ignition YAMAHA XJ6-S 2009 Owners Manual

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 and warning lights ............3-4
Multi-function meter unit .................3-8
Anti-theft alarm (optional) .............3-11
Handlebar switches ......................3-12
Clutch lever ...................................3-13
Shift pedal .....................................3-13
Brake lever ...................................3-14
Brake pedal ..................................3-14
ABS (for ABS models) ..................3-14
Fuel tank cap ................................3-15
Fuel ...............................................3-16
Fuel tank breather/overflow
hose ..........................................3-17
Catalytic converter ........................3-18
Seat ..............................................3-18
Helmet holder ...............................3-19
Storage compartment ...................3-20
Handlebar position ........................3-20
Rear view mirrors .........................3-21Adjusting the shock absorber
assembly ................................... 3-21
Sidestand ..................................... 3-22
Ignition circuit cut-off system ........ 3-23
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 ............................... 6-1
Periodic maintenance chart for the
emission control system ............. 6-2
General maintenance and
lubrication chart .......................... 6-3
Removing and installing cowlings
and panels .................................. 6-7
Checking the spark plugs ............... 6-9
Engine oil and oil filter cartridge ... 6-10
Coolant ......................................... 6-13
Replacing the air filter element ..... 6-17Adjusting the engine idling
speed ........................................ 6-18
Checking the throttle cable
free play .................................... 6-19
Valve clearance ........................... 6-19
Tires ............................................. 6-20
Cast wheels ................................. 6-22
Adjusting the clutch lever
free play .................................... 6-22
Adjusting the rear brake
light switch ................................ 6-23
Checking the front and rear
brake pads ................................ 6-24
Checking the brake fluid level ...... 6-24
Changing the brake fluid .............. 6-25
Drive chain slack .......................... 6-26
Cleaning and lubricating the
drive chain ................................ 6-27
Checking and lubricating the
cables ....................................... 6-28
Checking and lubricating the
throttle grip and cable ............... 6-28
Checking and lubricating the
brake and shift pedals .............. 6-28
Checking and lubricating the
brake and clutch levers ............ 6-29
Checking and lubricating the
centerstand and sidestand ....... 6-30
Lubricating the swingarm
pivots ........................................ 6-30
Checking the front fork ................. 6-31U36CE0E0.book Page 1 Friday, December 5, 2008 2:33 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-2
3


Keep other immobilizer system
keys away from the main switch
as they may cause signal inter-ference.
EAU10471
Main switch/steering lock The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering.TIPBe sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code re-
registering key (red bow), keep it in a
safe place and only use it for code re-registering.
EAU38530
ON
All electrical circuits are supplied with
power; the meter lighting, taillight, li-
cense plate light and auxiliary light
come on, and the engine can be start-
ed. The key cannot be removed.TIPThe headlight comes on automatically
when the engine is started and stays on
until the key is turned to “OFF”, even ifthe engine stalls.
EAU10661
OFF
All electrical systems are off. The key
can be removed.
WARNING
EWA10061
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving.
Otherwise the electrical systems will
be switched off, which may result inloss of control or an accident.
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INSTRUMENT AND CONTROL FUNCTIONS
3-16
3
TIPThe fuel tank cap cannot be closed un-
less the key is in the lock. In addition,
the key cannot be removed if the cap isnot properly closed and locked.
WARNING
EWA11091
Make sure that the fuel tank cap is
properly closed after filling fuel.Leaking fuel is a fire hazard.
EAU13221
Fuel Make sure there is sufficient gasoline in
the tank.
WARNING
EWA10881
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, followthese instructions.
1. Before refueling, turn off the en-
gine and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the vi-
cinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.
2. Do not overfill the fuel tank. When
refueling, be sure to insert the
pump nozzle into the fuel tank filler
hole. Stop filling when the fuel
reaches the bottom of the filler
tube. Because fuel expands when
it heats up, heat from the engine or
the sun can cause fuel to spill out
of the fuel tank.3. 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-1. Fuel tank filler tube
2. Fuel level
1
2
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INSTRUMENT AND CONTROL FUNCTIONS
3-22
3


Do not tamper with or attempt to
open the cylinder assembly.


Do not subject the shock ab-
sorber assembly to an open
flame or other high heat source.
This may cause the unit to ex-
plode due to excessive gas
pressure.


Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.


