YAMAHA XJ600S 2000 Workshop Manual

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11*Wheel bearings¥ Check bearing for looseness or damage.
¥ Replace if necessary. ÖÖ
12
*Swingarm¥ Check swingarm pivoting point for play.
¥ Correct if necessary.
¥ Lubricate with molybdenum disulfide grease every 24,000 km or
24 months (whichever comes first).ÖÖ
13 Drive chain¥ Check chain slack.
¥ Adjust if necessary. Make sure that the rear wheel is properly
aligned.
¥ Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in rain.
14
*Steering bearings¥ Check bearing play and steering for roughness.
¥ Correct accordingly.
¥ Lubricate with lithium soap base grease every 24,000 km or
24 months (whichever comes first).ÖÖ
15
*Chassis fasteners¥ Make sure that all nuts, bolts and screws are properly tightened.
¥ Tighten if necessary.ÖÖ
16 Sidestand/centerstand¥ Check operation.
¥ Lubricate and repair if necessary.ÖÖ
17
*Sidestand switch¥ Check operation.
¥ Replace if necessary.ÖÖÖ
18
*Front fork¥ Check operation and for oil leakage.
¥ Correct accordingly.ÖÖ
19
*Rear shock absorber
assembly¥ Check operation and shock absorber for oil leakage.
¥ Replace shock absorber assembly if necessary. ÖÖ
20
*
Rear shock absorber
assembly pivoting
points¥ Check operation.
¥ Lubricate with molybdenum disulfide grease every 24,000 km or
24 months (whichever comes first).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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* 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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1. Panel A
EAU01777
Panel removal and installation
The panel illustrated needs to be re-
moved to perform some of the mainte-
nance described in this chapter. Refer
to this section each time the panel has
to be removed or installed.
1. Screw (´ 2)
EAU02926
Panel A
To remove
1. Remove the seat. (See page 3-14
for seat removal and installation
procedures.)
2. Remove the screws and slide it as
shown to unhook it.

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To install
1. Place in the original position and
install the screws.
2. Install the seat.
a. Spark plug gap
EAU01880
Spark plug inspection
The spark plug is an important engine
component and should be inspected
periodically, preferably by a Yamaha
dealer. The condition of the spark plug
can indicate the condition of the en-
gine.
Normally, all spark plugs from the
same engine should have the same
color on the white insulator around the
center electrode. The ideal color at this
point is a medium-to-light tan color for a
motorcycle that is being ridden normal-
ly. If one spark plug shows a distinctly
different color, there could be some-
thing wrong with the engine.Do not attempt to diagnose such prob-
lems yourself. Instead, take the motor-
cycle to a Yamaha dealer. The spark
plugs should be periodically removed
and inspected because heat and de-
posits will cause any spark plug to
slowly break down and erode. If elec-
trode erosion becomes excessive, or if
carbon and other deposits are exces-
sive, the spark plug should be replaced
with the specified plug.
Before installing any spark plug, mea-
sure the electrode gap with a wire
thickness gauge and adjust it to speci-
fication.Specified spark plug:
CR8E (NGK) or
U24ESR-N(DENSO)
Spark plug gap:
0.7 ~ 0.8 mm

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When installing a spark plug, the gas-
ket surface should always be cleaned
and a new gasket used. Any grime
should be wiped off from the threads
and the spark plug tightened to the
specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4 to 1/2 turn
past finger tight. The spark plug should
be tightened to the specified torque as
soon as possible.Tightening torque:
Spark plug:
12.5 Nm (1.25 mákg)
1. Level window
2. Maximum level mark
3. Minimum level mark
EAU02938
Engine oil
Oil level inspection
1. Place the motorcycle on the cen-
terstand. Warm up the engine for
several minutes.
NOTE:
Be sure the motorcycle is positioned
straight up when checking the oil level.
A slight tilt toward the side can result in
false readings.
1. Engine oil filler cap
2. With the engine stopped, check
the oil level through the level win-
dow located at the lower part of
the right side crankcase cover.
NOTE:
Wait a few minutes until the oil level
settles before checking.
3. The oil level should be between
the maximum and minimum
marks. If the level is low, fill the en-
gine with sufficient oil to reach the
specified level.

