2013 YAMAHA XJ6-S maintenance

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS .......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator lights and warning lights ............................................3-4
Multi-function meter unit .................3-7
Handlebar switches ......................3-11
Clutch lever ...................................3-12
Shift pedal .....................................3-13
Brake lever ...................................3-13
Brake pedal ..................................3-13
Fuel tank cap ................................3-14
Fuel ...............................................3-14
Fuel tank breather hose and overflow hose ............................3-15
Catalytic converter ........................3-16
Seat ..............................................3-16
Helmet holder ...............................3-17
Storage compartment ...................3-18
Handlebar position ........................3-18
Rear view mirrors .........................3-19
Adjusting the shock absorber assembly ...................................3-19 Sidestand ..................................... 3-20
Ignition circuit cut-off system ........ 3-21
FOR YOUR SAFETY –
PRE-OPERATION CHECKS ............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS ................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 6-1
Owner’s tool kit ............................... 6-2
Periodic maintenance chart for the emission control system ............. 6-3
General maintenance and lubrication chart .......................... 6-4
Removing and installing cowlings
and panels .................................. 6-8
Checking the spark plugs ............. 6-10
Engine oil and oil filter cartridge ... 6-11
Coolant ......................................... 6-14
Replacing the air filter element ..... 6-18
Adjusting the engine idling speed ........................................ 6-19 Checking the throttle grip free
play ........................................... 6-20
Valve clearance ........................... 6-20
Tires ............................................. 6-20
Cast wheels ................................. 6-23
Adjusting the clutch lever free play ........................................... 6-23
Checking the brake lever free
play ........................................... 6-24
Brake light switches ..................... 6-25
Checking the front and rear brake pads .......................................... 6-25
Checking the brake fluid level ...... 6-26
Changing the brake fluid .............. 6-27
Drive chain slack .......................... 6-28
Cleaning and lubricating the drive chain ......................................... 6-29
Checking and lubricating the cables ....................................... 6-30
Checking and lubricating the
throttle grip and cable ............... 6-30
Checking and lubricating the brake and shift pedals .............. 6-30
Checking and lubricating the brake and clutch levers ............ 6-31
Checking and lubricating the
centerstand and sidestand ....... 6-32
Lubricating the swingarm pivots ........................................ 6-32
Checking the front fork ................. 6-33
Checking the steering .................. 6-33U36CE3E0.book Page 1 Wednesday, May 30, 2012 11:51 AM

1-1
1
SAFETY INFORMATION
EAU1028A
Be a Responsible Owner
As the vehicle’s owner, you are respon-
sible for the safe and proper operation
of your motorcycle.
Motorcycles are single-track vehicles.
Their safe use and operation are de-
pendent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements before
riding this motorcycle.
He or she should:●
Obtain thorough instructions from
a competent source on all aspects
of motorcycle operation.
●
Observe the warnings and mainte-
nance requirements in this Own-
er’s Manual.
●
Obtain qualified training in safe
and proper riding techniques.
●
Obtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made neces-
sary by mechanical conditions.
●
Never operate a motorcycle with-
out proper training or instruction.
Take a training course. Beginners
should receive training from a cer-
tified instructor. Contact an autho-
rized motorcycle dealer to find out
about the training courses nearest
you.
Safe Riding
Perform the pre-operation checks each
time you use the vehicle to make sure it
is in safe operating condition. Failure to
inspect or maintain the vehicle properly
increases the possibility of an accident
or equipment damage. See page 4-1
for a list of pre-operation checks.
●
This motorcycle is designed to car-
ry the operator and a passenger.
●
The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore:
Wear a brightly colored jacket.
Use extra caution when you are approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.
Ride where other motorists can see you. Avoid riding in another
motorist’s blind spot.
Never maintain a motorcycle without proper knowledge. Con-
tact an authorized motorcycle
dealer to inform you on basic
motorcycle maintenance. Cer-
tain maintenance can only be
carried out by certified staff.
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INSTRUMENT AND CONTROL FUNCTIONS
3-15
33. Wipe up any spilled fuel immedi-ately. NOTICE: Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plastic
parts.
[ECA10071]
4. Be sure to securely close the fuel tank cap.
WARNING
EWA15151
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline in
your eyes, see your doctor immedi- ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.
EAU13322
NOTICE
ECA11400
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
95 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
EAU51190
Fuel tank breather hose and
overflow hose Before operating the motorcycle:●
Check each hose connection.
●
Check each hose for cracks or
damage, and replace if damaged.
●
Make sure that the end of each
hose is not blocked, and clean if
necessary.
●
Make sure that the end of each
hose is positioned inside of the
clamp.
1. Fuel tank filler tube
2. Maximum fuel level
1
2
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)
1. Fuel tank breather hose and overflow hose
2. Clamp
1 1
2
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INSTRUMENT AND CONTROL FUNCTIONS
3-16
3
EAU13433
Catalytic converter This model is equipped with a catalytic
converter in the exhaust system.
WARNING
EWA10862
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:●
Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
●
Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
●
Make sure that the exhaust sys-
tem has cooled down before do-
ing any maintenance work.
●
Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
NOTICE
ECA10701
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-
pairable damage to the catalytic
converter.
EAU32980
Seat To remove the seat1. Insert the key into the seat lock, and then turn it counterclockwise.
2. While holding the key in that posi- tion, lift the rear of the seat up, and
then pull the seat off.
To install the seat 1. Insert the projection on the front of the seat into the seat holder as
shown.1. Seat lock
2. Unlock.
12
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEMCHECKS PAGE
Fuel Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check fuel tank breather hose and overflow
hose for obstructions, cracks or dam-
age, and check hose connections. 3-14, 3-15
Engine oil Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage. 6-11
Coolant Check coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage. 6-14
Front brake Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add specified brake fluid to specified level.
Check hydraulic system for leakage. 6-25, 6-26
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
EAU17244
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 charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals 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
EWA15122
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 1-3 for more in-
formation about carbon monox-
ide.WARNING
EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
EAU17302
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replacement,
or repair of the emission control devic-
es and systems may be performed by
any repair establishment or individual
that is certified (if applicable). Yamaha
dealers are trained and equipped to
perform these particular services.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
6
EAU39691
Owner’s tool kit The owner’s tool kit is located on the
bottom of the seat. (See page 3-16.)
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
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
6
EAU46861
TIP●
The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.
●
From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
●
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
EAU46910
Periodic maintenance chart for the emission control system 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 *Fuel line Check fuel hoses for cracks or
damage. √√√√√
2 *Spark plugs Check condition.
Clean and regap.
√√
Replace. √√
3 *Valves Check valve clearance.
Adjust.
Every 40000 km (24000 mi)
4 *Fuel injection Adjust engine idling speed and
synchronization. √√√√√√
5 *Air induction sys-
tem Check the air cut-off valve, reed
valve, and hose for damage.
Replace the entire air induction system if necessary. √√√√√
U36CE3E0.book Page 3 Wednesday, May 30, 2012 11:51 AM