Yamaha Diversion Owner'S Manual Download Page 64 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-17

6

EAU00687

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 2–3 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.

1. Loosen the locknut at the clutch le-

ver.

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 crank-

case.

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

.

1. Clutch lever free play locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play

1. Clutch lever cable
2. Clutch lever free play adjusting nut
3. Locknut

E_4br.book Page 17 Thursday, August 17, 2000 11:29 AM

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Summary of Contents for Diversion

Page 1: ...4BR 28199 E7 OWNER S MANUAL XJ600S ...

Page 2: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 3: ... to enjoy all advantages of your XJ600S XJ600N The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yama...

Page 4: ... be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informat...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_4br book Page 2 Thursday August 17 2000 11 29 AM ...

Page 6: ... S MANUAL 2000 by Yamaha Motor Co Ltd 1st Edition May 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_4br book Page 3 Thursday August 17 2000 11 29 AM ...

Page 7: ...ENT AND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 E_4br book Page 1 Thursday August 17 2000 11 29 AM ...

Page 8: ...E_4br book Page 2 Thursday August 17 2000 11 29 AM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 E_4br book Page 1 Thursday August 17 2000 11 29 AM ...

Page 10: ... even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers Always wear a complete motorcycle suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots motorcycle gloves and a properly fitting helmet Optimum protective wear however shoul...

Page 11: ...N 2 Left view XJ600S 2 1 Right view XJ600S 2 2 Controls and instruments XJ600S 2 3 Left view XJ600N 2 4 Right view XJ600N 2 5 Controls and instruments XJ600N 2 6 E_4br book Page 1 Thursday August 17 2000 11 29 AM ...

Page 12: ... cock page 3 11 2 Helmet holder page 3 13 3 Fuse box page 6 29 4 Luggage strap holders page 3 15 5 Seat lock page 3 12 6 Rear shock absorber spring preload adjusting ring page 3 14 7 Shift pedal page 3 8 E_4br book Page 1 Thursday August 17 2000 11 29 AM ...

Page 13: ... 2 2 2 Right view XJ600S 8 Tail brake light 9 Storage compartment page 3 13 10 Seat page 3 12 11 Fuel tank page 3 9 12 Headlight page 6 30 13 Brake pedal page 3 9 E_4br book Page 2 Thursday August 17 2000 11 29 AM ...

Page 14: ...ndlebar switches page 3 6 16 Starter choke lever page 3 12 17 Speedometer unit page 3 4 18 Tachometer page 3 5 19 Right handlebar switches page 3 7 20 Brake lever page 3 8 21 Throttle grip page 6 13 22 Main switch steering lock page 3 1 E_4br book Page 3 Thursday August 17 2000 11 29 AM ...

Page 15: ... 2 Fuel cock page 3 11 3 Helmet holder page 3 13 4 Fuse box page 6 29 5 Luggage strap holders page 3 15 6 Seat lock page 3 12 7 Rear shock absorber spring preload adjusting ring page 3 14 8 Shift pedal page 3 8 E_4br book Page 4 Thursday August 17 2000 11 29 AM ...

Page 16: ...2 5 2 Right view XJ600N 9 Tail brake light 10 Storage compartment page 3 13 11 Seat page 3 12 12 Fuel tank page 3 9 13 Headlight page 6 30 14 Brake pedal page 3 9 E_4br book Page 5 Thursday August 17 2000 11 29 AM ...

Page 17: ...Left handlebar switches page 3 6 17 Starter choke lever page 3 12 18 Speedometer unit page 3 5 19 Tachometer page 3 5 20 Right handlebar switches page 3 7 21 Brake lever page 3 8 22 Throttle grip page 6 13 23 Main switch page 3 1 E_4br book Page 6 Thursday August 17 2000 11 29 AM ...

Page 18: ...E_4br book Page 7 Thursday August 17 2000 11 29 AM ...

Page 19: ...s 3 6 Clutch lever 3 7 Shift pedal 3 8 Brake lever 3 8 Brake pedal 3 9 Fuel tank cap 3 9 Fuel 3 10 Fuel tank breather hose for Germany only 3 10 Fuel cock 3 11 Starter choke lever 3 12 Seat 3 12 Helmet holders 3 13 Storage compartment 3 13 Adjusting the shock absorber assembly 3 14 Luggage strap holders 3 15 Sidestand 3 15 Ignition circuit cut off system 3 16 E_4br book Page 1 Thursday August 17 2...

