2000 YAMAHA XJ600N brake pads

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PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/E-6TOC.-
Tool kit ................................................................ 6-1
Periodic maintenance and lubrication................. 6-2
Panel removal and installation ........................... 6-5
Panel A ............................................................... 6-5
Spark plug inspection ......................................... 6-6
Engine oil............................................................ 6-7
Air filter ............................................................. 6-10
Carburetor adjustment ...................................... 6-11
Idle speed adjustment ...................................... 6-12
Throttle cable free play inspection .................... 6-12
Valve clearance adjustment ............................. 6-13
Tires ................................................................. 6-13
Wheels ............................................................. 6-15
Clutch lever free play adjustment ..................... 6-15
Rear brake pedal height adjustment ................ 6-17
Brake light switch adjustment ........................... 6-17
Checking the front and rear brake pads ........... 6-18
Inspecting the brake fluid level ......................... 6-19
Brake fluid replacement .................................... 6-20
Drive chain slack check .................................... 6-20
Drive chain slack adjustment ............................ 6-21Drive chain lubrication....................................... 6-21
Cable inspection and lubrication ....................... 6-22
Throttle cable and grip lubrication ..................... 6-22
Brake and shift pedal lubrication ....................... 6-22
Brake and clutch lever lubrication ..................... 6-23
Center and sidestand lubrication ...................... 6-23
Rear suspension lubrication.............................. 6-23
Front fork inspection ......................................... 6-24
Steering inspection ........................................... 6-24
Wheel bearings ................................................. 6-25
Battery............................................................... 6-25
Fuse replacement ............................................. 6-26
Headlight bulb replacement (for XJ600S) ......... 6-27
Headlight bulb replacement (for XJ600N) ......... 6-29
Front wheel removal ......................................... 6-31
Front wheel installation ..................................... 6-31
Rear wheel removal .......................................... 6-33
Rear wheel installation ...................................... 6-34
Troubleshooting ................................................ 6-34
Troubleshooting chart ....................................... 6-35

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6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/E-6.frame
EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
NO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
1
*Fuel line ¥ Check fuel hoses and vacuum hose for cracks or damage.
¥ Replace if necessary.ÖÖ
2
*Fuel filter¥ Check condition.
¥ Replace if necessary.Ö
3 Spark plugs¥ Check condition.
¥ Clean, regap or replace if necessary.ÖÖÖ
4
*Valves¥ Check valve clearance.
¥ Adjust if necessary.Every 24,000 km or 24 months
(whichever comes first)
5 Air filter¥ Clean or replace if necessary.ÖÖ
6Clutch¥ Check operation.
¥ Adjust or replace cable.ÖÖÖ
7
*Front brake¥ Check operation, fluid level and vehicle for fluid leakage. (See NOTE
on page 6-4.)
¥ Correct accordingly.
¥ Replace brake pads if necessary.ÖÖÖ
8
*Rear brake¥ Check operation, fluid level and vehicle for fluid leakage. (See NOTE
on page 6-4.)
¥ Correct accordingly.
¥ Replace brake pads if necessary.ÖÖÖ
9
*Wheels¥ Check balance, runout and for damage.
¥ Rebalance or replace if necessary.ÖÖ
10
*Tires¥ Check tread depth and for damage.
¥ Replace if necessary.
¥ Check air pressure.
¥ Correct if necessary.ÖÖ

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6-18
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/E-6.frame
1. Wear indicator groove (´ 2)
EAU00721
Checking the front and rear
brake pads
EAU00725
Front brake
A wear indicator groove is provided on
each brake pad. This indicator allows
checking of brake pad wear without
disassembling the brake. Inspect the
groove. If the groove has almost disap-
peared, ask a Yamaha dealer to re-
place the pads.
1. Wear indicator (´ 2)
EAU00728
Rear brake
Apply the brake and inspect the wear
indicator. If the wear indicator is
ALMOST in contact with the disc plate,
ask a Yamaha dealer to replace the
pads.

