Yamaha XJ6 Owner'S Manual Download Page 59

Page: 59 / 104

Perio

ic maintenance an

justment

6-15

11. Install the coolant reservoir and its

cover by placing them in the origi-
nal position, and then installing the
bolts.

12. Pour the specified amount of the

recommended coolant into the ra-
diator and reservoir.

13. Install the radiator cap.
14. Install the coolant reservoir cap.
15. Start the engine, let it idle for sev-

eral minutes, and then turn it off.

16. Remove the radiator cap to check

the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radi-
ator, and then install the radiator
cap, radiator cap retainer and ra-
diator cap retaining bolt.

17. Check the coolant level in the res-

ervoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.

18. Route the coolant reservoir

breather hose through the guide
as shown.

19. Start the engine, and then check

the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.

20. Install the cowling and the panel.

Antifreeze/water mixture ratio:

1:1

Recommen

antifreeze:

High-quality ethylene glycol anti-
freeze containing corrosion inhibi-
tors for aluminum engines

Coolant quantity:

Radiator (including all routes):

2.00 L (2.11 US qt, 1.76 Imp.qt)

Coolant reservoir (up to the maxi-
mum level mark):

0.25 L (0.26 US qt, 0.22 Imp.qt)

1. Radiator cap
2. Radiator cap retaining bolt
3. Radiator cap retainer

1. Coolant reservoir breather hose
2. Guide

UB61E1E0.book Page 15 Wednesday, October 21, 2015 11:19 AM

Summary of Contents for XJ6

Page 1: ...DIC183 XJ6N XJ6NA XJ6 XJ6 ABS OWNER S MANUAL B61 28199 E1 MOTORCYCLE English E Read this manual carefully before oper ating this vehicle ...

Page 2: ...0 330 2 V1 5 1 2010 Technical Construction File held by YAMAHA MOTOR ELECTRONICS CO LTD 1450 6 Mori Mori machi Shuchi gun Shizuoka 437 0292 Japan R TTE Directive Article 3 1 a Safety R TTE Directive Article 3 1 b EMC R TTE Directive Article 3 2 Spectrum DECLARATION of CONFORMITY For YAMAHA MOTOR ELECTRONICS CO LTD 1450 6 Mori Mori machi Shuchi gun Shizuoka ken 437 0292 Japan Standard used for comp...

Page 3: ...y 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 Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality There fore while this manual contains the most curren...

Page 4: ... A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehi cle or other property A TIP provides key information to make proce dures easier or clearer XJ6N XJ6NA OWNER S MANUAL 2015 by Yamaha Motor Co Ltd 1st edition August 2015 All rights reserved Any reprinting or una...

Page 5: ... maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing the cowling and panels 6 7 Checking the spark plugs 6 8 Engine oil and oil filter cartridge 6 9 Coolant 6 12 Replacing the air filter element 6 16 Adjusting the engine idling speed 6 17 Checking the throttle grip free play 6 18 Valve clearance 6 18 Tires 6 19 Cast wheels 6 2...

Page 6: ...9 Replacing the license plate light bulb 6 40 Supporting the motorcycle 6 40 Front wheel for non ABS models 6 41 Rear wheel for non ABS models 6 42 Troubleshooting 6 44 Troubleshooting charts 6 45 Motorcycle care and storage 7 1 Matte color caution 7 1 Care 7 1 Storage 7 4 Specifications 8 1 Consumer information 9 1 Identification numbers 9 1 Index 10 1 UB61E1E0 book Page 2 Wednesday October 21 20...

Page 7: ... Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehi cle properly increases the possibility of an accident or equipment damage See page 4 1 for a list of pre operation checks This motorcycle is designed to carry the operator and a passen ger The failure of motorists to detect and recognize...

Page 8: ...ain tain control of the motorcycle The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or other drugs This motorcycle is designed for on road use only It is not su...

Page 9: ...on of the motorcycle is changed To avoid the possibility of an accident use extreme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here along with the information about accessories below are some general guidelines to follow if loading cargo to your motorcycle The total weight of the operator pas senger access...

