spark plugs YAMAHA XJ900S 2002 Owners Manual

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
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM

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
E_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM

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·kgf)
E_4km.book Page 7 Tuesday, August 28, 2001 9:51 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
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.
E_4km.book Page 38 Tuesday, August 28, 2001 9:51 AM

MOTORCYCLE CARE AND STORAGE
7-4
7
Storage Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00014
CAUTION:@

Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.


To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
@
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” posi-
tion: Turn the fuel cock lever to
“OFF”.
3. Drain the carburetor float cham-
bers by loosening the drain bolts;
this will prevent fuel deposits from
building up. Pour the drained fuel
into the fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to pro-
tect the cylinders, piston rings, etc.
from corrosion.a. Remove the spark plug caps and
spark plugs.
b. Pour a teaspoonful of engine oil
into each spark plug bore.
c. Install the spark plug caps onto the
spark plugs, and then place the
spark plugs on the cylinder head
so that the electrodes are ground-
ed. (This will limit sparking during
the next step.)
d. Turn the engine over several times
with the starter. (This will coat the
cylinder walls with oil.)
e. Remove the spark plug caps from
the spark plugs, and then install
the spark plugs and the spark plug
caps.
EWA00003
WARNING
@ To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over. @
E_4km.book Page 4 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