Yamaha XJ6NA Owner'S Manual Download

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PERIODIC MAINTENANCE AND ADJUSTMENT

6-2

EAU46860

TIP

●

The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.

●

From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).

●

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.

EAU46910

Periodic maintenance chart for the emission control system

NO.

ITEM

CHECK OR MAINTENANCE JOB

ODOMETER READING

ANNUAL

CHECK

1000 km

(600 mi)

10000 km

(6000 mi)

20000 km

(12000 mi)

30000 km

(18000 mi)

40000 km

(24000 mi)

Fuel line

• Check fuel hoses for cracks or

damage.

√

Spark plugs

• Check condition.
• Clean and regap.

√

• Replace.

√

Valves

• Check valve clearance.
• Adjust.

Every 40000 km (24000 mi)

Fuel injection

• Adjust engine idling speed and

synchronization.

√

Air induction sys-
tem

• Check the air cut-off valve, reed

valve, and hose for damage.

• Replace the entire air induction

system if necessary.

√

U36BE0E0.book Page 2 Monday, October 6, 2008 4:47 PM

Summary of Contents for XJ6NA

Page 1: ...DIC183 XJ6NA OWNER S MANUAL Read this manual carefully before operating this vehicle 36B 28199 E0 ...

Page 2: ...ion record No Contents Date To change contact person and integrate type designation 9 Jun 2005 Date of issue 1 Aug 2002 Place of issue Shizuoka Japan R TTE Directive 1999 5 EC EN300 330 2 v1 1 1 2001 6 EN60950 1 2001 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC is in compliance with following norm s or documents Kind of equipment IMMOBILIZER Type designation 5SL 00 Hereby dec...

Page 3: ...n 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 Therefore while this manual contains the most cur rent p...

Page 4: ...ey all safety messages that follow this symbol to avoid possible injury or death 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 vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP U36BE0E0 book Page 1 M...

Page 5: ...AL 2008 by Yamaha Motor Co Ltd 1st edition September 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U36BE0E0 book Page 2 Monday October 6 2008 4 47 PM ...

Page 6: ... 6 1 Periodic maintenance chart for the emission control system 6 2 General maintenance and lubrication chart 6 3 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 cable free play 6 18 Valve clearance 6 18 Tires 6 19 C...

Page 7: ...6 36 Replacing the license plate light bulb 6 37 Replacing the auxiliary light bulb 6 37 Supporting the motorcycle 6 38 Troubleshooting 6 39 Troubleshooting charts 6 40 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U36BE0E0 book Page 2 Monday October 6 2008 4 47 PM ...

Page 8: ...passenger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when...

Page 9: ...d contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Always wear protective clothing that covers your legs ankles and feet The eng...

Page 10: ... of the motorcycle to minimize imbalance or instabili ty Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres sure of your tires Never attach any...

Page 11: ...ight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories may...

Page 12: ...adjusting screw page 6 17 3 Seat lock page 3 18 4 Main fuse page 6 32 5 Fuse box page 6 32 6 Owner s tool kit page 6 1 7 Storage compartment page 3 20 8 Shift pedal page 3 13 9 Engine oil filter cartridge page 6 9 10 Engine oil drain bolt page 6 9 U36BE0E0 book Page 1 Monday October 6 2008 4 47 PM ...

Page 13: ... fluid reservoir page 6 23 4 Engine oil filler cap page 6 9 5 Radiator cap page 6 12 6 Coolant reservoir page 6 12 7 Coolant drain bolt page 6 14 8 Engine oil dipstick page 6 9 9 Brake pedal page 3 14 10 Shock absorber assembly spring preload adjusting ring page 3 21 U36BE0E0 book Page 2 Monday October 6 2008 4 47 PM ...

Page 14: ... 13 2 Left handlebar switches page 3 12 3 Main switch steering lock page 3 2 4 Multi function meter unit page 3 8 5 Front brake fluid reservoir page 6 23 6 Right handlebar switches page 3 12 7 Throttle grip page 6 18 8 Brake lever page 3 14 U36BE0E0 book Page 3 Monday October 6 2008 4 47 PM ...

Page 15: ...R 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 highly recom mended to use either standard key an...

Page 16: ... it for code re registering EAU38530 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 headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls EAU10661 OFF All electrical systems are...

Page 17: ...he key in and then turn it to OFF while still pushing it EAU34341 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 key can be removed The steering must be locked before the key can be turned to NOTICE ECA11020 Do not use the parking position for an e...

Page 18: ...o equipped with a self diagnosis device for the oil level detection circuit If a problem is detected in the oil level detection circuit the following cycle will be repeated until the malfunction is corrected The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU11425 Coolant temperature warning light This warning light...

