service YAMAHA XJ600N 2000 Owners Manual

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3-16
INSTRUMENT AND CONTROL FUNCTIONS
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1. Special wrench
HardStan-
dardSoft
Adjusting
position7654 3 21
EAU00315
This shock absorber contains high-
ly pressurized nitrogen gas. Read
and understand the following infor-
mation before handling the shock
absorber. The manufacturer cannot
be held responsible for property
damage or personal injury that may
result from improper handling.
lDo not tamper with or attempt
to open the cylinder assembly.
lDo not subject the shock ab-
sorber to an open flame or other
high heat source. This may
cause the unit to explode due to
excessive gas pressure.
lDo not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
lTake your shock absorber to a
Yamaha dealer for any service.
1. Luggage strap holder (´4)
EAU01398
Luggage strap holders
This motorcycle is equipped with four
luggage strap holders. There is a hold-
er on each passenger footrest bracket
and below each side of the seat.

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6-1
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00464
Periodic inspection, adjustment and lu-
brication will keep your motorcycle in
the safest and most efficient condition
possible. Safety is an obligation of the
motorcycle owner. The maintenance
and lubrication schedule chart should
be considered strictly as a guide to
general maintenance and lubrication
intervals. YOU MUST TAKE INTO
CONSIDERATION THAT WEATHER,
TERRAIN, GEOGRAPHICAL LOCA-
TIONS, AND A VARIETY OF INDIVID-
UAL USES ALL TEND TO DEMAND
THAT EACH OWNER ALTER THIS
TIME SCHEDULE TO SHORTER IN-
TERVALS TO MATCH THE ENVI-
RONMENT. The most important points
of motorcycle inspection, adjustment,
and lubrication are explained in the fol-
lowing pages.
EW000060
If you are not familiar with motor-
cycle service, this work should be
done by a Yamaha dealer.
EAU00462
1. Tool kit
EAU00469
Tool kit
The service information included in this
manual is intended to provide you, the
owner, with the necessary information
for completing some of your own pre-
ventive maintenance and minor re-
pairs. The tools provided in the ownerÕs
tool kit are to assist you in the perfor-
mance of periodic maintenance. How-
ever, some other tools such as a torque
wrench are also necessary to perform
the maintenance correctly.
NOTE:
If you do not have necessary tools re-
quired during a service operation, take
your motorcycle to a Yamaha dealer
for service.
EW000063
Modifications to this motorcycle not
approved by Yamaha may cause
loss of performance, and render it
unsafe for use. Consult a Yamaha
dealer before attempting any chang-
es.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU01792
NOTE:
lThe air filter needs more frequent service if you are riding in unusually wet or dusty areas.
lHydraulic brake system
¥ When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level regularly
and fill as required.
¥ Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
¥ Replace the brake hoses every four years or if cracked or damaged.
21*Carburetors¥ Check engine idling speed, synchronization and starter operation.
¥ Adjust if necessary.ÖÖÖ
22 Engine oil¥ Check oil level and vehicle for oil leakage.
¥ Correct if necessary.
¥ Change. (Warm engine before draining.)ÖÖÖ
23 Engine oil filter cartridge¥ Replace.ÖÖ NO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)

