engine YAMAHA XJ900S 2001 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
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.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads. Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
a. Spark plug gap
Spark plug gap:
0.8–0.9 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
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. @
EAU02938
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.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6To change the engine oil (with or
without oil filter cartridge
replacement)
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
6-10
6 5. Apply a thin coat of engine oil to
the O-ring of the new oil filter
cartridge.
NOTE:@ Make sure that the O-ring is properly
seated. @6. Install the new oil filter cartridge,
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.
EC000072
CAUTION:@ l
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.
l
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. @
1. O-ring
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kg)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kg)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
3.2 L
With oil filter cartridge
replacement:
3.4 L
Total amount (dry engine):
4.4 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
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.
EAU03681
Final gear oil The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the motorcycle. In
addition, the final gear oil must be
changed as follows at the intervals
specified in the periodic maintenance
and lubrication chart.
EW000066
WARNING
_ l
Make sure that no foreign mate-
rial enters the final gear case.
l
Make sure that no oil gets on
the tire or wheel.
_To check the final gear oil level
1. Place the motorcycle on the cen-
terstand.
NOTE:_ l
The final gear oil level must be
checked on a cold engine.
l
Make sure that the motorcycle is
positioned straight up when
checking the oil level. A slight tilt to
the side can result in a false read-
ing.
_
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 6. Pull the air filter element out. 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:@ l
Make sure that the air filter ele-
ment is properly seated in the
air filter case.
l
The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
@9. Install the air filter case cover by
installing the screws.
10. Connect the fuel sender coupler,
and then install the fuel tank by in-
stalling the bolts.
11. Connect the fuel hose, and then
turn the fuel cock lever to “ON”.
12. Install the seat.
1. Air filter element
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
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. @
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
direction
b.NOTE:@ If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment. @ 1. Throttle stop screw
Engine idling speed:
950–1,050 r/min
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU00637
Adjusting the valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU00658
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000082
WARNING
@ l
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
l
The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
@
CE-01E
CE-07E
EWA00012
WARNING
@ Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your motorcycle, you should
keep the following precautions in
mind. l
NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg225 kPa
2.25 kg/cm
2
2.25 bar250 kPa
2.50 kg/cm
2
2.50 bar
90 kg–maximum250 kPa
2.50 kg/cm
2
2.50 bar290 kPa
2.90 kg/cm
2
2.90 bar
High-speed riding250 kPa
2.50 kg/cm
2
2.50 bar290 kPa
2.90 kg/cm
2
2.90 bar
Maximum load* 205 kg
* Total weight of rider, passenger, cargo and
accessories
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU03238
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the brake master cylinder and caliper
as well as the brake hose replaced at
the intervals listed below or whenever
they are damaged or leaking.l
Oil seals: Replace every two
years.
l
Brake hose: Replace every four
years.
EAU02962
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
@ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. @
EAU03209
Checking and lubricating the
throttle grip and cable The operation of the throttle grip and
the condition of the throttle cable
should be checked before each ride,
and the cable should be lubricated or
replaced if necessary.NOTE:@ Since the throttle grip must be removed
to access the throttle cable end, the
throttle grip and the cable should al-
ways be lubricated at the same time. @1. Remove the throttle grip by remov-
ing the screws.
2. Disconnect the throttle cable, hold
it up, and then apply several drops
of oil to the cable end, allowing it to
trickle into the sheath.
3. Connect the throttle cable, and
then grease the inside of the throt-
tle grip housing.
4. Grease the metal-to-metal contact
surface of the throttle grip, and
then install the grip by installing
the screws. Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU03370
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
EAU03164
Checking and lubricating the
brake and clutch levers The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary. Recommended lubricant:
Throttle cable:
Engine oil
Throttle grip housing and grip:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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