2000 YAMAHA XJ900S air filter

DESCRIPTION
2-2
2
Right view8. Tail/brake light (page 6-19)
9. Fuse boxes (page 6-25)
10. Seat (page 3-15)
11. Tool kit (page 6-1)
12. Air filter (page 6-11)13. Front fork spring preload
adjusting bolt (page 3-16)
14. Engine oil level window (page 6-8)
15. Rear brake pedal (page 3-11)

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit................................................................... 6-1
Periodic maintenance and lubrication ................... 6-2
Cowling removal and installation .......................... 6-5
Cowling A.............................................................. 6-5
Cowling B.............................................................. 6-6
Spark plug inspection ........................................... 6-7
Engine oil .............................................................. 6-8
Final gear oil replacement .................................. 6-11
Air filter ............................................................... 6-11
Carburetor adjustment ........................................ 6-13
Idle speed adjustment ........................................ 6-13
Throttle cable free play inspection ...................... 6-14
Valve clearance adjustment ................................ 6-14
Tires .................................................................... 6-15
Wheels ................................................................ 6-18
Clutch lever free play adjustment........................ 6-18
Brake light switch adjustment ............................. 6-19
Checking the front and rear brake pads.............. 6-19
Inspecting the brake fluid level............................ 6-20Brake fluid replacement ..................................... 6-21
Cable inspection and lubrication ........................ 6-21
Throttle cable and grip lubrication ...................... 6-21
Brake and shift pedal lubrication ........................ 6-22
Brake and clutch lever lubrication ...................... 6-22
Center and sidestand lubrication ....................... 6-22
Front fork inspection ........................................... 6-23
Steering inspection ............................................ 6-23
Wheel bearings .................................................. 6-24
Battery................................................................ 6-24
Fuse replacement .............................................. 6-25
Headlight bulb replacement ............................... 6-26
Front wheel removal ........................................... 6-27
Front wheel installation ...................................... 6-29
Rear wheel removal ........................................... 6-30
Rear wheel installation ....................................... 6-31
Troubleshooting .................................................. 6-31
Troubleshooting chart ......................................... 6-32

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
CP-01ENO. 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 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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU02970
NOTE:@ l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake system
• When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level regu-
larly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper every two years.
• Replace the brake hoses every four years or if cracked or damaged.
@22 Engine oil filter cartridge• Replace.ÖÖ
23 Final gear oil• Check oil level and vehicle for oil leakage.
• Change oil at initial 1,000 km and thereafter every 24,000 km
or 24 months (whichever comes first).ÖÖÖ 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)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
EAU02938
Engine oilOil 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. @
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.Engine oil and oil filter cartridge re-
placement
1. Warm up the engine for several
minutes.
2. Stop the engine. Place an oil pan
under the engine and remove the
oil filler cap.
1. Engine oil level window
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
63. Remove the drain bolt and drain
the oil.4. Remove the oil filter by using an oil
filter wrench.
NOTE:@ An oil filter wrench is available at a
nearby Yamaha dealer. @5. Install the drain bolt and tighten it
to the specified torque.6. Apply a light coat of engine oil to
the O-ring of the new oil filter.
NOTE:@ Make sure the O-ring is seated proper-
ly. @7. Install the new oil filter and tighten
it to the specified torque with an oil
filter wrench.NOTE:@ When installing the oil filter, tighten it to
the proper torque by using a torque
wrench. @
1. Engine oil drain bolt
1. Oil filter cartrige
2. Oil filter wrench
Tightening torque:
Drain bolt:
43 Nm (4.3 m·kg)
1. O-ring

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 8. Fill the engine with sufficient oil to
reach the specified level. Install
the oil filler cap and tighten it.
EC000066
CAUTION:@ l
Do not put in any chemical addi-
tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
l
Be sure no foreign material en-
ters the crankcase.
@9. Start the engine and warm it up for
several minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for the
cause.NOTE:@ After the engine is started, the oil level
indicator light should go off if the oil is at
the specified level. @
EC000067
CAUTION:@ If the indicator light flickers or re-
mains on, immediately stop the en-
gine and consult with a Yamaha
dealer. @
Tightening torque:
Oil filter:
17 Nm (1.7 m·kg)
Recommended oil:
See page 8-1.
Oil quantity:
Total amount:
4.4 L
Periodic oil change:
3.2 L
With oil filter replacement:
3.4 L

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
EAU02975
Final gear oil replacement1. Put the motorcycle on the center-
stand.
2. Place an oil pan under the final
gear case.
3. Remove the oil filler bolt and the
drain bolt to drain the oil.
4. Install and tighten the drain bolt to
the specified torque.5. Fill the gear case with the recom-
mended oil.
NOTE:@ “GL-4” is a quality and additive rating.
Hypoid gear oils rated “GL-5” or “GL-6”
may also be used. @
EW000066
WARNING
@ Do not let foreign material enter the
final gear case. Be sure oil does not
get on the tire or wheel. @6. Install the oil filler bolt.
7. After replacing the final gear oil, be
sure to check for oil leakage.
EAU00574*
Air filterThe air filter should be cleaned at the
specified intervals. It should be cleaned
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seat.
2. Turn the fuel cock lever to “OFF”
and disconnect the fuel hose.
1. Final gear oil drain bolt
2. Final gear oil
3. Correct level
4. Final gear oil filler boltTightening torque:
Drain bolt:
23 Nm (2.3 m·kg)
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
If desired, an SAE 80W90 hypoid
gear oil may be used for all condi-
tions.
Final gear oil quantity:
0.2 L
1. Fuel tank
2. Fuel sender lead
3. Fuel hose
4. Fuel cock