Page 10: ...ormed to your vehicle that change any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the per form...

Page 11: ...truc tions before transporting the motorcy cle in another vehicle Remove all loose items from the motorcycle Check that the fuel cock if equipped is in the OFF position and that there are no fuel leaks Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to pre vent movement Shift the transmission in gear for models with a manual transmis sion Secure the m...

Page 12: ...6 2 Idle adjusting screw page 6 17 3 Seat lock page 3 18 4 Fuses page 6 34 5 Owner s tool kit page 6 2 6 Storage compartment page 3 20 7 Shift pedal page 3 12 8 Engine oil filter cartridge page 6 9 9 Engine oil drain bolt page 6 9 UB61E1E0 book Page 1 Wednesday October 21 2015 11 19 AM ...

Page 13: ...gine oil filler cap page 6 9 5 Fuel tank cap page 3 15 6 Radiator cap page 6 12 7 Coolant reservoir page 6 12 8 Coolant drain bolt page 6 13 9 Engine oil dipstick page 6 9 10 Brake pedal page 3 13 11 Rear brake light switch page 6 23 12 Shock absorber assembly spring preload adjusting ring page 3 21 UB61E1E0 book Page 2 Wednesday October 21 2015 11 19 AM ...

Page 14: ... 2 Left handlebar switches page 3 10 3 Main switch steering lock page 3 2 4 Multi function meter unit page 3 6 5 Front brake fluid reservoir page 6 25 6 Right handlebar switches page 3 10 7 Throttle grip page 6 18 8 Brake lever page 3 13 UB61E1E0 book Page 3 Wednesday October 21 2015 11 19 AM ...

Page 15: ...LOSE THE CODE RE REGISTERING KEY CONTACT YOUR DEALER IMMEDIATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highl...

Page 16: ... the standard key black bow for regular use of the vehicle To minimize the risk of losing the code re registering key red bow keep it in a safe place and only use it for code re registering EAU38531 ON All electrical circuits are supplied with power the meter lighting taillight li cense plate light and auxiliary light come on and the engine can be start ed The key cannot be removed TIP The headlig...

Page 17: ... steering will not lock try turning the handlebars back to the right slight ly To unlock the steering 1 Insert the key 2 With the key in the LOCK posi tion push the key in and turn it to OFF EAU34342 Parking The steering is locked and the taillight license plate light and auxiliary light are on The hazard lights and turn signal lights can be turned on but all other electrical systems are off The k...

Page 18: ...flicker when rid ing on a slope or during sudden acceleration or deceleration but this is not a malfunction This model is equipped with a self diagnosis device for the oil level detection circuit If a problem is detected in the oil level detection circuit the oil level warning light will flash repeatedly If this occurs have a Yamaha dealer check the vehicle EAU72930 Coolant temperature warning lig...

Page 19: ... on have a Yamaha dealer check the electrical circuit TIP The engine trouble warning light will come on while the start switch is pushed but this does not indicate a malfunction EAU51781 ABS warning light for ABS models In normal operation the ABS warning light comes on when the key is turned to ON and goes off after traveling at a speed of 10 km h 6 mi h or higher If the ABS warning light does no...

Page 20: ...ON or if the indicator light remains on have a Yamaha dealer check the electrical circuit The self diagnosis device also detects problems in the immobilizer system circuits See page 3 9 for an explana tion of the self diagnosis device EAU4676A Multi function meter unit WARNING EWA12423 Be sure to stop the vehicle before making any setting changes to the multi function meter unit Changing settings ...

Page 21: ...min in order to test the electri cal circuit NOTICE ECA10032 Do not operate the engine in the ta chometer red zone Red zone 11666 r min and above Clock The clock uses a 12 hour time system When the main switch is not in the ON position the clock can be viewed for 10 seconds by pushing the SE LECT button To set the clock 1 Turn the key to ON 2 Push the SELECT button and RESET button together for tw...

