2013 YAMAHA XJ6-S brake

PERIODIC MAINTENANCE AND ADJUSTMENT
6-27
6
●
Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.
●
Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.
●
Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.
●
Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
NOTICE
ECA17640
Brake fluid may damage painted sur-
faces or plastic parts. Always clean
up spilled fluid immediately.As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake sys-
tem leakage; therefore, be sure to
check the brake pads for wear and thebrake system for leakage. If the brake
fluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
EAU22731
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the master cylinders and
calipers as well as the brake hoses re-
placed at the intervals listed below or
whenever they are damaged or leak-
ing.●
Oil seals: Replace every two
years.
●
Brake hoses: Replace every four
years.
U36CE3E0.book Page 27 Wednesday, May 30, 2012 11:51 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-30
6
EAU23095
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer housing of cables may result in in-
ternal rusting and cause interfer-
ence with cable movement. Replace
damaged cables as soon as possi-
ble to prevent unsafe conditions.[EWA10711] EAU49920
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated by a
Yamaha dealer at the intervals speci- fied in the periodic maintenance chart.
EAU44273
Checking and lubricating the
brake and sh ift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
Brake pedal
Shift pedal
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-31
6
EAU23143
Checking and lubricating the
brake and clutch levers The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Brake lever
Clutch lever
Recommended lubricant:Lithium-soap-based grease
Recommended lubricants:Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease
U36CE3E0.book Page 31 Wednesday, May 30, 2012 11:51 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-33
6
EAU23272
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10751]
2. While applying the front brake, push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
NOTICE
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU45511
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.1. Place the vehicle on the center- stand. WARNING! To avoid inju-
ry, securely support the vehicle
so there is no danger of it falling
over.
[EWA10751]
2. Hold the lower ends of the front fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
U36CE3E0.book Page 33 Wednesday, May 30, 2012 11:51 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-37
6
1. Remove cowling B. (See page
6-8.)
2. Disconnect the headlight coupler, and then remove the headlight
bulb cover. 3. Unhook the headlight bulb holder,
and then remove the burnt-out
bulb.
4. Place a new headlight bulb into po- sition, and then secure it with the
bulb holder.
5. Install the headlight bulb cover, and then connect the coupler.
6. Install the cowling.
7. Have a Yamaha dealer adjust the headlight beam if necessary.
EAU47021
Replacing the tail/brake light
bulb 1. Remove the seat. (See page3-16.)
2. Remove the tail/brake light bulb socket (together with the bulb) by
turning it counterclockwise.
3. Remove the burnt-out bulb by pull- ing it out.
1. Do not touch the glass part of the bulb.
1. Headlight bulb cover
2. Headlight coupler
1 2
1. Headlight bulb
2. Headlight bulb holder
1
2
1. Tail/brake light bulb socket
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-38
64. Insert a new bulb into the socket.
5. Install the socket (together with the
bulb) by turning it clockwise.
6. Install the seat.
EAU24204
Replacing a turn signal light
bulb 1. Remove the turn signal light lens by removing the screw.
2. Remove the burnt-out 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. NOTICE: Do not over-
tighten the screw, otherwise the
lens may break.
[ECA11191]
1. Tail/brake light bulb
2. Tail/brake light bulb socket
2
1
1. Turn signal light lens
2. Screw
1
2
1. Turn signal light bulb
1
U36CE3E0.book Page 38 Wednesday, May 30, 2012 11:51 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-40
6
EAU24360
Front wheel
EAU42642
To remove the front wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the front wheel axle pinchbolt, then the wheel axle and the
brake caliper bolts.
2. Place the vehicle on the center- stand. 3. 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 wheel1. 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, 14 ft·lbf)
Brake caliper bolt: 40 Nm (4.0 m·kgf, 29 ft·lbf)
U36CE3E0.book Page 40 Wednesday, May 30, 2012 11:51 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-41
6
EAU25080
Rear wheel
EAU32874
To remove the rear wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the locknut and drive chainslack adjusting nut on each side of
the swingarm.
2. Loosen the axle nut.
3. Place the motorcycle on the cen- terstand. 4. Remove the axle nut.
5. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
TIPThe drive chain does not need to be
disassembled in order to remove and
install the rear wheel.6. While supporting the brake caliperand slightly lifting the wheel, pull
the wheel axle out.
TIPA rubber mallet may be useful to tap the
wheel axle out.7. 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]
EAU48651
To install the rear wheel1. Install the wheel and the brake cal- iper bracket by inserting the wheel
axle from the right-hand side.
1. Axle nut
2. Drive chain slack adjusting nut
3. Locknut
1
3
2
1. Brake caliper
2. Wheel axle
1
2
U36CE3E0.book Page 41 Wednesday, May 30, 2012 11:51 AM