2001 YAMAHA XJ600S Owners Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6 7. Tighten the locknut at the clutch
lever and the crankcase.
EAU00712
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 40 mm below
the top of the footrest as shown. Peri-
odically check the brake pedal position
and, if necessary, have a Yamaha
dealer adjust it.
EW000109
WARNING
@ A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident.@
a. Distance between brake pedal and footrest
E_4br.book Page 18 Thursday, August 17, 2000 11:29 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU00713
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction
a. To
make the brake light come on later,
turn the adjusting nut in direction
b.
EAU00721
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU00725
Front brake pads
Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
1. Brake light switch
2. Brake light switch adjusting nut
1. Wear indicator groove (´ 2)Front
E_4br.book Page 19 Thursday, August 17, 2000 11:29 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
EAU00728
Rear brake pads
Each rear brake pad is provided with a
wear indicator, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicator while applying the
brake. If a brake pad has worn to the
point that the wear indicator almost
touches the brake disc, have a
Yamaha dealer replace the brake pads
as a set.
EAU03196
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.Observe these precautions:
l
When checking the fluid level,
make sure that the top of the mas-
ter cylinder or brake fluid reservoir
is level.
l
Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
1. Wear indicator groove (´ 2)Rear
1. Minimum level markFront
1. Minimum level markRecommended brake fluid: DOT 4Rear
E_4br.book Page 20 Thursday, August 17, 2000 11:29 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
l
Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU03238
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the brake master cylinder and caliper
as well as the brake hose replaced at
the intervals listed below or whenever
they are damaged or leaking.l
Oil seals: Replace every two
years.
l
Brake hose: Replace every four
years.
EAU00745
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
To check the drive chain slack
1. Place the motorcycle on the
centerstand.
2. Shift the transmission into the neu-
tral position.
3. Spin the rear wheel several times
to locate the tightest portion of the
drive chain.
4. Measure the drive chain slack as
shown.a. Drive chain slack
E_4br.book Page 21 Thursday, August 17, 2000 11:29 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6 5. If the drive chain slack is incorrect,
adjust it as follows.
EAU00762
To adjust the drive chain slack
1. Loosen the axle nut, then the
chain puller locknut at each end of
the swingarm.
2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction
a. To loos-
en the drive chain, turn the adjust-
ing nut at each end of the
swingarm in direction
b, and then
push the rear wheel forward.
NOTE:@ Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po-
sition for proper wheel alignment. @
EC000096
CAUTION:@ Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits. @3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque. Drive chain slack:
30–40 mm
1. Axle nut
2. Chain puller locknut
3. Drive chain slack adjusting nut
4. Alignment marks
Tightening torque:
Axle nut:
105 Nm (10.5 m·kg)
E_4br.book Page 22 Thursday, August 17, 2000 11:29 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU03006
Lubricating the drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
EC000097
CAUTION:@ The drive chain must be lubricated
after washing the motorcycle or
riding in the rain. @1. Clean the drive chain with kero-
sene and a small soft brush.
ECA00053
CAUTION:@ To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. @
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA00052
CAUTION:@ Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings. @
EAU02962
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
@ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. @
Recommended lubricant:
Engine oil
E_4br.book Page 23 Thursday, August 17, 2000 11:29 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU03209
Checking and lubricating the
throttle grip and cable The operation of the throttle grip and
the condition of the throttle cable
should be checked before each ride,
and the cable should be lubricated or
replaced if necessary.NOTE:@ Since the throttle grip must be removed
to access the throttle cable end, the
throttle grip and the cable should al-
ways be lubricated at the same time. @1. Remove the throttle grip by remov-
ing the screws.
2. Disconnect the throttle cable, hold
it up, and then apply several drops
of oil to the cable end, allowing it to
trickle into the sheath.
3. Connect the throttle cable, and
then grease the inside of the throt-
tle grip housing.
4. Grease the metal-to-metal contact
surface of the throttle grip, and
then install the grip by installing
the screws.
EAU03370
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary. Recommended lubricant:
Throttle cable:
Engine oil
Throttle grip housing and grip:
Lithium-soap-based grease
(all-purpose grease) Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
E_4br.book Page 24 Thursday, August 17, 2000 11:29 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU03164
Checking and lubricating the
brake and clutch levers The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
EAU03371
Checking and lubricating the
centerstand and sidestand The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to-
metal contact surfaces should be lubri-
cated if necessary.
EW000114
WARNING
@ If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it. @
EAU00790
Lubricating the rear
suspension The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Molybdenum disulfide grease
E_4br.book Page 25 Thursday, August 17, 2000 11:29 AM