front fork YAMAHA XJ6-N 2016 Owners Manual

Table of contents
Safety information ............................1-1
Description ........................................2-1
Left view ..........................................2-1
Right view........................................2-2
Controls and instruments ................2-3
Instrument an d 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 .................3-6
Handlebar switches.......................3-10
Clutch lever ...................................3-12
Shift pedal .....................................3-12
Brake lever ....................................3-13
Brake pedal ...................................3-13
ABS (for ABS models) ...................3-14
Fuel tank cap.................................3-15
Fuel................................................3-15
Fuel tank breather hose and overflow hose.............................3-17
Catalytic converter ........................3-17
Seat ...............................................3-18
Helmet holder ................................3-19
Storage compartment ...................3-20
Handlebar position .......................3-20
Adjusting the shock absorber assembly....................................3-21
Sidestand ......................................3-22
Ignition circuit cut-off system........3-22
For your safety – pre-operation
checks ...............................................4-1
Operation an d important ri din g
points .................................................5-1
Starting the engine ..........................5-2
Shifting ............................................5-3
Tips for reducing fuel consumption ................................5-4
Engine break-in ...............................5-4
Parking ............................................5-5 Perio
dic maintenance an d
a d justment ........................................ 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 the
cowling and panels...................... 6-7
Checking the spark plugs ............... 6-8
Engine oil and oil filter cartridge ..... 6-9
Coolant ......................................... 6-12
Replacing the air filter element ..... 6-16
Adjusting the engine idling speed......................................... 6-17
Checking the throttle grip free play ............................................ 6-18
Valve clearance ............................. 6-18
Tires .............................................. 6-19
Cast wheels .................................. 6-21
Adjusting the clutch lever free play ............................................ 6-22
Checking the brake lever free
play ............................................ 6-23
Brake light switches ...................... 6-23
Checking the front and rear brake pads................................. 6-24
Checking the brake fluid level....... 6-25
Changing the brake fluid............... 6-26
Drive chain slack ........................... 6-26
Cleaning and lubricating the drive chain ................................. 6-28
Checking and lubricating the cables ........................................ 6-28
Checking and lubricating the
throttle grip and cable ............... 6-29
Checking and lubricating the brake and shift pedals ............... 6-29
Checking and lubricating the brake and clutch levers ............. 6-30
Checking and lubricating the
sidestand ................................... 6-30
Lubricating the swingarm pivots... 6-31
Checking the front fork ................. 6-31
Checking the steering ................... 6-32
Checking the wheel bearings ....... 6-32
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Safety information
1-3
1
Avoi
d Car bon Monoxi de Poisonin g
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing
carbon monoxide can cause head-
aches, dizziness, drowsiness, nausea,
confusion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be pres-
ent even if you do not see or smell any
engine exhaust. Deadly levels of car-
bon monoxide can collect rapidly and
you can quickly be overcome and un-
able to save yourself. Also, deadly lev-
els of carbon monoxide can linger for
hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poi-
soning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.  Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
 Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
 Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loa din g
Adding accessories or cargo to your
motorcycle can adversely affect stabil-
ity and handling if the weight distribu-
tion of the motorcycle is changed. To
avoid the possibility of an accident, use
extreme caution when adding cargo or
accessories to your motorcycle. Use extra care when riding a motorcycle
that has added cargo or accessories.
Here, along with the information about
accessories below, are some general
guidelines to follow if loading cargo to
your motorcycle:
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
Operation of an overloa
ded vehicle
coul d cause an acci dent.
When loading within this weight limit,
keep the following in mind:  Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Se-
curely pack your heaviest items as
close to the center of the vehicle
as possible and make sure to dis-
tribute the weight as evenly as
possible on both sides of the mo-
torcycle to minimize imbalance or
instability.
 Shifting weights can create a sud-
den imbalance. Make sure that
accessories and cargo are se-
curely attached to the motorcycle
before riding. Check accessory
mounts and cargo restraints fre-
quently.
• Properly adjust the suspension for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
• Never attach any large or heavy items to the handlebar, front
fork, or front fender. These
Maximum loa d:
190 kg (419 lb) (XJ6NA)
195 kg (430 lb) (XJ6N)
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Safety information
1-4
1items, including such cargo as
sleeping bags, duffel bags, or
tents, can create unstable han-
dling or a slow steering re-
sponse.
