2000 YAMAHA XJ900S brake pads

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
6-19
6
EAU00713
Brake light switch adjustmentThe rear brake light switch is activated
by the brake pedal and is properly ad-
justed when the brake light comes on
just before braking takes effect. To ad-
just the rear brake light switch, hold the
switch body so it does not rotate while
turning the adjusting nut.
Turn the adjusting nut in direction
a to
make the brake light come on earlier.
Turn the adjusting nut in direction
b to
make the brake light come on later.
EAU01160
Checking the front and rear
brake padsWear indicator grooves are provided
on each brake pad. These indicators
allow checking of brake pad wear with-
out disassembling the brake. Inspect
the grooves. If they have almost disap-
peared, ask a Yamaha dealer to re-
place the pads.
1. Brake light switch
2. Adjusting nut
1. Wear indicator groove (´ 6)
1. Wear indicator groove (´ 2)

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)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU01558*
Rear wheel installation1. Apply a light coating of lithium
soap base grease to the final gear
case splines and the rear wheel
hub splines.
2. Install the wheel and the wheel ax-
le.
3. 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.4. Install the brake torque rod bolt
and nut.
5. Install the pinch bolt and tighten it
to the specified torque.
6. Take the motorcycle off the cen-
terstand.
7. Tighten the axle nut, caliper bolts
and brake torque rod nut to the
specified torques.
8. Secure the brake torque rod nut
with a new cotter pin.
EAU01008
TroubleshootingAlthough 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.
1. Splines
Tightening torque:
Pinch bolt:
16 Nm (1.6 m·kg)
Axle nut:
105 Nm (10.5 m·kg)
Caliper bolt:
35 Nm (3.5 m·kg)
Brake torque rod nut:
23 Nm (2.3 m·kg)

10-INDEXAAir filter .................................................. 6-11
Antitheft alarm (optional) ..........................3-7BBattery ................................................... 6-24
Brake and clutch lever lubrication........... 6-22
Brake and shift pedal lubrication ............ 6-22
Brake fluid replacement ......................... 6-21
Brake light switch adjustment ................. 6-19CCable inspection and lubrication ............ 6-21
Carburetor adjustment ........................... 6-13
Care.........................................................7-1
Center and sidestand lubrication ............ 6-22
Checking the front and
rear brake pads ................................... 6-19
Clutch lever ............................................ 3-10
Clutch lever free play adjustment ........... 6-18
Controls/Instruments ................................2-3
Cowling A ................................................6-5
Cowling B ................................................6-6
Cowling removal and installation ..............6-5DDiagnosis device......................................3-7
Digital clock..............................................3-8
Dimmer switch .........................................3-9EEngine break-in........................................5-5
Engine oil .................................................6-8
Engine stop switch ................................. 3-10
FFinal gear oil replacement ..................... 6-11
Front brake lever ................................... 3-11
Front fork adjustment............................. 3-16
Front fork inspection .............................. 6-23
Front wheel installation .......................... 6-29
Front wheel removal .............................. 6-27
Fuel ....................................................... 3-13
Fuel gauge .............................................. 3-8
Fuel indicator circuit check....................... 3-5
Fuel indicator light ................................... 3-3
Fuel tank breather hose
(for Germany only) .............................. 3-14
Fuel tank cap ......................................... 3-12
Fuse replacement.................................. 6-25GGive safety the right of way ..................... 1-1HHandlebar switches ................................. 3-9
Dimmer switch ................................... 3-9
Engine stop switch ........................... 3-10
Hazard switch .................................... 3-9
Horn switch ........................................ 3-9
Lights switch .................................... 3-10
Pass switch ........................................ 3-9
Start switch ...................................... 3-10
Turn signal switch .............................. 3-9
Hazard switch .......................................... 3-9
Headlight bulb replacement ................... 6-26
Helmet holder ........................................ 3-15
High beam indicator light ......................... 3-3
Horn switch ............................................. 3-9
IIdentification number records ...................9-1
Idle speed adjustment ............................6-13
Indicator lights ..........................................3-3
Fuel indicator light...............................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 ...............6-20KKey identification number .........................9-1LLeft view...................................................2-1
Lights switch ..........................................3-10MMain switch/Steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-3OOil level indicator circuit check .................3-4
Oil level indicator light ..............................3-3PParking.....................................................5-6
Pass switch ..............................................3-9
Periodic maintenance and lubrication .......6-2
Pre-operation check list ............................4-1