2001 YAMAHA XJ600S brake fluid

4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03328
Pre-operation check list
ITEM CHECKS PAGE
Front brake
• Check operation, fluid level and fluid leakage.
• Fill with DOT 4 brake fluid if necessary.6-19–6-21
Rear brake6-18–6-21
Clutch• Check operation, condition and free play.
• Adjust if necessary.6-17–6-18
Throttle grip and housing• Check smooth operation.
• Lubricate if necessary.6-13, 6-24
Engine oil• Check oil level.
• Fill with oil if necessary.6-7–6-10
Drive chain• Check chain slack and condition.
• Adjust if necessary.6-21–6-23
Wheels and tires• Check tire pressure, wear and damage.6-14–6-17,
6-33–6-36
Control and meter cables• Check smooth operation.
• Lubricate if necessary.6-23
Brake and shift pedal
shafts• Check smooth operation.
• Lubricate if necessary.6-24
Brake and clutch lever
pivots• Check smooth operation.
• Lubricate if necessary.6-25
Center and sidestand
pivots• Check smooth operation.
• Lubricate if necessary.6-25
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing the panel ....................... 6-5
Checking the spark plugs .................................... 6-6
Engine oil and oil filter cartridge .......................... 6-7
Cleaning the air filter element ............................ 6-10
Adjusting the carburetors ................................... 6-12
Adjusting the engine idling speed ...................... 6-13
Adjusting the throttle cable free play .................. 6-13
Adjusting the valve clearance ............................ 6-14
Tires ................................................................... 6-14
Wheels ............................................................... 6-17
Adjusting the clutch lever free play .................... 6-17
Adjusting the brake pedal position ..................... 6-18
Adjusting the rear brake light switch .................. 6-19
Checking the front and rear brake pads ............. 6-19
Checking the brake fluid level ............................ 6-20
Changing the brake fluid .................................... 6-21
Drive chain slack ................................................ 6-21
Lubricating the drive chain ................................. 6-23
Checking and lubricating the cables .................. 6-23Checking and lubricating the throttle grip and
cable ............................................................... 6-24
Checking and lubricating the brake and
shift pedals ...................................................... 6-24
Checking and lubricating the brake and
clutch levers .................................................... 6-25
Checking and lubricating the centerstand and
sidestand ......................................................... 6-25
Lubricating the rear suspension ........................ 6-25
Checking the front fork ...................................... 6-26
Checking the steering ....................................... 6-26
Checking the wheel bearings ............................ 6-27
Battery ............................................................... 6-27
Replacing the fuses .......................................... 6-29
Replacing a headlight bulb (for XJ600S) ............ 6-30
Replacing the headlight bulb (for XJ600N) ........ 6-31
Front wheel ....................................................... 6-33
Rear wheel ........................................................ 6-35
Troubleshooting ................................................. 6-36
Troubleshooting chart ........................................ 6-37
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03540
Periodic maintenance and lubrication chart
NOTE:l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
CP-01ECP-01ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
Annual
check
1 10203040
1
*Fuel line• Check fuel hoses and vacuum hose for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
• Replace.ÖÖ
4*Valves• Check valve clearance.
•Adjust.Every 20,000 km
5 Air filter element•Clean.ÖÖ
• Replace.ÖÖ
6Clutch• Check operation.
•Adjust.ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
9*Brake hoses• Check for cracks or damage.ÖÖÖÖ Ö
• Replace. (See NOTE on page 6-4.) Every 4 years
E_4br_Periodic.fm Page 2 Friday, December 15, 2000 9:27 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU03884
NOTE:_ l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
• Replace the brake hoses every four years and if cracked or damaged.
_25
*Front and rear brake
switches• Check operation.ÖÖÖÖÖ Ö
26 Moving parts and cables• Lubricate.ÖÖÖÖ Ö
27*Lights, signals and
switches• Check operation.
