2002 YAMAHA XJ600N brake light

DESCRIPTION
2-2
2
Right view (XJ600S)8. Tail/brake light
9. Storage compartment (page 3-14)
10. Seat (page 3-12)
11. Fuel tank (page 3-9)
12. Headlight (page 6-30)
13. Brake pedal (page 3-9)
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM

DESCRIPTION
2-5
2
Right view (XJ600N)9. Tail/brake light
10. Storage compartment (page 3-13)
11. Seat (page 3-12)
12. Fuel tank (page 3-9)
13. Headlight (page 6-30)
14. Brake pedal (page 3-9)
E_4br.book Page 5 Wednesday, July 25, 2001 1:40 PM

3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock ..................................... 3-1
Steering lock (for XJ600N).................................... 3-3
Indicator and warning lights ................................ 3-3
Speedometer unit (for XJ600S) ........................... 3-4
Speedometer unit (for XJ600N) ........................... 3-5
Tachometer .......................................................... 3-5
Handlebar switches ............................................. 3-6
Clutch lever .......................................................... 3-7
Shift pedal ............................................................ 3-8
Brake lever .......................................................... 3-8
Brake pedal .......................................................... 3-9
Fuel tank cap ....................................................... 3-9Fuel ................................................................... 3-10
Fuel tank breather hose (for Germany only) ..... 3-11
Fuel cock ........................................................... 3-11
Starter (choke) lever .......................................... 3-12
Seat ................................................................... 3-12
Helmet holders .................................................. 3-13
Storage compartment ....................................... 3-14
Adjusting the shock absorber assembly ............ 3-14
Luggage strap holders ...................................... 3-15
Sidestand .......................................................... 3-15
Ignition circuit cut-off system ............................. 3-16
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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
Cast 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 the 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 Wednesday, July 25, 2001 1:40 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU03884
NOTE:_

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


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.
_22
*CarburetorsCheck starter (choke) operation.
Adjust engine idling speed and synchronization.√√√√√ √
23 Engine oilChange.√√√√√ √
Check oil level and vehicle for oil leakage.√√√√√ √
24 Engine oil filter cartridgeReplace.√√√
25*Front and rear brake
switchesCheck operation.√√√√√ √
26 Moving parts and cablesLubricate.√√√√ √
27*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
Annual
check
1 10203040
E_4br.book Page 4 Wednesday, July 25, 2001 1:40 PM

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. Rear brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator groove (× 2)Front
E_4br.book Page 19 Wednesday, July 25, 2001 1:40 PM

MOTORCYCLE CARE AND STORAGE
7-2
7


Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments, switch-
es and lights), breather hoses
and vents.


For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it does
not leave any marks. If the wind-
shield is scratched, use a quali-
ty plastic polishing compound
after washing.
@After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.After riding in the rain, near the sea or
on salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:@ Salt sprayed on roads in the winter may
remain well into spring. @1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
CAUTION:@ Do not use warm water since it in-
creases the corrosive action of the
salt. @2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick-
el-plated, surfaces to prevent cor-
rosion.
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM

SPECIFICATIONS
8-4
8
Charging system
Type A.C. magneto
Standard output 14 V, 20 A @ 5,000 r/min
Battery
Model YTX9-BS
Voltage, capacity 12 V, 8 Ah
Headlight typeQuar tz bulb (halogen)
Bulb voltage, wattage × quantity
Headlight 12 V, 60/55 W × 1
Auxiliary light 12 V, 4 W × 1 (except for GB,
IRL)
12 V, 3.4 W × 1 (for GB, IRL)
Tail/brake light 12 V, 5/21 W × 1
Turn signal light 12 V, 21 W × 4
Meter lighting
XJ600S 12 V, 1.7 W × 3
XJ600N 14 V, 3 W × 2
12 V, 1.7 W × 2
Neutral indicator light 12 V, 3.4 W × 1
High beam indicator light 12 V, 3.4 W × 1
Oil level warning light
XJ600S 12 V, 3.4 W × 1
XJ600N 14 V, 3 W × 1
Turn signal indicator light 12 V, 3.4 W × 2Fuses
Main fuse 30 A
Ignition fuse 10 A
Signaling system fuse 15 A
Headlight fuse 15 A
Hazard fuse 10 A
E_4br.book Page 4 Wednesday, July 25, 2001 1:40 PM