brake YAMAHA XJ600S 2002 Owner's Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2002, Model line: XJ600S, Model: YAMAHA XJ600S 2002Pages: 104, PDF Size: 4.56 MB
Page 80 of 104
PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU00868
Front wheel To remove the front wheel
EW000122
WARNING
@
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor-
cycle so that there is no danger
of it falling over.
@1. Place the motorcycle on the cen-
terstand.
2. Disconnect the speedometer ca-
ble from the front wheel.
3. Remove the brake calipers by re-
moving the bolts.
ECA00047
CAUTION:@ Do not pull the brake lever after the
brake caliper has been removed,
otherwise the brake pads will be
forced shut. @4. Loosen the front wheel axle pinch
bolt.
5. Pull the wheel axle out, and then
remove the wheel.
EAU04164
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
2. Lift the wheel up between the fork
legs.NOTE:_ Make sure that the slot in the speedom-
eter gear unit fits over the retainer on
the fork leg. _3. Insert the wheel axle.
4. Take the motorcycle off the cen-
terstand so that the front wheel is
on the ground.
1. Speedometer cable
1. Front wheel axle
2. Front wheel axle pinch bolt
E_4br.book Page 33 Wednesday, July 25, 2001 1:40 PM
Page 81 of 104
PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6 5. Install the brake calipers by install-
ing the bolts.
NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs. _6. Tighten the wheel axle, then the
front wheel axle pinch bolt, and the
brake caliper bolts to the specified
torques.7. Connect the speedometer cable.
8. Push down hard on the handlebar
several times to check for proper
fork operation.
Tightening torques:
Wheel axle:
58 Nm (5.8 m·kgf)
Front wheel axle pinch bolt:
40 Nm (4.0 m·kgf)
Brake caliper bolt:
19 Nm (1.9 m·kgf)
E_4br.book Page 34 Wednesday, July 25, 2001 1:40 PM
Page 82 of 104
PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
EAU01480
Rear wheel To remove the rear wheel
EW000122
WARNING
@
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor-
cycle so that there is no danger
of it falling over.
@1. Place the motorcycle on the
centerstand.
2. Remove the axle nut.3. Disconnect the brake torque rod
from the brake caliper bracket by
removing the nut and the bolt.4. While supporting the brake caliper
bracket, pull the wheel axle out.
5. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:@ The drive chain does not need to be
disassembled in order to remove and
install the rear wheel. @6. Remove the wheel.
ECA00048
CAUTION:@ Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut. @
1. Rear wheel axle nut
1. Brake torque rod bolt
2. Nut
E_4br.book Page 35 Wednesday, July 25, 2001 1:40 PM
Page 83 of 104
PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6
EAU01468
To install the rear wheel
1. Insert the wheel axle from the
right-hand side.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-21 for
drive chain slack adjustment pro-
cedures.)
3. Install the axle nut and brake
torque rod bolt at the brake caliper
bracket.
4. Install the brake caliper by install-
ing the bolts.NOTE:@ Make sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brake
disc. @5. Take the motorcycle off the cen-
terstand so that the rear wheel is
on the ground.
6. Tighten the axle nut and brake
torque rod bolt to the specified
torques.
EAU01008
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills. Tightening torques:
Axle nut:
105 Nm (10.5 m·kgf)
Brake torque rod bolt:
23 Nm (2.3 m·kgf)
E_4br.book Page 36 Wednesday, July 25, 2001 1:40 PM
Page 87 of 104
MOTORCYCLE CARE AND STORAGE
7-2
7
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments, switch-
es and lights), breather hoses
and vents.
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it does
not leave any marks. If the wind-
shield is scratched, use a quali-
ty plastic polishing compound
after washing.
@After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.After riding in the rain, near the sea or
on salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:@ Salt sprayed on roads in the winter may
remain well into spring. @1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
CAUTION:@ Do not use warm water since it in-
creases the corrosive action of the
salt. @2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick-
el-plated, surfaces to prevent cor-
rosion.
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM
Page 88 of 104
MOTORCYCLE CARE AND STORAGE
7-3
7After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
EWA00001
WARNING
@
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.
Before operating the motor-
cycle test its braking perfor-
mance and cornering behavior.
@
ECA00013
CAUTION:@
Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing
compounds as they will wear
away the paint.
