brake YAMAHA XJ600S 2001 Owners Manual

DESCRIPTION
2-2
2
Right view (XJ600S)8. Tail/brake light
9. Storage compartment (page 3-13)
10. Seat (page 3-12)
11. Fuel tank (page 3-9)
12. Headlight (page 6-30)
13. Brake pedal (page 3-9)
E_4br.book Page 2 Thursday, August 17, 2000 11:29 AM

DESCRIPTION
2-3
2
Controls and instruments (XJ600S)14. Clutch lever (page 3-7)
15. Left handlebar switches (page 3-6)
16. Starter (choke) lever (page 3-12)
17. Speedometer unit (page 3-4)
18. Tachometer (page 3-5)
19. Right handlebar switches (page 3-7)
20. Brake lever (page 3-8)
21. Throttle grip (page 6-13)
22. Main switch/steering lock (page 3-1)E_4br.book Page 3 Thursday, August 17, 2000 11:29 AM

DESCRIPTION
2-5
2
Right view (XJ600N)9. Tail/brake light
10. Storage compartment (page 3-13)
11. Seat (page 3-12)
12. Fuel tank (page 3-9)
13. Headlight (page 6-30)
14. Brake pedal (page 3-9)
E_4br.book Page 5 Thursday, August 17, 2000 11:29 AM

DESCRIPTION
2-6
2
Controls and instruments (XJ600N)15. Clutch lever (page 3-7)
16. Left handlebar switches (page 3-6)
17. Starter (choke) lever (page 3-12)
18. Speedometer unit (page 3-5)
19. Tachometer (page 3-5)
20. Right handlebar switches (page 3-7)
21. Brake lever (page 3-8)
22. Throttle grip (page 6-13)
23. Main switch (page 3-1)
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3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock ..................................... 3-1
Steering lock (for XJ600N).................................... 3-3
Indicator lights ..................................................... 3-3
Speedometer unit (for XJ600S) ........................... 3-4
Speedometer unit (for XJ600N) ........................... 3-5
Tachometer .......................................................... 3-5
Handlebar switches ............................................. 3-6
Clutch lever .......................................................... 3-7
Shift pedal ............................................................ 3-8
Brake lever .......................................................... 3-8
Brake pedal .......................................................... 3-9
Fuel tank cap ....................................................... 3-9Fuel ................................................................... 3-10
Fuel tank breather hose (for Germany only) ..... 3-10
Fuel cock ........................................................... 3-11
Starter (choke) lever .......................................... 3-12
Seat ................................................................... 3-12
Helmet holders .................................................. 3-13
Storage compartment ....................................... 3-13
Adjusting the shock absorber assembly ............ 3-14
Luggage strap holders ...................................... 3-15
Sidestand .......................................................... 3-15
Ignition circuit cut-off system ............................. 3-16
E_4br.book Page 1 Thursday, August 17, 2000 11:29 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-8
3
EAU00157
Shift pedal The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU00160
Brake lever The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.The brake lever is equipped with a po-
sition adjusting nut. To adjust the dis-
tance between the brake lever and the
handlebar grip, turn the adjusting nut
while holding the lever pushed away
from the handlebar grip. Make sure that
the mark “ ” on the adjusting nut is
aligned with the mark “ ” on the brake
lever.
1. Shift pedal
1. Brake lever
2. Position adjusting nut
1. Brake lever position adjusting nut
2. Properly aligned marks
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INSTRUMENT AND CONTROL FUNCTIONS
3-9
3
EAU00162
Brake pedal The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU02935
Fuel tank cap To open the fuel tank cap
Open the fuel tank cap lock cover, in-
sert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be re-
leased and the fuel tank cap can be
opened.
To close the fuel tank cap
1. Push the fuel tank cap into position
with the key inserted in the lock.
2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
NOTE:@ The fuel tank cap cannot be closed un-
less the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked. @
EWA00025
WARNING
@ Make sure that the fuel tank cap is
properly closed before riding. @
1. Brake pedal
1. Fuel tank cap lock cover
2. Unlock.
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4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03328
Pre-operation check list
ITEM CHECKS PAGE
Front brake
• Check operation, fluid level and fluid leakage.
• Fill with DOT 4 brake fluid if necessary.6-19–6-21
Rear brake6-18–6-21
Clutch• Check operation, condition and free play.
• Adjust if necessary.6-17–6-18
Throttle grip and housing• Check smooth operation.
• Lubricate if necessary.6-13, 6-24
Engine oil• Check oil level.
• Fill with oil if necessary.6-7–6-10
Drive chain• Check chain slack and condition.
• Adjust if necessary.6-21–6-23
Wheels and tires• Check tire pressure, wear and damage.6-14–6-17,
6-33–6-36
Control and meter cables• Check smooth operation.
• Lubricate if necessary.6-23
Brake and shift pedal
shafts• Check smooth operation.
• Lubricate if necessary.6-24
Brake and clutch lever
pivots• Check smooth operation.
• Lubricate if necessary.6-25
Center and sidestand
pivots• Check smooth operation.
• Lubricate if necessary.6-25
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing the panel ....................... 6-5
Checking the spark plugs .................................... 6-6
Engine oil and oil filter cartridge .......................... 6-7
Cleaning the air filter element ............................ 6-10
Adjusting the carburetors ................................... 6-12
Adjusting the engine idling speed ...................... 6-13
Adjusting the throttle cable free play .................. 6-13
Adjusting the valve clearance ............................ 6-14
Tires ................................................................... 6-14
Wheels ............................................................... 6-17
Adjusting the clutch lever free play .................... 6-17
Adjusting the brake pedal position ..................... 6-18
Adjusting the rear brake light switch .................. 6-19
Checking the front and rear brake pads ............. 6-19
Checking the brake fluid level ............................ 6-20
Changing the brake fluid .................................... 6-21
Drive chain slack ................................................ 6-21
Lubricating the drive chain ................................. 6-23
Checking and lubricating the cables .................. 6-23Checking and lubricating the throttle grip and
cable ............................................................... 6-24
Checking and lubricating the brake and
shift pedals ...................................................... 6-24
Checking and lubricating the brake and
clutch levers .................................................... 6-25
Checking and lubricating the centerstand and
sidestand ......................................................... 6-25
Lubricating the rear suspension ........................ 6-25
Checking the front fork ...................................... 6-26
Checking the steering ....................................... 6-26
Checking the wheel bearings ............................ 6-27
Battery ............................................................... 6-27
Replacing the fuses .......................................... 6-29
Replacing a headlight bulb (for XJ600S) ............ 6-30
Replacing the headlight bulb (for XJ600N) ........ 6-31
Front wheel ....................................................... 6-33
Rear wheel ........................................................ 6-35
Troubleshooting ................................................. 6-36
Troubleshooting chart ........................................ 6-37
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03540
Periodic maintenance and lubrication chart
NOTE:l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
CP-01ECP-01ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
Annual
check
1 10203040
1
*Fuel line• Check fuel hoses and vacuum hose for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
• Replace.ÖÖ
4*Valves• Check valve clearance.
•Adjust.Every 20,000 km
5 Air filter element•Clean.ÖÖ
• Replace.ÖÖ
6Clutch• Check operation.
•Adjust.ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
9*Brake hoses• Check for cracks or damage.ÖÖÖÖ Ö
• Replace. (See NOTE on page 6-4.) Every 4 years
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