2002 YAMAHA XJ600S fuel filter

INSTRUMENT AND CONTROL FUNCTIONS
3-11
3
EAU00196
Fuel tank breather hose
(for Germany only) Before operating the motorcycle:

Check the fuel tank breather hose
connection.


Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.


Make sure that the end of the fuel
tank breather hose is not blocked
and clean it if necessary.
EAU00207
Fuel cock The fuel cock supplies fuel from the
tank to the carburetors while also filter-
ing it.
The fuel cock lever positions are ex-
plained as follows and shown in the il-
lustrations.
ON
With the fuel cock lever in this position,
fuel flows to the carburetors when the
engine is running. Turn the fuel cock le-
ver to this position when starting the
engine and riding.RES
This indicates reserve. With the fuel
cock lever in this position, the fuel re-
serve is made available. Quickly turn
the fuel cock lever to this position if you
run out of fuel while riding, otherwise
the engine may stall and will have to be
primed (see “PRI”). After turning the
fuel cock lever to “RES”, refuel as soon
as possible and be sure to turn the fuel
cock lever back to “ON”!
1. Fuel tank breather hose
1. Arrow mark positioned over “ON”ON: Normal position
1. Arrow mark positioned over “RES”RES: Reserve position
E_4br.book Page 11 Wednesday, July 25, 2001 1:40 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.


From 50,000 km, repeat the maintenance intervals starting from 10,000 km.


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 lineCheck fuel hoses and vacuum hose for cracks or damage.√√√√ √
2*Fuel filterCheck condition.√√
3 Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
4*ValvesCheck valve clearance.
Adjust.Every 20,000 km
5 Air filter elementClean.√√
Replace.√√
6ClutchCheck operation.
Adjust.√√√√√
7*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
8*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
EC000072
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a higher
grade than “CD”. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign mate-
rial enters the crankcase.
_9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.NOTE:_ After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient. _
EC000067
CAUTION:_ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. _10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU02928*
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the seat. (See page 3-12
for seat removal and installation
procedures.)
2. Turn the fuel cock lever to “ON”,
and then remove the fuel cock le-
ver by removing the screw.1. Screw
E_4br.book Page 10 Wednesday, July 25, 2001 1:40 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
63. Disconnect the hoses shown.4. Remove the fuel tank by removing
the bolts.5. Remove the air filter case cover by
removing the screws.
6. Pull the air filter element out.
1. Fuel hose
2. Vacuum hose
3. Fuel tank drain hose
1. Screw (× 4)
E_4br.book Page 11 Wednesday, July 25, 2001 1:40 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 7. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.
8. Insert the air filter element into the
air filter case.
EC000082*
CAUTION:@

Make sure that the air filter ele-
ment is properly seated in the
air filter case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
pistons and/or cylinders may
become excessively worn.
@9. Install the air filter case cover by
installing the screws.
10. Install the fuel tank by installing the
bolts.
11. Connect the hoses.
12. Install the fuel cock lever by install-
ing the screw.
13. Install the seat.
EAU00630
Adjusting the carburetors The carburetors are important parts of
the engine and require very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.
EC000095
CAUTION:@ The carburetors have been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine. @
1. Air filter element
E_4br.book Page 12 Wednesday, July 25, 2001 1:40 PM

8-1
8
EAU01038
8-SPECIFICATIONSSpecifications CS-01E
Model XJ600S/XJ600N
Dimensions
Overall length 2,170 mm
Overall width 735 mm
Overall height
XJ600S 1,205 mm
XJ600N 1,090 mm
Seat height 770 mm
Wheelbase 1,445 mm
Ground clearance 150 mm
Minimum turning radius 2,700 mm
Basic weight (with oil and
full fuel tank)
XJ600S 213 kg
XJ600N 210 kg
Engine
Engine type Air-cooled 4-stroke, DOHC
Cylinder arrangement Forward-inclined parallel
4-cylinder
Displacement 598 cm
3
Bore × Stroke 58.5 × 55.7 mm
Compression ratio 10:1
Starting system Electric starter
Lubrication system Wet sumpEngine oil
Ty p e
Recommended engine oil
classification API Service SE, SF, SG type or
higher
Quantity
Without oil filter cartridge
replacement 2.3 L
With oil filter car tridge
replacement 2.6 L
Total amount (dry engine) 3.1 L
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40
CAUTION:Be sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled
“ENERGY CONSERVING II”) contain anti-friction additives
which will cause clutch and/or starter clutch slippage, result-
ing in reduced component life and poor engine performance.
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM

SPECIFICATIONS
8-2
8
Air filterDry type element
Fuel
Type REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity 17.0 L
Reserve amount 3.5 L
Carburetor
Manufacturer MIKUNI
Model × quantity BDS28 × 4
Spark plug
Model/Manufacturer CR8E / NGK
U24ESR-N / DENSO
Gap 0.7–0.8 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 2.225
Secondary reduction system Chain drive
Secondary reduction ratio 3.000 (except for CH, A)
2.875 (for CH, A)
Number of drive chain
sprocket teeth (rear/front) 48/16 (except for CH, A)
46/16 (for CH, A)
Transmission type Constant mesh 6-speedOperation Left foot
Gear ratio
1st 2.733
2nd 1.778
3rd 1.333
4th 1.074
5th 0.913
6th 0.821
Chassis
Frame type Double cradle
Caster angle 25°
Trail 97 mm
Tire
Front
Type Tubeless tire
Size 110/80-17 57H
110/80-17 M/C 57H
Manufacturer/model MICHELIN / MACADAM 50
DUNLOP / D103FA
Rear
Type Tubeless tire
Size 130/70-18 63H
130/70-18 M/C 63H
Manufacturer/model MICHELIN / MACADAM 50
DUNLOP / D103A
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM

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
Conversion table ......................................8-5
DDimmer switch ......................................... 3-6
Drive chain, lubricating .......................... 6-23
Drive chain slack ................................... 6-21
Checking .......................................... 6-21
Adjusting .......................................... 6-22EEngine break-in ....................................... 5-4
Engine oil and oil filter cartridge ............... 6-7
Engine stop switch................................... 3-7FFront fork, checking ............................... 6-26
Fuel ....................................................... 3-10
Fuel cock ............................................... 3-11
Fuel consumption, tips for reducing ......... 5-4
Fuel tank breather hose
(Germany only) ................................... 3-11
Fuel tank cap ........................................... 3-9
Fuses, replacing .................................... 6-29HHandlebar switches ................................. 3-6
Hazard switch .......................................... 3-6
Headlight bulb, replacing (for XJ600S)... 6-30
Headlight bulb, replacing (for XJ600N) .. 6-31
Helmet holders ...................................... 3-13
High beam indicator light ......................... 3-4
Horn switch ............................................. 3-6
IIdentification numbers ..............................9-1
Idling speed, adjusting ...........................6-13
Ignition circuit cut-off system ..................3-16
Indicator and warning lights......................3-3KKey identification number (for XJ600N) ....9-1
Key identification number (for XJ600S) ....9-1LLight switch ..............................................3-7
Luggage strap holders ...........................3-15MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-3OOil level warning light ...............................3-4PPanel, removing and installing..................6-5
Parking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-6
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM