YAMAHA XJ900S 2001 Manual PDF

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 To store the battery
1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check it at
least once a month and fully
charge it if necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly con-
nected to the battery terminals.
EC000102
CAUTION:@ l
Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
l
To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is re-
quired. Using a conventional
battery charger will damage the
battery. If you do not have ac-
cess to a sealed-type (MF) bat-
tery charger, have a Yamaha
dealer charge your battery.
@
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU01110
Replacing the fuses The fuse boxes are located behind
cowling B. (See page 6-6 for cowling
removal and installation procedures.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
EC000103
CAUTION:@ Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire. @3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
1. Fuse box (´ 2)
1. Headlight fuse
2. Ignition fuse
3. Clock fuse
4. Hazard fuse
5. Main fuse
6. Spare fuse (´ 3)
7. Signaling system fuse
Specified fuses:
Main fuse: 30 A
Headlight fuse: 15 A
Signaling system fuse: 20 A
Ignition fuse: 10 A
Clock fuse: 10 A
Hazard fuse: 10 A
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EAU00829
Replacing a headlight bulb This motorcycle is equipped with
quartz bulb headlights. If a headlight
bulb burns out, replace it as follows.
1. Disconnect the headlight coupler,
and then remove the headlight
bulb cover.2. Unhook the headlight bulb holder,
and then remove the defective
bulb.
EW000119
WARNING
@ Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down. @
3. Place a new bulb into position, and
then secure it with the bulb holder.
EC000105
CAUTION:@ Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner. @4. Install the bulb cover, and then
connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Headlight coupler
2. Headlight bulb cover
1. Headlight bulb holder
1. Do not touch this area.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6
EAU03598
Front wheel To remove the front wheel
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
@1. Place the motorcycle on the
centerstand.
2. Disconnect the speedometer ca-
ble from the front wheel.3. Remove the brake hose holders
by removing the bolts.
4. 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. @
5. Loosen the front wheel axle pinch
bolt, then the wheel axle.
6. Pull the wheel axle out, and then
remove the wheel.
1. Speedometer cable
1. Bolt (´ 3)
2. Brake hose holder
3. Brake caliperLeft
Right
1. Wheel axle pinch bolt
2. Wheel axle
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
EAU03420
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.
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 front wheel axle pinch
bolt, then the wheel axle, 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.1. Retainer
Tightening torques:
Wheel axle:
59 Nm (5.9 m·kg)
Front wheel axle pinch bolt:
19 Nm (1.9 m·kg)
Brake caliper bolt:
40 Nm (4.0 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6
EAU03410
Rear wheel To remove the rear wheel
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
@
1. Loosen the rear wheel axle pinch
bolt, and then remove the axle nut.
2. Place the motorcycle on the
centerstand.3. Remove the brake caliper bolts
and the axle nut.
4. Disconnect the brake torque rod
from the brake caliper bracket by
removing the cotter pin, the nut,
and the bolt.
5. While supporting the brake cali-
per, pull the wheel axle out.
6. Pull the wheel to the right to sepa-
rate it from the final gear case, and
then remove it.
1. Wheel axle pinch bolt
1. Axle nut
1. Nut
2. Brake torque rod
3. Cotter pin
4. Bolt (´ 2)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6
ECA00062
CAUTION:@ Do not push the brake pedal after
the wheel has been removed togeth-
er with the brake disc, otherwise the
brake pads will be forced shut. @
EAU03411
To install the rear wheel
1. Apply a light coating of lithium-
soap-based grease to the splines
of the final gear case and wheel
hub.
2. Install the wheel by inserting the
wheel axle, and then install the
axle nut.
3. 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. @
4. Install the brake torque rod bolt,
nut and cotter pin at the brake cal-
iper bracket.
EW000124
WARNING
@ Always use a new cotter pin. @5. Tighten the rear wheel axle pinch
bolt to the specified torque.
6. Take the motorcycle off the cen-
terstand so that the rear wheel is
on the ground.
7. Tighten the axle nut, wheel axle
pinch bolt, brake caliper bolts and
brake torque rod nut to the speci-
fied torques.
1. Splines
Tightening torque:
Rear wheel axle pinch bolt:
16 Nm (1.6 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
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·kg)
Brake caliper bolt:
40 Nm (4.0 m·kg)
Brake torque rod nut:
23 Nm (2.3 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6
EAU01297
Troubleshooting chart
EW000125
WARNING
@ Keep away open flames and do not smoke while checking or working on the fuel system. @
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
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