Page 22: ...ripmeter mode F TRIP and start counting the distance traveled from that point In that case push the SELECT button to switch the display between the vari ous tripmeter and odometer modes in the following order F TRIP TRIP A TRIP B ODO F TRIP If you do not reset the fuel reserve trip meter manually it will reset itself auto matically and the display will return to the prior mode after refueling and ...

Page 23: ... gine if it is overheating Self diagnosis device This model is equipped with a self di agnosis device for various electrical circuits If a problem is detected in any of those circuits the engine trouble warning light will come on and the display will indicate an error code If the display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle The self diagnos...

Page 24: ...stering key and both standard keys to a Yamaha dealer and have the stan dard keys re registered NOTICE ECA11591 If the display indicates an error co de the vehicle should be checked as soon as possible in order to avoid engine damage EAU1234H Handlebar switches Left Right EAU12352 Pass switch Press this switch to flash the headlight TIP When the dimmer switch is set to the passing switch has no ef...

Page 25: ...ush this switch to crank the engine with the starter See page 5 2 for start ing instructions prior to starting the en gine EAU44712 The engine trouble warning light and ABS warning light ABS model only may come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunc tion EAU12735 Hazard switch With the key in the ON or posi tion use this switch to turn o...

Page 26: ...ased slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 22 EAU12872 Shift pedal The shift pedal is located on the left side of the motorcycle and is used in combination with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle 1 Clutch lever ...

Page 27: ...ottle grip turn the ad justing dial while holding the lever pushed away from the throttle grip Make sure that the appropriate setting on the adjusting dial is aligned with the mark on the brake lever EAU12944 Brake pedal The brake pedal is located on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Brake lever 2 Brake lever position adjusting dial 3 mark 4 D...

Page 28: ...stem to conven tional braking if a malfunction occurs TIP The ABS performs a self diagno sis test each time the vehicle first starts off after the key is turned to ON and the vehicle has traveled at a speed of 10 km h 6 mi h or higher During this test a click ing noise can be heard from un der the seat and if the brake lever or brake pedal is even slightly ap plied a vibration can be felt at the l...

Page 29: ...13222 Fuel Make sure there is sufficient gasoline in the tank WARNING EWA10882 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or while in the vi cinity of sparks open flame...

Page 30: ...ere damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 95 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol ...

Page 31: ...st system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system Make sure that the exhaust sys tem has cooled down before doing any maintenance work Do not allow the engine to idle more than...

Page 32: ...e rear of the seat up and then pull the seat off To install the seat 1 Insert the projection on the front of the seat into the seat holder as shown 2 Push the rear of the seat down to lock it in place 3 Remove the key TIP Make sure that the seat is properly se cured before riding 1 Seat lock 2 Unlock 1 Projection 2 Seat holder 1 2 1 2 UB61E1E0 book Page 18 Wednesday October 21 2015 11 19 AM ...

Page 33: ... over the helmet hold er 3 Place the helmet on the right side of the vehicle and then install the seat WARNING Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident EWA10162 To release the helmet from the hel met holder Remove the seat remove the helmet holding cable from the helmet holder and the helmet and then in...

Page 34: ...be careful not to let any water enter the storage compartment WARNING EWA10962 Do not exceed the load limit of 3 kg 7 lb for the storage com partment Do not exceed the maximum load of 190 kg 419 lb XJ6NA 195 kg 430 lb XJ6N for the ve hicle EAU46833 Handlebar position The handlebar can be adjusted to one of two positions to suit the rider s pref erence Have a Yamaha dealer adjust the position of th...

Page 35: ...kit to make the adjustment WARNING EWA10222 This shock absorber assembly con tains highly pressurized nitrogen gas Read and understand the fol lowing information before handling the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Do not subject the shock ab sorber assembly to an open flame or other high heat source This may cause the unit to ex plode due to exce...

Page 36: ...f system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly and have a Yamaha dealer repair it if it does not function properly EAU66730 Ignition circuit cut off system The ignition circuit cut off system comprising the sidestand switch clutch switch and neutral switch has the following func...

Page 37: ...ove the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch ...

