintenance specifications spec 30
- Maintenance specifications spe 31
- Maintenance specifications spec u 32
- Maintenance specifications spec u 33
- Maintenance specifications spec q 34
- Tightening torques 34
- Maintenance specifications spec u 35
- Maintenance specifications spec ct 36
- Maintenance specifications spec o 37
- Maintenance specifications spec o 38
- Tightening torques 38
- Maintenance specifications spec o 39
- Maintenance specifications spec ü 40
- Maintenance specifications spec ü 41
- Maintenance specifications spec 42
- Exclusive specification 43
- Spec exclusive specification u 43
- A distance across flats 44
- All specification data in this manual is listed 44
- Applicable sections of this book to avoid 44
- B outside thread diameter 44
- Call for clean dry threads components 44
- General torque 44
- General torque specifications spec o 44
- How to use the conversion 44
- How to use the conversion table 44
- In a crisscross fashion in progressive 44
- In si and metric units 44
- Metric multiplier imp 44
- Mm 10 mm 30 3 44
- Mm 12 mm 55 5 44
- Mm 14 mm 85 8 44
- Mm 16 mm 130 13 44
- Mm 6 mm 6 0 44
- Mm 8 mm 15 1 44
- Mm x 0 3937 0 8 in 44
- Mm x 0 3937 in 44
- Nents or assemblies are included in the 44
- Nm m kg 44
- Otherwise specified torque specifications 44
- Should be at room temperature conversion table 44
- Specifications 44
- Stages until full torque is reached unless 44
- Teners with standard i s o pitch threads 44
- This chart specifies torque for standard fas 44
- To imp unit data 44
- Torque specifications for special compo 44
- Use this table to convert metric unit data 44
- Warpage tighten multi fastener assemblies 44
- Lubrication point and grade of lubricant 45
- Lubrication point and grade of lubricant spe 45
- Lubrication point and grade of lubricant spec q 46
- Lubrication diagrams 47
- Lubrication diagrams spec q 47
- Lubrication diagrams 48
- Lubrication diagrams spec u 49
- Lubrication diagrams 50
- Cable routing 51
- Cable routing spec o 51
- Cable routing spec 0 52
- Cable routing spec u 53
- Cable routing 54
- Cable routing spec q 55
- Cable routing 56
- Cable routing spec q 57
- Introduction 58
- Introduction periodic maintenance nsp fob 58
- Lubrication intervals 58
- Periodic inspection and adjustment 58
- Periodic maintenance lubrication intervals 58
- Periodic maintenance lubrication intervals insp 59
- Cowling 60
- Insp fob 60
- Side cover fuel tank and 60
- Side cover fuel tank and cowling 60
- Warning 60
- Side cover fuel tank and cowling 61
- Insp m 62
- Side cover fuel tank and cowling 62
- Engine 63
- Insp foli 63
- Valve clearance adjustment 63
- Valve clearance adjustment 64
- Valve clearance adjustment insp fol 66
- 0 0 mm 67
- 0 5 mm 67
- Adj sk 67
- Ai psggshs bbbsspbgsggs 67
- Always install pad with number down 67
- Example installed is 250 67
- Exhaust 67
- Intake 67
- Measured clearance is 0 3 mm 67
- Pad no 250 2 0 mm 67
- Pad no 260 2 0 mm 67
- Pad no 265 2 5 mm 67
- Pad number example 67
- Rao number example 67
- Replace 250 pad with 260 pad 67
- Valve clearance adjustment insp fob 67
- Valve clearance cold 67
- Valve clearance adjustment 69
- Adj nv 70
- Carburetor synchronization insp oi 70
- Carburetor synchronization 71
- Adj wl 72
- Idling speed adjustment insp fob 72
- Idling speed adjustment insp 73
- Throttle cable adjustment 73
- Throttle cable adjustment 74
- Warning 74
- Insp gob 75
- Spark plug inspection 75
- Adj wc 76
- Compression pressure measurement adj 77
- Ignition timing check sp fol 77
- Compression pressure measurement insp fol 78
- Warning 78
- Compression pressure measurement 79
- Engine oil level inspection 79
- Engine oil level inspection nsp fol 80
- Engine oil replacement apj 80
