2009 YAMAHA XJ6-S clutch

PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
6
EAU1770B
General maintenance and lubrication chart NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1 Air filter elementReplace.√
2ClutchCheck operation.
Adjust.√√√√√
3*Front brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
4*Rear brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
5*Brake hosesCheck for cracks or damage.√√√√√
Replace. Every 4 years
6*WheelsCheck runout and for damage.√√√√
7*TiresCheck tread depth and for dam-
age.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√√
8*Wheel bearingsCheck bearing for looseness or
damage.√√√√
9*SwingarmCheck operation and for exces-
sive play.√√√√
Lubricate with lithium-soap-based
grease.Every 50000 km (30000 mi)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
10 Drive chainCheck chain slack, alignment and
condition.
Adjust and lubricate chain with a
special O-ring chain lubricant
thoroughly.Every 1000 km (600 mi) and after washing the motorcycle or riding in the rain
11*Steering bearingsCheck bearing play and steering
for roughness.√√√√√
Lubricate with lithium-soap-based
grease.Every 20000 km (12000 mi)
12*Chassis fastenersMake sure that all nuts, bolts and
screws are properly tightened.√√√√√
13Brake lever pivot
shaftLubricate with silicone grease.√√√√√
14Brake pedal pivot
shaftLubricate with lithium-soap-based
grease.√√√√√
15Clutch lever pivot
shaftLubricate with lithium-soap-based
grease.√√√√√
16Shift pedal pivot
shaftLubricate with lithium-soap-based
grease.√√√√√
17Sidestand, center-
standCheck operation.
Lubricate.√√√√√
18*Sidestand switchCheck operation.√√√√√√
19*Front forkCheck operation and for oil leak-
age.√√√√
20*Shock absorber as-
semblyCheck operation and shock ab-
sorber for oil leakage.√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
U36CE0E0.book Page 4 Friday, December 5, 2008 2:33 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
TIPAn oil filter wrench is available at aYamaha dealer.
6. Apply a thin coat of clean engine
oil to the O-ring of the new oil filter
cartridge.TIPMake sure that the O-ring is properlyseated.
7. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
TIPCheck the washer for damage and re-place it if necessary.9. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
TIPBe sure to wipe off spilled oil on any
parts after the engine and exhaust sys-tem have cooled down.NOTICE
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
1. O-ring
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
1
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replace-
ment:
2.50 L (2.64 US qt, 2.20 Imp.qt)
With oil filter cartridge replacement:
2.80 L (2.96 US qt, 2.46 Imp.qt)
U36CE0E0.book Page 12 Friday, December 5, 2008 2:33 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6 “broken in”. Therefore, it is ad-
visable before doing any high-
speed riding to ride conserva-
tively for approximately 100 km
(60 mi) after installing a new tire.


The tires must be warmed up
before a high-speed run.


Always adjust the tire air pres-
sure according to the operatingconditions.
EAU21960
Cast wheels To maximize the performance, durabil-
ity, and safe operation of your vehicle,
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.
EAU47590
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
To increase the clutch lever free play,
turn the clutch lever free play adjusting
bolt at the clutch lever in direction (a).
To decrease the clutch lever free play,
turn the adjusting bolt in direction (b).1. Clutch lever free play adjusting bolt
2. Clutch lever free play
U36CE0E0.book Page 22 Friday, December 5, 2008 2:33 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
6
TIPIf the specified clutch lever free play
cannot be obtained as describedabove, proceed as follows.
1. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loos-
en the clutch cable.
2. Remove cowling B. (See page
6-7.)
3. Loosen the locknut further down
the clutch cable.
4. To increase the clutch lever free
play, turn the clutch lever free play
adjusting nut in direction (a). To
decrease the clutch lever free play,
turn the adjusting nut in direction
(b).5. Tighten the locknut.
6. Install the cowling.
EAU22272
Adjusting the rear brake light
switch The rear brake light, which is activated
by the brake pedal, should come on just
before braking takes effect. If neces-
sary, adjust the rear brake light switch
as follows.
Turn the rear brake light switch adjust-
ing 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).
1. Locknut (clutch cable)
2. Clutch lever free play adjusting nut (clutch
cable)
1
2
(a)
(b)
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1
2(a)
(b)
U36CE0E0.book Page 23 Friday, December 5, 2008 2:33 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-29
6
EAU23142
Checking and lubricating the
brake and clutch levers Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease
U36CE0E0.book Page 29 Friday, December 5, 2008 2:33 PM

