2000 YAMAHA XJ600S engine oil

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3-4
INSTRUMENT AND CONTROL FUNCTIONS
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EC000000
CAUTION:
Do not run the motorcycle until you
know it has sufficient engine oil.
NOTE:
Even if the oil is filled to the specified
level, the indicator light may flicker
when riding on a slope or during sud-
den acceleration or deceleration, but
this is normal.

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3-5
INSTRUMENT AND CONTROL FUNCTIONS
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EAU00071
Oil level indicator circuit check
Turn the main switch to ÒONÓ and
the engine stop switch to Ò Ó.
Oil level indicator light
does not come on.Oil level indicator light
comes on.
Check engine oil level.
Oil level indicator light
comes on.Oil level indicator light
does not come on.
Engine oil level and
electrical circuit are OK.
Go ahead with riding.
Put the transmission in neutral
or apply the clutch lever, then
push the start switch.
Oil level
is OK.
Supply
engine oil.
Oil level
is low.
Ask a Yamaha dealer to
inspect electrical circuit.

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4-1
PRE-OPERATION CHECKS
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Owners are personally responsible for their vehicleÕs condition. Your motorcycleÕs vital functions can start to deteriorate
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or
loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual in-
spection, you check the following points before each ride.
EAU00340
PRE-OPERATION CHECK LIST
ITEM CHECKS PAGE
Front brake
¥ Check operation, fluid level and fluid leakage.
¥ Fill with DOT 4 (or DOT 3) brake fluid if necessary.6-18 ~ 6-20
Rear brake6-17 ~ 6-20
Clutch¥ Check operation, condition and free play.
¥ Adjust if necessary.6-15 ~ 6-16
Throttle grip and housing¥ Check for smooth operation.
¥ Lubricate if necessary.6-12, 6-22
Engine oil¥ Check oil level.
¥ Fill with oil if necessary.6-7 ~ 6-9
Drive chain¥ Check chain slack and condition.
¥ Adjust if necessary.6-20 ~ 6-21
Wheels and tires¥ Check tire pressure, wear and damage.6-13 ~ 6-15,
6-31 ~ 6-34
Control and meter cables¥ Check for smooth operation.
¥ Lubricate if necessary.6-22
Brake and shift pedal
shafts¥ Check for smooth operation.
¥ Lubricate if necessary.6-22
Brake and clutch lever
pivots¥ Check for smooth operation.
¥ Lubricate if necessary.6-23
Center and sidestand
pivots¥ Check for smooth operation.
¥ Lubricate if necessary.6-23
EAU01114

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5-3
OPERATION AND IMPORTANT RIDING POINTS
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1. Turn the fuel cock to ÒONÓ.
2. Turn the main switch to ÒONÓ and
the engine stop switch to Ò Ó.
3. Shift transmission into neutral.
NOTE:
When the transmission is in neutral, the
neutral indicator light should be on. If
the light does not come on, ask a
Yamaha dealer to inspect it.
4. Turn on the starter (choke) and
completely close the throttle grip.
5. Start the engine by pushing the
start switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, then
try again. Each attempt should be as
short as possible to preserve the bat-
tery. Do not crank the engine more
than 10 seconds on any one attempt.
EC000034
CAUTION:
The oil level indicator light should
come on when the start switch is
pushed and should go off when the
start switch is released. If the indica-
tor light flickers or remains on, im-
mediately stop the engine and
check the engine oil level and for oil
leakage. If necessary, fill the engine
with oil and check to see that the oil
level indicator light goes off. If the
light does not go off even with suffi-
cient oil in the crankcase or the light
does not come on when pushing the
start switch, consult a Yamaha
dealer.
6. After starting the engine, move the
starter (choke) halfway back.
NOTE:
For maximum engine life, never accel-
erate hard with a cold engine!7. After the engine is warm, turn off
the starter (choke) completely.
NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.

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5-6
OPERATION AND IMPORTANT RIDING POINTS
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EAU00440
0 ~ 150 km
Avoid operation above 5,000 r/min.
Stop the engine and let it cool for 5 to
10 minutes after every hour of opera-
tion. Vary the speed of the motorcycle
from time to time. Do not operate it at
one set throttle position.
150 ~ 500 km
Avoid prolonged operation above
6,000 r/min. Rev the motorcycle freely
through the gears, but do not use full
throttle at any time.
500 ~ 1,000 km
Avoid prolonged full throttle operation.
Avoid cruising speeds in excess of
7,000 r/min.
EC000052
CAUTION:
After 1,000 km of operation, be sure
to replace the engine oil and oil fil-
ter.1,000 km and beyond
Full throttle can be used.
EC000053
CAUTION:
lNever let engine speeds enter
the red zone.
lIf any engine trouble should oc-
cur during the break-in period,
consult a Yamaha dealer imme-
diately.
EAU00460
Parking
When parking the motorcycle, stop the
engine and remove the ignition key.
EW000058
The exhaust system is hot. Park the
motorcycle in a place where pedes-
trians or children are not likely to
touch the motorcycle. Do not park
the motorcycle on a slope or soft
ground; the motorcycle may over-
turn.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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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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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
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* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU01792
NOTE:
lThe air filter needs more frequent service if you are riding in unusually wet or dusty areas.
lHydraulic brake system
¥ When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level regularly
and fill as required.
¥ Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
¥ Replace the brake hoses every four years or if cracked or damaged.
21*Carburetors¥ Check engine idling speed, synchronization and starter operation.
¥ Adjust if necessary.ÖÖÖ
22 Engine oil¥ Check oil level and vehicle for oil leakage.
¥ Correct if necessary.
¥ Change. (Warm engine before draining.)ÖÖÖ
23 Engine oil filter cartridge¥ Replace.ÖÖ 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)

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6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
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When installing a spark plug, the gas-
ket surface should always be cleaned
and a new gasket used. Any grime
should be wiped off from the threads
and the spark plug tightened to the
specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4 to 1/2 turn
past finger tight. The spark plug should
be tightened to the specified torque as
soon as possible.Tightening torque:
Spark plug:
12.5 Nm (1.25 mákg)
1. Level window
2. Maximum level mark
3. Minimum level mark
EAU02938
Engine oil
Oil level inspection
1. Place the motorcycle on the cen-
terstand. Warm up the engine for
several minutes.
NOTE:
Be sure the motorcycle is positioned
straight up when checking the oil level.
A slight tilt toward the side can result in
false readings.
1. Engine oil filler cap
2. With the engine stopped, check
the oil level through the level win-
dow located at the lower part of
the right side crankcase cover.
NOTE:
Wait a few minutes until the oil level
settles before checking.
3. The oil level should be between
the maximum and minimum
marks. If the level is low, fill the en-
gine with sufficient oil to reach the
specified level.