- Engine oil replacement insp fol 81
- Engine oil replacement clutch adjustment 82
- Adj xk 83
- Air filter cleaning insp fob 83
- Chassis 85
- Front brake lever position adjustment 85
- Rear brake adjustment insp 85
- Insp fob 86
- Rear brake adjustment 86
- Warning 86
- Brake fluid level inspection insp fol 87
- Warning 87
- Brake fluid level inspection brake pad sp 88
- Inspection brake light switch adjustment 88
- Brake hose inspection pj 89
- Brake light switch adjustment sp fol 89
- Air bleeding steps 90
- Warning 90
- Air bleeding hydraulic brake system nsp fob 91
- Final gear oil level inspection 91
- Warning 91
- Final gear oil replacement nsp fol 92
- Steering head inspection 92
- Warning 92
- Adjustment steps 93
- Steering head inspection 93
- Warning 93
- Steering head inspection 94
- Front fork inspection 95
- Rear shock absorber adjustment insp 95
- Rear shock absorber adjustment 96
- Tire inspection insp 96
- Warning 96
- Tire inspection insp fob 97
- Tire inspection insp 98
- A warning 99
- Cable inspection and lubrication adj 99
- Warning 99
- Wheel inspection nsp ioh 99
- Electrical 101
- Adj wl 102
- Battery inspection insp 102
- Warning 102
- Battery inspection insp 103
- Battery inspection insp fob 104
- Battery inspection fuse inspection insp tofe 107
- Insp fuse inspection 108
- Warning 108
- Headlight beam adjustment nsp dûl 109
- Headlight bulb replacement 109
- Warning 109
- Digital clock adjustment adj wv 110
- Headlight bulb replacement nsp gal 110
- Engine overhaul 112
- Engine removal 112
- Engine removal eng 112
- Warning 112
- Engine removal eng 113
- Engine removal eng 114
- Engine removal 115
- Engine removal eng 116
- Warning 116
- Engine disassembly 117
- Engine disassembly eng 117
- Engine disassembly eng 118
- Engine disassembly eng 119
- Engine disassembly eng 120
- Engine disassembly eng 121
- Engine disassembly eng 122
- Engine disassembly eng 123
- Engine disassembly eng 124
- Engine disassembly eng 125
- Engine disassembly eng 126
- Engine disassembly eng 127
- Engine disassembly eng 129
- Inspection and repair 130
- Inspection and repair en 130
- Inspection and repair eng 131
- Inspection and repair eng 132
- Inspection and repair eng 133
- Inspection and repair en 134
- Inspection and repair eng 135
- Inspection and repair en 136
- Inspection and repair eng 137
- Inspection and repair 138
- Inspection and repair eng 139
- Inspection and repair eng 140
- Inspection and repair eng 141
- Inspection and repair 142
- Inspection and repair eng 143
- Inspection and repair eng 144
- Inspection and repair eng 145
- Inspection and repair eng 146
- Inspection and repair eng 147
- Inspection and repair eng 148
- Inspection and repair eng 149
- Inspection and repair eng 150
- A warning 151
- Inspection and repair eng 151
- Inspection and repair eng 152
- Inspection and repair 153
- Inspection and repair eng 154
- Middle gear service 155
- Middle gear service eng 155
- Middle gear service eng 156
- Middle gear service 157
- Middle gear service 158
- Middle gear service eng 159
- Middle gear service eng 160
- Middle gear service 161
- Middle gear service 162
- Middle gear service 163
- Middle gear service 164
- Adjustment 165
- Engine assembly and 165
- Engine assembly and adjustment 165
- Warning 165
- Connecting rod and crankshaft 166
- Engine assembly and adjustment eng 166
- Engine assembly and adjustment eng 167
- Engine assembly and adjustment 168
- Engine assembly and adjustment 169
- Engine assembly and adjustment 170
- Transmission 170
- Engine assembly and adjustment eng 171
- Warning 171
- Engine assembly and adjustment 172
- Crankcase 173
- Engine assembly and adjustment 173
- Engine assembly and adjustment eng 174