SPECIFICATIONS
8-1
8
Dimensions:Overall length:
2120 mm (83.5 in)
Overall width:
770 mm (30.3 in)
Overall height:
1210 mm (47.6 in)
Seat height:
785 mm (30.9 in)
Wheelbase:
1440 mm (56.7 in)
Ground clearance:
140 mm (5.51 in)
Minimum turning radius:
2800 mm (110.2 in)Weight:With oil and fuel:
XJ6S 211.0 kg (465 lb)
XJ6SA 216.0 kg (476 lb)Engine:Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward-inclined parallel 4-cylinder
Displacement:
600.0 cm³
Bore × stroke:
65.5 × 44.5 mm (2.58 × 1.75 in)
Compression ratio:
12.20 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:Type:
SAE 10W-30, SAE 10W-40, SAE 15W-40,
SAE 20W-40 or SAE 20W-50
Recommended engine oil grade:
API service SG type or higher, JASO
standard MA
Engine oil quantity:
Without oil filter cartridge replacement:
2.50 L (2.64 US qt, 2.20 Imp.qt)
With oil filter cartridge replacement:
2.80 L (2.96 US qt, 2.46 Imp.qt)Cooling system:Coolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator capacity (including all routes):
2.00 L (2.11 US qt, 1.76 Imp.qt)Air filter:Air filter element:
Oil-coated paper element
Fuel:Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
17.3 L (4.57 US gal, 3.81 Imp.gal)
Fuel reserve amount:
3.2 L (0.85 US gal, 0.70 Imp.gal)Fuel injection:Throttle body:
Type/quantity:
32EIDW/1Spark plug (s):Manufacturer/model:
NGK/CR9E
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)Clutch:Clutch type:
Wet, multiple-discTransmission:Primary reduction system:
Spur gear
Primary reduction ratio:
86/44 (1.955)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
46/16 (2.875)
Transmission type:
Constant mesh 6-speed
Operation:
Left foot operation
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40SAE 10W-50
U36CE0E0.book Page 1 Friday, December 5, 2008 2:33 PM

INDEX
AABS (for ABS models) .......................... 3-14
ABS warning light (for ABS models) ....... 3-7
Air filter element, replacing ................... 6-17
Anti-theft alarm (optional) ..................... 3-11
Auxiliary light bulb................................. 6-38BBattery .................................................. 6-32
Brake and clutch levers,
checking and lubricating ..................... 6-29
Brake and shift pedals,
checking and lubricating ..................... 6-28
Brake fluid, changing ............................ 6-25
Brake fluid level, checking .................... 6-24
Brake lever ........................................... 3-14
Brake pedal .......................................... 3-14CCables, checking and lubricating .......... 6-28
Care ........................................................ 7-1
Catalytic converter ................................ 3-18
Centerstand and sidestand,
checking and lubricating ..................... 6-30
Clutch lever........................................... 3-13
Clutch lever free play, adjusting ........... 6-22
Coolant ................................................. 6-13
Coolant temperature warning light.......... 3-4
Cowlings and panels,
removing and installing......................... 6-7DDimmer switch ...................................... 3-12
Drive chain, cleaning and lubricating .... 6-27
Drive chain slack .................................. 6-26EEngine break-in ...................................... 5-3Engine idling speed ............................... 6-18
Engine oil and oil filter cartridge ............ 6-10
Engine stop switch ................................ 3-12
Engine trouble warning light .................... 3-7
FFront and rear brake pads, checking .... 6-24
Front fork, checking...............................6-31
Fuel ....................................................... 3-16
Fuel consumption, tips for reducing ........ 5-3
Fuel tank breather/overflow hose .......... 3-17
Fuel tank cap......................................... 3-15
Fuses, replacing .................................... 6-33HHandlebar position, adjusting ................ 3-20
Handlebar switches ............................... 3-12
Hazard switch........................................ 3-13
Headlight bulb, replacing....................... 6-35
Helmet holder ........................................ 3-19
High beam indicator light......................... 3-4
Horn switch ........................................... 3-12IIdentification numbers ............................. 9-1
Ignition circuit cut-off system ................. 3-23
Immobilizer system .................................3-1
Immobilizer system indicator light ........... 3-7
Indicator and warning lights .................... 3-4KKey identification number ........................ 9-1LLicense plate light bulb, replacing ......... 6-37MMain switch/steering lock ........................ 3-2
Maintenance and lubrication, periodic..... 6-3
Maintenance, emission control system ... 6-2Matte color, caution ................................ 7-1
Model label ............................................. 9-2
Multi-function meter unit ......................... 3-8
NNeutral indicator light .............................. 3-4OOil level warning light .............................. 3-4PParking.................................................... 5-4
Part locations .......................................... 2-1
Pass switch ........................................... 3-12RRear brake light switch, adjusting ......... 6-23
Rear view mirrors.................................. 3-21SSafety information ................................... 1-1
Seat ...................................................... 3-18
Shifting .................................................... 5-2
Shift pedal ............................................. 3-13
Shock absorber assembly, adjusting .... 3-21
Sidestand .............................................. 3-22
Spark plugs, checking............................. 6-9
Specifications.......................................... 8-1
Starting the engine.................................. 5-1
Start switch ........................................... 3-12
Steering, checking ................................ 6-31
Storage ................................................... 7-3
Storage compartment ........................... 3-20
Swingarm pivots, lubricating ................. 6-30TTail/brake light bulb, replacing .............. 6-36
Throttle cable free play, checking ......... 6-19
Throttle grip and cable,
checking and lubricating ..................... 6-28
U36CE0E0.book Page 1 Friday, December 5, 2008 2:33 PM