 This vehicle is not desi gne d to
pull a trailer or to be attached to
a si decar.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail- able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection
to Yamaha manufacture parts and ac-
cessories or offer other modifications
for Yamaha vehicles. Yamaha is not in
a position to test the products that
these aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories, an d
Mo difications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accesso-
ries or modifications are not suitable
because of potential safety hazards to
you or others. Installing aftermarket
products or having other modifications
performed to your vehicle that change
any of the vehicle’s design or operation
characteristics can put you and others at greater risk of serious injury or
death. You are responsible for injuries
related to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
 Never install accessories or carry
cargo that would impair the per-
formance of your motorcycle.
Carefully inspect the accessory
before using it to make sure that it
does not in any way reduce
ground clearance or cornering
clearance, limit suspension travel,
steering travel or control opera-
tion, or obscure lights or reflec-
tors.
• Accessories fitted to the han- dlebar or the front fork area can
create instability due to improp-
er weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
• Bulky or large accessories may seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become
unstable in cross winds. These
accessories may also cause in-
stability when passing or being
passed by large vehicles.
• Certain accessories can dis- place the operator from his or
her normal riding position. This
improper position limits the
freedom of movement of the
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Safety information
1-5
1
operator and may limit control
ability, therefore, such accesso-
ries are not recommended.
 Use caution when adding electri-
cal accessories. If electrical ac-
cessories exceed the capacity of
the motorcycle’s electrical sys-
tem, an electric failure could re-
sult, which could cause a
dangerous loss of lights or engine
power.
Aftermarket Tires an d Rims
The tires and rims that came with your
motorcycle were designed to match
the performance capabilities and to
provide the best combination of han-
dling, braking, and comfort. Other
tires, rims, sizes, and combinations
may not be appropriate. Refer to page
6-19 for tire specifications and more in-
formation on replacing your tires.
Transportin g the Motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.  Remove all loose items from the
motorcycle.
 Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.
 Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
 Shift the transmission in gear (for
models with a manual transmis-
sion).
 Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo- torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or
parts that could break). Choose
the location for the straps carefully
so the straps will not rub against
painted surfaces during transport.
 The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce exces-
sively during transport.
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Periodic maintenance an d a djustment
6-5
6
13 *Chassis fasteners • Make sure that all nuts, bolts
and screws are properly tight-
ened. √√√√√
14 Brake lever pivot
shaft
• Lubricate with silicone grease.
√√√√√
15 Brake ped
al pivot
shaft • Lubricate with lithium-soap-
based grease. √√√√√
16 Clutch lever pivot
shaft • Lubricate with lithium-soap-
based grease. √√√√√
17 Shift ped
al pivot
shaft • Lubricate with lithium-soap-
based grease. √√√√√
18 Si destan d • Check operation.
• Lubricate with lithium-soap-
based grease. √√√√√
19 *Sidestan d switch • Check operation. √√√√√√
20 *Front fork • Check operation and for oil
leakage. √√√√
21 *Shock a
bsor ber
assem bly • Check operation and shock ab-
sorber for oil leakage. √√√√
22 En gine oil • Change.
• Check oil level and vehicle for
oil leakage. √√√√√√
23 En
gine oil filter
cartri dge • Replace.
√√√
24 *Coolin g system • Check coolant level and vehicle
for coolant leakage. √√√√√
• Change coolant. Every 3 years
25 *Front an
d rear
b rake switches • Check operation.
√√√√√√
26 Mo
v

in g parts an d
cab les • Lubricate.
√√√√√
27 *Throttle grip • Check operation.
• Check throttle grip free play,
and adjust if necessary.
• Lubricate cable and grip hous- ing. √√√√√
NO. ITEM
X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER READINGS
ANNUAL CHECK
110203040
0.66121824
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Periodic maintenance an d a djustment
6-31
6
EAUM1653
Lub ricatin g the swin garm piv-
ots
The swingarm pivots must be lubricat-
ed by a Yamaha dealer at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU23273
Checkin g the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
To check the con dition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation 1. Place the vehicle on a level surfa- ce and hold it in an upright posi-
tion. WARNING! To avoi d injury,
securely support the vehicle so
there is no d anger of it fallin g
over.
[EWA10752]
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.
NOTICE
ECA10591
If any damag e is foun d or the front
fork does not operate smoothly,
have a Yamaha d ealer check or re-
pair it.
Recommen ded lu bricant:
Lithium-soap-based grease
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Periodic maintenance an d a djustment
6-32
6
EAU23285
Checkin g the steerin g
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
periodic maintenance and lubrication
chart.
1. Raise the front wheel off the ground. (See page 6-40.)
WARNING! To avoi d injury, se-
curely support the vehicle so
there is no dan ger of it fallin g
over.