Page 20: ...The key cannot be removed EAU00038 OFF All electrical systems are off The key can be removed EAU00040 LOCK for XJ600S The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push...

Page 21: ... are off The key can be removed The steering must be locked before the key can be turned to ECA00043 CAUTION Do not use the parking position for an extended length of time other wise the battery may discharge EAU00055 P Parking for XJ600N The taillight and auxiliary light are on but all other electrical systems are off The key can be removed The key must be pushed in and then released before it ca...

Page 22: ...er and then insert the key 2 Push the key in turn it 1 8 turn counterclockwise so that it moves out and then release it 3 Remove the key and then close the lock cover EAU03034 Indicator and warning lights EAU03299 Turn signal indicator lights The corresponding indicator light flash es when the turn signal switch is pushed to the left or right EAU00061 Neutral indicator light This indicator light c...

Page 23: ...l is sufficient the warning light may flicker when riding on a slope or during sudden acceleration or deceleration but this is not a mal function EAU00094 Speedometer unit for XJ600S The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter shows the distance traveled since it was ...

Page 24: ...ith a full tank of fuel This information will en able you to plan future fuel stops EAU00101 Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range EC000003 CAUTION Do not operate the engine in the ta chometer red zone Red zone 9 500 r min and above except for CH A 8 500 r min and above for CH A 1 Speedometer 2 Odometer 3 Tripmeter ...

Page 25: ...n your motorcycle is stopped where it might be a traffic hazard EC000006 CAUTION Do not use the hazard light for an ex tended length of time otherwise the battery may discharge EAU00127 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When released the switch returns to the cen ter position To cancel the turn signal lights push the s...

Page 26: ...05 CAUTION See page 5 1 for starting instruc tions prior to starting the engine EAU00152 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which...

Page 27: ...ip To apply the front brake pull the lever toward the handle bar grip The brake lever is equipped with a po sition adjusting nut To adjust the dis tance between the brake lever and the handlebar grip turn the adjusting nut while holding the lever pushed away from the handlebar grip Make sure that the mark on the adjusting nut is aligned with the mark on the brake lever 1 Shift pedal 1 Brake lever ...

Page 28: ... tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked EWA00025 WARNING Make sur...

Page 29: ...s EAU00191 NOTE If knocking or pinging occurs use gasoline of a different brand or with a higher octane grade EAU00196 Fuel tank breather hose for Germany only Before operating the motorcycle Check the fuel tank breather hose connection Check the fuel tank breather hose for cracks or damage and replace it if damaged Make sure that the end of the fuel tank breather hose is not blocked and clean it ...

Page 30: ...ou run out of fuel while riding otherwise the engine may stall and will have to be primed see PRI After turning the fuel cock lever to RES refuel as soon as possible and be sure to turn the fuel cock lever back to ON PRI This indicates prime With the fuel cock lever in this position the engine can be primed Turn the fuel cock lever to this position when the engine has been allowed to run out of fu...

Page 31: ...starter choke EAU02925 Seat To remove the seat Insert the key into the seat lock turn it counterclockwise and then pull the seat off To install the seat Insert the projections on the front of the seat into the seat holder push the rear of the seat down to lock it in place and then remove the key NOTE Make sure that the seat is properly se cured before riding 1 Starter choke lever 1 Unlock 1 Projec...

Page 32: ...eat remove the helmet from the helmet holder and then install the seat EAU01688 Storage compartment This storage compartment is designed to hold a genuine Yamaha U LOCK Other locks may not fit When placing a U LOCK in the storage compartment securely fasten it with the straps When the U LOCK is not in the storage com partment be sure to secure the straps to prevent losing them When storing the own...

Page 33: ...EAU00315 WARNING This shock absorber contains high ly pressurized nitrogen gas For proper handling read and under stand the following information be fore handling the shock absorber The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an...

Page 34: ...r an explanation of the ignition circuit cut off system EW000044 WARNING The motorcycle must not be ridden with the sidestand down or if the sidestand cannot be properly moved up or does not stay up oth erwise the sidestand could contact the ground and distract the opera tor resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in...

Page 35: ... not pulled It prevents starting when the trans mission is in gear and the clutch lever is pulled but the sidestand is still down It cuts the running engine when the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure EW000046 WARNING The vehicle must be placed on the centerstand during this in spection If a malfuncti...