Page 19: ...adiator fan equipped vehi cles the radiator fan s automati cally switch on or off according to the coolant temperature in the ra diator If the engine overheats see page 6 40 for further instructions U36BE0E0 book Page 5 Monday October 6 2008 4 47 PM ...

Page 20: ...o ahead with riding 117 139 C 243 283 F Temperature display flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 6 40 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 40 ABS ABS U36BE0E0 book Page 6 Monday October 6 20...

Page 21: ...ot to cause the wheels to lock during emergen cy braking If the warning light comes on or flashes while riding have a Yamaha dealer check the brake system as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on or remains on have a Yamaha dealer check the electrical circuit EAU38621 Immobilizer system indicator l...

Page 22: ... to turn the key to ON be fore using the SELECT and RE SET buttons For the U K only To switch the speedometer and odometer trip meter displays between kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will sw...

Page 23: ...d TRIP B in the following order TRIP A TRIP B ODO TRIP A When the fuel amount in the fuel tank decreases to 3 2 L 0 85 US gal 0 70 Imp gal the left segment of the fuel meter will start flashing and the odometer display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point In that case push the SELECT button to switch the displa...

Page 24: ...e electrical circuit Coolant temperature mode The coolant temperature display indi cates the temperature of the coolant NOTICE ECA10021 Do not continue to operate the en gine if it is overheating Self diagnosis device This model is equipped with a self diag nosis device for various electrical cir cuits If a problem is detected in any of those circuits the engine trouble warning light will come on ...

Page 25: ... off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start the engine take the vehicle the code re registering key and both standard keys to a Yamaha dealer and have the stan dard keys re registered If the display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle NOTICE ECA11590 If the display indicates an...

Page 26: ...this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12711 Start switch Push this switch to crank the engine with the starter See page 5 1 for start ing instructions prior to starting the en gine EAU42340 The eng...

Page 27: ...20 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 is part of the igni tion circuit cut off system See page 3 22 EAU12870 Shift pedal Th...

Page 28: ...stem features a dual electronic con trol system which acts on the front and rear brakes independently The ABS is monitored by an ECU Electronic Con trol Unit which will have recourse to manual braking if a malfunction occurs WARNING EWA10090 The ABS performs best on long braking distances On certain rough or gravel roads the braking distance may be longer with than without the ABS Therefore always...

Page 29: ...Keep any type of magnets including magnetic pick up tools magnetic screwdrivers etc away from the front and rear wheel hubs otherwise the magnetic rotors equipped in the wheel hubs may be damaged result ing in improper performance of the ABS system EAU13074 Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise Th...

Page 30: ... ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any spilled fuel immedi ate...

Page 31: ...s use a gasoline of a different brand or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance costs EAU39451 Fuel tank breather overflow hose Before operating the motorcycle Check the fuel tank breather over flow hose connection Check the fuel tank breather over flow hose for cracks or damage and replace it if damaged Make sure that the end of the fuel tan...

Page 32: ...ust sys tem has cooled down before do ing any maintenance work Do not allow the engine to idle more than a few minutes Long idling can cause a build up of heat NOTICE ECA10701 Use only unleaded gasoline The use of leaded gasoline will cause unre pairable damage to the catalytic converter EAU32980 Seat To remove the seat 1 Insert the key into the seat lock and then turn it counterclockwise 2 While ...

Page 33: ...the helmet strap as shown and then hook the cable loop over the helmet holder 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 EWA10161 To release the helmet from the hel met holder Remove the seat remove the helmet holding ca...

Page 34: ...storing the Owner s Manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the vehicle be careful not to let any water enter the storage compartment EAU46830 Handlebar position The handlebars can be adjusted to one of two positions to suit the rider s pref erence Have a Yamaha dealer adjust the position of the handleba...

Page 35: ...r s tool kit to make the adjustment WARNING EWA10221 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 du...

Page 36: ...en designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU44892 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol low...

Page 37: ... Move 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 switc...

Page 38: ...a dealer Before using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 3 16 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...

Page 39: ...le free play and lubricate cable and grip housing 6 18 6 27 Control cables Make sure that operation is smooth Lubricate if necessary 6 27 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 6 25 6 26 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 19 6 21 Brake and shift pedals Make sure tha...

Page 40: ...tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle 3 22 ITEM CHECKS PAGE U36BE0E0 book Page 3 Monday October 6 2008 4 47 PM ...

Page 41: ...h an engine auto stop system The engine stops automatically if left idling for 20 minutes In this case the multi function meter unit indi cates error code 70 but this is not a malfunction Push the start switch to clear the error code and to restart the engine EAU43123 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met...

Page 42: ...tempt EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration TIP To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE ECA10260 Even with the transmission in t...

