clutch YAMAHA XJ6-S 2012 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 lights 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 .....................................3-14
Brake lever ...................................3-14
Brake pedal ..................................3-14
ABS ..............................................3-15
Fuel tank cap ................................3-16
Fuel ...............................................3-16
Fuel tank breather hose and
overflow hose ............................3-17
Catalytic converter ........................3-18
Seat ..............................................3-18
Rear view mirrors .........................3-19
Sidecases .....................................3-20
Adjusting the shock absorber
assembly ...................................3-21 Carrier .......................................... 3-22
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 ............................... 6-2
Periodic maintenance chart for the emission control system ....... 6-3
General maintenance and lubrication chart .......................... 6-4
Removing and installing cowlings and panels .................................. 6-8
Checking the spark plugs ............. 6-10
Engine oil and oil filter cartridge ... 6-11
Coolant ......................................... 6-14
Replacing the air filter element ..... 6-18
Adjusting the engine idling
speed ........................................ 6-19 Checking the throttle grip free
play ........................................... 6-20
Valve clearance ........................... 6-20
Tires ............................................. 6-20
Cast wheels ................................. 6-23
Adjusting the clutch lever free play ........................................... 6-23
Checking the brake lever free
play ........................................... 6-24
Brake light switches ..................... 6-25
Checking the front and rear brake pads .......................................... 6-25
Checking the brake fluid level ...... 6-26
Changing the brake fluid .............. 6-27
Drive chain slack .......................... 6-27
Cleaning and lubricating the drive chain ......................................... 6-29
Checking and lubricating the cables ................................. 6-29
Checking and lubricating
the throttle grip and cable ......... 6-30
Checking and lubricating the brake and shift pedals ........ 6-30
Checking and lubricating the brake and clutch levers ...... 6-31
Checking and lubricating the
centerstand and sidestand ....... 6-31
Lubricating the swingarm pivots ........................................ 6-32
Checking the front fork ................. 6-32
Checking the steering .................. 6-33U1PWEAE0.book Page 1 Tuesda y, February 7, 2012 4:21 PM

DESCRIPTION
2-3
2
EAU10430
Controls and instruments
125678
3
4
1. Clutch lever (page 3-13)
2. Left handlebar switches (page 3-12)
3. Main switch/steering lock (page 3-2)
4. Multi-function meter unit (page 3-8)
5. Front brake fluid reservoir (page 6-26)
6. Right handlebar switches (page 3-12)
7. Throttle grip (page 6-20)
8. Brake lever (page 3-14)
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INSTRUMENT AND CONTROL FUNCTIONS
3-13
3
EAU12733
Hazard switch “ ”
With the key in the “ON” or “ ” posi-
tion, use this switch to turn on the haz-
ard lights (simultaneous flashing of all
turn signal lights).
The hazard lights are used in case of
an emergency or to warn other drivers
when your vehicle is stopped where it
might be a traffic hazard.NOTICE
ECA10061
Do not use the hazard lights for an
extended length of time with the en-
gine not running, otherwise the bat-
tery may discharge.
EAU52080
Siren switch “OFF/SIREN”
The siren sounds continuously when
the siren switch is in the “SIREN” posi-
tion. The siren can be used only when
the main switch is in the “ON” position.
EAU52160
Patrol switch “S/M/P/OFF”
With the key in the “ON” position, use
this switch to turn on the patrol lights.The following table indicates which ac-
cessories are enabled when the patrol
switch is turned to the “P”, “M” or “S” po-
sition.
EAU12820
Clutch lever The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-23.)
Accessory
Patrol light
Flasher light
Siren
Position
OFF P M S
1. Clutch lever
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INSTRUMENT AND CONTROL FUNCTIONS
3-14
3
EAU12871
Shift pedal The shift pedal is located on the left
side of the motorcycle and is used in
combination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU26824
Brake lever The brake lever is located on the right
side of the handlebar. To apply the front
brake, pull the lever toward the throttle
grip.
The brake lever is equipped with a
brake lever position adjusting dial. To
adjust the distance between the brake
lever and the throttle grip, turn the ad-
justing dial while holding the lever
pushed away from the throttle grip.
Make sure that the appropriate setting
on the adjusting dial is aligned with
the “ ” mark on the brake lever.
EAU12941
Brake pedal The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
1. Shift pedal
1
1. Brake lever
2. Brake lever position adjusting dial
3. “ ” mark
4. Distance between brake lever and throttle grip
1. Brake pedal
1
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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
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
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INSTRUMENT AND CONTROL FUNCTIONS
3-24
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.
YES NO YES NO YES NO
The neutral switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.The sidestand switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.• The vehicle must be placed on the center-
stand during this inspection.• If a malfunction is noted, have a Yamaha
dealer check the system before riding.
WARNING
”.
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
Rear brake Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add specified brake fluid to specified level.
Check hydraulic system for leakage. 6-25, 6-26
Clutch Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
6-23
Throttle grip Make sure that operation is smooth.
Check throttle grip free play.
If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable
and grip housing. 6-20, 6-30
Control cables Make sure that operation is smooth.
Lubricate if necessary. 6-29
Drive chain Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
6-27, 6-29
Wheels and tires Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
6-20, 6-23
Brake and shift pedals Make sure that operation is smooth.
Lubricate pedal pivoting points if necessary. 6-30
Brake and clutch levers Make sure that operation is smooth.
Lubricate lever pivoting points if necessary.
6-31
Centerstand, sidestand Make sure that operation is smooth.
Lubricate pivots if necessary.
6-31
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 accident
or 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 and
to restart the engine.
EAU43125
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
sidestand 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
●
Immobilizer system indicator
light
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OPERATION AND IMPORTANT RIDING POINTS
5-2
5
NOTICE
ECA11833
If a warning or indicator light does
not come on initially when the key is
turned to “ON”, or if a warning or in-
dicator light remains on, see page
3-4 for the corresponding warning
and indicator light circuit check.2. Shift the transmission into the neu-tral position. The neutral indicator
light should come on. If not, ask a
Yamaha dealer to check the elec-
trical circuit.
3. Start the engine by pushing the start switch.
If the engine fails to start, release
the start switch, wait a few sec-
onds, and then try again. Each
starting attempt should be as short
as possible to preserve the bat-
tery. Do not crank the engine more
than 10 seconds on any one at-
tempt.NOTICE
ECA11042
For maximum engine life, never ac-
celerate hard when the engine is
cold!
EAU16671
Shifting Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.TIPTo shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
NOTICE
ECA10260
●
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
●
Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
1. Shift pedal
2. Neutral position
1
N
2 3
4
5
6
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770E
General maintenance and lubrication chart NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
1 Air filter element Replace. √
2Clutch Check operation.
Adjust.
√√√√√
3 *Front brake Check operation, fluid level and
vehicle for fluid leakage. √√√√√√
Replace brake pads. Whenever worn to the limit
4 *Rear brake Check operation, fluid level and
vehicle for fluid leakage. √√√√√√
Replace brake pads. Whenever worn to the limit
5 *Brake hoses Check for cracks or damage.
Check for correct routing and
clamping. √√√√√
Replace. Every 4 years
6 *Wheels Check runout and for damage. √√√√
7 *Tires Check tread depth and for dam-
age.
Replace if necessary.
Check air pressure.
Correct if necessary. √√√√√
8 *Wheel bearings Check bearing for looseness or
damage. √√√√
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