2002 YAMAHA XJ600S wheel

4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEM CHECKS PAGE
Front brake
Check operation, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.6-19–6-21
Rear brake6-18–6-21
ClutchCheck operation, condition and free play.
Adjust if necessary.6-17–6-18
Throttle grip and housing
Make sure that operation is smooth.
Check free play.
If necessary, have Yamaha dealer make adjustment or lubricate.
6-13, 6-24
Engine oilCheck oil level.
Fill with oil if necessary.6-7–6-10
Drive chainCheck chain slack and condition.
Adjust if necessary.6-21–6-23
Wheels and tiresCheck tire pressure, wear and damage. 6-14–6-17
Control and meter cablesCheck smooth operation.
Lubricate if necessary.6-23
Brake and shift pedal
shaftsCheck smooth operation.
Lubricate if necessary.6-24
Brake and clutch lever
pivotsCheck smooth operation.
Lubricate if necessary.6-25
Center and sidestand
pivotsCheck smooth operation.
Lubricate if necessary.6-25
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM

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
6-3
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
E_4br.book Page 3 Wednesday, July 25, 2001 1:40 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
EW000079
WARNING
@

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
@
Tire information
This motorcycle is equipped with tube
tires.
EW000078
WARNING
@

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.
@CE-10EEAU00683
WARNING
@

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
@
FRONT
Manufacturer Size Model
DUNLOP 110/80-17 57H D103FA
DUNLOP 110/80-17 M/C 57H D103FA
MICHELIN 110/80-17 57H MACADAM 50
MICHELIN 110/80-17 M/C 57H MACADAM 50
REAR
Manufacturer Size Model
DUNLOP 130/70-18 63H D103A
DUNLOP 130/70-18 M/C 63H D103A
MICHELIN 130/70-18 63H MACADAM 50
MICHELIN 130/70-18 M/C 63H MACADAM 50
E_4br.book Page 16 Wednesday, July 25, 2001 1:40 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU03773
Cast wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU00694
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 2–3 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.
1. Loosen the locknut at the clutch le-
ver.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
bolt in direction
b.3. If the specified clutch lever free
play could be obtained as de-
scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.
4. Fully turn the adjusting bolt at the
clutch lever in direction
a to loos-
en the clutch cable.
5. Loosen the locknut at the crank-
case.
6. To increase the clutch lever free
play, turn the adjusting nut in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
nut in direction
b.1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
1. Clutch lever cable
2. Clutch lever free play adjusting nut
3. Locknut
E_4br.book Page 17 Wednesday, July 25, 2001 1:40 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU03985*
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the brake master
cylinders and calipers as well as the
brake hose replaced at the intervals
listed below or whenever they are dam-
aged or leaking.

Oil seals: Replace every two
years.


Brake hose: Replace every four
years.
EAU00745
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
To check the drive chain slack
1. Place the motorcycle on the
centerstand.
2. Shift the transmission into the neu-
tral position.
3. Spin the rear wheel several times
to locate the tightest portion of the
drive chain.
4. Measure the drive chain slack as
shown.a. Drive chain slack
E_4br.book Page 21 Wednesday, July 25, 2001 1:40 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6 5. If the drive chain slack is incorrect,
adjust it as follows.
EAU03752
To adjust the drive chain slack
1. Loosen the axle nut, then loosen
the locknut at each end of the
swingarm.
2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction
a. To loos-
en the drive chain, turn the adjust-
ing nut at each end of the
swingarm in direction
b, and then
push the rear wheel forward.
NOTE:_ Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po-
sition for proper wheel alignment. _
EC000096
CAUTION:_ Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits. _3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque. Drive chain slack:
30–40 mm
1. Axle nut
2. Locknut
3. Drive chain slack adjusting nut
4. Alignment marks
Tightening torque:
Axle nut:
105 Nm (10.5 m·kgf)
E_4br.book Page 22 Wednesday, July 25, 2001 1:40 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @Check the inner tubes for scratches,
damage and excessive oil leakage.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. @
E_4br.book Page 26 Wednesday, July 25, 2001 1:40 PM