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2009 Diversion XJ6S
Yamaha 2009 Diversion XJ6S User Manual
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SER
VICE MANU
AL
XJ6S(Y)
2009
36C-28197-E0
XJ6SA
❄❆❍✤✤❇
✣
2
Table of Contents
Table of Contents
7
Symbols
6
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
11
Outline of Fi System
11
Fi System
12
Instrument Functions
13
Outline of the Abs
16
Abs Component Functions
20
Abs Operation
25
Abs Self-Diagnosis Function
28
Abs Warning Light and Operation
31
Important Information
33
Preparation for Removal and Disassembly
33
Replacement Parts
33
Gaskets, Oil Seals and O-Rings
33
Lock Washers/Plates and Cotter Pins
33
Bearings and Oil Seals
34
Circlips
34
Checking the Connections
35
Removing the Quick Fastener
36
Installing the Quick Fastener
37
Special Tools
38
Specifications
45
General Specifications
46
Engine Specifications
47
Chassis Specifications
54
Electrical Specifications
57
Tightening Torques
60
General Tightening Torque Specifications
60
Engine Tightening Torques
60
Chassis Tightening Torques
64
Lubrication Points and Lubricant Types
69
Engine
69
Chassis
70
Lubrication System Chart and Diagrams
72
Engine Oil Lubrication Chart
72
Lubrication Diagrams
74
Cooling System Diagrams
86
Cable Routing
88
Periodic Checks and Adjustments
137
Introduction
138
Periodic Maintenance
138
Periodic Maintenance Chart for the Emission Control System
138
General Maintenance and Lubrication Chart
139
Checking the Fuel Line
141
Checking the Spark Plugs
141
Adjusting the Valve Clearance
142
Adjusting the Engine Idling Speed
144
Synchronizing the Throttle Bodies
145
Checking the Air Induction System
147
Checking the Crankcase Breather Hose
147
Replacing the Air Filter Element
147
Adjusting the Clutch Cable Free Play
148
Checking the Brake Fluid Level
148
Adjusting the Front Disc Brake
149
Checking the Front Brake Pads
149
Adjusting the Rear Disc Brake
150
Checking the Rear Brake Pads
150
Bleeding the Hydraulic Brake System
151
Checking the Front Brake Hoses
153
Checking the Rear Brake Hose
153
Checking the Tires
153
Checking the Wheels
153
Adjusting the Drive Chain Slack
155
Checking the Swingarm
155
Checking the Wheel Bearing
155
Checking and Adjusting the Steering Head
156
Lubricating the Drive Chain
156
Adjusting the Handlebar Position
157
Lubricating the Levers
158
Adjusting the Shift Pedal
159
Checking the Front Fork
159
Checking the Sidestand Switch
159
Lubricating the Centerstand
159
Lubricating the Pedal
159
Lubricating the Sidestand
159
Adjusting the Rear Shock Absorber Assembly
160
Checking the Engine Oil Level
160
Lubricating the Rear Suspension
160
Changing the Engine Oil
161
Measuring the Engine Oil Pressure
162
Checking the Coolant Level
163
Changing the Coolant
164
Checking the Cooling System
164
Adjusting the Rear Brake Light Switch
166
Checking and Lubricating the Cables
166
Checking the Front and Rear Brake Switch
166
Adjusting the Throttle Cable Free Play
167
Adjusting the Headlight Beams
168
Checking and Charging the Battery
168
Checking the Fuses
168
Replacing the Headlight Bulbs
168
Chassis
171
General Chassis
174
Front Wheel
180
Removing the Front Wheel
180
Checking the Front Wheel
180
Maintenance of the Front Wheel Sensor and Sensor Rotor
181
Adjusting the Front Wheel Static Balance
184
Installing the Front Wheel
185
Rear Wheel
186
Removing the Rear Wheel
190
Checking the Rear Wheel
190
Checking the Rear Wheel Drive Hub
190
Checking and Replacing the Rear Wheel Sprocket
190
Maintenance of the Rear Wheel Sensor and Sensor Rotor
191
Adjusting the Rear Wheel Static Balance
193
Installing the Rear Wheel
193
Front Brake
195
Introduction
202
Checking the Front Brake Discs
202
Replacing the Front Brake Pads
203
Removing the Front Brake Calipers
204
Disassembling the Front Brake Calipers
204
Checking the Front Brake Calipers
204
Assembling the Front Brake Calipers
205
Installing the Front Brake Calipers
205
Removing the Front Brake Master Cylinder
206
Checking the Front Brake Master Cylinder
206
Assembling the Front Brake Master Cylinder
207
Installing the Front Brake Master Cylinder
207
Rear Brake
209
Introduction
214
Checking the Rear Brake Disc
214
Replacing the Rear Brake Pads
214
Removing the Rear Brake Caliper
215