Page 36: ...e clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle shoul...

Page 37: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_4br book Page 1 Thursday August 17 2000 11 29 AM ...

Page 38: ...ke fluid if necessary 6 19 6 21 Rear brake 6 18 6 21 Clutch Check operation condition and free play Adjust if necessary 6 17 6 18 Throttle grip and housing Check smooth operation Lubricate if necessary 6 13 6 24 Engine oil Check oil level Fill with oil if necessary 6 7 6 10 Drive chain Check chain slack and condition Adjust if necessary 6 21 6 23 Wheels and tires Check tire pressure wear and damag...

Page 39: ...d EWA00033 WARNING If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Fuel Check fuel level Fill with fuel if necessary 3 9 3 10 Lights signals and switches Check proper operation ITEM CHECKS PAGE E_4br book Page 2 Th...

Page 40: ...E_4br book Page 3 Thursday August 17 2000 11 29 AM ...

Page 41: ...5 Starting a cold engine 5 1 Starting a warm engine 5 2 Shifting 5 3 Recommended shift points for Switzerland only 5 3 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 E_4br book Page 1 Thursday August 17 2000 11 29 AM ...

Page 42: ...n is in the neutral position The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 WARNING Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 16 Never ride with the sidestand down 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set t...

Page 43: ...ng the start switch or if it does not go off after starting with sufficient engine oil have a Yamaha dealer check the electrical circuit 6 After starting the engine move the starter choke knob lever back halfway ECA00045 CAUTION For maximum engine life never ac celerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normal...

Page 44: ...rcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU02937 Recommended shift points for Switzerland only The recommended shift point...

Page 45: ...your engine than the period between 0 and 1 000 km For this rea son you should read the following ma terial carefully Since the engine is brand new do not put an excessive load on it for the first 1 000 km The various parts in the en gine wear and polish themselves to the correct operating clearances During this period prolonged full throttle oper ation or any condition that might result in engine...

Page 46: ... Keep the engine speed out of the tachometer red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU00460 Parking When parking stop the engine and then remove the key from the main switch EW000058 WARNING Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely...

Page 47: ...ds 6 19 Checking the brake fluid level 6 20 Changing the brake fluid 6 21 Drive chain slack 6 21 Lubricating the drive chain 6 23 Checking and lubricating the cables 6 23 Checking and lubricating the throttle grip and cable 6 24 Checking and lubricating the brake and shift pedals 6 24 Checking and lubricating the brake and clutch levers 6 25 Checking and lubricating the centerstand and sidestand 6...

Page 48: ... SHORT ENED EW000060 WARNING If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you EAU00469 Owner s tool kit The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary ...

Page 49: ... 20 30 40 1 Fuel line Check fuel hoses and vacuum hose for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust Every 20 000 km 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Wheneve...

Page 50: ...ghness Lubricate with lithium soap based grease Every 20 000 km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand centerstand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Rear shock absorber assembly Check operation and shock absorber for oil leakage 21 Rear suspension relay arm an...

Page 51: ...ce 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 switches Check operation 26 Moving parts and cables Lubricate 27 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1 000 km Annual check 1 10 20...

Page 52: ...ce jobs described in this chapter Refer to this section each time the pan el needs to be removed and installed EAU02926 Panel A To remove the panel 1 Remove the seat See page 3 12 for seat removal and installation procedures 2 Remove the screws and then slide the panel as shown to re lease it 1 Panel A 1 Screw 2 E_4br book Page 5 Thursday August 17 2000 11 29 AM ...

Page 53: ...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 sp...

Page 54: ... and lubrication chart To check the engine oil level 1 Place the motorcycle on the cen terstand NOTE Make sure that the motorcycle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the ch...

Page 55: ...lect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 1 Engine oil filler cap 1 Engine oil drain bolt 1 Oil filter cartridge 2 Oil filter wrench E_4br book Page 8...

Page 56: ...n bolt and then tighten it to the specified torque 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kg Tightening torque Engine oil drain bolt 43 Nm 4 3 m kg Recommended engine oil See page 8 1 Oil quantity Without oil filter cartridge replacement 2 3 L With oil filte...

