brake fluid YAMAHA XJ900S 2002 Owners Manual

4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-9–3-10
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-8
Final gear oilCheck vehicle for oil leakage. 6-11–6-12
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-22–6-23
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-21–6-23
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-20
Throttle gripMake sure that operation is smooth.
Check free play.
If necessary, have Yamaha dealer make adjustment or lubricate.6-16
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-24
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing cowlings ........................ 6-5
Checking the spark plugs .................................... 6-7
Engine oil and oil filter cartridge .......................... 6-8
Final gear oil ...................................................... 6-11
Cleaning the air filter element ............................ 6-13
Adjusting the carburetors ................................... 6-15
Adjusting the engine idling speed ...................... 6-15
Adjusting the throttle cable free play .................. 6-16
Adjusting the valve clearance ............................ 6-16
Tires ................................................................... 6-17
Cast wheels ....................................................... 6-20
Adjusting the clutch lever free play .................... 6-20
Adjusting the brake pedal position ..................... 6-21
Adjusting the rear brake light switch .................. 6-21
Checking the front and rear brake pads ............. 6-22
Checking the brake fluid level ............................ 6-23
Changing the brake fluid .................................... 6-24
Checking and lubricating the cables .................. 6-24Checking and lubricating the throttle grip and
cable ............................................................... 6-24
Checking and lubricating the brake and
shift pedals ...................................................... 6-25
Checking and lubricating the brake and
clutch levers .................................................... 6-25
Checking and lubricating the centerstand and
sidestand ......................................................... 6-25
Lubricating the rear suspension ........................ 6-26
Checking the front fork ...................................... 6-27
Checking the steering ....................................... 6-27
Checking the wheel bearings ............................ 6-28
Battery ............................................................... 6-29
Replacing the fuses .......................................... 6-30
Replacing the headlight bulb ............................. 6-31
Replacing the tail/brake light bulb ..................... 6-32
Replacing a turn signal light bulb ...................... 6-32
Front wheel ....................................................... 6-33
Rear wheel ........................................................ 6-35
Troubleshooting ................................................. 6-37
Troubleshooting chart ........................................ 6-38
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.


From 50,000 km, repeat the maintenance intervals starting from 10,000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2*Fuel filterCheck condition.√√
3 Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
4*ValvesCheck valve clearance.
Adjust.Every 20,000 km
5 Air filter elementClean.√√
Replace.√√
6ClutchCheck operation.
Adjust.√√√√√
7*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
8*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
9*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU03884
NOTE:_

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
Replace the brake hoses every four years and if cracked or damaged.
_25
*Front and rear brake
switchesCheck operation.√√√√√ √
26 Moving parts and cablesLubricate.√√√√ √
27*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
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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
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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

SPECIFICATIONS
8-3
8
Manufacturer/
model Dunlop / K505
Metzeler / ME55A
Bridgestone / G602
Maximum load* 205 kg
Tire air pressure (measured
on cold tires)
up to 90 kg*
Front 225 kPa (2.25 kgf/cm
2, 2.25 bar)
Rear 250 kPa (2.50 kgf/cm2, 2.50 bar)
90 kg–maximum*
Front 250 kPa (2.50 kgf/cm2, 2.50 bar)
Rear 290 kPa (2.90 kgf/cm2, 2.90 bar)
High-speed riding
Front 250 kPa (2.50 kgf/cm2, 2.50 bar)
Rear 290 kPa (2.90 kgf/cm2, 2.90 bar)
* Total weight of rider, passenger, cargo and accessories
Wheels
Front
Type Cast wheel
Size 17 × MT 3.00
17 M/C × MT 3.00
Rear
Type Cast wheel
Size 17 × MT 4.00
17 M/C × MT 4.00Brakes
Fr o n t
Type Dual disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Single disc brake
Operation Right foot
Fluid DOT 4
Suspension
Front Telescopic fork
Rear Swingarm (link suspension)
Spring/shock absorber
Front Coil spring / oil damper
Rear Coil spring / gas-oil damper
Wheel travel
Front 140 mm
Rear 110 mm
Electrical systems
Ignition system T.C.I. (digital)
Charging system
Model A.C. generator
Standard output 13.5 V, 34 A @ 5,000 r/min
Battery
Model YTX14-BS
E_4km.book Page 3 Tuesday, August 28, 2001 9:51 AM

10-INDEXAAir filter element, cleaning ...................... 6-13
Anti-theft alarm ........................................3-5BBattery ................................................... 6-29
Brake and clutch levers, checking and
lubricating ............................................ 6-25
Brake and shift pedals, checking and
lubricating ............................................ 6-25
Brake fluid, changing ............................. 6-24
Brake fluid level, checking...................... 6-23
Brake lever...............................................3-8
Brake light switch (rear), adjusting ......... 6-21
Brake pads, checking............................. 6-22
Brake pedal..............................................3-8
Brake pedal position, adjusting .............. 6-21CCables, checking and lubricating............ 6-24
Carburetors, adjusting............................ 6-15
Care.........................................................7-1
Centerstand and sidestand,
checking and ubricating ....................... 6-25
Clock .......................................................3-5
Clutch lever ..............................................3-7
Clutch lever free play, adjusting ............. 6-20
Conversion table ......................................8-5
Cowlings, removing and installing ............6-5DDimmer switch .........................................3-6EEngine break-in........................................5-4
Engine oil and oil filter cartridge ............... 6-8
Engine stop switch................................... 3-7FFinal gear oil .......................................... 6-11
Front fork, adjusting ............................... 3-13
Front fork, checking ............................... 6-27
Fuel ......................................................... 3-9
Fuel consumption, tips for reducing ......... 5-4
Fuel gauge .............................................. 3-5
Fuel level warning light ............................ 3-2
Fuel tank breather hose
(Germany only) ................................... 3-11
Fuel tank cap ........................................... 3-9
Fuses, replacing .................................... 6-30HHandlebar switches ................................. 3-6
Hazard switch .......................................... 3-6
Headlight bulb, replacing ....................... 6-31
Helmet holder ........................................ 3-12
High beam indicator light ......................... 3-3
Horn switch ............................................. 3-6IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-15
Ignition circuit cut-off system.................. 3-16
Indicator and warning lights ..................... 3-2KKey identification number ........................ 9-1LLight switch.............................................. 3-7
Luggage strap holders ...........................3-15MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-3OOil level warning light ...............................3-3PParking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-6
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1RRear suspension, lubricating ..................6-26SSafety information ....................................1-1
Seat .......................................................3-11
Self-diagnosis device ...............................3-4
Shifting .....................................................5-3
Shift pedal ................................................3-8
Shift points (for Switzerland only) .............5-4
Shock absorber assembly, adjusting ......3-14
Sidestand ...............................................3-15
Spark plugs, checking ..............................6-7
Specifications ...........................................8-1
Speedometer unit.....................................3-3
Starter (choke) lever...............................3-11
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM