Yamaha XSR900 2022 Manuals

Manuals and User Guides for Yamaha XSR900 2022. We have 2 Yamaha XSR900 2022 manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha XSR900 2022 Service Manual

Yamaha XSR900 2022 Service Manual (726 pages)

Brand: Yamaha | Category: Motorcycle | Size: 21.48 MB

Table of Contents

Table of Contents

7
- General Information
  9
- Identification
  10
- Vehicle Identification Number
  10
- Model Label
  10
- Glossary
  11
- Display
  11
- Basic Service Information
  20
- Electrical System
  20
- Special Tools
  21
Specifications

29
- General Specifications
  30
- Engine Specifications
  31
- Chassis Specifications
  35
- Electrical Specifications
  38
- Chassis Tightening Torques
  40
- Engine Tightening Torques
  40
- Tightening Torques
  40
- Cable Routing
  42
Periodic Checks and Adjustments

85
- General Maintenance and Lubrication Chart
  87
- Introduction
  87
- Periodic Maintenance
  87
- Periodic Maintenance Chart for the Emission Control System
  87
- Checking the Fuel Line
  90
- Checking the Vehicle Using the Yamaha Diagnostic Tool
  90
- Adjusting the Valve Clearance
  91
- Checking the Spark Plugs
  91
- Checking the Engine Idling Speed
  94
- Synchronizing the Throttle Bodies
  94
- Checking the Cylinder Head Breather Hose
  96
- Checking the Throttle Body Joints
  96
- Adjusting the Exhaust Gas Volume
  97
- Checking the Canister
  97
- Checking the Exhaust System
  97
- Checking the Purge Cut Valve Solenoid
  97
- Adjusting the Clutch Lever Free Play
  98
- Replacing the Air Filter Element
  98
- Checking the Brake Fluid Level
  99
- Checking the Brake Operation
  99
- Adjusting the Front Disc Brake
  100
- Adjusting the Rear Disc Brake
  100
- Checking the Front Brake Pads
  100
- Bleeding the Hydraulic Brake System (Abs)
  101
- Checking the Front Brake Hose
  101
- Checking the Rear Brake Hose
  101
- Checking the Rear Brake Pads
  101
- Checking the Wheels
  102
- Checking the Tires
  103
- Checking the Swingarm Operation
  104
- Checking the Wheel Bearings
  104
- Drive Chain Slack
  104
- Lubricating the Swingarm Pivot
  104
- Checking and Adjusting the Steering Head
  105
- Lubricating the Drive Chain
  105
- Checking the Chassis Fasteners
  106
- Lubricating the Brake Lever
  106
- Lubricating the Steering Head
  106
- Adjusting the Front Fork Legs
  107
- Adjusting the Shift Pedal
  107
- Checking the Front Fork
  107
- Checking the Sidestand
  107
- Checking the Sidestand Switch
  107
- Lubricating the Clutch Lever
  107
- Lubricating the Pedal
  107
- Lubricating the Sidestand
  107
- Adjusting the Rear Shock Absorber Assembly
  109
- Checking the Rear Shock Absorber Assembly
  109
- Checking the Connecting Arm and Relay Arm
  110
- Checking the Engine Oil Level
  110
- Changing the Engine Oil
  111
- Measuring the Engine Oil Pressure
  112
- Checking the Coolant Level
  113
- Changing the Coolant
  114
- Checking the Cooling System
  114
- Adjusting the Rear Brake Light Switch
  116
- Checking and Lubricating the Cables
  116
- Checking the Front Brake Light Switch
  116
- Adjusting the Headlight Beam
  117
- Checking and Charging the Battery
  117
- Checking the Fuses
  117
- Checking the Throttle Grip
  117
Chassis

