2002 YAMAHA XJ900S fuel filter

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
6-13
6
EAU03597*
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 3-11
for seat removal and installation
procedures.)
2. Turn the fuel cock lever to “OFF”,
and then disconnect the fuel hose.3. Remove the fuel tank bolts.
4. Disconnect the fuel sender cou-
pler, and then take the fuel tank
off.5. Remove the air filter case cover by
removing the screws.1. Fuel tank
2. Fuel hose
3. Fuel sender coupler
4. Fuel cock lever
1. Bolt (× 2)
1. Screw (× 4)
E_4km.book Page 13 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 6. Pull the air filter element out. 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. Connect the fuel sender coupler,
and then install the fuel tank by in-
stalling the bolts.
11. Connect the fuel hose, and then
turn the fuel cock lever to “ON”.
12. Install the seat.
1. Air filter element
E_4km.book Page 14 Tuesday, August 28, 2001 9:51 AM

8-1
8
EAU01038
8-SPECIFICATIONSSpecifications CS-01E
Model XJ900S
Dimensions
Overall length 2,230 mm
Overall width 750 mm
Overall height 1,300 mm
Seat height 795 mm
Wheelbase 1,505 mm
Ground clearance 130 mm
Minimum turning radius 3,000 mm
Basic weight (with oil and full
fuel tank)
265 kg
Engine
Engine type Air-cooled 4-stroke, DOHC
Cylinder arrangement Forward-inclined parallel
4-cylinder
Displacement 892 cm
3
Bore × Stroke 68.5 × 60.5 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 or
higher
Quantity
Without oil filter cartridge
replacement 3.2 L
With oil filter car tridge
replacement 3.4 L
Total amount (dry engine) 4.4 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_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM

SPECIFICATIONS
8-2
8
Final gear oil
Type Hypoid gear oil SAE 80 (API GL4)
or multi-grade hypoid gear oil
SAE 80W-90
Quantity 0.2 L
Air filterDry element
Fuel
Type REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity 24 L
Fuel reserve amount 5 L
Carburetor
Manufacturer MIKUNI
Model ×
quantity BDSR34 × 4
Spark plug
Manufacturer/model NGK / DPR8EA-9 or
DENSO / X24EPR-U9
Gap 0.8–0.9 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.672
Secondary reduction system Shaft drive
Secondary reduction ratio 1.278
Transmission type Constant-mesh, 5-speedOperation Left foot
Gear ratio
1st 2.188
2nd 1.500
3rd 1.154
4th 0.933
5th 0.813
Chassis
Frame type Double cradle
Caster angle 27°
°° °
Trail 121 mm
Tire
Front
Type Tubeless tire
Size 120/70-17 58V
120/70-17 M/C 58V
Manufacturer/
model Dunlop / K505F
Metzeler / ME33
Bridgestone / G601
Rear
Type Tubeless tire
Size 150/70-17 69V
150/70-17 M/C 69V
E_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM

10-INDEXAAir filter element, cleaning ...................... 6-13
Anti-theft alarm ........................................3-5BBattery ................................................... 6-29
Brake and clutch levers, checking and
lubricating ............................................ 6-25
Brake and shift pedals, checking and
lubricating ............................................ 6-25
Brake fluid, changing ............................. 6-24
Brake fluid level, checking...................... 6-23
Brake lever...............................................3-8
Brake light switch (rear), adjusting ......... 6-21
Brake pads, checking............................. 6-22
Brake pedal..............................................3-8
Brake pedal position, adjusting .............. 6-21CCables, checking and lubricating............ 6-24
Carburetors, adjusting............................ 6-15
Care.........................................................7-1
Centerstand and sidestand,
checking and ubricating ....................... 6-25
Clock .......................................................3-5
Clutch lever ..............................................3-7
Clutch lever free play, adjusting ............. 6-20
Conversion table ......................................8-5
Cowlings, removing and installing ............6-5DDimmer switch .........................................3-6EEngine break-in........................................5-4
Engine oil and oil filter cartridge ............... 6-8
Engine stop switch................................... 3-7FFinal gear oil .......................................... 6-11
Front fork, adjusting ............................... 3-13
Front fork, checking ............................... 6-27
Fuel ......................................................... 3-9
Fuel consumption, tips for reducing ......... 5-4
Fuel gauge .............................................. 3-5
Fuel level warning light ............................ 3-2
Fuel tank breather hose
(Germany only) ................................... 3-11
Fuel tank cap ........................................... 3-9
Fuses, replacing .................................... 6-30HHandlebar switches ................................. 3-6
Hazard switch .......................................... 3-6
Headlight bulb, replacing ....................... 6-31
Helmet holder ........................................ 3-12
High beam indicator light ......................... 3-3
Horn switch ............................................. 3-6IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-15
Ignition circuit cut-off system.................. 3-16
Indicator and warning lights ..................... 3-2KKey identification number ........................ 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 ...............................3-3PParking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-6
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1RRear suspension, lubricating ..................6-26SSafety information ....................................1-1
Seat .......................................................3-11
Self-diagnosis device ...............................3-4
Shifting .....................................................5-3
Shift pedal ................................................3-8
Shift points (for Switzerland only) .............5-4
Shock absorber assembly, adjusting ......3-14
Sidestand ...............................................3-15
Spark plugs, checking ..............................6-7
Specifications ...........................................8-1
Speedometer unit.....................................3-3
Starter (choke) lever...............................3-11
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM