2002 YAMAHA XJ600S maintenance

TABLE OF CONTENTS
1 GIVE SAFETY THE RIGHT OF WAY
1
2 DESCRIPTION
2
3 INSTRUMENT AND CONTROL FUNCTIONS
3
4 PRE-OPERATION CHECKS
4
5 OPERATION AND IMPORTANT RIDING POINTS
5
6 PERIODIC MAINTENANCE AND MINOR REPAIR
6
7 MOTORCYCLE CARE AND STORAGE
7
8 SPECIFICATIONS
8
9 CONSUMER INFORMATION
9
INDEX
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1
1-1
1-GIVE SAFETY THE RIGHT OF WAY
EAU00021
Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and
freedom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and
passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant
synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.
Optimum protective wear, however, should not encourage carelessness. Although full-coverage
helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will
always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to
take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,
predictably and defensively—avoiding all dangers, including those caused by others.
Enjoy your ride!
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INSTRUMENT AND CONTROL FUNCTIONS
3-10
3
EAU03753
Fuel Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
EW000130
WARNING
_

Do not overfill the fuel tank, oth-
erwise it may overflow when the
fuel warms up and expands.


Avoid spilling fuel on the hot
engine.
_
EAU00185
CAUTION:@ Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfac-
es or plastic parts.@
EAU04202
ECA00102
CAUTION:_ Use only unleaded gasoline. The
use of leaded gasoline will cause se-
vere damage to the engine internal
parts such as valves, piston rings,
exhaust system, etc. _
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark plug
life and reduce maintenance costs.
1. Fuel tank filler tube
2. Fuel level
Recommended fuel:
REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity:
Total amount:
17.0 L
Reserve amount:
3.5 L
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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
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6-1
6
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6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
EW000060
WARNING
@ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. @
EAU00469
Owner’s tool kit The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.NOTE:@ If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you. @
EW000063
WARNING
@ Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es. @
1. Owner’s tool kit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9
*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
10*WheelsCheck runout and for damage.√√√√
11*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
12*Wheel bearingsCheck bearing for looseness or damage.√√√√
13*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
14 Drive chainCheck 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 bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease Every 20,000 km
16*Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.√√√√ √
17 Sidestand/centerstandCheck operation.
Lubricate.√√√√ √
18*Sidestand switchCheck operation.√√√√√ √
19*Front forkCheck operation and for oil leakage.√√√√
20*Shock absorber
assemblyCheck operation and shock absorber for oil leakage.√√√√
21*Rear suspension relay
arm and connecting arm
pivoting pointsCheck operation.√√√√
Lubricate with lithium-soap-based grease.√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
Annual
check
1 10203040
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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
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