brake YAMAHA XJ600S 2000 Owners Manual

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2-2
DESCRIPTION
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Right view (XJ600S)
8. Tail/brake light (page 6-17)
9. Storage compartment (page 3-15)
10. Seat (page 3-14)
11. Fuel tank (page 3-11)
12. Headlight (page 6-27)
13. Rear brake pedal (page 3-11)

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2-3
DESCRIPTION
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/E-2.frame
Controls/Instruments (XJ600S)
14. Clutch lever (page 3-9)
15. Left handlebar switches (page 3-7)
16. Starter (choke) Ò Ó (page 3-14)
17. Speedometer (page 3-6)
18. Tachometer (page 3-7)
19. Right handlebar switches (page 3-9)
20. Front brake lever (page 3-10)
21. Throttle grip (page 6-12)
22. Main switch (page 3-1)

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2-5
DESCRIPTION
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/E-2.frame
Right view (XJ600N)
9. Tail/brake light (page 6-17)
10. Storage compartment (page 3-15)
11. Seat (page 3-14)
12. Fuel tank (page 3-11)
13. Headlight (page 6-27)
14. Rear brake pedal (page 3-11)

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2-6
DESCRIPTION
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/E-2.frame
Controls/Instruments (XJ600N)
15. Clutch lever (page 3-9)
16. Left handlebar switches (page 3-7)
17. Starter (choke) Ò Ó (page 3-14)
18. Speedometer (page 3-6)
19. Tachometer (page 3-7)
20. Right handlebar switches (page 3-9)
21. Front brake lever (page 3-10)
22. Throttle grip (page 6-12)
23. Main switch (page 3-1)

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INSTRUMENT AND CONTROL FUNCTIONS
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Main switch ......................................................... 3-1
Steering lock (for XJ600N) ................................ 3-3
Indicator lights .................................................... 3-3
Oil level indicator circuit check ........................... 3-5
Speedometer (for XJ600S) ................................. 3-6
Speedometer (for XJ600N) ................................ 3-6
Tachometer ........................................................ 3-7
Handlebar switches ............................................ 3-7
Clutch lever ........................................................ 3-9
Shift pedal ........................................................ 3-10
Front brake lever .............................................. 3-10
Rear brake pedal .............................................. 3-11Fuel tank cap .................................................... 3-11
Fuel ................................................................... 3-12
Fuel tank breather hose (for Germany only) ..... 3-12
Fuel cock........................................................... 3-13
Starter (choke) Ò Ó ......................................... 3-14
Seat................................................................... 3-14
Helmet holders .................................................. 3-15
Storage compartment ....................................... 3-15
Rear shock absorber adjustment ...................... 3-15
Luggage strap holders ...................................... 3-16
Sidestand .......................................................... 3-17
Sidestand/clutch switch operation check .......... 3-17

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3-10
INSTRUMENT AND CONTROL FUNCTIONS
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1. Shift pedal
EAU00157
Shift pedal
This motorcycle is equipped with a con-
stant-mesh 6-speed transmission.
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch when shifting.
1. Front brake lever
2. Position adjusting nut
EAU00160
Front brake lever
The front brake lever is located on the
right handlebar and is equipped with a
position adjuster. To activate the front
brake, pull the lever toward the handle-
bar.
1. Position adjusting nut
2. Proper position
To adjust the front brake lever position,
turn the adjusting nut while pulling the
lever forward. Make sure the mark Ò Ó
on the adjusting nut is aligned with the
mark Ò Ó on the lever.

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3-11
INSTRUMENT AND CONTROL FUNCTIONS
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1. Rear brake pedal
EAU00162
Rear brake pedal
The rear brake pedal is on the right
side of the motorcycle. Press down on
the brake pedal to apply the rear brake.
1. Lock cover
2. Open
EAU02935
Fuel tank cap
To open
Open the lock cover. Insert the key and
turn it 1/4 turn clockwise. The lock will
be released and the cap can be
opened.
To close
Push the tank cap into position with the
key inserted. To remove the key, turn it
counterclockwise to the original posi-
tion. Then, close the lock cover.
NOTE:
This tank cap cannot be closed unless
the key is in the lock. The key cannot
be removed if the cap is not locked
properly.
EW000023
Be sure the cap is properly installed
and locked in place before riding the
motorcycle.

