YAMAHA XJ6-S 2009 Workshop Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
6-6
6


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.Replace the brake hoses every four years and if cracked or damaged.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6
EAU18712
Removing and installing cowl-
ings and panels The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
a cowling or panel needs to be re-
moved and installed.
EAU46770
Panel A
To remove the panelRemove the bolt and the quick fasten-
er, and then take the panel off.
To install the panelPlace the panel in the original position,
and then install the bolt and the quick
fastener.
EAU47880
Panels B and C
To remove one of the panels1. Remove the bolts.
1. Cowling A
2. Cowling B12
1. Panel A
2. Cowling C
1. Panel B
2. Panel C
2
1
2 1
1. Panel A
2. Bolt
3. Quick fastener
1
2
3
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-8
6 2. Push the panel outwards to un-
hook the projection underneath
the panel, and then pull the panel
off as shown.To install the panel
Place the panel in the original position,
and then install the bolts.
EAU46740
Cowling A
To remove the cowlingRemove the bolts, and then take the
cowling off.To install the cowling
Place the cowling in the original posi-
tion, and then install the bolts.
EAU47581
Cowlings B and C
To remove one of the cowlings1. Remove panel B (if removing cowl-
ing B) or panel C (if removing cowl-
ing C).
2. Remove the quick fastener and
the bolts, and then take the cowl-
ing off.
1. Panel B
2. Bolt
1. Projection
2 1
1
1. Cowling A
2. Bolt
2 2
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-9
63. Disconnect the turn signal light
lead connectors.
To install the cowling
1. Connect the turn signal light lead
connectors.2. Place the cowling in the original
position, and then install the bolts
and the quick fastener.
3. Install panel B or C.
EAU19642
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 color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be operating im-
properly. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
1. Cowling B
2. Bolt
3. Quick fastener
1. Turn signal light lead connector
3
1
21
Specified spark plug:
NGK/CR9E
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6 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.
TIPIf 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.
EAU47550
Engine oil and oil filter car-
tridge 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 vehicle on the center-
stand. 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.
4. Remove the engine oil dipstick and
wipe it clean, insert it back into the
hole (without screwing it in), and
then remove it again to check the
oil level.
1. Spark plug gapSpark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
TIPThe engine oil should be between theminimum and maximum level marks.
5. If the engine oil is at or below the
minimum level mark, remove the
oil filler cap, and then add sufficient
oil of the recommended type to
raise it to the correct level.6. Insert and tighten the engine oil
dipstick, and then install and tight-
en the oil filler cap.
To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Remove cowling A. (See page
6-7.)
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.
4. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
TIPSkip steps 5–7 if the oil filter cartridge isnot being replaced.
5. Remove the oil filter cartridge with
an oil filter wrench.
1. Engine oil dipstick
2. Maximum level mark
3. Minimum level mark
1
2
3
1. Engine oil filler cap
1
1. Engine oil drain bolt
1. Oil filter cartridge
2. Oil filter wrench
1
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
TIPAn oil filter wrench is available at aYamaha dealer.
6. Apply a thin coat of clean engine
oil to the O-ring of the new oil filter
cartridge.TIPMake sure that the O-ring is properlyseated.
7. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
TIPCheck the washer for damage and re-place it if necessary.9. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
TIPBe sure to wipe off spilled oil on any
parts after the engine and exhaust sys-tem have cooled down.NOTICE
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
1. O-ring
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
1
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replace-
ment:
2.50 L (2.64 US qt, 2.20 Imp.qt)
With oil filter cartridge replacement:
2.80 L (2.96 US qt, 2.46 Imp.qt)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-rial enters the crankcase.
10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
TIPAfter the engine is started, the engine
oil level warning light should go off if theoil level is sufficient.
NOTICE
ECA10400
If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha dealercheck the vehicle.
11. Turn the engine off, and then
check the oil level and correct it if
necessary.
12. Install the cowling.
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU47560
To check the coolant level
1. Place the vehicle on the center-
stand.TIP

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to theside can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
TIPThe coolant should be between theminimum and maximum level marks.
1.“CD” specification
2.“ENERGY CONSERVING II”
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6 3. If the coolant is at or below the
minimum level mark, remove the
coolant reservoir breather hose
from the guide, and then remove
the coolant reservoir cap.4. Add coolant to the maximum level
mark, and then install the coolant
reservoir cap. WARNING! Re-
move only the coolant reservoir
cap. Never attempt to remove
the radiator cap when the en-
gine is hot.
[EWA15161]
NOTICE: If
coolant is not available, use dis-
tilled water or soft tap water in-
stead. Do not use hard water or
salt water since it is harmful to
the engine. If water has been
used instead of coolant, replace
it with coolant as soon as possi-
ble, otherwise the cooling sys-
tem will not be protectedagainst frost and corrosion. If
water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
[ECA10472]
5. Route the coolant reservoir breath-
er hose through the guide as
shown.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1 2
3
1. Coolant reservoir cap
2. Coolant reservoir breather hose
3. Guide
3
1
2
Coolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)
1. Coolant reservoir breather hose
2. Guide
2 1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
6
EAU47570
To change the coolant
1. Place the vehicle on the center-
stand.
2. Remove cowlings A and C. (See
page 6-7.)
3. Place a container under the engine
to collect the used coolant.
4. Remove the radiator cap retaining
bolt, radiator cap retainer and radi-
ator cap. WARNING! Never at-
tempt to remove the radiator
cap when the engine is hot.
[EWA10381]
5. Remove the coolant reservoir
breather hose from the guide, and
then remove the coolant reservoir
cap.
6. Remove the coolant reservoir cov-
er and coolant reservoir by remov-
ing the bolts.7. Drain the coolant from the coolant
reservoir by turning it upside down.
8. Remove the coolant drain bolt to
drain the cooling system.
1. Radiator cap
2. Radiator cap retaining bolt
3. Radiator cap retainer
2 2
1 1
3 3
1. Coolant reservoir cap
2. Coolant reservoir breather hose
3. Guide
3
1
2
1. Bolt
2. Coolant reservoir cover
3. Coolant reservoir
1. Coolant drain bolt
23 1
1
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