YAMAHA XJ900S 2000 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU01065
Cowling removal and
installationThe cowlings indicated in the illustra-
tion need to be removed to perform
some of the maintenance described in
this chapter. Refer to this section each
time a cowling has to be removed or re-
installed.
EAU00490*
Cowling ATo remove
1. Remove the seat. (See page 3-15
for seat removal and installation
procedures.)
2. Remove the screws shown.3. Pull the cowling up, and then slide
it back.
To install
1. Place the cowling in the original
position, and then install the
screws.
2. Install the seat.
1. Cowling A
2. Cowling B
1. Cowling A
2. Screw (´ 2)

PERIODIC MAINTENANCE AND MINOR REPAIR
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6
EAU00486*
Cowling BTo remove
1. Remove the cowling A.2. Remove the bolts and the grab
bar.3. Remove the screws and pull the
cowling off as shown.
To install
1. Place the cowling in the original
position, and then install the
screws.
2. Install the grab bar, cowling A and
seat.1. Grab bar
2. Cowling B
1. Bolt (´ 4)
1. Screw (´ 2)

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU01880
Spark plug inspectionThe 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 specifi-
cation.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. @
a. Spark plug gap
Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
Spark plug gap:
0.8 ~ 0.9 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kg)

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU02938
Engine oilOil 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. @
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.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.
1. Engine oil level window
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap

PERIODIC MAINTENANCE AND MINOR REPAIR
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63. Remove the drain bolt and drain
the oil.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.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. @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. @
1. Engine oil drain bolt
1. Oil filter cartrige
2. Oil filter wrench
Tightening torque:
Drain bolt:
43 Nm (4.3 m·kg)
1. O-ring

PERIODIC MAINTENANCE AND MINOR REPAIR
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6 8. Fill the engine with sufficient oil to
reach the specified level. Install
the oil filler cap and tighten it.
EC000066
CAUTION:@ l
Do not put in any chemical addi-
tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
l
Be sure no foreign material en-
ters the crankcase.
@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. @
Tightening torque:
Oil filter:
17 Nm (1.7 m·kg)
Recommended oil:
See page 8-1.
Oil quantity:
Total amount:
4.4 L
Periodic oil change:
3.2 L
With oil filter replacement:
3.4 L

PERIODIC MAINTENANCE AND MINOR REPAIR
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6
EAU02975
Final gear oil replacement1. Put the motorcycle on the center-
stand.
2. Place an oil pan under the final
gear case.
3. Remove the oil filler bolt and the
drain bolt to drain the oil.
4. Install and tighten the drain bolt to
the specified torque.5. Fill the gear case with the recom-
mended oil.
NOTE:@ “GL-4” is a quality and additive rating.
Hypoid gear oils rated “GL-5” or “GL-6”
may also be used. @
EW000066
WARNING
@ Do not let foreign material enter the
final gear case. Be sure oil does not
get on the tire or wheel. @6. Install the oil filler bolt.
7. After replacing the final gear oil, be
sure to check for oil leakage.
EAU00574*
Air filterThe 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.
2. Turn the fuel cock lever to “OFF”
and disconnect the fuel hose.
1. Final gear oil drain bolt
2. Final gear oil
3. Correct level
4. Final gear oil filler boltTightening torque:
Drain bolt:
23 Nm (2.3 m·kg)
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
If desired, an SAE 80W90 hypoid
gear oil may be used for all condi-
tions.
Final gear oil quantity:
0.2 L
1. Fuel tank
2. Fuel sender lead
3. Fuel hose
4. Fuel cock

PERIODIC MAINTENANCE AND MINOR REPAIR
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6 3. Remove the fuel tank bolts.
4. Disconnect the fuel sender lead
and remove the fuel tank.5. Remove the air filter case cover by
removing the screws.6. Pull out the air filter.
1. Bolt (´ 2)
1. Screw (´ 4)
1. Air filter

PERIODIC MAINTENANCE AND MINOR REPAIR
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67. Tap the air filter lightly to remove
most of the dust and dirt and blow
out the remaining dirt with com-
pressed as shown. If the air filter is
damaged, replace it.
8. Reassemble by reversing the re-
moval procedure.
EC000082
CAUTION:@ l
Make sure the air filter is prop-
erly seated in the air filter case.
l
The engine should never be run
without the air filter installed.
Excessive piston and/or cylin-
der wear may result.
@
EAU00630
Carburetor adjustmentThe 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. @
EAU00632
Idle speed adjustment1. 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.

PERIODIC MAINTENANCE AND MINOR REPAIR
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6 2. Set the idle to the specified engine
speed by adjusting the throttle
stop screw. Turn the screw in di-
rection
a 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. @
EAU00635
Throttle cable free play
inspectionThere 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.
EAU00637
Valve clearance adjustmentThe correct valve clearance changes
with use, resulting in improper fuel/air
supply or engine noise. To prevent this,
the valve clearance must be adjusted
regularly. This adjustment however,
should be left to a professional
Yamaha service technician.
1. Throttle stop screw
Standard idle speed:
950 ~ 1,050 r/min
a. Free play