2002 YAMAHA XJ900S air filter

DESCRIPTION
2-2
2
Right view9. Tail/brake light (page 6-32)
10. Grab bar
11. Fuse box (page 6-30)
12. Main fuse (page 6-30)
13. Seat (page 3-11)
14. Owner’s tool kit (page 6-1)15. Air filter element (page 6-13)
16. Front fork spring preload
adjusting bolt (page 3-13)
17. Engine oil level check window (page 6-8)
18. Brake pedal (page 3-8)
E_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing cowlings ........................ 6-5
Checking the spark plugs .................................... 6-7
Engine oil and oil filter cartridge .......................... 6-8
Final gear oil ...................................................... 6-11
Cleaning the air filter element ............................ 6-13
Adjusting the carburetors ................................... 6-15
Adjusting the engine idling speed ...................... 6-15
Adjusting the throttle cable free play .................. 6-16
Adjusting the valve clearance ............................ 6-16
Tires ................................................................... 6-17
Cast wheels ....................................................... 6-20
Adjusting the clutch lever free play .................... 6-20
Adjusting the brake pedal position ..................... 6-21
Adjusting the rear brake light switch .................. 6-21
Checking the front and rear brake pads ............. 6-22
Checking the brake fluid level ............................ 6-23
Changing the brake fluid .................................... 6-24
Checking and lubricating the cables .................. 6-24Checking and lubricating the throttle grip and
cable ............................................................... 6-24
Checking and lubricating the brake and
shift pedals ...................................................... 6-25
Checking and lubricating the brake and
clutch levers .................................................... 6-25
Checking and lubricating the centerstand and
sidestand ......................................................... 6-25
Lubricating the rear suspension ........................ 6-26
Checking the front fork ...................................... 6-27
Checking the steering ....................................... 6-27
Checking the wheel bearings ............................ 6-28
Battery ............................................................... 6-29
Replacing the fuses .......................................... 6-30
Replacing the headlight bulb ............................. 6-31
Replacing the tail/brake light bulb ..................... 6-32
Replacing a turn signal light bulb ...................... 6-32
Front wheel ....................................................... 6-33
Rear wheel ........................................................ 6-35
Troubleshooting ................................................. 6-37
Troubleshooting chart ........................................ 6-38
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM

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-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel lineCheck fuel hoses 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
9*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
E_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
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*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20,000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 Sidestand, centerstandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber
assemblyCheck operation and shock absorber for oil leakage.√√√√
20*Rear suspension relay
arm and connecting arm
pivoting pointsCheck operation.√√√√
Lubricate with lithium-soap-based grease.√√
21*CarburetorsCheck starter (choke) operation.
Adjust engine idling speed and synchronization.√√√√√ √
22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter cartridgeReplace.√√√
24 Final gear oilCheck oil level and vehicle for oil leakage.√√ √
Change.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
E_4km.book Page 3 Tuesday, August 28, 2001 9:51 AM

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.
_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_4km.book Page 4 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
NOTE:@ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @
EAU04261
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on the cen-
terstand.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _2. Start the engine, warm it up for
several minutes, and then turn it
off.3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.
NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
E_4km.book Page 8 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:_ Skip steps 4–6 if the oil filter cartridge is
not being replaced. _
4. Remove the oil filter cartridge with
an oil filter wrench.NOTE:_ An oil filter wrench is available at a
Yamaha dealer. _
1. Engine oil filler cap
1. Engine oil drain bolt
1. Oil filter cartridge
2. Oil filter wrench
E_4km.book Page 9 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 5. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.
NOTE:_ Make sure that the O-ring is properly
seated. _6. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
ECA00105
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 grade “CD”
or higher. In addition, do not
use oils labeled “ENERGY CON-
SERVING 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. _
1. O-ring
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
3.2 L
With oil filter cartridge
replacement:
3.4 L
Total amount (dry engine):
4.4 L
E_4km.book Page 10 Tuesday, August 28, 2001 9:51 AM