Page 57: ...evel warning light should go off if the oil level is sufficient EC000067 CAUTION If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha deal er check the vehicle 10 Turn the engine off and then check the oil level and correct it if necessary EAU02928 Cleaning the air filter element The air filter element should be cleaned at the intervals specified ...

Page 58: ...e hoses shown 4 Remove the fuel tank by removing the bolts 5 Remove the air filter case cover by removing the screws 6 Pull the air filter element out 1 Fuel hose 2 Vacuum hose 3 Fuel tank drain hose 1 Screw 4 E_4br book Page 11 Thursday August 17 2000 11 29 AM ...

Page 59: ...ll the fuel tank by installing the bolts 11 Connect the hoses 12 Install the fuel cock lever by install ing the screw 13 Install the seat EAU00630 Adjusting the carburetors The carburetors are important parts of the engine and require very sophisti cated adjustment Therefore most car buretor adjustments should be left to a Yamaha dealer who has the neces sary professional knowledge and expe rience...

Page 60: ...necessary adjust it to spec ification by turning the throttle stop screw To increase the engine idling speed turn the screw in di rection a To decrease the engine idling speed turn the screw in di rection b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EAU00635 Adjusting the throttle cable free play The throttle cable free play sh...

Page 61: ...sted before each ride EW000082 WARNING The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model CE 01E CE 07E Tire air pressure measured on cold tires Load ...

Page 62: ...ift during a ride Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides Adjust the suspension and tire air pressure with regard to the load Check the tire condition and air pressure before each ride 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 o...

Page 63: ...ling 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 CE 10E EAU00683 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 a...

Page 64: ... play The clutch lever free play should mea sure 2 3 mm as shown Periodically check the clutch lever free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch le ver 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...

Page 65: ...ition 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...

Page 66: ...n direction b EAU00721 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 EAU00725 Front brake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear che...

Page 67: ... 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 mas ter cylinder or brake fluid reservoir is level Use only...

Page 68: ...fluid at the intervals specified in the periodic maintenance and lubrica tion chart In addition have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hose Replace every four years EAU00745 Drive chain slack The drive chain slack should be checked be...

Page 69: ...he alignment marks on each side of the swingarm make sure that both adjusting nuts are in the same po sition for proper wheel alignment EC000096 CAUTION Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 3 Tighten the lock...

Page 70: ...2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECA00052 CAUTION Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings 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 ...

Page 71: ...d then apply several drops of oil to the cable end allowing it to trickle into the sheath 3 Connect the throttle cable and then grease the inside of the throt tle grip housing 4 Grease the metal to metal contact surface of the throttle grip and then install the grip by installing the screws EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals sho...

Page 72: ... 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 EAU00790 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 Lith...

Page 73: ...on 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 ch...

Page 74: ... a Yamaha dealer check the wheel bearings 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 c...

Page 75: ...ith 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 in stallation 4 After installation make sure that the...

Page 76: ... 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 1 Main fuse 2 Ignition fuse 3 Signaling system fuse 4 Headlight fuse 5 ...

Page 77: ...cts 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 fi...

Page 78: ...the headlight bulb for XJ600N This motorcycle is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlight coupler and then remove the headlight unit and bulb cover 1 Screw 2 1 Headlight coupler 2 Headlight bulb cover E_4br book Page 31 Thursday August 17 2000 11 29 AM ...

Page 79: ...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 5 Install the bulb cover and then connect the coupler 6 Install the headlight unit by install ing ...

Page 80: ...per has been removed otherwise the brake pads will be forced shut 4 Loosen the front wheel axle pinch bolt 5 Pull the wheel axle out and then remove the wheel 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...

Page 81: ...rake 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 Tightening torques Wheel axle 58 Nm 5 8 m kg Front wheel axle pinch bolt 40 Nm 4 0 m kg Brake caliper bolt 19 Nm 1 9 m kg E_4br book Page 34 Thursday August 17...

Page 82: ...per bracket by removing the nut and the bolt 4 While supporting the brake caliper bracket pull the wheel axle out 5 Push the wheel forward and then remove the drive chain from the rear sprocket NOTE The drive chain does not need to be disassembled in order to remove and install the rear wheel 6 Remove the wheel ECA00048 CAUTION Do not apply the brake after the wheel has been removed together with ...

Page 83: ...es 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 you...

Page 84: ...ition 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 qu...

