YAMAHA XJ900S 2001 Service Manual

OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU02941
Recommended shift points
(for Switzerland only) The recommended shift points during
acceleration are shown in the table
below.CF-01ENOTE:@ When shifting down two gears at a
time, reduce the speed accordingly
(e.g., down to 35 km/h when shifting
from 4th to 2nd gear). @
EAU00424
Tips for reducing fuel
consumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:l
Thoroughly warm up the engine.
l
Turn the starter (choke) off as
soon as possible.
l
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
l
Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the engine.
l
Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
EAU00436
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1,000 km. For this rea-
son, you should read the following ma-
terial carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,000 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full-throttle oper-
ation or any condition that might result
in engine overheating must be avoided.
Shift point
(km/h)
1st®2nd
2nd®3rd
3rd®4th
4th®5th23
36
50
60
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OPERATION AND IMPORTANT RIDING POINTS
5-5
5
EAU00448*
0–500 kml
Avoid prolonged operation above
5,000 r/min.
l
After every hour of operation, stop
the engine, and then let it cool for
five to ten minutes.
l
Vary the engine speed from time
to time. Do not operate the engine
at one set throttle position.
500–1,000 km
l
Avoid prolonged operation above
6,000 r/min.
l
Rev the engine freely through the
gears, but do not use full throttle at
any time.
EC000056*
CAUTION:@ After 1,000 km of operation, the en-
gine oil and final gear oil must be
changed, and the oil filter cartridge
replaced. @
1,000 km and beyond
The vehicle can now be operated
normally.
EC000053
CAUTION:@ l
Keep the engine speed out of
the tachometer red zone.
l
If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the
vehicle.
@
EAU00460
Parking When parking, stop the engine, and
then remove the key from the main
switch.
EW000058
WARNING
@ l
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.
l
Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
@
E_4km.book Page 5 Thursday, September 7, 2000 9:32 AM

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing cowlings ........................ 6-5
Checking the spark plugs .................................... 6-7
Engine oil and oil filter cartridge .......................... 6-8
Final gear oil ...................................................... 6-11
Cleaning the air filter element ............................ 6-13
Adjusting the carburetors ................................... 6-15
Adjusting the engine idling speed ...................... 6-15
Adjusting the throttle cable free play .................. 6-16
Adjusting the valve clearance ............................ 6-17
Tires ................................................................... 6-17
Wheels ............................................................... 6-20
Adjusting the clutch lever free play .................... 6-20
Adjusting the rear brake light switch .................. 6-21
Checking the front and rear brake pads ............. 6-21
Checking the brake fluid level ............................ 6-22
Changing the brake fluid .................................... 6-23
Checking and lubricating the cables .................. 6-23Checking and lubricating the throttle grip and
cable ............................................................... 6-23
Checking and lubricating the brake and
shift pedals ...................................................... 6-24
Checking and lubricating the brake and
clutch levers .................................................... 6-24
Checking and lubricating the centerstand and
sidestand ......................................................... 6-25
Checking the front fork ...................................... 6-25
Checking the steering ....................................... 6-26
Checking the wheel bearings ............................ 6-27
Battery ............................................................... 6-27
Replacing the fuses .......................................... 6-29
Replacing a headlight bulb ................................ 6-30
Front wheel ....................................................... 6-31
Rear wheel ........................................................ 6-33
Troubleshooting ................................................. 6-35
Troubleshooting chart ........................................ 6-36
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6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, 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, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE
SHORTENED.
EW000060
WARNING
@ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. @
EAU03394
Owner’s tool kit The owner’s tool kit is located under
the rider seat. (See page 3-11 for rider
seat removal and installation proce-
dures.)
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.
NOTE:@ If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you. @
EW000063
WARNING
@ Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any
changes. @
1. Owner’s tool kit
E_4km.book Page 1 Thursday, September 7, 2000 9:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03540
Periodic maintenance and lubrication chart
NOTE:@ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
@CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
• Replace.ÖÖ
4*Valves• Check valve clearance.
•Adjust.Every 20,000 km
5 Air filter element•Clean.ÖÖ
• Replace.ÖÖ
6Clutch• Check operation.
•Adjust.ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
9*Brake hoses• Check for cracks or damage.ÖÖÖÖ Ö
• Replace. (See NOTE on page 6-4.) Every 4 years
E_4km.book Page 2 Thursday, September 7, 2000 9:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10
*Wheels• Check runout and for damage.ÖÖÖÖ
11*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖÖÖ
12*Wheel bearings• Check bearing for looseness or damage.ÖÖÖÖ
13*Swingarm• Check operation and for excessive play.ÖÖÖÖ
• Lubricate with lithium-soap-based grease. Every 50,000 km
14*Steering bearings• Check bearing play and steering for roughness.ÖÖÖÖÖ
• Lubricate with lithium-soap-based grease. Every 20,000 km
15*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖ Ö
16 Sidestand/centerstand• Check operation.
• Lubricate.ÖÖÖÖ Ö
17*Sidestand switch• Check operation.ÖÖÖÖÖ Ö
18*Front fork• Check operation and for oil leakage.ÖÖÖÖ
19*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.ÖÖÖÖ
20*Rear suspension relay
arm and connecting arm
pivoting points• Check operation.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease.ÖÖ
21*Carburetors• Check starter (choke) operation.
• Adjust engine idling speed and synchronization.ÖÖÖÖÖ Ö
22 Engine oil• Change.ÖÖÖÖÖ Ö
23 Engine oil filter cartridge•Replace.ÖÖÖ
24 Final gear oil• Check oil level and vehicle for oil leakage.ÖÖ Ö
• Change.ÖÖÖ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
E_4km.book Page 3 Thursday, September 7, 2000 9:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU03541
NOTE:@l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
@25
*Front and rear brake
switches• Check operation.ÖÖÖÖÖ Ö
26 Moving parts and cables• Lubricate.ÖÖÖÖ Ö
27*Lights, signals and
switches• Check operation.
• Adjust headlight beam.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
E_4km.book Page 4 Thursday, September 7, 2000 9:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU01065
Removing and installing
cowlings The cowlings shown above need to be
removed to perform some of the main-
tenance jobs described in this chapter.
Refer to this section each time a cowl-
ing needs to be removed and installed.
EAU03595
Cowling A
To remove the cowling1. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
2. Remove the screws, and then pull
the cowling off as shown.
NOTE:@ Pull the cowling up, then back to re-
move it. @To install the cowling1. Place the cowling in the original
position, and then install the
screws.
2. Install the seat.
1. Cowling A
2. Cowling B
1. Cowling A
2. Screw (´ 2)
E_4km.book Page 5 Thursday, September 7, 2000 9:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU03596
Cowling B
To remove the cowling1. Remove cowling A. (See page 6-5
for cowling removal and installa-
tion procedures.)2. Remove the grab bar by removing
the bolts.3. Remove the screws, and then pull
the cowling off as shown.
To install the cowling
1. Place the cowling in the original
position, and then install the
screws.
2. Install the grab bar by installing the
bolts.
3. Install cowling A.
1. Grab bar
2. Cowling B
1. Bolt (´ 2)
1. Screw (´ 2)
E_4km.book Page 6 Thursday, September 7, 2000 9:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAU01880
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal col-
or when the motorcycle is ridden nor-
mally), and all spark plugs installed in
the engine should have the same color.
If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
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. Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
a. Spark plug gap
Spark plug gap:
0.8–0.9 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kg)
E_4km.book Page 7 Thursday, September 7, 2000 9:32 AM