2010 YAMAHA XJ6-S torque

PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
EAU17241
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, depending on the
weather, terrain, geographical location,
and individual use, the maintenance in-
tervals may need to be shortened.
WARNING
EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15121
Turn off the engine when performing
maintenance unless otherwise
specified.

A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.


Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more in-
formation about carbon monox-
ide.
EAU39691
Owner’s tool kit The owner’s tool kit is located on the
bottom of the seat. (See page 3-18.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.TIPIf you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.1. Owner’s tool kit
1
U36CE1E0.book Page 1 Thursday, July 30, 2009 11:32 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6 Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
TIPIf 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.
EAU47551
Engine oil and oil filter car-
tridge 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 vehicle on the center-
stand. 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.
4. Remove the engine oil dipstick and
wipe it clean, insert it back into the
hole (without screwing it in), and
then remove it again to check the
oil level.TIPThe engine oil should be between the
minimum and maximum level marks.
1. Spark plug gapSpark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
U36CE1E0.book Page 10 Thursday, July 30, 2009 11:32 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
TIPAn oil filter wrench is available at a
Yamaha 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 properly
seated.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
its new gasket, and then tighten
the bolt to the specified torque.
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
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-
rial enters the crankcase.
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)
U36CE1E0.book Page 12 Thursday, July 30, 2009 11:32 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
65. Remove the coolant reservoir
breather hose from the guide, and
then remove the coolant reservoir
cap.
6. Remove the coolant reservoir cov-
er and coolant reservoir by remov-
ing the bolts.7. Drain the coolant from the coolant
reservoir by turning it upside down.
8. Remove the coolant drain bolt and
its gasket to drain the cooling sys-
tem.9. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
10. Install the coolant drain bolt and its
new gasket, and then tighten the
bolt to the specified torque.
11. Install the coolant reservoir and its
cover by placing them in the origi-
nal position, and then installing the
bolts.
12. Pour the specified amount of the
recommended coolant into the ra-
diator and reservoir.
1. Coolant reservoir cap
2. Coolant reservoir breather hose
3. Guide
3
1
2
1. Bolt
2. Coolant reservoir cover
3. Coolant reservoir
1. Coolant drain bolt
2. Gasket
23 1
1
12
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
U36CE1E0.book Page 15 Thursday, July 30, 2009 11:32 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-27
63. Tighten the axle nut, and then
tighten the locknuts to the speci-
fied torques.
EAU23025
Cleaning and lubricating the
drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.NOTICE
ECA10583
The drive chain must be lubricated
after washing the motorcycle, riding
in the rain or riding in wet areas.1. Clean the drive chain with kero-
sene and a small soft brush.
NOTICE: To prevent damaging
the O-rings, do not clean the
drive chain with steam cleaners,
high-pressure washers or inap-
propriate solvents.
[ECA11121]
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant. NOTICE: Do not use
engine oil or any other lubri-
cants for the drive chain, as theymay contain substances that
could damage the O-rings.
[ECA11111]
1. Alignment plate
2. NotchTightening torques:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
12
U36CE1E0.book Page 27 Thursday, July 30, 2009 11:32 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-39
63. Remove the brake caliper on each
side by removing the bolts.
NOTICE: Do not apply the brake
after the brake calipers have
been removed, otherwise the
brake pads will be forced shut.
[ECA11051]
4. Pull the wheel axle out, and then
remove the wheel.
EAU48660
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Install the brake calipers by install-
ing the bolts.TIPMake sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs.
4. Take the motorcycle off the center-
stand so that the front wheel is on
the ground, and then put the side-
stand down.
5. Tighten the wheel axle, the front
wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.
6. Push down hard on the handlebar
several times to check for proper
fork operation.
1. Wheel axle
2. Front wheel axle pinch bolt
3. Brake caliper bolt
13
2
1. Brake caliper
2. Brake caliper bolt
1 2
Tightening torques:
Wheel axle:
65 Nm (6.5 m·kgf, 47 ft·lbf)
Front wheel axle pinch bolt:
19 Nm (1.9 m·kgf, 13 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
U36CE1E0.book Page 39 Thursday, July 30, 2009 11:32 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-41
67. Remove the wheel. NOTICE: Do
not apply the brake after the
wheel has been removed to-
gether with the brake disc, oth-
erwise the brake pads will be
forced shut.
[ECA11071]
EAU48650
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the right-hand side.TIP

Make sure that the retainer on the
swingarm is inserted into the slot in
the brake caliper bracket.


Make sure that there is enough
space between the brake pads be-
fore installing the wheel.
2. Install the drive chain onto the rear
sprocket.
3. Install the axle nut.
4. Take the motorcycle off the center-
stand so that the rear wheel is on
the ground, and then put the side-
stand down.
5. Adjust the drive chain slack. (See
page 6-26.)
6. Tighten the axle nut, and then
tighten the locknuts to the speci-
fied torques.1. Slot
2. Retainer
12
Tightening torques:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
U36CE1E0.book Page 41 Thursday, July 30, 2009 11:32 AM