Disassembling the Rear Brake Caliper
215
Checking the Rear Brake Caliper
216
Assembling the Rear Brake Caliper
216
Installing the Rear Brake Caliper
216
Removing the Rear Brake Master Cylinder
218
Checking the Rear Brake Master Cylinder
218
Assembling the Rear Brake Master Cylinder
218
Installing the Rear Brake Master Cylinder
219
Abs (Anti-Lock Brake System)
221
Abs Components Chart
221
Removing the Hydraulic Unit Assembly
223
Checking the Hydraulic Unit Assembly
223
Checking the Brake Pipes
223
Installing the Hydraulic Unit Assembly
224
Hydraulic Unit Operation Tests
225
Trial Run
228
Handlebar
229
Removing the Handlebars
230
Checking the Handlebar
230
Installing the Handlebar
230
Front Fork
233
Removing the Front Fork Legs
235
Disassembling the Front Fork Legs
235
Checking the Front Fork Legs
236
Assembling the Front Fork Legs
237
Installing the Front Fork Legs
239
Steering Head
240
Removing the Lower Bracket
242
Checking the Steering Head
242
Installing the Steering Head
243
Rear Shock Absorber Assembly
244
Handling the Rear Shock Absorber
245
Disposing of a Rear Shock Absorber
245
Removing the Rear Shock Absorber Assembly
245
Checking the Rear Shock Absorber Assembly
245
Installing the Rear Shock Absorber Assembly
246
Swingarm
247
Removing the Swingarm
248
Checking the Swingarm
248
Installing the Swingarm
249
Chain Drive
250
Removing the Drive Chain
251
Checking the Drive Chain
251
Checking the Drive Sprocket
252
Checking the Rear Wheel Sprocket
252
Checking the Rear Wheel Drive Hub
252
Installing the Drive Chain
252
Engine
253
Engine Removal
255
Installing the Engine
260
Installing the Drive Chain
261
Camshafts
262
Removing the Camshafts
264
Checking the Camshafts
265
Checking the Timing Chain and Camshaft Sprocket
266
Checking the Timing Chain Guides
266
Checking the Timing Chain Tensioner
266
Installing the Camshafts
267
Cylinder Head
270
Removing the Cylinder Head
271
Checking the Cylinder Head
271
Installing the Cylinder Head
271
Measuring the Compression Pressure
272
Valves and Valve Springs
274
Removing the Valves
275
Checking the Valves and Valve Guides
275
Checking the Valve Seats
277
Checking the Valve Springs
279
Checking the Valve Lifters
280
Installing the Valves
280
Generator and Starter Clutch
282
Removing the Generator
284
Removing the Starter Clutch
284
Checking the Starter Clutch
284
Installing the Starter Clutch
285
Installing the Generator
285
Pickup Rotor
287
Removing the Pickup Rotor
288
Installing the Pickup Rotor
288
Electric Starter
290
Checking the Starter Motor
292
Assembling the Starter Motor
293
Installing the Starter Motor
293
Oil Pump
294
Removing the Oil Pan
297
Checking the Oil Pump
297
Checking the Relief Valve
297
Checking the Oil Delivery Pipes
298
Checking the Oil Strainer
298
Checking the Oil Nozzles
298
Checking the Oil Pump Drive Chain
298
Assembling the Oil Pump
298
Installing the Oil Pump
299
Installing the Oil Strainer
299
Installing the Oil Pan
299
Clutch
301
Removing the Clutch
304
Checking the Friction Plates
305
Checking the Clutch Plates
305
Checking the Clutch Springs
306
Checking the Clutch Housing
306
Checking the Clutch Boss
306
Checking the Pressure Plate
306
Checking the Clutch Push Rods
307
Installing the Clutch
307
Shift Shaft
310
Removing the Shift Shaft
311
Checking the Shift Shaft
311
Checking the Stopper Lever
311
Installing the Shift Shaft
311
Crankcase
313
Disassembling the Crankcase
315
Checking the Crankcase
315
Checking the Bearings and Oil Seals
315
Assembling the Crankcase
315
Crankshaft
318
Removing the Connecting Rods and Pistons
320
Removing the Crankshaft Assembly
320
Checking the Cylinder and Piston
321
Checking the Piston Rings
321
Checking the Piston Pins
322
Checking the Big End Bearings
323
Installing the Connecting Rod and Piston
325
Checking the Crankshaft
327
Checking the Crankshaft Journal Bearings
327
Installing the Crankshaft
329
Transmission
330
Removing the Transmission
335
Checking the Shift Forks
335
Checking the Shift Drum Assembly
335
Checking the Transmission
336
Assembling the Main Axle and Drive Axle
336
Installing the Transmission
337
Cooling System
339
Radiator
340
Checking the Radiator
342
Installing the Radiator
342
Oil Cooler
343
Checking the Oil Cooler
344
Installing the Oil Cooler
344
Thermostat
345
