YAMAHA XJ600S 2002 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU03884
NOTE:_

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
Replace the brake hoses every four years and if cracked or damaged.
_22
*CarburetorsCheck starter (choke) operation.
Adjust engine idling speed and synchronization.√√√√√ √
23 Engine oilChange.√√√√√ √
Check oil level and vehicle for oil leakage.√√√√√ √
24 Engine oil filter cartridgeReplace.√√√
25*Front and rear brake
switchesCheck operation.√√√√√ √
26 Moving parts and cablesLubricate.√√√√ √
27*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
Annual
check
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU01777
Removing and installing the
panel The panel shown above needs to be
removed to perform some of the main-
tenance jobs described in this chapter.
Refer to this section each time the pan-
el needs to be removed and installed.
EAU02926
Panel A
To remove the panel1. Remove the seat. (See page 3-12
for seat removal and installation
procedures.)
2. Remove the screws, and then
slide the panel as shown to re-
lease it.
1. Panel A
1. Screw (× 2)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6 To install the panel
1. Place the panel in the original po-
sition, and then install the screws.
2. Install the seat.
EAU01880
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal col-
or when the motorcycle is ridden nor-
mally), and all spark plugs installed in
the engine should have the same color.
If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.a. Spark plug gap
Specified spark plug:
CR8E (NGK) or
U24ESR-N (DENSO)
Spark plug gap:
0.7–0.8 mm
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:@ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @
EAU04185
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on the cen-
terstand.
NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level. Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf)
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6 To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:_ Skip steps 4–6 if the oil filter cartridge is
not being replaced. _
4. Remove the oil filter cartridge with
an oil filter wrench.NOTE:_ An oil filter wrench is available at a
Yamaha dealer. _
1. Engine oil filler cap
1. Engine oil drain bolt
1. Oil filter cartridge
2. Oil filter wrench
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
65. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.
NOTE:_ Make sure that the O-ring is properly
seated. _
6. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.
7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
1. O-ring
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
2.3 L
With oil filter cartridge
replacement:
2.6 L
Total amount (dry engine):
3.1 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
EC000072
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a higher
grade than “CD”. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign mate-
rial enters the crankcase.
_9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.NOTE:_ After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient. _
EC000067
CAUTION:_ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. _10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU02928*
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the seat. (See page 3-12
for seat removal and installation
procedures.)
2. Turn the fuel cock lever to “ON”,
and then remove the fuel cock le-
ver by removing the screw.1. Screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
63. Disconnect the hoses shown.4. Remove the fuel tank by removing
the bolts.5. Remove the air filter case cover by
removing the screws.
6. Pull the air filter element out.
1. Fuel hose
2. Vacuum hose
3. Fuel tank drain hose
1. Screw (× 4)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 7. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.
8. Insert the air filter element into the
air filter case.
EC000082*
CAUTION:@

Make sure that the air filter ele-
ment is properly seated in the
air filter case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
pistons and/or cylinders may
become excessively worn.
@9. Install the air filter case cover by
installing the screws.
10. Install the fuel tank by installing the
bolts.
11. Connect the hoses.
12. Install the fuel cock lever by install-
ing the screw.
13. Install the seat.
EAU00630
Adjusting the carburetors The carburetors are important parts of
the engine and require very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.
EC000095
CAUTION:@ The carburetors have been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine. @
1. Air filter element
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
EAU00632
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Start the engine and warm it up for
several minutes at 1,000–
2,000 r/min while occasionally rev-
ving it to 4,000–5,000 r/min.NOTE:@ The engine is warm when it quickly re-
sponds to the throttle. @
2. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
rection
a. To decrease the engine
idling speed, turn the screw in di-
rection
b.NOTE:@ If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment. @
EAU00635
Adjusting the throttle cable
free play The throttle cable free play should
measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
1. Throttle stop screw
Engine idling speed:
1,200 – 1,300 r/min
a. Throttle cable free play
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