2002 YAMAHA XJ900S brake light

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

3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock ..................................... 3-1
Indicator and warning lights ................................ 3-2
Speedometer unit ................................................ 3-3
Tachometer .......................................................... 3-4
Self-diagnosis device ........................................... 3-4
Fuel gauge ........................................................... 3-5
Clock .................................................................... 3-5
Anti-theft alarm (optional) .................................... 3-5
Handlebar switches ............................................. 3-6
Clutch lever .......................................................... 3-7
Shift pedal ............................................................ 3-8
Brake lever .......................................................... 3-8
Brake pedal .......................................................... 3-8Fuel tank cap ...................................................... 3-9
Fuel ..................................................................... 3-9
Fuel tank breather hose (for Germany only) ..... 3-11
Starter (choke) lever .......................................... 3-11
Seat ................................................................... 3-11
Helmet holder .................................................... 3-12
Storage compartment ....................................... 3-13
Adjusting the front fork ...................................... 3-13
Adjusting the shock absorber assembly ............ 3-14
Luggage strap holders ...................................... 3-15
Sidestand .......................................................... 3-15
Ignition circuit cut-off system ............................. 3-16
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM

PRE-OPERATION CHECKS
4-2
4
NOTE:@ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. @
EWA00033
WARNING
@ If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle. @Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-17–6-20
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-25
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-25
Centerstand, sidestandMake sure that operation is smooth.
Lubricate pivots if necessary.6-25–6-26
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-15 ITEM CHECKS PAGE
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
6-4
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
6-21
6
EAU00712
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 30 mm below
the top of the footrest as shown. Peri-
odically check the brake pedal position
and, if necessary, have a Yamaha
dealer adjust it.
EW000109
WARNING
_ A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident. _
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.
a. Distance between brake pedal and footrest
1. Rear brake light switch
2. Rear brake light switch adjusting nut
E_4km.book Page 21 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6 3. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
EC000105
CAUTION:_ Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner. _4. Install the headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU01623
Replacing the tail/brake light
bulb 1. Remove the tail/brake light lens by
removing the screws.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screws.
EC000108
CAUTION:_ Do not overtighten the screws, oth-
erwise the lens may break. _
EAU03497
Replacing a turn signal light
bulb 1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
ECA00065
CAUTION:_ Do not overtighten the screw, other-
wise the lens may break. _
1. Do not touch this area.
1. Screw (× 2)
1. Screw
E_4km.book Page 32 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6
ECA00062
CAUTION:_ Do not push the brake pedal after
the wheel has been removed togeth-
er with the brake disc, otherwise the
brake pads will be forced shut. _
EAU04362
To install the rear wheel
1. Apply a light coating of lithium-
soap-based grease to the splines
of the final gear case and wheel
hub.
2. Install the wheel, brake caliper
bracket, spacer and wheel axle.
3. Install the brake caliper by install-
ing the bolts.NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brake
disc. _
4. Connect the brake torque rod to
the brake caliper bracket by in-
stalling the bolt and the nut.
5. Install the axle nut, and then slight-
ly tighten it.
6. Take the motorcycle off the cen-
terstand so that the rear wheel is
on the ground.
7. Tighten the rear wheel axle pinch
bolt, the axle nut, the brake caliper
bolts and the brake torque rod nut
to the specified torques.
1. Splines
Tightening torques:
Axle nut:
105 Nm (10.5 m·kgf)
Brake caliper bolt:
40 Nm (4.0 m·kgf)
Brake torque rod nut:
23 Nm (2.3 m·kgf)
Rear wheel axle pinch bolt:
16 Nm (1.6 m·kgf)
E_4km.book Page 36 Tuesday, August 28, 2001 9:51 AM