Page 38: ...e and check hose con nections 3 15 3 17 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 9 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 12 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pa...

Page 39: ... if necessary 6 19 6 21 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 29 Brake and clutch le vers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 30 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 30 Chassis fasteners Make sure that all nuts bolts and screws are properly tighten...

Page 40: ... stop the en gine in case of a turnover In this case the display will indicate error code 30 but this is not a malfunc tion Turn the key to OFF and then to ON to clear the error co de Failing to do so will prevent the engine from starting even though the engine will crank when push ing the start switch an engine auto stop system The engine stops automatically if left idling for 20 minutes In this ...

Page 41: ...r light remains on see page 3 4 for the correspond ing warning and indicator light cir cuit check For ABS models The ABS warning light should come on when the main switch is turned to ON and then go off af ter traveling at a speed of 10 km h 6 mi h or higher NOTICE ECA17682 If the ABS warning light does not come on and then go off as ex plained above see page 3 4 for the warning light circuit chec...

Page 42: ... raise it NOTICE ECA10261 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle 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 d...

Page 43: ...fully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17094 0 1000 km 0 600 mi Avoid prolonged operation above 5800 r min NOTICE...

Page 44: ...exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not park near grass or other flammable materials which might catch fire UB61E1E0 book Page 5 Wednesday October 21 2015 11 19 AM ...

Page 45: ...ntain the vehi cle or performing maintenance ac tivities incorrectly may increase your risk of injury or death during service or while using the vehicle If you are not familiar with vehicle ser vice have a Yamaha dealer perform service WARNING EWA15123 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothi...

Page 46: ...at is certified if applicable Yamaha dealers are trained and equipped to perform these particular services EAU39692 Owner s tool kit The owner s tool kit is located on the bottom of the seat See page 3 18 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 a...

Page 47: ... skills EAU63321 Periodic maintenance chart for the emission control system NO ITEM 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 24000 mi 4 Fuel injection Adjust engine idling speed and synchronization 5 Air induction sys tem Check the air cut off valve reed valve and hose for damage Rep...

Page 48: ... tread depth and for damage Replace if necessary Check air pressure Correct if necessary 9 Wheel bearings Check bearings for looseness or damage 10 Swingarm Check operation and for exces sive play Lubricate with lithium soap based grease Every 50000 km 30000 mi 11 Drive chain Check chain slack alignment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every...

Page 49: ...ront fork Check operation and for oil leakage 21 Shock absorber assembly Check operation and shock ab sorber for oil leakage 22 Engine oil Change Check oil level and vehicle for oil leakage 23 Engine oil filter cartridge Replace 24 Cooling system Check coolant level and vehicle for coolant leakage Change coolant Every 3 years 25 Front and rear brake switches Check operation 26 Moving parts and cab...

Page 50: ...eas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cyl inders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 28 Lights signals and switches Check operation Adjust headlight beam NO ITEM X 1000 km CHECK OR MAINTENANCE JOB X 1000 mi O...

Page 51: ...hen take the cowling off To install the cowling Place the cowling in the original posi tion and then install the bolts EAU56070 Panel A To remove the panel Remove the bolt and the quick fasten er and then take the panel off To install the panel Place the panel in the original position and then install the bolt and the quick fastener Panel B To remove the panel Remove the bolts and then take the pa...

Page 52: ...r around the center electrode of each spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally and all spark plugs installed in the engine should have the same color If any spark plug shows a dis tinctly different color the engine could be operating improperly Do not at tempt to diagnose such problems yourself Instead have a Yamaha deal er check the vehicle If...

Page 53: ...ied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on a level surfa ce and hold it in an upright posi tion 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 4 Remove the engine oil dipstick and wipe it clean insert it back int...

Page 54: ... several minutes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap the engine oil drain bolt and its gasket to drain the oil from the crankcase TIP Skip steps 5 7 if the oil filter cartridge is not being replaced 5 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a Yamaha dealer 6 Ap...

Page 55: ... additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 10 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause T...

