engine YAMAHA XJ600S 2002 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:@ If 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. @
EAU04185
Engine oil and oil filter
cartridge 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 motorcycle on the cen-
terstand.
NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. 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, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level. Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf)
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6 To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:_ Skip steps 4–6 if the oil filter cartridge is
not being replaced. _
4. Remove the oil filter cartridge with
an oil filter wrench.NOTE:_ An oil filter wrench is available at a
Yamaha dealer. _
1. Engine oil filler cap
1. Engine oil drain bolt
1. Oil filter cartridge
2. Oil filter wrench
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
65. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.
NOTE:_ Make sure that the O-ring is properly
seated. _
6. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.
7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
1. O-ring
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
2.3 L
With oil filter cartridge
replacement:
2.6 L
Total amount (dry engine):
3.1 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
EC000072
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a higher
grade than “CD”. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign mate-
rial enters the crankcase.
_9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.NOTE:_ After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient. _
EC000067
CAUTION:_ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. _10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU02928*
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the seat. (See page 3-12
for seat removal and installation
procedures.)
2. Turn the fuel cock lever to “ON”,
and then remove the fuel cock le-
ver by removing the screw.1. Screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 7. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.
8. Insert the air filter element into the
air filter case.
EC000082*
CAUTION:@

Make sure that the air filter ele-
ment is properly seated in the
air filter case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
pistons and/or cylinders may
become excessively worn.
@9. Install the air filter case cover by
installing the screws.
10. Install the fuel tank by installing the
bolts.
11. Connect the hoses.
12. Install the fuel cock lever by install-
ing the screw.
13. Install the seat.
EAU00630
Adjusting the carburetors The carburetors are important parts of
the engine and require very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.
EC000095
CAUTION:@ The carburetors have been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine. @
1. Air filter element
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
EAU00632
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Start the engine and warm it up for
several minutes at 1,000–
2,000 r/min while occasionally rev-
ving it to 4,000–5,000 r/min.NOTE:@ The engine is warm when it quickly re-
sponds to the throttle. @
2. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
rection
a. To decrease the engine
idling speed, turn the screw in di-
rection
b.NOTE:@ If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment. @
EAU00635
Adjusting the throttle cable
free play The throttle cable free play should
measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
1. Throttle stop screw
Engine idling speed:
1,200 – 1,300 r/min
a. Throttle cable free play
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6
EAU00637
Adjusting the valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU03362
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000082
WARNING
@

The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).


The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
@
CE-01E
CE-07E
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg200 kPa
(2.00 kgf/cm
2,
2.00 bar)225 kPa
(2.25 kgf/cm
2,
2.25 bar)
90 kg–maximum200 kPa
(2.00 kgf/cm
2,
2.00 bar)250 kPa
(2.50 kgf/cm
2,
2.50 bar)
High-speed riding200 kPa
(2.00 kgf/cm
2,
2.00 bar)250 kPa
(2.50 kgf/cm
2,
2.50 bar)
Maximum load*XJ600S: 184 kg
XJ600N: 187 kg
* Total weight of rider, passenger, cargo and
accessories
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6 5. If the drive chain slack is incorrect,
adjust it as follows.
EAU03752
To adjust the drive chain slack
1. Loosen the axle nut, then loosen
the locknut at each end of the
swingarm.
2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction
a. To loos-
en the drive chain, turn the adjust-
ing nut at each end of the
swingarm in direction
b, and then
push the rear wheel forward.
NOTE:_ Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po-
sition for proper wheel alignment. _
EC000096
CAUTION:_ Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits. _3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque. Drive chain slack:
30–40 mm
1. Axle nut
2. Locknut
3. Drive chain slack adjusting nut
4. Alignment marks
Tightening torque:
Axle nut:
105 Nm (10.5 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU03006
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.
EC000097
CAUTION:@ The drive chain must be lubricated
after washing the motorcycle or
riding in the rain. @1. Clean the drive chain with kero-
sene and a small soft brush.
ECA00053
CAUTION:@ To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. @
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA00052
CAUTION:@ Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings. @
EAU02962
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.
EW000112
WARNING
@ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. @
Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU02939
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
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:@ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. @
EAU00794
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 a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @
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