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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00637
Valve clearance adjustment
The correct valve clearance changes
with use, resulting in improper fuel/air
supply or engine noise. To prevent this,
the valve clearance must be adjusted
regularly. This adjustment however,
should be left to a professional
Yamaha service technician.
EAU00647
Tires
To ensure maximum performance,
long service, and safe operation, note
the following:
Tire air pressure
Always check and adjust the tire pres-
sure before operating the motorcycle.
EW000082
Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla-
tion pressure must be adjusted ac-
cording to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if approved
for this model), and vehicle speed.
Maximum load* XJ600S: 184 kg
XJ600N: 187 kg
Cold tire pressure Front Rear
Up to 90 kg*200 kPa
(2.00 kg/cm
2,
2.00 bar)225 kPa
(2.25 kg/cm2,
2.25 bar)
90 kg load ~
Maximum load*200 kPa
(2.00 kg/cm
2,
2.00 bar)250 kPa
(2.50 kg/cm2,
2.50 bar)
High speed riding200 kPa
(2.00 kg/cm
2,
2.00 bar)250 kPa
(2.50 kg/cm2,
2.50 bar)
* Load is the total weight of cargo, rider, passenger
and accessories.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00683
Operating the motorcycle with ex-
cessively worn tires decrease riding
stability and can lead to loss of con-
trol. Have excessively worn tires re-
placed by a Yamaha dealer
immediately. Brakes, tires, and re-
lated wheel parts replacement
should be left to a Yamaha Service
Technician.
EAU00687
Wheels
To ensure maximum performance,
long service, and safe operation, note
the following:
lAlways inspect the wheels before
a ride. Check for cracks, bends, or
warpage of the wheels. If any ab-
normal condition exists in a wheel,
consult a Yamaha dealer. Do not
attempt even small repairs to the
wheel. If a wheel is deformed or
cracked, it must be replaced.
lTires and wheels should be bal-
anced whenever either one is
changed or replaced. Failure to
have a wheel balanced can result
in poor performance, adverse han-
dling characteristics, and short-
ened tire life.
lRide at moderate speeds after
changing a tire since the tire sur-
face must first be broken in for it to
develop its optimal characteristics.
1. Locknut
2. Adjusting bolt
c. Free play
EAU00694
Clutch lever free play
adjustment
The clutch lever free play should be ad-
justed to 2 ~ 3 mm.
1. Loosen the locknut at the clutch le-
ver.
2. Turn the adjusting bolt at the
clutch lever in direction a
to in-
crease free play or in direction b
to decrease free play.
3. Tighten the locknut at the clutch
lever.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00742
Brake fluid replacement
The brake fluid should be replaced only
by trained Yamaha service personnel.
Have the Yamaha dealer replace the
following components during periodic
maintenance or when they are dam-
aged or leaking:
loil seals (every two years)
lbrake hoses (every four years)a. Chain slack
EAU00745
Drive chain slack check
NOTE:
Spin the wheel several times and find
the tightest position of the chain. Check
and/or adjust the chain slack while itÕs
in this tightest position.
Inspect the drive chain when the motor-
cycle is on the centerstand. Check the
slack at the position shown in the illus-
tration. Normal slack is approximately
30 ~ 40 mm. If the slack exceeds
40 mm, adjust.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Axle nut
2. Locknut
3. Adjusting nut
4. Alignment marks
EAU00762
Drive chain slack adjustment
1. Loosen the axle nut.
2. Loosen the locknuts on each side.
To tighten the chain, turn the chain
adjusting nuts in direction a
. To
loosen the chain, turn the adjust-
ing nuts in direction b
and push
the wheel forward. Turn each ad-
justing nut exactly the same
amount to maintain correct axle
alignment. There are marks oneach side of the swingarm. Use
these marks to align the rear
wheel.
EC000096
CAUTION:
Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits.
3. After adjusting, tighten the lock-
nuts. Then tighten the axle nut to
the specified torque.
Tightening torque:
Axle nut:
105 Nm (10.5 mákg)
EAU00769
Drive chain lubrication
The chain consists of many parts which
work with each other. If the chain is not
maintained properly, it will wear out
quickly. Therefore, the chain must be
serviced regularly. This service is es-
pecially necessary when riding in dusty
areas. This motorcycle is equipped
with a sealed type chain. Steam clean-
ing, high-pressure washes, and sol-
vents can damage chain so do not use
these for cleaning it. Use only kerosene
to clean the drive chain. Wipe it dry,
and thoroughly lubricate it with SAE 30
~ 50W motor oil. Do not use any other
lubricants on the drive chain. They may
contain solvents that could damage the
sealed chain.
EC000097
CAUTION:
Be sure to oil the chain after wash-
ing the motorcycle or riding in the
rain.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Speedometer cable
EAU00868
Front wheel removal
EW000122
lIt is advisable to have a Yamaha
dealer service the wheel.
lSecurely support the motor-
cycle so there is no danger of it
falling over.
1. Place the motorcycle on the cen-
terstand.
2. Remove the speedometer cable
from the front wheel side.
3. Remove the calipers.
1. Wheel axle
2. Pinch bolt
NOTE:
Do not depress the brake lever when
the disc and caliper are separated.
4. Loosen the pinch bolt.
5. Remove the wheel axle. Make
sure the motorcycle is properly
supported.
EAU01469
Front wheel installation
1. Install the speedometer gear unit
into the wheel hub. Make sure the
wheel hub and the speedometer
gear unit are installed with the pro-
jections meshed into the slots.
2. Lift up the wheel between the front
fork legs. Make sure the slot in the
speedometer gear unit fits over
the stopper on the front fork outer
tube.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Axle nut
EAU01480
Rear wheel removal
EW000122
lIt is advisable to have a Yamaha
dealer service the wheel.
lSecurely support the motor-
cycle so there is no danger of it
falling over.
1. Place the motorcycle on the cen-
terstand.
2. Remove the axle nut.
1. Brake torque rod bolt
2. Nut
3. Remove the brake torque rod bolt
by removing the nut.
4. While supporting the brake cali-
per, pull out the wheel axle.
5. Push the wheel forward and re-
move the drive chain.
6. Remove the wheel assembly.
NOTE:
lDo not depress the brake pedal
when the disc and caliper are sep-
arated.
lYou do not have to disassemble
the chain in order to remove or in-
stall the rear wheel.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU01468
Rear wheel installation
1. Install the wheel assembly and in-
sert the axle.
2. Install and adjust the drive chain.
(See page 6-20 for details about
adjusting the drive chain slack.)
3. Install the axle nut.
4. Install the caliper and caliper bolts.
Make sure there is enough gap
between the brake pads before in-
stalling the caliper onto the brake
disc.
5. Take the motorcycle off the cen-
terstand.
6. Tighten the axle nut and brake
torque rod bolt to the specified
torques.
Tightening torque:
Axle nut:
105 Nm (10.5 mákg)
Brake torque rod bolt:
23 Nm (2.3 mákg)
EAU01008
Troubleshooting
Although Yamaha motorcycles receive
a rigid inspection before shipment from
the factory, trouble may occur during
operation.
Any problem in the fuel, compression,
or ignition systems can cause poor
starting and loss of power. The trouble-
shooting chart describes a quick, easy
procedure for making checks.
If your motorcycle requires any repair,
bring it to a Yamaha dealer. The skilled
technicians at a Yamaha dealership
have the tools, experience, and know-
how to properly service your motor-
cycle. Use only genuine Yamaha parts
on your motorcycle. Imitation parts may
look like Yamaha parts, but they are of-
ten inferior. Consequently, they have a
shorter service life and can lead to ex-
pensive repair bills.