[EWA10752]
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 steer-
ing.
EAU23292
Checkin g the wheel b earings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
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Periodic maintenance an d a djustment
6-41
6
EAU44792
Front wheel (for non-ABS
mo dels)
WARNING
EWA14841
For the ABS mo del, have a Yamaha
d ealer remove an d install the wheel.
EAU56270
To remove the front wheel
WARNING
EWA10822
To avoi d injury, securely support the
vehicle so there is no d anger of it
fallin g over.
1. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.
2. Lift the front wheel off the ground according to the procedure in the
previous section “Supporting the
motorcycle”.
3. Remove the brake caliper on each side by removing the bolts.
NOTICE: Do not apply the b rake
after the b rake calipers have b
een removed , otherwise the
b rake pa ds will be forced shut.
[ECA11052]
4. Pull the wheel axle out, and then
remove the wheel.
To install the front wheel 1. Lift the wheel up between the fork legs.
2. Insert the wheel axle.
3. Install the brake calipers by install- ing the bolts.
TIP
Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs.
4. Lower the front wheel so that it ison the ground, and then put the
sidestand down.
5. Tighten the wheel axle, the front wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.1. Wheel axle
2. Front wheel axle pinch bolt
3. Brake caliper bolt
1
3
2
1. Brake caliper
2. Brake caliper bolt
1 2
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Periodic maintenance an d a djustment
6-42
6 6. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU44802
Rear wheel (for non-ABS
mo dels)
WARNING
EWA14841
For the ABS mo del, have a Yamaha
d ealer remove an d install the wheel.
EAU56662
To remove the rear wheel
WARNING
EWA10822
To avoi d injury, securely support the
vehicle so there is no dan ger of it
fallin g over.
1. Loosen the locknut and drive
chain slack adjusting nut on each
side of the swingarm.
2. Loosen the axle nut.
3. Lift the rear wheel off the ground according to the procedure on
page 6-40.
4. Remove the axle nut.
5. Push the wheel forward, and then remove the drive chain from the
rear sprocket.
Tightenin g 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)
1. Axle nut
2. Drive chain slack adjusting nut
3. Locknut
1
3
2
UB61E1E0.book Page 42 Wednesday, October 21, 2015 11:19 AM

Specifications
8-2
8
2nd:1.947 (37/19)
3rd: 1.556 (28/18)
4th:
1.333 (32/24)
5th: 1.190 (25/21)
6th: 1.083 (26/24)
Chassis:
Frame type:Diamond
Caster angle: 26.0 °
Trail: 103 mm (4.1 in)
Front tire:
Type:Tubeless
Size: 120/70 ZR17M/C (58W)
Manufacturer/model:
BRIDGESTONE/BT021F
Manufacturer/model: DUNLOP/SPORTMAX-ROADSMART
Rear tire:
Type:
Tubeless
Size: 160/60 ZR17M/C (69W)
Manufacturer/model: BRIDGESTONE/BT021R
Manufacturer/model:
DUNLOP/SPORTMAX-ROADSMART
Loa din g:
Maximum load:
190 kg (419 lb) (XJ6NA)
195 kg (430 lb) (XJ6N)
(Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measure d on col d
tires):
Up to 90 kg (198 lb) load:
Front: 225 kPa (2.25 kgf/cm², 33 psi)
Rear: 250 kPa (2.50 kgf/cm², 36 psi) 90 kg (198 lb) load - maximum load:
Front:
250 kPa (2.50 kgf/cm², 36 psi)
Rear: 290 kPa (2.90 kgf/cm², 42 psi)
Front wheel:
Wheel type:
Cast wheel
Rim size: 17M/C x MT3.50
Rear wheel:
Wheel type:
Cast wheel
Rim size:
17M/C x MT4.50
Front brake:
Type:
Hydraulic dual disc brake
Specified brake fluid:
DOT 4
Rear brake:
Type:
Hydraulic single disc brake
Specified brake fluid:
DOT 4
Front suspension:
Type:Telescopic fork
Spring:
Coil spring
Shock absorber: Hydraulic damper
Wheel travel: 130 mm (5.1 in)
Rear suspension:
Type:Swingarm
Spring: Coil spring
Shock absorber:
Gas-hydraulic damper
Wheel travel: 130 mm (5.1 in)
Electrical system:
System voltage:
12 V
Ignition system: TCI
Charging system: AC magneto
UB61E1E0.book Page 2 Wednesday, October 21, 2015 11:19 AM