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4-1
PRE-OPERATION CHECKS
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Owners are personally responsible for their vehicleÕs condition. Your motorcycleÕs vital functions can start to deteriorate
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or
loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual in-
spection, you check the following points before each ride.
EAU00340
PRE-OPERATION CHECK LIST
ITEM CHECKS PAGE
Front brake
¥ Check operation, fluid level and fluid leakage.
¥ Fill with DOT 4 (or DOT 3) brake fluid if necessary.6-18 ~ 6-20
Rear brake6-17 ~ 6-20
Clutch¥ Check operation, condition and free play.
¥ Adjust if necessary.6-15 ~ 6-16
Throttle grip and housing¥ Check for smooth operation.
¥ Lubricate if necessary.6-12, 6-22
Engine oil¥ Check oil level.
¥ Fill with oil if necessary.6-7 ~ 6-9
Drive chain¥ Check chain slack and condition.
¥ Adjust if necessary.6-20 ~ 6-21
Wheels and tires¥ Check tire pressure, wear and damage.6-13 ~ 6-15,
6-31 ~ 6-34
Control and meter cables¥ Check for smooth operation.
¥ Lubricate if necessary.6-22
Brake and shift pedal
shafts¥ Check for smooth operation.
¥ Lubricate if necessary.6-22
Brake and clutch lever
pivots¥ Check for smooth operation.
¥ Lubricate if necessary.6-23
Center and sidestand
pivots¥ Check for smooth operation.
¥ Lubricate if necessary.6-23
EAU01114

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PERIODIC MAINTENANCE AND MINOR REPAIR
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Tool kit ................................................................ 6-1
Periodic maintenance and lubrication................. 6-2
Panel removal and installation ........................... 6-5
Panel A ............................................................... 6-5
Spark plug inspection ......................................... 6-6
Engine oil............................................................ 6-7
Air filter ............................................................. 6-10
Carburetor adjustment ...................................... 6-11
Idle speed adjustment ...................................... 6-12
Throttle cable free play inspection .................... 6-12
Valve clearance adjustment ............................. 6-13
Tires ................................................................. 6-13
Wheels ............................................................. 6-15
Clutch lever free play adjustment ..................... 6-15
Rear brake pedal height adjustment ................ 6-17
Brake light switch adjustment ........................... 6-17
Checking the front and rear brake pads ........... 6-18
Inspecting the brake fluid level ......................... 6-19
Brake fluid replacement .................................... 6-20
Drive chain slack check .................................... 6-20
Drive chain slack adjustment ............................ 6-21Drive chain lubrication....................................... 6-21
Cable inspection and lubrication ....................... 6-22
Throttle cable and grip lubrication ..................... 6-22
Brake and shift pedal lubrication ....................... 6-22
Brake and clutch lever lubrication ..................... 6-23
Center and sidestand lubrication ...................... 6-23
Rear suspension lubrication.............................. 6-23
Front fork inspection ......................................... 6-24
Steering inspection ........................................... 6-24
Wheel bearings ................................................. 6-25
Battery............................................................... 6-25
Fuse replacement ............................................. 6-26
Headlight bulb replacement (for XJ600S) ......... 6-27
Headlight bulb replacement (for XJ600N) ......... 6-29
Front wheel removal ......................................... 6-31
Front wheel installation ..................................... 6-31
Rear wheel removal .......................................... 6-33
Rear wheel installation ...................................... 6-34
Troubleshooting ................................................ 6-34
Troubleshooting chart ....................................... 6-35

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6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
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)
1
*Fuel line ¥ Check fuel hoses and vacuum hose for cracks or damage.
¥ Replace if necessary.ÖÖ
2
*Fuel filter¥ Check condition.
¥ Replace if necessary.Ö
3 Spark plugs¥ Check condition.
¥ Clean, regap or replace if necessary.ÖÖÖ
4
*Valves¥ Check valve clearance.
¥ Adjust if necessary.Every 24,000 km or 24 months
(whichever comes first)
5 Air filter¥ Clean or replace if necessary.ÖÖ
6Clutch¥ Check operation.
¥ Adjust or replace cable.ÖÖÖ
7
*Front brake¥ Check operation, fluid level and vehicle for fluid leakage. (See NOTE
on page 6-4.)
¥ Correct accordingly.
¥ Replace brake pads if necessary.ÖÖÖ
8
*Rear brake¥ Check operation, fluid level and vehicle for fluid leakage. (See NOTE
on page 6-4.)
¥ Correct accordingly.
¥ Replace brake pads if necessary.ÖÖÖ
9
*Wheels¥ Check balance, runout and for damage.
¥ Rebalance or replace if necessary.ÖÖ
10
*Tires¥ Check tread depth and for damage.
¥ Replace if necessary.
¥ Check air pressure.
¥ Correct if necessary.ÖÖ