Checking the Thermostat
346
Installing the Thermostat Assembly
346
Water Pump
348
Disassembling the Water Pump
350
Checking the Water Pump
350
Assembling the Water Pump
350
Installing the Water Pump
351
Fuel System
353
Fuel Tank
355
Checking the Fuel Pump Body
355
Checking the Fuel Pump Operation
355
Installing the Fuel Pump
355
Removing the Fuel Pump
355
Removing the Fuel Tank
355
Installing the Fuel Tank
356
Throttle Bodies
357
Checking the Throttle Body Joints
358
Checking the Fuel Injectors
360
Installing the Injectors
360
Checking the Injector Pressure
360
Checking and Cleaning the Throttle Bodies
361
Checking the Fuel Pressure
362
Adjusting the Throttle Position Sensor
363
Air Induction System
364
Checking the Air Induction System
367
Installing the Air Induction System
367
Electrical System
369
Ignition System
372
Circuit Diagram
372
Troubleshooting
376
Electric Starting System
378
Circuit Diagram
378
Starting Circuit Cut-Off System Operation
382
Troubleshooting
384
Charging System
386
Circuit Diagram
386
Troubleshooting
390
Lighting System
392
Circuit Diagram
392
Troubleshooting
396
Signaling System
398
Circuit Diagram
398
Troubleshooting
402
Cooling System
406
Circuit Diagram
406
Troubleshooting
410
Fuel Injection System
412
Circuit Diagram
412
Ecu Self-Diagnostic Function
416
Fail-Safe Actions (Substitute Characteristics Operation Control)
416
Trouble Shooting Chart
418
Diagnostic Mode
419
Troubleshooting Details
420
Adjusting the Exhaust Gas Volume
451
Other Diagnostic Monitoring Codes
452
Fuel Pump System
454
Circuit Diagram
454
Troubleshooting
458
Immobilizer System
460
Circuit Diagram
460
General Information
464
Part Replacement and Key Code Registration Requirements
464
Troubleshooting
467
Self-Diagnosis Fault Code Indication
467
Abs (Anti-Lock Brake System)
470
Circuit Diagram
470
Abs Components Chart
472
Abs Coupler Location Chart
474
Maintenance of the Abs Ecu
476
Abs Troubleshooting Outline
476
Basic Instructions for Troubleshooting
477
Basic Process for Troubleshooting
478
[A] Checking the Abs Warning Light
479
[B-1] the Abs Warning Light Fails to Come on
479
[B-2] the Abs Warning Light Flashes
479
[B-3] the Abs Warning Light Remains on
479
[B-4] the Abs Warning Light Comes on for 2 Seconds, then Goes off
479
[B-5] Malfunction Are Currently Detected
480
[C-1] Only the Abs Warning Light Fails to Come on
480
[C-2] All Indicator Lights Fail to Come on
480
[C-3] the Abs Warning Light Remains on
481
[C-4] the Abs Warning Light Flashes
481
[C-5] Diagnosis Using the Fault Codes
482
[D-1] Deleting the Fault Codes
513
[D-2] Delete Function Test
513
Specifications
514
[D-3] Final Check
515
Electrical Components
516
Checking the Switches
520
Checking the Bulbs and Bulb Sockets
523
Checking the Fuses
524
Checking and Charging the Battery
525
Checking the Relays
528
Checking the Turn Signal/Hazard Relay
529
Checking the Relay Unit (Diode)
530
Checking the Ignition Coil
531
Checking the Ignition Spark Gap
531
Checking the Spark Plug Caps
531
Checking the Crankshaft Position Sensor
532
Checking the Lean Angle Sensor
533
Checking the Starter Motor Operation
533
Checking the Horn
534
Checking the Rectifier/Regulator
534
Checking the Stator Coil
534
Checking the Air Induction System Solenoid
535
Checking the Engine Oil Level Switch
535
Checking the Fuel Sender
536
Checking the Coolant Temperature Sensor
537
Checking the Radiator Fan Motor
537
Checking the Speed Sensor
537
Checking the Intake Air Pressure Sensor
538
Checking the Throttle Position Sensor
538
Checking the Intake Air Temperature Sensor
539
Troubleshooting
541
General Information
542
Incorrect Engine Idling Speed
542
Starting Failures
542
Troubleshooting
542
Faulty Clutch
543
Faulty Gear Shifting
543
Jumps out of Gear
543
Overheating
543
Overcooling
544
Poor Braking Performance
544
Faulty Front Fork Legs
544
Unstable Handling
544
Faulty Lighting or Signaling System
544
Poor Medium-And-High-Speed Performance
543
Shift Pedal Does Not Move
543
Electrical System
544
Troubleshooting at the Abs Warning Light
545
4
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Yamaha 2009 Diversion XJ6S Specifications
General
Brand
Yamaha
Model
2009 Diversion XJ6S
Category
Motorcycle
Language
English
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