Page 56: ...t the intervals specified in the periodic maintenance and lubrication chart EAU46804 To check the coolant level 1 Place the vehicle on a level surfa ce and hold it in an upright posi tion TIP The coolant level must be checked on a cold engine since the level varies with engine tem perature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the si...

Page 57: ...rrosion If water has been added to the coolant have a Yamaha dealer check the anti freeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10473 5 Route the coolant reservoir breather hose through the guide as shown EAU46824 To change the coolant 1 Place the vehicle on a level surfa ce and let the engine cool if neces sary 2 Remove cowling A ...

Page 58: ...sys tem 9 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 10 Install the coolant drain bolt and its new gasket and then tighten the bolt to the specified torque 1 Radiator cap 2 Radiator cap retaining bolt 3 Radiator cap retainer 1 Coolant reservoir cap 2 Coolant reservoir breather hose 3 Guide 2 1 3 3 1 2 1 Bolt 2 Coolant reservoir cover 3 Coolant...

Page 59: ...in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximum level mark and then install the cap 18 Route the coolant reservoir breather hose through the guide as shown 19 Start the engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system 20 Install the cowling and the panel Antifreeze water mixture rati...

Page 60: ... air filter element is properly seated in the air filter case The engine should never be operated without the air filter element installed otherwise the piston s and or cylinder s may become excessively worn ECA10482 6 Install the air filter case cover by installing the screws 7 Place the fuel tank in its original position Make sure that the fuel hoses are properly connected and routed and are not...

Page 61: ...engine should be warm before making this adjustment Check the engine idling speed and if necessary adjust it to specification by turning the idle adjusting screw To in crease the engine idling speed turn the screw in direction a To decrease the engine idling speed turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adj...

Page 62: ...just it EAU21402 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart 1 Throttle grip free play Throttle grip free play 3 0 5 0 mm 0 12 0 20 in UB61E1E0 book Page 18 Wednesday O...

Page 63: ...r 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 WARNING EWA10512 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident 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 ...

Page 64: ...lves Tires age even if they have not been used or have only been used occasion ally Cracking of the tread and sidewall rubber sometimes accompanied by carcass deformation is an evidence of ageing Old and aged tires shall be checked by tire specialists to ascertain their suitability for further use WARNING EWA10902 The front and rear tires should be of the same make and de sign otherwise the handli...

Page 65: ...o maximize the performance durabil ity and safe operation of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends warp age or other damage before each ride If any damage is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A de formed or cracked wheel must be replaced The wheel should...

Page 66: ...direction b TIP If the specified clutch lever free play cannot be obtained as described above proceed as follows 1 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 2 Loosen the locknut further down the clutch cable 3 To increase the clutch lever free play turn the clutch lever free play adjusting nut in direction a To decrease the clutch lever free play ...

Page 67: ...vated by the brake pedal and brake lever should come on just before braking takes effect If necessary adjust the rear brake light switch as follows but the front brake light switch should be adjusted by a Yamaha dealer Turn the rear brake light switch adjust ing nut while holding the rear brake light switch in place To make the brake light come on earlier turn the ad justing nut in direction a To ...

Page 68: ...r groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU46292 Rear brake pads Each rear brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad ...

Page 69: ...efill with the same type of brake fluid Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water or dust does not enter the brake fluid reservoir when refilling Water will significantly lower the boil ing point of the fluid and may re sult in vapor lock and dirt may clog the ABS hydraulic unit valves NOTICE ECA17641 Brake fluid may damage painted surfac...

Page 70: ...ould be checked before each ride and adjusted if necessary EAU2277B To check the drive chain slack 1 Place the motorcycle on the side stand TIP When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neutral position 3 Measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows EAU53911 ...

Page 71: ...ep the drive chain slack with in the specified limits ECA10572 TIP Using the alignment marks on each drive chain puller make sure that both chain pullers are in the same position for proper wheel alignment 3 Tighten the axle nut and then tighten the locknuts to the speci fied torques 4 Make sure that the drive chain pullers are in the same position the drive chain slack is correct and the drive ch...

