service YAMAHA XJ900S 2000 Owners Manual

INSTRUMENT AND CONTROL FUNCTIONS
3-17
3
EAU00295*
Rear shock absorber
adjustmentThis shock absorber is equipped with a
spring preload adjusting ring. Adjust
spring preload as follows. Turn the ad-
justing ring in direction
a to increase
spring preload and in direction
b to de-
crease spring preload. Make sure that
the appropriate notch in the adjusting
ring is aligned with the position indica-
tor on the rear shock absorber.
CI-18EEAU00315
WARNING
@ This shock absorber contains high-
ly pressurized nitrogen gas. Read
and understand the following infor-
mation before handling the shock
absorber. The manufacturer cannot
be held responsible for property
damage or personal injury that may
result from improper handling.l
Do not tamper with or attempt to
open the cylinder assembly.
l
Do not subject the shock ab-
sorber to an open flame or other
high heat source. This may
cause the unit to explode due to
excessive gas pressure.
l
Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
l
Take your shock absorber to a
Yamaha dealer for any service.
@
1. Spring preload adjusting ring
2. Position indicator
1. Special wrench
SoftStan-
dardHard
Adjusting
position12 3 4567

6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Periodic inspection, adjustment and lu-
brication will keep your motorcycle in
the safest and most efficient condition
possible. Safety is an obligation of the
motorcycle owner. The maintenance
and lubrication schedule chart should
be considered strictly as a guide to
general maintenance and lubrication
intervals. YOU MUST TAKE INTO
CONSIDERATION THAT WEATHER,
TERRAIN, GEOGRAPHICAL LOCA-
TIONS, AND A VARIETY OF INDIVID-
UAL USES ALL TEND TO DEMAND
THAT EACH OWNER ALTER THIS
TIME SCHEDULE TO SHORTER IN-
TERVALS TO MATCH THE ENVI-
RONMENT. The most important points
of motorcycle inspection, adjustment,
and lubrication are explained in the fol-
lowing pages.
EW000060
WARNING
@ If you are not familiar with motor-
cycle service, this work should be
done by a Yamaha dealer. @
EAU00469
Tool kitThe service information included in this
manual is intended to provide you, the
owner, with the necessary information
for completing some of your own pre-
ventive maintenance and minor re-
pairs. The tools provided in the owner’s
tool kit are to assist you in the perfor-
mance of periodic maintenance. How-
ever, some other tools such as a torque
wrench are also necessary to perform
the maintenance correctly.
NOTE:@ If you do not have necessary tools re-
quired during a service operation, take
your motorcycle to a Yamaha dealer for
service. @
EW000063
WARNING
@ Modifications to this motorcycle not
approved by Yamaha may cause
loss of performance, and render it
unsafe for use. Consult a Yamaha
dealer before attempting any chang-
es. @
1. Tool kit

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU02970
NOTE:@ l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake system
• When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level regu-
larly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper every two years.
• Replace the brake hoses every four years or if cracked or damaged.
@22 Engine oil filter cartridge• Replace.ÖÖ
23 Final gear oil• Check oil level and vehicle for oil leakage.
• Change oil at initial 1,000 km and thereafter every 24,000 km
or 24 months (whichever comes first).ÖÖÖ 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)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
EAU00658
TiresTo ensure maximum performance,
long service and safe operation, note
the following:
Tire air pressure
Always check and adjust the tire pres-
sure before operating the motorcycle.
EW000082
WARNING
@ Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla-
tion pressure must be adjusted ac-
cording to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if approved
for this model), and vehicle speed. @
CE-33EEW000083
WARNING
@ Proper loading of your motorcycle
is important for several characteris-
tics of your motorcycle, such as
handling, braking, performance and
safety. Do not carry loosely packed
items that can shift. Securely pack
your heaviest items close to the
center of the motorcycle, and dis-
tribute the weight evenly from side
to side. Properly adjust the suspen-
sion for your load, and check the
condition and pressure of your tires.
NEVER OVERLOAD YOUR MOTOR-
CYCLE. Make sure the total weight
of the cargo, rider, passenger, and
accessories (fairing, saddlebags,
etc. if approved for this model) does
not exceed the maximum load of the
motorcycle. Operation of an over-
loaded motorcycle could cause tire
damage, an accident, or even injury. @
Maximum load* 205 kg
Cold tire pressure Front Rear
Up to 90 kg load*225 kPa
(2.25 kg/cm
2,
2.25 bar)250 kPa
(2.50 kg/cm
2,
2.50 bar)
90 kg Maximum load*250 kPa
(2.50 kg/cm
2,
2.50 bar)290 kPa
(2.90 kg/cm
2,
2.90 bar)
High speed riding250 kPa
(2.50 kg/cm
2,
2.50 bar)290 kPa
(2.90 kg/cm
2,
2.90 bar)
* Load is the total weight of cargo, rider, passenger
and accessories.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 Tire inspection
Always check the tires before operating
the motorcycle. If center tread depth
reaches the limit as shown, if the tire
has a nail or glass fragments in it, or if
the side wall is cracked, contact a
Yamaha dealer immediately and have
the tire replaced.
EW000095
WARNING
@ Operating the motorcycle with ex-
cessively worn tires decrease riding
stability and can lead to loss of con-
trol. Have excessively worn tires re-
placed by a Yamaha dealer
immediately. Brakes, tires, and relat-
ed wheel parts replacement should
be left to a Yamaha Service Techni-
cian. @CE-26ENOTE:@ These limits may be different by regula-
tion from country to country. If so, con-
form to the limits specified by the
regulations of your own country. @
Tire information
This motorcycle is equipped with tube-
less tires, tire valves and cast wheels.
1. Side wall
a. Tread depth
Minimum tire tread depth
(front and rear)1.6 mm
1. Tire valve
2. Valve core
3. Valve cap with seal

PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
EAU00687
WheelsTo ensure maximum performance,
long service, and safe operation, note
the following:l
Always inspect the wheels before
a ride. Check for cracks, bends, or
warpage of the wheels. If any ab-
normal condition exists in a wheel,
consult a Yamaha dealer. Do not
attempt even small repairs to the
wheel. If a wheel is deformed or
cracked, it must be replaced.
l
Tires and wheels should be bal-
anced whenever either one is
changed or replaced. Failure to
have a wheel balanced can result
in poor performance, adverse han-
dling characteristics, and short-
ened tire life.
l
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be broken in for it to
develop its optimal characteristics.
EAU00694
Clutch lever free play
adjustmentThe clutch lever free play should be ad-
justed to 10 ~ 15 mm.
1. Loosen the locknut at the clutch le-
ver.
2. Turn the adjusting bolt at the
clutch lever in direction
a to in-
crease free play or in direction
b
to decrease free play.
3. Tighten the locknut at the clutch
lever.If the specified free play cannot be ob-
tained, proceed with the following
steps.
4. Loosen the locknut at the clutch le-
ver.
5. Turn the adjusting bolt at the
clutch lever in direction
a to loos-
en the cable.
6. Loosen the locknut at the crank-
case side.
7. Turn the adjusting nut at the
crankcase in direction
a to in-
crease free play or in direction
b
to decrease free play.
8. Tighten the locknut at the crank-
case and the clutch lever.1. Locknut
2. Adjusting bolt
c. Free play
1. Locknut
2. Adjusting nut

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU00742
Brake fluid replacementThe brake fluid should be replaced only
by trained Yamaha service personnel.
Have the Yamaha dealer replace the
following components during periodic
maintenance or when they are dam-
aged or leaking:l
oil seals (every two years)
l
brake hoses (every four years)
EAU02962
Cable inspection and
lubrication
EW000112
WARNING
@ Damage to the outer housing of ca-
bles may lead to internal rusting and
interfere with the cable movement.
Replace damaged cables as soon as
possible to prevent unsafe condi-
tions. @Lubricate the cables and cable ends. If
a cable does not operate smoothly, ask
a Yamaha dealer to replace it.
EAU00773
Throttle cable and grip
lubricationThe throttle twist grip assembly should
be greased at the time that the cable is
lubricated, since the grip must be re-
moved to get at the end of the throttle
cable. After removing the screws, hold
the end of the cable up in the air and
put in several drops of lubricant. With
the throttle grip disassembled, coat the
metal surface of the grip assembly with
a suitable all-purpose grease.
Recommended lubricant:
Engine oil

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
63. Put a new bulb into position and
secure it in place with the bulb
holder.
EC000105
CAUTION:@ Avoid touching the glass part of a
bulb. Keep it free from oil; other-
wise, the transparency of the glass,
life of the bulb, and luminous flux
will be adversely affected. If oil gets
on a bulb, thoroughly clean it with a
cloth moistened with alcohol or lac-
quer thinner. @
4. Install the bulb holder cover and
the headlight connector.
If a headlight beam adjustment is
necessary, ask a Yamaha dealer
to make adjustment.
EAU00869
Front wheel removal
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so there is no danger of it
falling over.
@1. Place the motorcycle on the cen-
terstand.
2. Remove the speedometer cable
from the front wheel side.
1. Don’t touch
1. Speedometer cable

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EAU01557
Rear wheel removal
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so there is no danger of it
falling over.
@1. Loosen the wheel axle nut and
pinch bolt.
2. Place the motorcycle on the cen-
terstand.3. Remove the caliper bolts and
wheel axle nut.
4. Remove the brake torque rod cot-
ter pin, nut and bolt.
5. While supporting the brake cali-
per, pull out the wheel axle.
6. Move the wheel to the right to sep-
arate it from the final gear case,
then remove the wheel.
NOTE:@ Do not depress the brake pedal when
the disc and caliper are separated. @
1. Axle nut
1. Pinch bolt
1. Nut
2. Brake torque rod
3. Cotter pin
4. Bolt (´ 2)