YAMAHA XJ900S 2002 Repair Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6 Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.
CE-08ENOTE:@ The tire tread depth limits may differ
from country to country. Always comply
with the local regulations. @
EW000079
WARNING
@

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
@
1. Tire sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
E_4km.book Page 18 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
EW000080
WARNING
@

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.


Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.


Use only the tire valves and
valve cores listed below to
avoid tire deflation during a
high-speed ride.
@CE-10E
CE-14EEAU00684
WARNING
@ This motorcycle is fitted with super-
high-speed tires. Note the following
points in order to make the most ef-
ficient use of these tires.

Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.


Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is ad-
visable before doing any high-
speed riding to ride conserva-
tively for approximately 100 km
after installing a new tire.


The tires must be warmed up
before a high-speed run.


Always adjust the tire air pres-
sure according to the operating
conditions.
@
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
FRONT
Manufacturer Size Model
Metzeler120/70-17 58V
ME33
120/70-17 M/C 58V
Dunlop120/70-17 58V
K505F
120/70-17 M/C 58V
Bridgestone120/70-17 58V
G601
120/70-17 M/C 58V
REAR
Manufacturer Size Model
Metzeler150/70-17 69V
ME55A
150/70-17 M/C 69V
Dunlop150/70-17 69V
K505
150/70-17 M/C 69V
Bridgestone150/70-17 69V
G602
150/70-17 M/C 69V
FRONT & REAR
Tire air valve TR412
Valve core #9000A (original)
E_4km.book Page 19 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
EAU03773
Cast wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU00694
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10–15 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
bolt in direction
b.3. If the specified clutch lever free
play could be obtained as de-
scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.
4. Fully turn the adjusting bolt at the
clutch lever in direction
a to loos-
en the clutch cable.
5. Loosen the locknut at the
crankcase.
6. To increase the clutch lever free
play, turn the adjusting nut in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
nut in direction
b.
7. Tighten the locknut at the clutch
lever and the crankcase.1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
1. Locknut
2. Clutch lever free play adjusting nut
E_4km.book Page 20 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU00712
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 30 mm below
the top of the footrest as shown. Peri-
odically check the brake pedal position
and, if necessary, have a Yamaha
dealer adjust it.
EW000109
WARNING
_ A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident. _
EAU00713
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction
a. To
make the brake light come on later,
turn the adjusting nut in direction
b.
a. Distance between brake pedal and footrest
1. Rear brake light switch
2. Rear brake light switch adjusting nut
E_4km.book Page 21 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU01160
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. Each brake pad is
provided with wear indicator grooves,
which allow you to check the brake pad
wear without having to disassemble the
brake. If a brake pad has worn to the
point that the wear indicator grooves
have almost disappeared, have a
Yamaha dealer replace the brake pads
as a set.1. Brake pad wear indicator groove (× 3)Front
1. Brake pad wear indicator grooveRear
E_4km.book Page 22 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU03294
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level markFront
1. Minimum level mark
Recommended brake fluid: DOT 4Rear
E_4km.book Page 23 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU03976
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.


Brake hoses: 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. @
EAU04034
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.
Recommended lubricant:
Engine oil
E_4km.book Page 24 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
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.
EAU03371
Checking and lubricating the
centerstand and sidestand The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to-
metal contact surfaces should be lubri-
cated if necessary.
EW000114
WARNING
@ If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it. @
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
E_4km.book Page 25 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU04282
Lubricating the rear
suspension The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart. Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)Recommended lubricant:
Lithium-soap-based grease
E_4km.book Page 26 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:@ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. @
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @
E_4km.book Page 27 Tuesday, August 28, 2001 9:51 AM