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 EAU17093 0 1000 km 0 600 mi Avoid prolonged operation above 5800 r min NOTICE...

Page 44: ...d 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 U36BE0E0 book Page 4 Monday October 6 2008 4 47 PM ...

Page 45: ...with vehicle ser vice have a Yamaha dealer perform service WARNING EWA15121 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to dea...

Page 46: ...0 Periodic maintenance chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 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 ...

Page 47: ...ce brake pads Whenever worn to the limit 4 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout and for damage 7 Tires Check tread depth and for dam age Replace if necessary Check air pressure Correct if necessary 8 Wheel bearings Check bearing for loos...

Page 48: ... 13 Brake lever pivot shaft Lubricate with silicone grease 14 Brake pedal pivot shaft Lubricate with lithium soap based grease 15 Clutch lever pivot shaft Lubricate with lithium soap based grease 16 Shift pedal pivot shaft Lubricate with lithium soap based grease 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leak age 20 Shock a...

Page 49: ... Replace 23 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 24 Front and rear brake switches Check operation 25 Moving parts and cables Lubricate 26 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 27 Lights signals and switches Check operation Adjust...

Page 50: ... and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U36BE0E0 book Page 6 Monday October 6 2008 4 47 PM ...

Page 51: ...n take the cowling off To install the cowling Place the cowling in the original posi tion and then install the bolts EAU46770 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 EAU19193 Panel B To remove the panel Remove the bolts and then take...

Page 52: ...park 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 color when the vehicle is ridden normally and all spark plugs installed in the en gine should have the same color If any spark plug shows a distinctly different color the engine could be operating im properly Do not attempt to diagnose...

Page 53: ...il level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on a level sur face 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...

Page 54: ...ilter cartridge replace ment 1 Remove cowling A See page 6 7 2 Start the engine warm it up for 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 and drain bolt 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 ...

Page 55: ...hen install and tighten the oil filler cap TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust sys tem have cooled down NOTICE ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In 1 O ring 1 Torque wre...

Page 56: ... the oil level and correct it if necessary 12 Install the cowling EAU20070 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU46801 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion TIP The coolant level must be chec...

Page 57: ... If water has been used instead of coolant replace it with coolant as soon as possi ble otherwise the cooling sys tem will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10472 5 Route the coolant reservoir breath er ...

Page 58: ...ngine is hot EWA10381 5 Remove the coolant reservoir breather hose from the guide and then remove the coolant reservoir cap 6 Remove the coolant reservoir cov er and coolant reservoir by remov ing the bolts 7 Drain the coolant from the coolant reservoir by turning it upside down 8 Remove the coolant drain bolt to drain the cooling system 1 Radiator cap 2 Radiator cap retaining bolt 3 Radiator cap ...

Page 59: ... necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap radiator cap retainer and radi ator 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 breath er hose through the guide as shown Tighteni...

Page 60: ...t more frequently if you are riding in un usually wet or dusty areas 1 Remove the seat See page 3 18 2 Remove the fuel tank bolts and then lift the fuel tank away from the air filter case 3 Remove the air filter case cover by removing the screws NOTICE When removing the air filter case cover be careful not to al low foreign objects to drop into the air intake manifold ECA12881 4 Pull the air filte...

Page 61: ...tank overflow hose are not dam aged that they are properly con nected and routed and that they are not pinched If any hose is damaged have a Yamaha dealer replace the hose before starting the engine otherwise fuel may leak creating a fire hazard EWA12463 8 Install the fuel tank bolts 9 Install the seat EAU34301 Adjusting the engine idling speed The engine idling speed must be checked and if necess...

Page 62: ...eriodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 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 Engine idling speed...

Page 63: ...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 glass fragments in it or if the sidewall is cracked have a Yamaha dealer re place the tire immediately TIP The tire tread depth limits may differ from country to country Always co...

Page 64: ...to prevent air pressure leakage Use only the tire valves and valve cores listed below to avoid tire deflation during a high speed ride After extensive tests only the tires list ed below have been approved for this model by Yamaha Motor Co Ltd WARNING EWA10600 This motorcycle is fitted with super high speed tires Note the following points in order to make the most ef ficient use of these tires Use ...

Page 65: ... 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 EAU46730 Adjusting the clutch l...

Page 66: ... locknut EAU22272 Adjusting the rear brake light switch The rear brake light which is activated by the brake pedal should come on just before braking takes effect If neces sary adjust the rear brake light switch as follows 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 adjusting nut in direction a ...

Page 67: ...rn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pads Check each rear brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 1 5 mm 0 06 in have a Yamaha dealer replace the brake pads as a set EAU39371 Checking the brake fluid level Front b...

Page 68: ... braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the bra...