• Adjust headlight beam.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
Annual
check
1 10203040
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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

SPECIFICATIONS
8-3
8
Maximum load*
XJ600S 184 kg
XJ600N 187 kg
Tire air pressure (measured on
cold tires)
Up to 90 kg*
Front 200 kPa (2.00 kg/cm
2, 2.00 bar)
Rear 225 kPa (2.25 kg/cm2, 2.25 bar)
90 kg maximum*
Front 200 kPa (2.00 kg/cm2, 2.00 bar)
Rear 250 kPa (2.50 kg/cm2, 2.50 bar)
High-speed riding
Front 200 kPa (2.00 kg/cm2, 2.00 bar)
Rear 250 kPa (2.50 kg/cm2, 2.50 bar)
* Total weight of rider, passenger, cargo and accessories
Wheels
Front
Type Cast wheel
Size 17 ´ MT 2.50
Rear
Type Cast wheel
Size 18 ´ MT 3.50Brakes
Front
Type Dual disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Single disc brake
Operation Right foot
Fluid DOT 4
Suspension
Front Telescopic fork
Rear Swingarm (monocross suspen-
sion)
Spring/shock absorbers
Front Coil spring / oil damper
Rear Coil spring / gas-oil damper
Wheel travel
Front 140 mm
Rear 110 mm
Electrical systems
Ignition system Transistorized coil ignition
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10-INDEXAAir filter element, cleaning ...................... 6-10BBattery ................................................... 6-27
Brake and clutch levers, checking and
lubricating ............................................ 6-25
Brake and shift pedals, checking and
lubricating ............................................ 6-24
Brake fluid, changing ............................. 6-21
Brake fluid level, checking...................... 6-20
Brake lever...............................................3-8
Brake light switch (rear), adjusting ......... 6-19
Brake pads, checking............................. 6-19
Brake pedal..............................................3-9
Brake pedal position, adjusting .............. 6-18CCables, checking and lubricating............ 6-23
Carburetors, adjusting............................ 6-12
Care.........................................................7-1
Centerstand and sidestand, checking
and lubricating ..................................... 6-25
Clutch lever ..............................................3-7
Clutch lever free play, adjusting ............. 6-17
Controls and instruments (XJ600N) .........2-6
Controls and instruments (XJ600S)..........2-3
Conversion table ......................................8-5DDimmer switch .........................................3-6
Drive chain, lubricating ........................... 6-23
Drive chain slack ................................... 6-21
Adjusting .......................................... 6-22
Checking .......................................... 6-21EEngine break-in ....................................... 5-4
Engine oil and oil filter cartridge ............... 6-7
Engine stop switch................................... 3-7FFront fork, checking ............................... 6-26
Front wheel ........................................... 6-33
Installing........................................... 6-33
Removing......................................... 6-33
Fuel ....................................................... 3-10
Fuel cock ............................................... 3-11
Fuel consumption, tips for reducing ......... 5-4
Fuel tank breather hose
(Germany only) ................................... 3-10
Fuel tank cap ........................................... 3-9
Fuses, replacing .................................... 6-29HHandlebar switches ................................. 3-6
Hazard switch .......................................... 3-6
Headlight bulb, replacing (for XJ600N) .. 6-31
Headlight bulb, replacing (for XJ600S) .. 6-30
Helmet holders ...................................... 3-13
High beam indicator light ......................... 3-4
Horn switch ............................................. 3-6IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-13
Ignition circuit cut-off system ..................3-16
Indicator lights ..........................................3-3KKey identification number (for XJ600N) ....9-1
Key identification number (for XJ600S) ....9-1LLeft view (XJ600N) ...................................2-4
Left view (XJ600S) ...................................2-1
Light switch ..............................................3-7
Luggage strap holders ...........................3-15NNeutral indicator light ...............................3-3MMain switch/steering lock .........................3-1
Maintenance and lubrication, periodic ......6-2
Model label ..............................................9-2OOperation .................................................5-1
Oil level warning light ...............................3-4PPass switch ..............................................3-6
Panel, removing and installing..................6-5
Parking.....................................................5-5
Part locations ...........................................2-1
Pre-operation check list ............................4-1RRear wheel.............................................6-35
Installing...........................................6-36
Removing .........................................6-35
E_4br.book Page 1 Thursday, August 17, 2000 11:29 AM