Do not dispose of a damaged or
worn-out shock absorber as-
sembly yourself. Take the shock
absorber assembly to a Yamahadealer for any service.
EAU15301
Sidestand The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.TIPThe built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation ofthe ignition circuit cut-off system.)
WARNING
EWA10240
The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the respon-
sibility of raising the sidestand be-
fore starting off. Therefore, check
this system regularly as describedbelow and have a Yamaha dealer re-
pair it if it does not function proper-
ly.
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INSTRUMENT AND CONTROL FUNCTIONS
3-23
3
EAU44902
Ignition circuit cut-off system The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.

It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is
not pulled.


It prevents starting when the trans-
mission is in gear and the clutch le-
ver is pulled, but the sidestand is
still down.


It cuts the running engine when the
transmission is in gear and the sid-
estand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-3
4
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switch Check operation of ignition circuit cut-off system.
If system is not working correctly, have Yamaha dealer check vehicle.3-22 ITEM CHECKS PAGE
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OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accidentor injury.
EAU47150
TIPThis model is equipped with:

a lean angle sensor to stop the en-
gine in case of a turnover. In this
case, the multi-function meter unit
indicates error code 30, but this is
not a malfunction. Turn the key to
“OFF” and then to “ON” to clear the
error code. Failing to do so will pre-
vent the engine from starting even
though the engine will crank when
pushing the start switch.


an engine auto-stop system. The
engine stops automatically if left
idling for 20 minutes. In this case,
the multi-function meter unit indi-
cates error code 70, but this is not
a malfunction. Push the start
switch to clear the error code andto restart the engine.
EAU44725
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met.

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
See page 3-23 for more informa-
tion.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to“”.
The following warning lights and
indicator light should come on for a
few seconds, then go off.

Oil level warning light


Coolant temperature warning
light


Engine trouble warning light


ABS warning light (for ABS
models)


Immobilizer system indicator
light
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-34
6 XJ6S XJ6SA XJ6SA
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage. WARNING! Do not
use a fuse of a higher amperage
1. Taillight fuse
2. Spare fuse
3. Headlight fuse
4. Ignition fuse
5. Signaling system fuse
6. Backup fuse (for odometer, clock and immo-
bilizer system)
7. Fuel injection system fuse
8. Radiator fan fuse
1
2
3
4
5
6
7
8
1. Starter relay cover
2. Main fuse
3. Spare main fuse
4. Fuse box
2
4 3 1
1. Taillight fuse
2. ABS control unit fuse
3. ABS solenoid fuse
4. ABS motor fuse
5. Spare fuse
6. Headlight fuse
7. Ignition fuse
8. Signaling system fuse
9. Backup fuse (for odometer, clock and immo-
bilizer system)
10.Fuel injection system fuse
11.Radiator fan fuse
1
5
56
7
8
9
10
11 234
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-35
6rating than recommended to
avoid causing extensive dam-
age to the electrical system and
possibly a fire.
[EWA15131]
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU47600
Replacing the headlight bulb This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.NOTICE
ECA10650
Take care not to damage the follow-
ing parts:

Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it free
from oil, otherwise the transpar-
ency of the glass, the luminosity
of the bulb, and the bulb life will
be adversely affected. Thor-
oughly clean off any dirt and fin-
gerprints on the headlight bulb
using a cloth moistened with al-
cohol or thinner.


Headlight lens
Do not affix any type of tinted
film or stickers to the headlight
lens.
Do not use a headlight bulb of awattage higher than specified.
Specified fuses:
Main fuse:
30.0 A
Headlight fuse:
20.0 A
Taillight fuse:
10.0 A
Signaling system fuse:
7.5 A
Ignition fuse:
10.0 A
Radiator fan fuse:
20.0 A
Fuel injection system fuse:
10.0 A
Backup fuse:
7.5 A
ABS motor fuse:
XJ6SA 30.0 A
ABS control unit fuse:
XJ6SA 7.5 A
ABS solenoid fuse:
XJ6SA 20.0 A
U36CE0E0.book Page 35 Friday, December 5, 2008 2:33 PM

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]
EAU34432
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. Adjust the drive chain slack. (See
page 6-26.)
5. Lower the rear wheel so that it is
on the ground, and then put the
sidestand down.
6. Tighten the axle nut, and then
tighten the locknuts to the speci-
fied torques.
EAU25871
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
WARNING
EWA15141
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from water
1. Slot
2. RetainerTightening torques:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)12
U36CE0E0.book Page 41 Friday, December 5, 2008 2:33 PM