Page 85: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_4br book Page 1 Thursday August 17 2000 11 29 AM ...

Page 86: ...ctrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION Avoid using strong acidic wheel cleaners e...

Page 87: ...d shield is scratched use a quali ty plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After ridin...

Page 88: ...paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it EWA00001 WARNING Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before operating the motor cycle test i...

Page 89: ... 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 cyli...

Page 90: ...aded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C or more than 30 C For more information on storing the battery see page 6 27 NOTE Make any necessary repairs before storing ...

Page 91: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 E_4br book Page 1 Thursday August 17 2000 11 29 AM ...

Page 92: ...o 10 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher Quantity Without oil filter cartridge replacement 2 3 L With oil filter cartridge replacement 2 6 L Total amount dry engine 3 1 L 20 10 0 10 20 30 40 50 C SAE 10W 30 SAE 15W 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 CAUTION Be sure to use motor oil...

Page 93: ... Chain drive Secondary reduction ratio 3 000 except for CH A 2 875 for CH A Number of drive chain sprocket teeth rear front 48 16 except for CH A 46 16 for CH A Transmission type Constant mesh 6 speed Operation Left foot Gear ratio 1st 2 733 2nd 1 778 3rd 1 333 4th 1 074 5th 0 913 6th 0 821 Chassis Frame type Double cradle Caster angle 25 Trail 97 mm Tire Front Type Tubeless Size 110 80 17 57H Man...

Page 94: ...eight of rider passenger cargo and accessories Wheels Front Type Cast wheel Size 17 MT 2 50 Rear Type Cast wheel Size 18 MT 3 50 Brakes Front 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 monocross suspen sion Spring shock absorbers Front Coil spring oil damper Rear Coil spring gas o...

Page 95: ...V 3 4 W 1 for GB IRL Tail brake light 12 V 5 21 W 1 Turn signal light 12 V 21 W 4 Meter lighting XJ600S 12 V 1 7 W 3 XJ600N 14 V 3 W 2 12 V 1 7 W 2 Neutral indicator light 12 V 3 4 W 1 High beam indicator light 12 V 3 4 W 1 Oil level warning light XJ600S 12 V 3 4 W 1 XJ600N 14 V 3 W 1 Turn signal indicator light 12 V 3 4 W 2 Fuses Main fuse 30 A Ignition fuse 10 A Signaling system fuse 15 A Headli...

Page 96: ...etric unit Multiplier Imperial unit Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centigrade C 55...

Page 97: ...ATION 9 Identification numbers 9 1 Key identification number for XJ600S 9 1 Key identification number for XJ600N 9 1 Vehicle identification number 9 2 Model label 9 2 E_4br book Page 1 Thursday August 17 2000 11 29 AM ...

Page 98: ...ICATION NUMBER CA 02E 3 MODEL LABEL INFORMATION CA 01E EAU01041 Key identification number for XJ600S The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01042 Key identification number for XJ600N The key identification number is stamped into the key Record this num ber in the space provided and use i...

Page 99: ... and may be used to register your motor cycle with the licensing authority in your area EAU01050 Model label The model label is affixed to the frame under the seat See page 3 12 for seat removal and installation procedures Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Vehicle identification number 1 Model...

Page 100: ...26 Front wheel 6 33 Installing 6 33 Removing 6 33 Fuel 3 10 Fuel cock 3 11 Fuel consumption tips for reducing 5 4 Fuel tank breather hose Germany only 3 10 Fuel tank cap 3 9 Fuses replacing 6 29 H Handlebar switches 3 6 Hazard switch 3 6 Headlight bulb replacing for XJ600N 6 31 Headlight bulb replacing for XJ600S 6 30 Helmet holders 3 13 High beam indicator light 3 4 Horn switch 3 6 I Identificati...

Page 101: ... Starting a warm engine 5 2 Start switch 3 7 Steering checking 6 26 Steering lock for XJ600N 3 3 Storage 7 4 Storage compartment 3 13 Suspension rear lubricating 6 25 T Tachometer 3 5 Throttle cable free play adjusting 6 13 Throttle grip and cable checking and lubricating 6 24 Tires 6 14 Tool kit 6 1 Troubleshooting 6 36 Troubleshooting chart 6 37 Turn signal indicator lights 3 3 Turn signal switc...

Page 102: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 103: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 104: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2000 5 0 3 3 CR E ...

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