2000 YAMAHA XJ600S maintenance

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6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/E-6.frame
1. DonÕt touch
4. Put a new bulb into position and
secure it in place with the bulb
holder.
EC000105
CAUTION:
Avoid touching the glass part of a
bulb. Keep it free from oil; other-
wise, the transparency of the glass,
life of the bulb, and luminous flux
will be adversely affected. If oil gets
on a bulb, thoroughly clean it with a
cloth moistened with alcohol or lac-
quer thinner.5. Install the bulb cover, connectors
and headlight unit. Ask a Yamaha
dealer to adjust the headlight
beam if necessary.

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6-31
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/E-6.frame
1. Speedometer cable
EAU00868
Front wheel removal
EW000122
lIt is advisable to have a Yamaha
dealer service the wheel.
lSecurely support the motor-
cycle so there is no danger of it
falling over.
1. Place the motorcycle on the cen-
terstand.
2. Remove the speedometer cable
from the front wheel side.
3. Remove the calipers.
1. Wheel axle
2. Pinch bolt
NOTE:
Do not depress the brake lever when
the disc and caliper are separated.
4. Loosen the pinch bolt.
5. Remove the wheel axle. Make
sure the motorcycle is properly
supported.
EAU01469
Front wheel installation
1. Install the speedometer gear unit
into the wheel hub. Make sure the
wheel hub and the speedometer
gear unit are installed with the pro-
jections meshed into the slots.
2. Lift up the wheel between the front
fork legs. Make sure the slot in the
speedometer gear unit fits over
the stopper on the front fork outer
tube.

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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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6-33
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/E-6.frame
1. Axle nut
EAU01480
Rear wheel removal
EW000122
lIt is advisable to have a Yamaha
dealer service the wheel.
lSecurely support the motor-
cycle so there is no danger of it
falling over.
1. Place the motorcycle on the cen-
terstand.
2. Remove the axle nut.
1. Brake torque rod bolt
2. Nut
3. Remove the brake torque rod bolt
by removing the nut.
4. While supporting the brake cali-
per, pull out the wheel axle.
5. Push the wheel forward and re-
move the drive chain.
6. Remove the wheel assembly.
NOTE:
lDo not depress the brake pedal
when the disc and caliper are sep-
arated.
lYou do not have to disassemble
the chain in order to remove or in-
stall the rear wheel.

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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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6-35
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/E-6.frame
EAU01297
Troubleshooting chart
EW000125
Never check the fuel system while smoking or in the vicinity of an open flame.
Check if there is fuel
in the fuel tank.
1. FuelEnough fuel.
No fuel.Go to compression check.
Supply fuel.
Use the electric starter.
2. CompressionThere is compression.
No compression.Go to ignition check.
Ask a Yamaha dealer to
inspect.
Remove spark
plugs and
check electrodes.
3. IgnitionWet.
Dry.Wipe clean with dry cloth and correct
spark gap or replace spark plugs.
Ask a Yamaha dealer to inspect.
Engine doesnÕt start, go to battery
check.
Open throttle half-way and start
the engine.
Use the electric starter.
4. BatteryEngine turns over
quickly.
Engine turns over
slowly.Battery good.
Check connections or
recharge.
Engine doesnÕt start, ask a Yamaha
dealer to inspect.
Engine doesnÕt start, go to compression check.

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7-5
MOTORCYCLE CARE AND STORAGE
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/E-7.frame
c. Install the spark plug caps onto the
spark plugs and place the spark
plugs on the cylinder head so that
the electrodes are grounded. (This
will limit sparking during the next
step.)
d. Turn the engine over several times
with the starter. (This will coat the
cylinder walls with oil.)
e. Remove the spark plug caps from
the spark plugs, install the spark
plugs and then the spark plug
caps.
EWA00003
When turning the engine over, be
sure to ground the spark plug elec-
trodes to prevent damage or injury
from sparking.
6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the side-
stand/centerstand.7. Check and, if necessary, correct
the tire air pressure, then raise the
motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover up the muffler outlets with
plastic bags to prevent moisture
from entering.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and recharge it once a
month. Do not store the battery in
an excessively cold or warm place
(less than 0ûC or more than 30ûC).
For more information, see ÒBattery
storageÓ in the chapter ÒPERIOD-
IC MAINTENANCE AND MINOR
REPAIRSÓ.
NOTE:
Make any necessary repairs before
storing the motorcycle.

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INDEX
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/EEIX.frame
O
Oil level indicator circuit check .............. 3-5
Oil level indicator light ............................ 3-3
P
Panel A .................................................. 6-5
Panel removal and installation ............... 6-5
Parking .................................................. 5-6
Pass switch ............................................ 3-7
Periodic maintenance and lubrication .... 6-2
Pre-operation check list ......................... 4-1
R
Rear brake pedal ................................. 3-11
Rear brake pedal height adjustment .... 6-17
Rear shock absorber adjustment ......... 3-15
Rear suspension lubrication ................ 6-23
Rear wheel installation ........................ 6-34
Rear wheel removal ............................. 6-33
Recommended shift points
(for Switzerland only) .......................... 5-5
Right view (XJ600N) .............................. 2-5
Right view (XJ600S) .............................. 2-2
S
Seat ..................................................... 3-14
Shift pedal ............................................ 3-10
Shifting ................................................... 5-4
Sidestand ............................................. 3-17
Sidestand/clutch switch operation
check ................................................. 3-17
Spark plug inspection ............................ 6-6
Specifications ......................................... 8-1
Speedometer (for XJ600N) .................... 3-6
Speedometer (for XJ600S) .................... 3-6
Start switch ............................................ 3-9
Starter (choke) Ò Ó ............................ 3-14
Starting a warm engine .......................... 5-4
Starting the engine ................................. 5-1
Steering inspection .............................. 6-24
Steering lock (for XJ600N) ..................... 3-3
Storage ................................................... 7-4
Storage compartment .......................... 3-15
T
Tachometer ............................................ 3-7
Throttle cable and grip lubrication ........ 6-22
Throttle cable free play inspection ....... 6-12
Tips for reducing fuel consumption ........ 5-5
Tires ..................................................... 6-13
Tool kit ................................................... 6-1
Troubleshooting ................................... 6-34
Troubleshooting chart .......................... 6-35
Turn indicator lights ............................... 3-3
Turn signal switch .................................. 3-8
V
Valve clearance adjustment ................. 6-13
Vehicle identification number ................. 9-2
W
Wheel bearings .................................... 6-25
Wheels ................................................. 6-15