119
- General Chassis (1)
  123
- Installing the Imu
  125
- Removing the Seat
  125
- Removing the Side Cover
  125
- Installing the Seat
  126
- Installing the Side Cover
  126
- General Chassis (2)
  127
- General Chassis (3)
  127
- Installing the Radiator Cover
  130
- Removing the Radiator Cover
  130
- General Chassis (4)
  131
- General Chassis (5)
  131
- Front Wheel
  133
- Checking the Front Wheel
  135
- Disassembling the Front Wheel
  135
- Removing the Front Wheel
  135
- Assembling the Front Wheel
  136
- Adjusting the Front Wheel Static Balance
  137
- Maintenance of the Front Wheel Sensor and Sensor Rotor
  137
- Installing the Front Wheel (Front Brake Discs)
  138
- Rear Wheel
  140
- Checking the Rear Wheel
  143
- Checking the Rear Wheel Drive Hub
  143
- Disassembling the Rear Wheel
  143
- Removing the Rear Wheel
  143
- Assembling the Rear Wheel
  144
- Checking and Replacing the Rear Wheel Sprocket
  144
- Adjusting the Rear Wheel Static Balance
  145
- Installing the Rear Wheel (Rear Brake Disc)
  145
- Maintenance of the Rear Wheel Sensor and Sensor Rotor
  145
- Front Brake
  148
- Checking the Front Brake Discs
  154
- Introduction
  154
- Replacing the Front Brake Pads
  154
- Checking the Front Brake Calipers
  156
- Disassembling the Front Brake Calipers
  156
- Removing the Front Brake Calipers
  156
- Assembling the Front Brake Calipers
  157
- Installing the Front Brake Calipers
  157
- Assembling the Front Brake Master Cylinder
  158
- Checking the Front Brake Master Cylinder
  158
- Installing the Front Brake Master Cylinder
  158
- Removing the Front Brake Master Cylinder
  158
- Rear Brake
  161
- Adjusting the Footrest Position
  167
- Checking the Rear Brake Disc
  167
- Introduction
  167
- Replacing the Rear Brake Pads
  168
- Checking the Rear Brake Caliper
  169
- Disassembling the Rear Brake Caliper
  169
- Removing the Rear Brake Caliper
  169
- Assembling the Rear Brake Caliper
  170
- Installing the Rear Brake Caliper
  170
- Assembling the Rear Brake Master Cylinder
  171
- Checking the Rear Brake Master Cylinder
  171
- Installing the Rear Brake Master Cylinder
  171
- Removing the Rear Brake Master Cylinder
  171
- Abs (Anti-Lock Brake System)
  173
- Checking the Hydraulic Unit Assembly
  175
- Removing the Hydraulic Unit Assembly
  175
- Checking the Brake Pipes
  176
- Installing the Hydraulic Unit Assembly
  176
- Hydraulic Unit Operation Tests
  177
- Checking the Abs Warning Light
  180
- Handlebar
  181
- Adjusting the Handlebar Position
  183
- Removing the Handlebar
  183
- Checking the Handlebar
  184
- Installing the Handlebar
  184
- Front Fork
  187
- Disassembling the Front Fork Legs
  190
- Removing the Front Fork Legs
  190
- Checking the Front Fork Legs
  191
- Assembling the Front Fork Legs
  192
- Installing the Front Fork Legs
  196
- Checking the Steering Head
  200
- Removing the Lower Bracket
  200
- Steering Head
  200
- Installing the Steering Head
  201
- Rear Shock Absorber Assembly
  202
- Checking the Connecting Arm and Relay Arm
  203
- Checking the Rear Shock Absorber Assembly
  203
- Disposing of a Rear Shock Absorber
  203
- Handling the Rear Shock Absorber
  203
- Removing the Rear Shock Absorber Assembly
  203
- Installing the Rear Shock Absorber Assembly
  204
- Installing the Relay Arm
  204
- Swingarm
  205
- Checking the Swingarm
  207
- Removing the Swingarm
  207
- Installing the Swingarm
  208
- Chain Drive
  209
- Checking the Drive Chain
  210
- Removing the Drive Chain
  210
- Checking the Drive Sprocket
  211
- Checking the Rear Wheel Sprocket
  211
- Checking the Rear Wheel Drive Hub
  212
- Installing the Drive Chain
  212
- Adjusting the Shift Pedal
  214
Engine