Page 72: ...ive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubri cants for the drive chain as they may contain substances that could damage the O rings ECA11112 EAU23098 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 a...

Page 73: ...icat ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart EAU44276 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 Brake pedal Shift pedal Recommended lubricant Lithium soap based grease UB61E1E0 book Page 29 Wednesday October 21 2...

Page 74: ...hould be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10732 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control Recommended lubricants Brake lever Silicone gre...

Page 75: ...the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level surfa ce and hold it in an upright posi tion WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10752 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 sm...

Page 76: ... vehicle so there is no danger of it falling over EWA10752 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 steer ing EAU23292 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...

Page 77: ... 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 quick ly if the vehicle is equipped with op tional electrical accessories NOTICE ECA16522 To charge a V...

Page 78: ...attery can cause permanent battery damage EAU47174 Replacing the fuses The main fuse and the fuse boxes which contain the fuses for the individ ual circuits are located under the seat See page 3 18 TIP To access the main fuse remove the starter relay cover as shown XJ6N XJ6N 1 Starter relay cover 2 Main fuse 3 Spare main fuse 4 Fuse box 1 Taillight fuse 2 Spare fuse 3 Headlight fuse 4 Ignition fus...

Page 79: ... Yamaha dealer check the electrical system 1 Starter relay cover 2 Main fuse 3 Spare main fuse 4 Fuse box 1 Taillight fuse 2 ABS control unit fuse 3 ABS solenoid fuse 4 ABS motor fuse 5 Spare fuse 6 Headlight fuse 7 Ignition fuse 8 Signaling system fuse 9 Backup fuse for clock and immobilizer sys tem 10 Fuel injection system fuse 11 Radiator fan motor fuse 2 4 3 1 1 5 5 6 7 8 9 10 11 2 34 Specifie...

Page 80: ...gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 1 Remove the headlight unit side covers by removing the bolts on each side 2 Remove the multi function meter unit bolts and then lift up the me ter to unhook its projecti...

Page 81: ...into the grommet in the head light stay and then install the headlight unit by installing the bolts 9 Fit the projections on the multi function meter unit into the slots in the meter stay place the meter in the original position and then in stall the bolts 10 Place the headlight unit side cov ers in their original position and then install the bolts 1 Headlight unit 2 Bolt 1 Headlight bulb cover 2...

Page 82: ...the auxiliary light coupler together with the socket and bulb by turning the coupler coun terclockwise 3 Remove the burnt out bulb by pulling it out 4 Insert a new bulb into the socket 5 Install the coupler together with the socket and bulb by turning it clockwise 6 Install the headlight unit 1 Auxiliary light coupler 1 Auxiliary light bulb 2 Auxiliary light bulb socket 3 Auxiliary light coupler 1...

Page 83: ...5 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the burnt out bulb by pushing it in and turning it coun terclockwise 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 NOTICE Do not over tighten the screw otherwise the lens may break ECA11192 1 Brake tail light ...

Page 84: ...d upright Check that the motorcy cle is in a stable and level position be fore starting any maintenance A strong wooden box can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcy cle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack under the frame in front of the rear wheel 2 Raise the fr...

Page 85: ...y the brake after the brake calipers have been removed otherwise the brake pads will be forced shut ECA11052 4 Pull the wheel axle out and then remove the wheel To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Install the brake calipers by install ing the bolts TIP Make sure that there is enough space between the brake pads before install ing the brake...

Page 86: ...t falling over 1 Loosen the locknut and drive chain slack adjusting nut on each side of the swingarm 2 Loosen the axle nut 3 Lift the rear wheel off the ground according to the procedure on page 6 40 4 Remove the axle nut 5 Push the wheel forward and then remove the drive chain from the rear sprocket Tightening torques Wheel axle 65 Nm 6 5 m kgf 47 ft lbf Front wheel axle pinch bolt 19 Nm 1 9 m kg...

