Piston, Pickup Coil, Shifter, Starter, Generator and Clutch Removal

C. Piston

1. Mark each piston to aid in reassembly.

2.   Place a clean towel or rag into the crank-case to keep circlips and material from falling into the engine.

3.    Remove piston pin clips, piston pins, and pistons.

D. Pick-up Coil Assembly


Repairing Second Gear

Note: this fix does require mechanical ability and judgement. If you have never done anything like this before, you may decide to disassemble the transmission yourself (hey, everyone has to start somewhere) but I suggest you seek out the assistance of someone with some mechanical experience once you get inside. Just changing/repairing the gears may not be enough.

Problem: The transmission kicks and jumps out of second gear, under load. This rapidly gets worse and soon the bike won't take second gear at all.


Bench Checking Fuel Levels

A simple check of the float levels can be done on the bike, with the bike properly leveled on the centre stand, etc. Adjusting them is best done off the bike.


Replacement TCI Transistors

The original transistors used in our Transistor Controlled Ignition igniter boxes are Fuji made ETD41-035. They were discontinued many years ago.

ETD41-035 transistor

Various sources dedicated to old Yamaha motorcycles such as the Vision and the Virago suggest that the MJE5742 is a drop-in replacement.


TCI Repair

For many years my Police Special had a very nasty habit of dying like I had hit the kill switch.
It never sputtered first and would almost always do it within the first 1 km from my home.

Maintenance Intervals


This chapter includes all information necessary to perform recommend inspection and adjustments. These preventative maintenance procedures, if followed, will insure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies not only to vehicles already in service, but also to new vehicles that are being prepared for sale. Any service technician performing preparation work should be familiar with this entire chapter.


Chapter 1. General Information


Frame serial number

The frame seria number is stamped into the right side of the steering head pipe.

Starting serial number: XJ900RL 33F-001101


Chapter 2. Periodic Inspections


XJ900RL Service Manual

Table of Contents




The motorcycle you have purchased may differ slightly from those shown in the photographs.