215
- Engine Oil Lubrication Chart
  218
- Lubrication System Chart and Diagrams
  218
- Lubrication Diagrams
  219
- Engine Inspection
  224
- Measure the Compression Pressure
  224
- Engine Removal
  226
- Installing the Engine
  231
- Removing the Engine
  231
- Camshafts
  233
- Removing the Camshafts
  237
- Checking the Camshafts
  238
- Checking the Timing Chain and Camshaft Sprocket
  239
- Checking the Timing Chain Guides
  239
- Checking the Timing Chain Tensioner
  239
- Installing the Camshafts
  240
- Cylinder Head
  244
- Checking the Cylinder Head
  245
- Checking the Timing Chain Guide (Exhaust Side)
  245
- Removing the Cylinder Head
  245
- Installing the Cylinder Head
  246
- Valves and Valve Springs
  247
- Checking the Valves and Valve Guides
  249
- Removing the Valves
  249
- Checking the Valve Seats
  251
- Checking the Valve Lifters
  252
- Checking the Valve Springs
  252
- Installing the Valves
  252
- Generator and Starter Clutch
  254
- Checking the Starter Clutch
  256
- Removing the Generator
  256
- Removing the Starter Clutch
  256
- Installing the Generator
  257
- Installing the Starter Clutch
  257
- Electric Starter
  259
- Assembling the Starter Motor
  261
- Checking the Starter Motor
  261
- Installing the Starter Motor
  262
- Clutch
  263
- Removing the Clutch
  267
- Checking the Clutch Plates
  268
- Checking the Friction Plates
  268
- Checking the Clutch Housing
  269
- Checking the Clutch Springs
  269
- Checking the Clutch Boss
  270
- Checking the Pressure Plate
  270
- Checking the Primary Drive Gear
  270
- Checking the Primary Driven Gear
  270
- Checking the Pull Lever Shaft and Pull Rod
  270
- Installing the Clutch
  270
- Shift Shaft
  273
- Checking the Shift Shaft
  274
- Checking the Stopper Lever
  274
- Installing the Shift Shaft
  274
- Oil Pump
  275
- Assembling the Oil Pump
  277
- Checking the Oil Pump
  277
- Checking the Relief Valve
  277
- Checking the Sprocket and Chain
  277
- Installing the Oil Pump
  278
- Oil Pan
  279
- Checking the Oil Strainer
  280
- Installing the Oil Pan
  280
- Removing the Oil Pan
  280
- Crankcase
  281
- Assembling the Crankcase
  283
- Checking the Crankcase
  283
- Disassembling the Crankcase
  283
- Installing the Oil Pressure Switch
  285
- Installing the Gear Position Sensor
  286
- Connecting Rods and Pistons
  287
- Checking the Cylinder and Piston
  288
- Removing the Connecting Rods and Pistons
  288
- Checking the Piston Rings
  289
- Checking the Connecting Rods
  290
- Checking the Piston Pin
  290
- Installing the Connecting Rod and Piston
  293
- Checking the Crankshaft
  299
- Checking the Oil Nozzles
  299
- Crankshaft and Balancer Shaft
  299
- Removing the Crankshaft and Balancer Shaft
  299
- Checking the Balancer Shaft
  301
- Installing the Balancer Assembly
  303
- Installing the Crankshaft
  303
- Transmission
  304
- Checking the Shift Forks
  309
- Removing the Transmission
  309
- Checking the Shift Drum Assembly
  310
- Checking the Transmission
  310
- Assembling the Main Axle and Drive Axle
  311
- Installing the Transmission
  312
Cooling System

315
- Cooling System Diagrams
  316
- Radiator
  319
- Checking the Radiator
  320
- Installing the Radiator
  320
- Oil Cooler
  322
- Checking the Oil Cooler
  323
- Installing the Oil Cooler
  323
- Thermostat
  324
- Checking the Thermostat
  325
- Installing the Thermostat Assembly
  325
- Water Pump
  326
- Assembling the Water Pump
  328
- Checking the Water Pump
  328
- Disassembling the Water Pump
  328
Fuel System

331
- Fuel Tank
  332
- Checking the Fuel Pump Body
  335
- Checking the Fuel Pump Operation
  335
- Removing the Fuel Pump
  335
- Removing the Fuel Tank
  335
- Checking the Purge Cut Valve Solenoid
  336
- Installing the Fuel Pump
  336
- Installing the Fuel Tank
  336
- Checking the Injectors
  339
- Checking the Injectors (before Removing)
  339
- Removing the Fuel Hose (Fuel Rail Side)
  339
- Removing the Injectors
  339
- Checking and Cleaning the Throttle Bodies
  340
- Installing the Injectors
  341
- Replacing the Throttle Bodies
  341
- Checking the Fuel Pressure
  342
- Checking the Injector Pressure
  342
- Adjusting the Throttle Position Sensor
  343
- Installing the Fuel Hose (Fuel Rail Side)
  343
Electrical System