- Engine assembly and adjustment 175
- Warning 175
- A warning 176
- Engine assembly and adjustment eng 176
- Clutch 177
- Engine assembly and adjustment 177
- Engine assembly and adjustment eng 178
- Warning 178
- Engine assembly and adjustment eng 179
- Warning 179
- Engine assembly and adjustment 180
- Piston and cylinder 180
- Engine assembly and adjustment eng 181
- Engine assembly and adjustment eng 182
- Warning 182
- Engine assembly and adjustment eng 183
- Warning 183
- Cylinder head and cylinder head cover 184
- Engine assembly and adjustment eng 184
- Camshaft valve and timing chain 185
- Engine assembly and adjustment 185
- Engine assembly and adjustment 186
- Engine assembly and adjustment eng 187
- Engine assembly and adjustment 188
- Engine assembly and adjustment eng 189
- Engine assembly and adjustment 190
- Engine assembly and adjustment eng 191
- 1 050 r min 192
- 1 2 turns out 192
- Carburetion 192
- Carburetor 192
- Engine idle speed 192
- Fuel level 192
- I d mark 4km00 4pr00 192
- Jet needle 192
- Main air jet 192
- Main jet 192
- Pilot air jet 1 192
- Pilot jet 192
- Pilot screw 192
- Specifications 192
- Throttle valve 192
- Carb 9 193
- Carburetor 193
- Carburetor 194
- Carburetor 195
- Carb h 196
- Carburetor 196
- Carburetor 197
- Carb 9 198
- Carburetor 198
- Carburetor 199
- Carb ç 200
- Carburetor 200
- Carb if 201
- Carburetor 201
- Carb v 202
- Carburetor 202
- A i s air induction system 203
- A i s air induction system 204
- A i s air induction system diagrams 204
- A i s air induction system 205
- A i s air induction system 206
- A i s air induction system 207
- Warning 207
- 2 oil seal 208
- 3 bearing 208
- 6 clutch retainer 208
- 7 speedometer gear unit 208
- 70 17 58v 208
- A tire size 208
- B rim size 208
- Chassis 208
- D collar 208
- D wear limit 208
- Front wheel 208
- Lateral 0 mm 208
- Meter clutch 208
- Nm 5 m kg 208
- Radial 1 mm 208
- Rim runout limit 208
- Spacer 208
- X mt3 0 208
- Front wheel 209
- Warning 209
- Front wheel 210
- Warning 210
- Front wheel 211
- Front wheel 212
- Warning 212
- Front wheel 213
- Rear wheel 214
- Rear wheel 215
- Warning 215
- Rear wheel 216
- Rear wheel 217
- Front and rear brake 218
- Front brake 218
- Front and rear brake 219
- Rear brake 219
- Front and rear brake 220
- Cau b__________________________ 221
- Front and rear brake 221
- Front and rear brake 222
- Front and rear brake 223
- Front and rear brake 224
- Front and rear brake 225
- Warning 225
- Front and rear brake 226
- Warning 226
- Front and rear brake 227
- Front and rear brake 228
- Front and rear brake 229
- Warning 229
- Front and rear brake 230
- Warning 230
- Front and rear brake 231
- Front and rear brake 232
- Warning 232
- Caution ____________________ 233
- Front and rear brake 233
- Warning 233
- Front and rear brake 234
- Warning 234
- Front and rear brake 235
- Warning 235
- Front and rear brake 236
- Warning 236
- Front and rear brake 237
- Warning 237
- Front and rear brake 238
- Warning 238
- ________ 238
- Front and rear brake 239
- Front and rear brake 240
- Warning 240
- Front and rear brake 241
- Front fork 242
- Front fork 243
- Warning 243
- Front for 244
- Front fork 245
- Warning 245
- Caution i___________________ 247
- Front fork 247
- Front fork 248
- Chas 2 249
- Front fork 249
- Warning 249
- Steering head and handlebar 250
- Steering head and handlebar 251
- Warning 251
- Steering head and handlebar 252
- Steering head and handlebar 253
- A warning 254
- Steering head and handlebar 254
- Steering head and handlebar 255
- Warning 255
- Steering head and handlebar 256
- Steering head and handlebar 257
- Warning 257
- Steering head and handlebar 258
- A liberal amount of molybdenum disulfide 259
