YAMAHA XJ900S 2002 Manual PDF

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the
steering.
EAU01144
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
E_4km.book Page 28 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU00800
Battery This motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.
EC000101
CAUTION:@ Never attempt to remove the battery
cell seals, as this would permanent-
ly damage the battery. @
EW000116
WARNING
@

Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
EXTERNAL: Flush with plenty
of water.INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
EYES: Flush with water for
15 minutes and seek prompt
medical attention.


Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.


KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
@To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the motorcycle is equipped with op-
tional electrical accessories.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.
E_4km.book Page 29 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EC000102
CAUTION:@

Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.


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.
@
EAU04359*
Replacing the fuses The main fuse and the fuse box, which
contains the fuses for the individual cir-
cuits, 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.1. Fuse box
2. Main fuse
1. Headlight fuse
2. Ignition fuse
3. Clock fuse
4. Hazard fuse
5. Main fuse
6. Spare fuse (× 3)
7. Signaling system fuseSpecified 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
E_4km.book Page 30 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
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.
EAU04136
Replacing the headlight bulb This motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.
1. Disconnect the headlight coupler,
and then remove the 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. _
1. Headlight coupler
2. Bulb cover
1. Headlight bulb holder
E_4km.book Page 31 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6 3. Place a new headlight 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 headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU01623
Replacing the tail/brake light
bulb 1. Remove the tail/brake light lens by
removing the screws.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screws.
EC000108
CAUTION:_ Do not overtighten the screws, oth-
erwise the lens may break. _
EAU03497
Replacing a turn signal light
bulb 1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
ECA00065
CAUTION:_ Do not overtighten the screw, other-
wise the lens may break. _
1. Do not touch this area.
1. Screw (× 2)
1. Screw
E_4km.book Page 32 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU03598
Front wheel To remove the front wheel
EW000122
WARNING
@

It is advisable to have a Yamaha
dealer service the wheel.


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. Front wheel axle pinch bolt
2. Wheel axle
E_4km.book Page 33 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6
EAU04360
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. 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. _
5. Install the brake hose holders by
installing the bolts.
6. Take the motorcycle off the cen-
terstand so that the front wheel is
on the ground.
7. Tighten the wheel axle, then the
front wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.
8. Connect the speedometer cable.
9. 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·kgf)
Front wheel axle pinch bolt:
19 Nm (1.9 m·kgf)
Brake caliper bolt:
40 Nm (4.0 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
EAU04361
Rear wheel To remove the rear wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_
1. Remove the axle nut, and then
loosen the rear wheel axle pinch
bolt.
2. Place the motorcycle on the cen-
terstand.3. Remove the brake caliper by re-
moving the bolts.
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 rear wheel,
pull the wheel axle out.
6. Remove the brake caliper bracket
and spacer.
7. Pull the wheel to the right to sepa-
rate it from the final gear case, and
then remove it.
1. Rear wheel axle pinch bolt
1. Axle nut
1. Nut
2. Bolt
3. Brake torque rod
4. Cotter pin
5. Brake caliper bracket
6. Bolt (× 2)
E_4km.book Page 35 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
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. _
EAU04362
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, brake caliper
bracket, spacer and wheel axle.
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. Connect the brake torque rod to
the brake caliper bracket by in-
stalling the bolt and the nut.
5. Install the axle nut, and then slight-
ly tighten it.
6. Take the motorcycle off the cen-
terstand so that the rear wheel is
on the ground.
7. Tighten the rear wheel axle pinch
bolt, the axle nut, the brake caliper
bolts and the brake torque rod nut
to the specified torques.
1. Splines
Tightening torques:
Axle nut:
105 Nm (10.5 m·kgf)
Brake caliper bolt:
40 Nm (4.0 m·kgf)
Brake torque rod nut:
23 Nm (2.3 m·kgf)
Rear wheel axle pinch bolt:
16 Nm (1.6 m·kgf)
E_4km.book Page 36 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
68. Install the brake torque rod cotter
pin.
EW000124
WARNING
_ Always use a new cotter pin. _
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.
E_4km.book Page 37 Tuesday, August 28, 2001 9:51 AM