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1. Engine oil drain bolt
Engine oil and oil filter cartridge re-
placement
1. Warm up the engine for several
minutes.
2. Stop the engine. Place an oil pan
under the engine and remove the
oil filler cap.
3. Remove the drain bolt and drain
the oil.
1. Oil filter cartridge
2. Oil filter wrench
4. Remove the oil filter by using an oil
filter wrench.
NOTE:
An oil filter wrench is available at a
nearby Yamaha dealer.
5. Install the drain bolt and tighten it
to the specified torque.
Tightening torque:
Drain bolt:
43 Nm (4.3 mákg)
1. O-ring
6. Apply a light coat of engine oil to
the O-ring of the new oil filter.
NOTE:
Make sure the O-ring is seated proper-
ly.

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1. Torque wrench
7. Install the new oil filter and tighten
it to the specified torque with an oil
filter wrench.
NOTE:
When installing the oil filter, tighten it to
the proper torque by using a torque
wrench.
Tightening torque:
Oil filter:
17 Nm (1.7 mákg)
8. Fill the engine with sufficient oil to
reach the specified level. Install
the oil filler cap and tighten it.
EC000066
CAUTION:
lDo not put in any chemical addi-
tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
lBe sure no foreign material en-
ters the crankcase. Recommended oil:
See page 8-1.
Oil quantity:
Total amount:
3.1 L
Periodic oil change:
2.3 L
With oil filter replacement:
2.6 L
9. Start the engine and warm it up for
several minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for the
cause.
NOTE:
After the engine is started, the oil level
indicator light should go off if the oil is at
the specified level.
EC000067
CAUTION:
If the indicator light flickers or re-
mains on, immediately stop the en-
gine and consult with a Yamaha
dealer.

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1. Screw
EAU02928
Air filter
The air filter should be cleaned at the
specified intervals. It should be cleaned
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seat. (See page 3-14
for seat removal and installation
procedures.)
2. Turn the fuel cock lever to ÒONÓ.
Then, remove the fuel cock lever
by removing the screw.
1. Fuel hose
2. Vacuum hose
3. Drain hose
3. Disconnect the hoses.
4. Remove the fuel tank.

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1. Screw (´ 4)
5. Remove the air filter case cover by
removing the screws.
6. Pull out the air filter.7. Tap the air filter lightly to remove
most of the dust and dirt. Blow out
the remaining dirt with com-
pressed air as shown. If the air fil-
ter is damaged, replace it.
8. Reassemble by reversing the re-
moval procedure.
EC000082
CAUTION:
lMake sure the air filter is prop-
erly seated in the air filter case.
lThe engine should never be run
without the air filter installed.
Excessive piston and/or cylin-
der wear may result.
EAU00630
Carburetor adjustment
The carburetors are important parts of
the engine and require very sophisti-
cated adjustment. Most adjustments
should be left to a Yamaha dealer who
has the professional knowledge and
experience to do so. However, the idle
speed may be adjusted by the owner
as part of routine maintenance.
EC000095
CAUTION:
The carburetors were set at the
Yamaha factory after many tests. If
they are changed, poor engine per-
formance and damage may result.

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1. Throttle stop screw
EAU00632
Idle speed adjustment
1. Start the engine and warm it up for
a few minutes at approximately
1,000 to 2,000 r/min. Occasionally
rev the engine to 4,000 to
5,000 r/min. The engine is warm
when it quickly responds to the
throttle.
2. Set the idle to the specified engine
speed by adjusting the throttle
stop screw. Turn the screw in di-
rectiona
to increase engine
speed and in direction b
to de-
crease engine speed.
NOTE:
If the specified idle speed cannot be
obtained by performing the above ad-
justment, consult a Yamaha dealer.Standard idle speed:
1,200 ~ 1,300 r/min
a. Free play
EAU00635
Throttle cable free play
inspection
There should be a free play of 3 ~
5 mm at the throttle grip. If the free play
is incorrect, ask a Yamaha dealer to
make this adjustment.