@NOTE:@ Consult a Yamaha dealer for advice on
what products to use. @
E_4br.book Page 3 Wednesday, July 25, 2001 1:40 PM
Page 94 of 104
SPECIFICATIONS
8-3
8
Maximum load*
XJ600S 184 kg
XJ600N 187 kg
Tire air pressure (measured on
cold tires)
Up to 90 kg*
Front 200 kPa (2.00 kgf/cm
2, 2.00 bar)
Rear 225 kPa (2.25 kgf/cm2, 2.25 bar)
90 kg–maximum*
Front 200 kPa (2.00 kgf/cm2, 2.00 bar)
Rear 250 kPa (2.50 kgf/cm2, 2.50 bar)
High-speed riding
Front 200 kPa (2.00 kgf/cm2, 2.00 bar)
Rear 250 kPa (2.50 kgf/cm2, 2.50 bar)
* Total weight of rider, passenger, cargo and accessories
Wheels
Front
Type Cast wheel
Size 17 × MT 2.50
Rear
Type Cast wheel
Size 18 × MT 3.50Brakes
Front
Type Dual disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Single disc brake
Operation Right foot
Fluid DOT 4
Suspension
Front Telescopic fork
Rear Swingarm (monocross suspen-
sion)
Spring/shock absorbers
Front Coil spring / oil damper
Rear Coil spring / gas-oil damper
Wheel travel
Front 140 mm
Rear 110 mm
Electrical systems
Ignition system Transistorized coil ignition
E_4br.book Page 3 Wednesday, July 25, 2001 1:40 PM
Page 95 of 104
SPECIFICATIONS
8-4
8
Charging system
Type A.C. magneto
Standard output 14 V, 20 A @ 5,000 r/min
Battery
Model YTX9-BS
Voltage, capacity 12 V, 8 Ah
Headlight typeQuar tz bulb (halogen)
Bulb voltage, wattage × quantity
Headlight 12 V, 60/55 W × 1
Auxiliary light 12 V, 4 W × 1 (except for GB,
IRL)
12 V, 3.4 W × 1 (for GB, IRL)
Tail/brake light 12 V, 5/21 W × 1
Turn signal light 12 V, 21 W × 4
Meter lighting
XJ600S 12 V, 1.7 W × 3
XJ600N 14 V, 3 W × 2
12 V, 1.7 W × 2
Neutral indicator light 12 V, 3.4 W × 1
High beam indicator light 12 V, 3.4 W × 1
Oil level warning light
XJ600S 12 V, 3.4 W × 1
XJ600N 14 V, 3 W × 1
Turn signal indicator light 12 V, 3.4 W × 2Fuses
Main fuse 30 A
Ignition fuse 10 A
Signaling system fuse 15 A
Headlight fuse 15 A
Hazard fuse 10 A
E_4br.book Page 4 Wednesday, July 25, 2001 1:40 PM
Page 100 of 104
10-INDEXAAir filter element, cleaning ...................... 6-10BBattery ................................................... 6-27
Brake and clutch levers, checking and
lubricating ............................................ 6-25
Brake and shift pedals, checking and
lubricating ............................................ 6-24
Brake fluid, changing ............................. 6-21
Brake fluid level, checking...................... 6-20
Brake lever...............................................3-8
Brake light switch (rear), adjusting ......... 6-19
Brake pads, checking............................. 6-19
Brake pedal..............................................3-9
Brake pedal position, adjusting .............. 6-18CCables, checking and lubricating............ 6-23
Carburetors, adjusting............................ 6-12
Care.........................................................7-1
Centerstand and sidestand,
checking and lubricating ...................... 6-25
Clutch lever ..............................................3-7
Clutch lever free play, adjusting ............. 6-17
Conversion table ......................................8-5
DDimmer switch ......................................... 3-6
Drive chain, lubricating .......................... 6-23
Drive chain slack ................................... 6-21
Checking .......................................... 6-21
Adjusting .......................................... 6-22EEngine break-in ....................................... 5-4
Engine oil and oil filter cartridge ............... 6-7
Engine stop switch................................... 3-7FFront fork, checking ............................... 6-26
Fuel ....................................................... 3-10
Fuel cock ............................................... 3-11
Fuel consumption, tips for reducing ......... 5-4
Fuel tank breather hose
(Germany only) ................................... 3-11
Fuel tank cap ........................................... 3-9
Fuses, replacing .................................... 6-29HHandlebar switches ................................. 3-6
Hazard switch .......................................... 3-6
Headlight bulb, replacing (for XJ600S)... 6-30
Headlight bulb, replacing (for XJ600N) .. 6-31
Helmet holders ...................................... 3-13
High beam indicator light ......................... 3-4
Horn switch ............................................. 3-6
IIdentification numbers ..............................9-1
Idling speed, adjusting ...........................6-13
Ignition circuit cut-off system ..................3-16
Indicator and warning lights......................3-3KKey identification number (for XJ600N) ....9-1
Key identification number (for XJ600S) ....9-1LLight switch ..............................................3-7
Luggage strap holders ...........................3-15MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-3OOil level warning light ...............................3-4PPanel, removing and installing..................6-5
Parking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-6
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM