Yamaha 2009 Diversion XJ6SY Manuals

Manuals and User Guides for Yamaha 2009 Diversion XJ6SY. We have 1 Yamaha 2009 Diversion XJ6SY manual available for free PDF download: Service Manual

Yamaha 2009 Diversion XJ6SY Service Manual

Yamaha 2009 Diversion XJ6SY Service Manual (554 pages)

Brand: Yamaha | Category: Motorcycle | Size: 45.21 MB

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
- 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
- Rear Wheel
  
  186
- Front Brake
  
  195
- 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
- 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

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