2001 YAMAHA XJ900S warning

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6 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. @
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the
steering.
E_4km.book Page 26 Thursday, September 7, 2000 9:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU01144
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
EAU00800
Battery This motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.
EC000101
CAUTION:@ Never attempt to remove the battery
cell seals, as this would permanent-
ly damage the battery. @
EW000116
WARNING
@ l
Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
• EXTERNAL: Flush with plenty
of water.• INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
• EYES: Flush with water for
15 minutes and seek prompt
medical attention.
l
Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.
l
KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
@To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the motorcycle is equipped with op-
tional electrical accessories.
E_4km.book Page 27 Thursday, September 7, 2000 9:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EAU00829
Replacing a headlight bulb This motorcycle is equipped with
quartz bulb headlights. If a headlight
bulb burns out, replace it as follows.
1. Disconnect the headlight coupler,
and then remove the headlight
bulb cover.2. Unhook the headlight bulb holder,
and then remove the defective
bulb.
EW000119
WARNING
@ Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down. @
3. Place a new bulb into position, and
then secure it with the bulb holder.
EC000105
CAUTION:@ Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner. @4. Install the bulb cover, and then
connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Headlight coupler
2. Headlight bulb cover
1. Headlight bulb holder
1. Do not touch this area.
E_4km.book Page 30 Thursday, September 7, 2000 9:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU03598
Front wheel To remove the front wheel
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
@1. Place the motorcycle on the
centerstand.
2. Disconnect the speedometer ca-
ble from the front wheel.3. Remove the brake hose holders
by removing the bolts.
4. Remove the brake calipers by re-
moving the bolts.
ECA00047
CAUTION:@ Do not pull the brake lever after the
brake caliper has been removed,
otherwise the brake pads will be
forced shut. @
5. Loosen the front wheel axle pinch
bolt, then the wheel axle.
6. Pull the wheel axle out, and then
remove the wheel.
1. Speedometer cable
1. Bolt (´ 3)
2. Brake hose holder
3. Brake caliperLeft
Right
1. Wheel axle pinch bolt
2. Wheel axle
E_4km.book Page 31 Thursday, September 7, 2000 9:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU03410
Rear wheel To remove the rear wheel
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
@
1. Loosen the rear wheel axle pinch
bolt, and then remove the axle nut.
2. Place the motorcycle on the
centerstand.3. Remove the brake caliper bolts
and the axle nut.
4. Disconnect the brake torque rod
from the brake caliper bracket by
removing the cotter pin, the nut,
and the bolt.
5. While supporting the brake cali-
per, pull the wheel axle out.
6. Pull the wheel to the right to sepa-
rate it from the final gear case, and
then remove it.
1. Wheel axle pinch bolt
1. Axle nut
1. Nut
2. Brake torque rod
3. Cotter pin
4. Bolt (´ 2)
E_4km.book Page 33 Thursday, September 7, 2000 9:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6
ECA00062
CAUTION:@ Do not push the brake pedal after
the wheel has been removed togeth-
er with the brake disc, otherwise the
brake pads will be forced shut. @
EAU03411
To install the rear wheel
1. Apply a light coating of lithium-
soap-based grease to the splines
of the final gear case and wheel
hub.
2. Install the wheel by inserting the
wheel axle, and then install the
axle nut.
3. Install the brake caliper by install-
ing the bolts.NOTE:@ Make sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brake
disc. @
4. Install the brake torque rod bolt,
nut and cotter pin at the brake cal-
iper bracket.
EW000124
WARNING
@ Always use a new cotter pin. @5. Tighten the rear wheel axle pinch
bolt to the specified torque.
6. Take the motorcycle off the cen-
terstand so that the rear wheel is
on the ground.
7. Tighten the axle nut, wheel axle
pinch bolt, brake caliper bolts and
brake torque rod nut to the speci-
fied torques.
1. Splines
Tightening torque:
Rear wheel axle pinch bolt:
16 Nm (1.6 m·kg)
E_4km.book Page 34 Thursday, September 7, 2000 9:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6
EAU01297
Troubleshooting chart
EW000125
WARNING
@ Keep away open flames and do not smoke while checking or working on the fuel system. @
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
E_4km.book Page 36 Thursday, September 7, 2000 9:32 AM

MOTORCYCLE CARE AND STORAGE
7-3
7After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean-
er to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely
before storing or covering it.
EWA00031
WARNING
@ l
Make sure that there is no oil or
wax on the brakes or tires.
l
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-
nering behavior.
@
ECA00013
CAUTION:@ l
Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.
l
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
l
Avoid using abrasive polishing
compounds as they will wear
away the paint.
@NOTE:@ Consult a Yamaha dealer for advice on
what products to use. @
E_4km.book Page 3 Thursday, September 7, 2000 9:32 AM