2001 YAMAHA XJ900S wheel bolts

PRE-OPERATION CHECKS
4-2
4
NOTE:@ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. @
EWA00033
WARNING
@ If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle. @Wheels and tires• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.6-17–6-20
Brake and shift pedals• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.6-24
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-24
Centerstand, sidestand• Make sure that operation is smooth.
• Lubricate pivots if necessary.6-25
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
Instruments, lights, signals
and switches• Check operation.
• Correct if necessary.—
Sidestand switch• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.3-15 ITEM CHECKS PAGE
E_4km.book Page 2 Thursday, September 7, 2000 9:32 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 lithium-soap-based grease. Every 50,000 km
14*Steering bearings• Check bearing play and steering for roughness.ÖÖÖÖÖ
• Lubricate with lithium-soap-based grease. Every 20,000 km
15*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖ Ö
16 Sidestand/centerstand• Check operation.
• Lubricate.ÖÖÖÖ Ö
17*Sidestand switch• Check operation.ÖÖÖÖÖ Ö
18*Front fork• Check operation and for oil leakage.ÖÖÖÖ
19*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.ÖÖÖÖ
20*Rear suspension relay
arm and connecting arm
pivoting points• Check operation.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease.ÖÖ
21*Carburetors• Check starter (choke) operation.
• Adjust engine idling speed and synchronization.ÖÖÖÖÖ Ö
22 Engine oil• Change.ÖÖÖÖÖ Ö
23 Engine oil filter cartridge•Replace.ÖÖÖ
24 Final gear oil• Check oil level and vehicle for oil leakage.ÖÖ Ö
• Change.ÖÖÖ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
E_4km.book Page 3 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
6-32
6
EAU03420
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
2. Lift the wheel up between the fork
legs.NOTE:@ Make sure that the slot in the speedom-
eter gear unit fits over the retainer on
the fork leg. @3. Insert the wheel axle.4. Take the motorcycle off the cen-
terstand so that the front wheel is
on the ground.
5. Install the brake calipers by install-
ing the bolts.
NOTE:@ Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs. @6. Tighten the front wheel axle pinch
bolt, then the wheel axle, and the
brake caliper bolts to the specified
torques.7. Connect the speedometer cable.
8. Push down hard on the handlebar
several times to check for proper
fork operation.1. Retainer
Tightening torques:
Wheel axle:
59 Nm (5.9 m·kg)
Front wheel axle pinch bolt:
19 Nm (1.9 m·kg)
Brake caliper bolt:
40 Nm (4.0 m·kg)
E_4km.book Page 32 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