2000 YAMAHA XJ900S maintenance

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU02984
Brake and shift pedal
lubricationLubricate the pivoting parts.
EAU02985
Brake and clutch lever
lubricationLubricate the pivoting parts.
EAU02965
Center and sidestand
lubricationLubricate the pivoting and mating
joints.
Check to see that the center and side-
stand move up and down smoothly.
EW000114
WARNING
@ If the center and/or sidestand does
not move smoothly, consult a
Yamaha dealer. @
Recommended lubricant:
Engine oil
Recommended lubricant:
Engine oil
Recommended lubricant:
Engine oil

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU02939
Front fork inspectionVisual check
EW000115
WARNING
@ Securely support the motorcycle so
there is no danger of it falling over. @Check for scratches or damage on the
inner tube and excessive oil leakage
from the front fork.
Operation check
1. Place the motorcycle on a level
place.
2. Hold the motorcycle in an upright
position and apply the front brake.
3. Push down hard on the handle-
bars several times and check if the
fork rebounds smoothly.
EC000098
CAUTION:@ If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer. @
EAU00794
Steering inspectionPeriodically inspect the condition of the
steering. Worn out or loose steering
bearings may be dangerous. Place a
stand under the engine to raise the
front wheel off the ground. Hold the
lower end of the front forks and try to
move them forward and backward. If
any free play can be felt, ask a Yamaha
dealer to inspect and adjust the steer-
ing. Inspection is easier if the front
wheel is removed.
EW000115
WARNING
@ Securely support the motorcycle so
there is no danger of it falling over. @

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU01144
Wheel bearingsIf there is play in the front or rear wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer in-
spect the wheel bearings.
EAU00800
BatteryThis motorcycle is equipped with a
sealed-type battery. Therefore it is not
necessary to check the electrolyte or fill
the battery with distilled water.l
If the battery seems to have dis-
charged, consult a Yamaha deal-
er.
l
If the motorcycle is equipped with
optional electrical accessories, the
battery tends to discharge more
quickly, so be sure to recharge it
periodically.
EC000101
CAUTION:@ Never try to remove the sealing caps
of the battery cells. The battery will
be damaged. @
EW000116
WARNING
@ Battery electrolyte is poisonous and
dangerous, causing severe burns,
etc. It contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
ANTIDOTE:l
EXTERNAL: Flush with water.
l
INTERNAL: Drink large quanti-
ties of water or milk. Follow with
milk of magnesia, beaten egg,
or vegetable oil. Call a physi-
cian immediately.
l
EYES: Flush with water for
15 minutes and get prompt
medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes etc.,
away. Ventilate when charging or
using in an enclosed space. Always
shield your eyes when working near
batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
@

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6Battery storage
When the motorcycle is not used for a
month or longer, remove the battery,
fully charge it and store it in a cool, dry
place.
EC000102
CAUTION:@ l
Completely recharge the bat-
tery before storing. Storing a
discharged battery can cause
permanent battery damage.
l
Use a battery charger designed
for a sealed-type (MF) battery.
Using a conventional battery
charger will cause battery dam-
age. If you do not have a sealed-
type battery charger, contact
your Yamaha dealer.
l
Always make sure the connec-
tions are correct when reinstall-
ing the battery.
@
EAU01110*
Fuse replacementThe fuse boxes are located behind
cowling B. (See page 6-6 for removal
and installation procedures.)
If any fuse is blown, turn off the ignition
switch and the switch of the circuit in
question. Install a new fuse of proper
amperage. Turn on the switches and
see if the electrical device operates. If
the fuse immediately blows again, con-
sult a Yamaha dealer.
EC000103
CAUTION:@ Do not use fuses of higher amper-
age rating than those recommend-
ed. Substitution of a fuse of
improper rating can cause extensive
electrical system damage and pos-
sibly a fire. @
1. Fuse box (´ 2)
1. Headlight fuse
2. Ignition fuse
3. Clock fuse
4. Hazard light fuse
5. Main fuse
6. Spare fuse (´ 3)
7. Signaling system fuse

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU00829
Headlight bulb replacementThis motorcycle is equipped with a
quartz bulb headlight.
If a headlight bulb burns out, replace it
as follows:
1. Remove the headlight connector
and the bulb holder cover.2. Unhook the bulb holder and re-
move the defective bulb.
EW000119
WARNING
@ Keep flammable products and your
hands away from a bulb while it is
on, as it is hot. Do not touch a bulb
until it cools down. @
Specified fuses:
Main fuse: 30 A
Headlight fuse: 15 A
Signaling system fuse: 20 A
Hazard light fuse: 10 A
Ignition fuse: 10 A
Clock fuse: 10 A
1. Connector
2. Bulb holder cover
1. Bulb holder

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
63. 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. @
4. Install the bulb holder cover and
the headlight connector.
If a headlight beam adjustment is
necessary, ask a Yamaha dealer
to make adjustment.
EAU00869
Front wheel removal
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely 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.
1. Don’t touch
1. Speedometer cable

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 3. Remove the brake hose holders
and the calipers by removing the
bolts.
NOTE:@ Do not depress the brake lever when
the disc and caliper are separated. @
4. Loosen the pinch bolt and wheel
axle.
5. Elevate the front wheel by placing
a suitable stand under the engine.
6. Remove the wheel axle. Make
sure the motorcycle is properly
supported.
1. Bolt (´ 3)
2. Brake hose holder
3. CaliperLeft
Right
1. Pinch bolt
2. Wheel axle

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU01469
Front wheel installation1. 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.
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. Tighten the wheel axle, pinch bolt
and caliper bolts to the specified
torque.6. Push down hard on the handle-
bars several times to check for
proper fork operation.
7. Install the speedometer cable.
Tightening torque:
Wheel axle:
59 Nm (5.9 m·kg)
Pinch bolt:
19 Nm (1.9 m·kg)
Caliper bolt:
40 Nm (4.0 m·kg)