2009-2012 Yamaha Diversion (XJ6S/XJ6SY/XJ6SA) OEM Service & Repair Manual

SERVICE MANUAL XJ6S(Y) 2009 36C-28197-E0 XJ6SA

EAS20040 XJ6S(Y) XJ6SA SERVICE MANUAL ©2009 by Yamaha Motor Co., Ltd. First edition, January 2009 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig- nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. TIP Designs and specifications are subject to change without notice. EAS20081 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property. A TIP provides key information to make procedures easier or clearer. WARNING NOTICE TIP

EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. ● The manual is divided into chapters and each chapter is divided into sections. The current section title is shown at the top of each page “1”. ● Sub-section titles appear in smaller print than the section title “2”. ● To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section “3”. ● Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step “4”. ● Symbols indicate parts to be lubricated or replaced “5”. Refer to “SYMBOLS”. ● A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc “6”. ● Jobs requiring more information (such as special tools and technical data) are described sequentially “7”. 5 3 4 6 1 2 7

EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. TIP The following symbols are not relevant to every vehicle. G M BF B T R . . LS M S LT E New Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data Engine oil Gear oil Molybdenum disulfide oil Brake fluid Wheel bearing grease Lithium-soap-based grease Molybdenum disulfide grease Silicone grease Apply locking agent (LOCTITE®). Replace the part with a new one. SYMBOL DEFINITION SYMBOL DEFINITION

GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 EAS20110 TABLE OF CONTENTS

1 2 3 4 5 6 7 8 9 GENERAL INFORMATION IDENTIFICATION .......................................................................................... 1-1 VEHICLE IDENTIFICATION NUMBER ................................................... 1-1 MODEL LABEL........................................................................................ 1-1 FEATURES .................................................................................................... 1-2 OUTLINE OF FI SYSTEM ....................................................................... 1-2 FI SYSTEM.............................................................................................. 1-3 INSTRUMENT FUNCTIONS ................................................................... 1-4 OUTLINE OF THE ABS........................................................................... 1-7 ABS COMPONENT FUNCTIONS ........................................................... 1-11 ABS OPERATION ................................................................................... 1-16 ABS SELF-DIAGNOSIS FUNCTION....................................................... 1-19 ABS WARNING LIGHT AND OPERATION............................................. 1-22 IMPORTANT INFORMATION ....................................................................... 1-24 PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-24 REPLACEMENT PARTS......................................................................... 1-24 GASKETS, OIL SEALS AND O-RINGS .................................................. 1-24 LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-24 BEARINGS AND OIL SEALS .................................................................. 1-25 CIRCLIPS ................................................................................................ 1-25 CHECKING THE CONNECTIONS ................................................................ 1-26 REMOVING THE QUICK FASTENER .................................................... 1-27 INSTALLING THE QUICK FASTENER ................................................... 1-28 SPECIAL TOOLS .......................................................................................... 1-29

IDENTIFICATION 1-1 EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts. 1 1

2009-2012 Yamaha Diversion (XJ6S/XJ6SY/XJ6SA) OEM Service & Repair Manual

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