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6-32
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/E-6.frame
3. Install the wheel axle and let the
motorcycle down.
4. Install the calipers and caliper
bolts. Make sure there is enough
gap between the brake pads be-
fore installing the calipers onto the
brake discs.
5. Push down hard on the handle-
bars several times to check for
proper fork operation.
6. Tighten the wheel axle, pinch bolt
and caliper bolts to the specified
torque.7. Install the speedometer cable.Tightening torque:
Wheel axle:
58 Nm (5.8 mákg)
Pinch bolt:
40 Nm (4.0 mákg)
Caliper bolt:
19 Nm (1.9 mákg)

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6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/E-6.frame
EAU01468
Rear wheel installation
1. Install the wheel assembly and in-
sert the axle.
2. Install and adjust the drive chain.
(See page 6-20 for details about
adjusting the drive chain slack.)
3. Install the axle nut.
4. Install the caliper and caliper bolts.
Make sure there is enough gap
between the brake pads before in-
stalling the caliper onto the brake
disc.
5. Take the motorcycle off the cen-
terstand.
6. Tighten the axle nut and brake
torque rod bolt to the specified
torques.
Tightening torque:
Axle nut:
105 Nm (10.5 mákg)
Brake torque rod bolt:
23 Nm (2.3 mákg)
EAU01008
Troubleshooting
Although Yamaha motorcycles receive
a rigid inspection before shipment from
the factory, trouble may occur during
operation.
Any problem in the fuel, compression,
or ignition systems can cause poor
starting and loss of power. The trouble-
shooting chart describes a quick, easy
procedure for making checks.
If your motorcycle requires any repair,
bring it to a Yamaha dealer. The skilled
technicians at a Yamaha dealership
have the tools, experience, and know-
how to properly service your motor-
cycle. Use only genuine Yamaha parts
on your motorcycle. Imitation parts may
look like Yamaha parts, but they are of-
ten inferior. Consequently, they have a
shorter service life and can lead to ex-
pensive repair bills.

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INDEX
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/EEIX.frame
A
Air filter .................................................6-10
B
Battery ..................................................6-25
Brake and clutch lever lubrication ........6-23
Brake and shift pedal lubrication ..........6-22
Brake fluid replacement ........................6-20
Brake light switch adjustment ...............6-17
C
Cable inspection and lubrication ..........6-22
Carburetor adjustment ..........................6-11
Care ........................................................7-1
Center and sidestand lubrication ..........6-23
Checking the front and rear brake
pads ...................................................6-18
Clutch lever ............................................3-9
Clutch lever free play adjustment .........6-15
Controls/Instruments (XJ600N) ..............2-6
Controls/Instruments (XJ600S) ..............2-3
D
Dimmer switch ........................................3-7
Drive chain lubrication ..........................6-21
Drive chain slack adjustment ................6-21
Drive chain slack check ........................6-20
E
Engine break-in ......................................5-5
Engine oil ................................................6-7
Engine stop switch .................................3-9
F
Front brake lever ................................. 3-10
Front fork inspection ............................ 6-24
Front wheel installation ........................ 6-31
Front wheel removal ............................ 6-31
Fuel ...................................................... 3-12
Fuel cock ............................................. 3-13
Fuel tank breather hose
(for Germany only) ............................ 3-12
Fuel tank cap ....................................... 3-11
Fuse replacement ................................ 6-26
G
Give safety the right of way ................... 1-1
H
Handlebar switches ............................... 3-7
Dimmer switch ................................. 3-7
Engine stop switch ........................... 3-9
Hazard switch .................................. 3-8
Horn switch ...................................... 3-8
Lights switch .................................... 3-9
Pass switch ...................................... 3-7
Start switch ...................................... 3-9
Turn signal switch ............................ 3-8
Hazard switch ........................................ 3-8
Headlight bulb replacement
(for XJ600N) ...................................... 6-29
Headlight bulb replacement
(for XJ600S) ...................................... 6-27
Helmet holders ..................................... 3-15
High beam indicator light ....................... 3-3
Horn switch ............................................ 3-8
I
Identification number records ................ 9-1
Idle speed adjustment .......................... 6-12
Indicator lights ........................................ 3-3
High beam indicator light .................. 3-3
Neutral indicator light ....................... 3-3
Oil level indicator light ...................... 3-3
Turn indicator lights .......................... 3-3
Inspecting the brake fluid level ............ 6-19
K
Key identification number
(for XJ600N) ........................................ 9-1
Key identification number
(for XJ600S) ........................................ 9-1
L
Left view (XJ600N) ................................ 2-4
Left view (XJ600S) ................................. 2-1
Lights switch .......................................... 3-9
Luggage strap holders ......................... 3-16
M
Main switch ............................................ 3-1
Model label ............................................ 9-2
N
Neutral indicator light ............................. 3-3