- Coat the bearings oil seals and collars with 259
- Grease before installing after installing 259
- Note _______________________________ 259
- Rear shock absorber and swingarm 259
- Thoroughly wipe off excess grease 259
- Rear shock absorber and swingarm 260
- Warning 260
- Rear shock absorber and swingarm 261
- Rear shock absorber and swingarm 262
- Warning 262
- Rear shock absorber and swingarm 263
- Chas 7 264
- Rear shock absorber and swingarm 264
- Rear shock absorber and swingarm 265
- Caution _______________________ 266
- Rear shock absorber and swingarm 266
- A warning 267
- Rear shock absorber and swingarm 267
- Shaft drive 268
- Shaft drive 269
- Shaft drive 270
- Warning 270
- Faulty lighting and signal system 271
- Instable handling 271
- Faulty brake 272
- Front fork oil leakage and front fork malfunction 272
- Instable handling 272
- Overheating 272
- Trblt o 272
- Clutch slipping dragging 273
- Clutch slipping dragging shtg 273
- Faulty gear shifting 273
- Trbl o 273
- Poor idle speed performance 274
- Poor medium and high speed performance 274
- Trbl q 274
- Starting failure hard starting 275
- Troubleshooting 275
- Tps throttle position sensor self diagnosis 277
- Sensor self diagnosis 278
- Tps throttle position 278
- Carburetor heater system 279
- Carburetor heater system 280
- Carburetor heater system 281
- Carburetor heater system 282
- Fuel pump system 284
- Warning 284
- Fuel pump system 285
- Elec p 287
- Fuel pump system 287
- Fuel pump system 288
- Signal system 291
- Signal system 292
- Signal system 293
- Signal system 295
- Signal system 296
- Signal system 297
- Signal system 298
- Signal system 299
- Signal system 300
- Signal system 301
- Lighting system 305
- Lighting system 307
- Lighting system 308
- Lighting system 309
- Lighting system 311
- Charging system 313
- Charging system 315
- A c generator 316
- Battery 316
- Charging system 316
- Circuit diagram 316
- Fuse mam 316
- Electric starting system 317
- Warning 317
- Electric starting system 318
- Electric starting system 319
- Electric starting system 321
- Starter motor 321
- Electric starting system 322
- Electric starting system 323
- Electric starting system 324
- Electric starting system 325
- Warning 326
- Electric starting system elec 327
- Electric starting system elec 328
- Ignition system 331
- Ignition system 332
- Ignition system 333
- Ignition system 335
- Checking of connections 337
- Electrical 339
- Electrical components 339
- Shaft drive 340
- Shaft drive 341
- Shaft driv 342
- Shaft drive 343
- Shaft drive 344
- Shaft drive 345
- Shaft drive 346
- Shaft drive 347
- Shaft drive 348
- A warning 350
- Shaft drive 350
- Chas 2 351
- Shaft drive 351
- Shaft drive 352
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TIRE INSPECTION 3 39 WHEEL INSPECTION 3 42 CABLE INSPECTION AND LUBRICATION 3 42 LEVER AND PEDAL LUBRICATION 3 43 SIDESTAND LUBRICATION 3 43 CENTERSTAND LUBRICATION 3 43 REAR SUSPENSION LUBRICATION 3 43 ELECTRICAL 3 44 BATTERY INSPECTION 3 44 FUSE INSPECTION 3 50 HEADLIGHT BEAM ADJUSTMENT 3 52 HEADLIGHT BULB REPLACEMENT 3 52 DIGITAL CLOCK ADJUSTMENT 3 53 CHAPTER 4 ENGINE OVERHAUL ENGINE REMOVAL 4 1 FUEL TANK AND COWLINGS 4 1 ENGINE OIL 4 1 BATTERY LEADS 4 1 AIR FILTER CASE 4 2 A I S AIR INDUCTION SYSTEM 4 2 CARBURETOR 4 2 HOSES AND LEADS 4 2 CLUTCH CABLE 4 3 SHIFT PEDAL 4 3 STARTER MOTOR 4 3 A C GENERATOR 4 4 EXHAUST PIPE 4 4 OIL COOLER 4 4 DRIVE SHAFT RUBBER BOOT 4 5 ENGINE REMOVAL 4 5 ENGINE DISASSEMBLY 4 6 CYLINDER HEAD COVER CAMSHAFT AND CYLINDER HEAD 4 6 CYLINDER AND PISTON 4 8 PICKUP COIL 4 10 CLUTCH 4 10 OIL PAN AND OIL PUMP 4 11 SHIFT SHAFT 4 12 MIDDLE GEAR 4 13 CRANKCASE DISASSEMBLY 4 13 SHIFT FORK AND SHIFT CAM 4 14 TRANSMISSION 4 15