2001 YAMAHA XJ600S steering wheel

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
E_4br.book Page 1 Thursday, August 17, 2000 11:29 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10
*Wheels• Check runout and for damage.ÖÖÖÖ
11*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖÖÖ
12*Wheel bearings• Check bearing for looseness or damage.ÖÖÖÖ
13*Swingarm• Check operation and for excessive play.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease. Every 50,000 km
14 Drive chain• Check chain slack.
• Make sure that the rear wheel is properly aligned.
• Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in the rain.
15*Steering bearings• Check bearing play and steering for roughness.ÖÖÖÖÖ
• Lubricate with lithium-soap-based grease Every 20,000 km
16*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖ Ö
17 Sidestand/centerstand• Check operation.
• Lubricate.ÖÖÖÖ Ö
18*Sidestand switch• Check operation.ÖÖÖÖÖ Ö
19*Front fork• Check operation and for oil leakage.ÖÖÖÖ
20*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.ÖÖÖÖ
21*Rear suspension relay
arm and connecting arm
pivoting points• Check operation.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease.ÖÖ
22*Carburetors• Check starter (choke) operation.
• Adjust engine idling speed and synchronization.ÖÖÖÖÖ Ö
23 Engine oil• Change.ÖÖÖÖÖ Ö
24 Engine oil filter cartridge•Replace.ÖÖÖ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
Annual
check
1 10203040
E_4br_Periodic.fm Page 3 Friday, December 15, 2000 9:27 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:@ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. @
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @
E_4br.book Page 26 Thursday, August 17, 2000 11:29 AM

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

INDEX
Right view (XJ600N) ................................ 2-5
Right view (XJ600S) ................................ 2-2SSafety information.................................... 1-1
Seat....................................................... 3-12
Shifting .................................................... 5-3
Shift pedal ............................................... 3-8
Shift points (for Switzerland only)............. 5-3
Shock absorber assembly, adjusting ..... 3-14
Sidestand .............................................. 3-15
Spark plugs, checking ............................. 6-6
Specifications .......................................... 8-1
Speedometer unit (for XJ600N) ............... 3-5
Speedometer unit (for XJ600S) ............... 3-4
Starter (choke) lever .............................. 3-12
Starting a cold engine .............................. 5-1
Starting a warm engine ............................ 5-2
Start switch .............................................. 3-7
Steering, checking ................................. 6-26
Steering lock (for XJ600N)....................... 3-3
Storage.................................................... 7-4
Storage compartment ............................ 3-13
Suspension (rear), lubricating ................ 6-25TTachometer ............................................. 3-5
Throttle cable free play, adjusting .......... 6-13
Throttle grip and cable, checking and
lubricating............................................ 6-24
Tires ...................................................... 6-14
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-36
Troubleshooting chart ............................ 6-37
Turn signal indicator lights ....................... 3-3
Turn signal switch ................................... 3-6VValve clearance, adjusting .................... 6-14
Vehicle identification number................... 9-2WWheel bearings, checking ..................... 6-27
Wheels .................................................. 6-17
E_4br.book Page 2 Thursday, August 17, 2000 11:29 AM