345
- Circuit Diagram
  348
- Ignition System
  348
- Engine Stopping Due to Sidestand Operation
  350
- Troubleshooting
  351
- Circuit Diagram
  354
- Electric Starting System
  354
- Starting Circuit Cut-Off System Operation
  356
- Troubleshooting
  357
- Charging System
  360
- Circuit Diagram
  360
- Troubleshooting
  362
- Circuit Diagram
  364
- Lighting System
  364
- Troubleshooting
  366
- Circuit Diagram
  368
- Signaling System
  368
- Troubleshooting
  370
- Circuit Diagram
  376
- Cooling System
  376
- Troubleshooting
  378
- Circuit Diagram
  380
- Fuel Pump System
  380
- Troubleshooting
  382
- Electrical Components
  384
- Checking the Switches
  386
- Checking and Charging the Battery
  388
- REPLACING the ECU (Engine Control Unit)
  388
- Checking the Relays
  389
- Checking the Relay Unit (Diode)
  390
- Checking the Ignition Coils
  391
- Checking the Ignition Spark Gap
  391
- Checking the Crankshaft Position Sensor
  392
- Checking the Starter Motor Operation
  392
- Checking the Fuel Sender
  393
- Checking the Horn
  393
- Checking the Rectifier/Regulator
  393
- Checking the Stator Coil
  393
- Checking the Coolant Temperature Sensor
  394
- Checking the Fuel Level Warning Light
  394
- Checking the Radiator Fan Motor
  394
- Checking the Throttle Servo Motor
  395
- Checking the Fuel Injectors
  396
- Checking the Intake Air Temperature Sensor
  396
- Checking the Purge Cut Valve Solenoid
  397
- Checking the Wheel Switch
  397
Self Diagnostic