Page 69: ...h end of the swingarm 2 To tighten the drive chain turn the drive chain slack adjusting nut at each end of the swingarm in direc tion a To loosen the drive chain turn the adjusting nut at each end of the swingarm in direction b and then push the rear wheel for ward NOTICE Improper drive chain slack will overload the en gine as well as other vital parts of the motorcycle and can lead to chain slipp...

Page 70: ...ashing the motorcycle and riding in the rain 1 Clean the drive chain with kero sene and a small soft brush NOTICE To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inap propriate solvents ECA11121 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other l...

Page 71: ...l cause the in ner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EWA10721 EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU44271 Checking and lubricating the brake and ...

Page 72: ...er The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease U36BE0E0 book Page 28 Monday October 6 2008 4 47 PM ...

Page 73: ...c maintenance and lubrication chart EAU23272 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright...

Page 74: ...ff the ground See page 6 38 for more information WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be ch...

Page 75: ...lation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories NOTICE ECA16520 To charge a VRLA Valve Regulated Lead Aci...

Page 76: ...er the seat See page 3 18 TIP To access the main fuse remove the starter relay cover as shown If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Do not use a fuse of a higher amperage rating than recommended to 1 Starter relay cover 2 Main fuse 3 Spare m...

Page 77: ...art of the headlight bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin 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...

Page 78: ...slots in the meter stay 3 Remove the headlight unit by re moving the bolts 4 Disconnect the headlight coupler and then remove the headlight bulb cover 1 Do not touch the glass part of the bulb 1 Headlight unit side cover 2 Bolt 1 1 2 2 1 Multi function meter unit 2 Bolt 1 Projection 2 Slot 1 2 1 2 1 Headlight unit 2 Bolt 1 Headlight bulb cover 2 Headlight coupler 1 2 2 2 1 U36BE0E0 book Page 34 Mo...

Page 79: ... 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 11 Have a Yamaha dealer adjust the headlight beam if necessary 1 Headlight b...

Page 80: ...AU24204 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 counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw NOTICE Do not over tighten the screw otherwise the lens may break ECA11191 1 Tail brake ...

Page 81: ...it in 6 Install the license plate light unit by installing the screws EAU42872 Replacing the auxiliary light bulb If the auxiliary light bulb burns out re place it as follows 1 Remove the headlight unit See page 6 33 2 Remove the auxiliary light socket together with the coupler by turn ing the socket counterclockwise 3 Remove the burnt out bulb by pull ing it out 1 License plate light unit 2 Screw...

Page 82: ...ny maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the r...

Page 83: ...quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills WARNING EWA15141 When checking the fuel system do not smoke and ...

Page 84: ...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 eng...

Page 85: ... hissing 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 The coolant level is OK The coolant level is low Check th...

Page 86: ...utlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical 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...

Page 87: ...ild 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 riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corros...

Page 88: ...stic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU26181 Storage Short term Always ...

Page 89: ...ark plugs and then install the spark plugs and the spark plug caps 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires ...

Page 90: ... oil filter cartridge replacement 2 80 L 2 96 US qt 2 46 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity 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 only Fuel tank capacity 17 3 L 4 57 US gal 3 81 Imp gal Fuel re...

Page 91: ... 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi Loading condition 90 190 kg 198 419 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi High speed riding Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 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 Dual disc brake Operation Right...

Page 92: ...2 V 5 0 W 1 Meter lighting LED Neutral indicator light LED High beam 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 Immobilizer system indicator light LED Fuses 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 Rad...

Page 93: ...tification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification 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 mot...

Page 94: ...bel is affixed to the frame under the seat See page 3 18 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label 1 U36BE0E0 book Page 2 Monday October 6 2008 4 47 PM ...

Page 95: ...ches 3 12 Hazard switch 3 13 Headlight bulb replacing 6 33 Helmet holder 3 19 High beam indicator light 3 4 Horn switch 3 12 I Identification numbers 9 1 Ignition circuit cut off system 3 22 Immobilizer system 3 1 Immobilizer system indicator light 3 7 Indicator and warning lights 3 4 K Key identification number 9 1 L License plate light bulb replacing 6 37 M Main switch steering lock 3 2 Maintena...

Page 96: ... charts 6 40 Turn signal indicator light 3 4 Turn signal light bulb replacing 6 36 Turn signal switch 3 12 V Valve clearance 6 18 Vehicle identification number 9 1 W Wheel bearings checking 6 30 Wheels 6 21 U36BE0E0 book Page 2 Monday October 6 2008 4 47 PM ...

Page 97: ...U36BE0E0 book Page 3 Monday October 6 2008 4 47 PM ...

Page 98: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2008 11 0 3 2 CR E DIC183 ...

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Yamaha XJ6NA, Owner'S Manual

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