Page 87: ...brake pads will be forced shut ECA11073 To install the rear wheel 1 Install the wheel and the brake cal iper bracket by inserting the wheel axle from the right side TIP Make sure that the slot in the brake caliper bracket is fit over the retainer on the swingarm Make sure that there is enough space between the brake pads before installing the wheel 2 Install the drive chain onto the rear sprocket ...

Page 88: ...se 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 WARNING EWA15142 When checking the fuel system do not smoke and make sure there are no open flames or sparks in ...

Page 89: ...ave a Yamaha dealer charge the battery if necessary 2 Battery The battery is good The engine does not start Check the ignition 3 Ignition Wet Operate the electric starter Dry There is compression There is no compression The engine does not start Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle The engine does not start Check the compression Have a Yamaha dealer check t...

Page 90: ...issing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator Add coolant See TIP The coolant level is OK There is no lea...

Page 91: ...appearance of a mo torcycle Frequent and proper care does not only comply with the terms of the warranty but it will also keep your motorcycle looking good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and cov ers as well as all electrical cou plers and connectors including the s...

Page 92: ...d lights breather hoses and vents For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plastic may leave scratches on the wind shield Test the product on a small hidden part of the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quality plastic polis...

Page 93: ... the motorcycle dry completely before storing or covering it WARNING EWA11132 Contaminants on the brakes or tires can cause loss of control 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 acetone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the moto...

Page 94: ...rk plugs and then pla ce the spark plugs on the cylin der head so that the electrodes are grounded 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 WARNING To prevent dam age or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10952 e Remove the spark plu...

Page 95: ...Motorcycle care and storage 7 5 7 TIP Make any necessary repairs before storing the motorcycle UB61E1E0 book Page 5 Wednesday October 21 2015 11 19 AM ...

Page 96: ... oil quantity Oil change 2 50 L 2 64 US qt 2 20 Imp qt With oil filter removal 2 80 L 2 96 US qt 2 46 Imp qt Coolant quantity Coolant reservoir up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator including all routes 2 00 L 2 11 US qt 1 76 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline Gasohol E10 acceptable Fuel tank c...

Page 97: ...98 lb load Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi 90 kg 198 lb load maximum load Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT4 50 Front brake Type Hydraulic dual disc brake Specified brake fluid DOT 4 Rear brake Type Hydraulic single disc brak...

Page 98: ...am indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED ABS warning light LED XJ6NA Immobilizer system indicator light LED Fuse s Main fuse 30 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 7 5 A Ignition fuse 10 0 A Radiator fan motor fuse 20 0 A Fuel injection system fuse 10 0...

Page 99: ...cation number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area EAU26442 Engine serial number The engine serial number is stamped into the crankcase EAU26481 Model label The ...

Page 100: ...Consumer information 9 2 9 space provided This information will be needed when ordering spare parts from a Yamaha dealer UB61E1E0 book Page 2 Wednesday October 21 2015 11 19 AM ...

Page 101: ...ng 5 4 Fuel tank breather hose and overflow hose 3 17 Fuel tank cap 3 15 Fuses replacing 6 34 H Handlebar position adjusting 3 20 Handlebar switches 3 10 Hazard switch 3 11 Headlight bulb replacing 6 36 Helmet holder 3 19 High beam indicator light 3 4 Horn switch 3 11 I Identification numbers 9 1 Ignition circuit cut off system 3 22 Immobilizer system 3 1 Immobilizer system indicator light 3 6 Ind...

Page 102: ...45 Turn signal indicator light 3 4 Turn signal light bulb replacing 6 39 Turn signal switch 3 11 V Valve clearance 6 18 Vehicle identification number 9 1 W Wheel bearings checking 6 32 Wheel front for non ABS models 6 41 Wheel rear for non ABS models 6 42 Wheels 6 21 UB61E1E0 book Page 2 Wednesday October 21 2015 11 19 AM ...

Page 103: ...UB61E1E0 book Page 3 Wednesday October 21 2015 11 19 AM ...

Page 104: ...DIC183 Original instructions PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2015 10 0 3 1 CR E ...

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Yamaha XJ6, Owner'S Manual

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