399
- Glossary
  407
- Outline
  407
- Self-Diagnostic Function
  407
- Checking the Warning Light
  408
- Ydt
  409
- Cope with the Mil Flashing
  410
- Parts Connected to the Abs Ecu
  410
- Parts Connected to the Ecu
  410
- Precautions for Road Test
  410
- Ecu Circuit Diagram
  411
- System Diagram
  411
- Ecu Coupler Layout
  414
- Circuit Diagram
  418
- Fuel Injection System
  418
- Basic Process for Troubleshooting
  420
- [A] the Mil Comes On/Flashes and Engine Operation Is Not Normal
  421
- [B] the Mil Does Not Come On, but the Engine Operation Is Not Normal
  421
- Circuit Diagram
  422
- Immobilizer System
  422
- System Outline
  424
- Part Replacement and Key Code Registration Requirements
  425
- Troubleshooting
  428
- How to Check Dtc
  429
- Circuit Diagram
  430
- Cruise Control System
  430
- Cruise Control Circuit Operation
  432
- Basic Instructions for Troubleshooting
  433
- Basic Process for Troubleshooting
  434
- [A] Checking the Cruise Control System Indicator Light
  435
- [B-1] Diagnosis Using the Dtc
  435
- [B-2] Diagnosis Using the Malfunction History Codes
  435
- [B-3] Malfunction History Is Not Displayed
  435
- [C-1] Erasing the Dtc
  436
- [C-2] Final Check
  436
- ABS (Anti-Lock Brake System)
  438
- Circuit Diagram
  438
- Abs Components Chart
  440
- Abs Coupler Location Chart
  441
- Abs Troubleshooting Outline
  442
- Maintenance of the Abs Ecu
  442
- Basic Instructions for Troubleshooting
  443
- [A-1] Only the Abs Warning Light Fails to Come on
  445
- [A-2] All Indicator Lights Fail to Come on
  445
- [A-3] the Abs Warning Light Comes on
  445
- [A] Checking the Abs Warning Light
  445
- [A-4] Only the Abs Ecu Fails to Communicate
  446
- [A-5] Abs Ecu and Fi Ecu Fail to Communicate
  446
- [B-1] Malfunction Are Currently Detected
  446
- [B-2] Diagnosis Using the Dtc
  447
- [B-3] Deleting the Dtc
  447
- [C-1] Final Check
  447
- Dtc Table
  449
- Self-Diagnostic Function and Diagnostic Code Table
  449
- Self-Diagnostic Function Table (for Fuel Injection System)
  457
- Self-Diagnostic Function Table (for Immobilizer System)
  477
- SELF-DIAGNOSTIC FUNCTION TABLE (for ABS (Anti-Lock Brake System))
  478
- Communication Error with the Meter
  483
- Diagnostic Code: Sensor Operation Table
  483
- Event Code Table
  490
- 30_Event
  493
- Troubleshooting
  493
- 70_Event
  495
- Troubleshooting
  495
- C0520
  496
- Troubleshooting
  496
- P0030
  500
- Troubleshooting
  500
- P00D1, P2195
  504
- Troubleshooting
  504
- P0105
  508
- Troubleshooting
  508
- P0106
  510
- Troubleshooting
  510
- P0107, P0108
  512
- Troubleshooting
  512
- P0110
  516
- Troubleshooting
  516
- P0111
  518
- Troubleshooting
  518
- P0112, P0113
  521
- Troubleshooting
  521
- P0115
  525
- Troubleshooting
  525
- P0116
  526
- Troubleshooting
  526
- P0117, P0118
  529
- Troubleshooting
  529
- P0122, P0123, P0222, P0223
  533
- Troubleshooting
  533
- P0132
  538
- Troubleshooting
  538
- Outline
  542
- P0133
  542
- Fail-Safe System
  543
- Troubleshooting
  543
- P0134
  544
- Troubleshooting
  544
- P0201
  546
- Troubleshooting
  546
- P0202
  549
- Troubleshooting
  549
- P0203
  552
- Troubleshooting
  552
- Outline
  555
- Fail-Safe System
  556
- Troubleshooting
  556
- P0335
  559
- Troubleshooting
  559
- P0351
  563
- Troubleshooting
  563
- P0352
  567
- Troubleshooting
  567
- P0353
  571
- Troubleshooting
  571
- P0458
  575
- Troubleshooting
  575
- P0480
  579
- Troubleshooting
  579
- P0500, P1500
  582
- Troubleshooting
  582
- P0560, P0563
  594
- Troubleshooting
  594
- P0564
  595
- Troubleshooting
  595
- P056C
  601
- Troubleshooting
  601
- P0601
  608
- Troubleshooting
  608
- P0606
  609
- Troubleshooting
  609
- P062F
  610
- Troubleshooting
  610
- P0638
  612
- Troubleshooting
  612
- P0657
  616
- Troubleshooting
  616
- P0914
  620
- Troubleshooting
  620
- P0915
  622
- Troubleshooting
  622
- P0916, P0917
  624
- Troubleshooting
  624
- P1004
  628
- Troubleshooting
  628
- P1600
  630
- Troubleshooting
  630
- P1601
  634
- Troubleshooting
  634
- P1602
  638
- Troubleshooting
  638
- P1606, P1607
  642
- Troubleshooting
  642
- P1608
  646
- Troubleshooting
  646
- P1609
  648
- Troubleshooting
  648
- P1806, P1807
  650
- Troubleshooting
  650
- P2122, P2123, P2127, P2128, P2138
  654
- Troubleshooting
  654
- P2135
  658
- Troubleshooting
  658
- P2158
  661
- Troubleshooting
  661
- Troubleshooting
  666
- U0125
  666
- Troubleshooting
  669
- U0155 or Err
  669
- 51_Immobilizer
  673
- Troubleshooting
  673
- 52_Immobilizer
  674
- Troubleshooting
  674
- 53_Immobilizer
  675
- Troubleshooting
  675
- 54_Immobilizer
  678
- Troubleshooting
  678
- 55_Immobilizer
  679
- Troubleshooting
  679
- 56_Immobilizer
  680
- Troubleshooting
  680
- 11_Abs
  683
- Troubleshooting
  683
- 12_Abs
  684
- Troubleshooting
  684
- 13, 26_Abs
  685
- Troubleshooting
  685
- 14, 27_Abs
  686
- Troubleshooting
  686
- 15_Abs
  687
- Troubleshooting
  687
- 16_Abs
  689
- Troubleshooting
  689
- 21_Abs
  691
- Troubleshooting
  691
- 31_Abs
  692
- Troubleshooting
  692
- 33_Abs
  694
- Troubleshooting
  694
- 34_Abs
  696
- Troubleshooting
  696
- 41_Abs
  697
- Troubleshooting
  697
- 42_Abs
  698
- Troubleshooting
  698
- 43, 45_Abs
  699
- Troubleshooting
  699
- 44, 46_Abs
  700
- Troubleshooting
  700
- 51_Abs
  701
- Troubleshooting
  701
- 53_Abs
  702
- Troubleshooting
  702
- 55_Abs
  704
- Troubleshooting
  704
- 56_Abs
  705
- Troubleshooting
  705
- 57_Abs
  706
- Troubleshooting
  706
- 62_Abs
  710
- Troubleshooting
  710
- 68_Abs
  711
- Troubleshooting
  711
- 89_Abs
  712
- Troubleshooting
  712
- 90_Abs
  715
- Troubleshooting
  715
- 91_Abs
  718
- Troubleshooting
  718

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Yamaha XSR900 2022 Owner's Manual

Yamaha XSR900 2022 Owner's Manual (124 pages)

Brand: Yamaha | Category: Motorcycle | Size: 5.16 MB

Table of Contents

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