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PERIODIC MAINTENANCE AND MINOR REPAIR

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Tool kit................................................................ 6-1
Periodic maintenance and lubrication................. 6-2
Panel removal and installation ........................... 6-5
Panel A............................................................... 6-5
Spark plug inspection ......................................... 6-6
Engine oil............................................................ 6-7
Air filter ............................................................. 6-10
Carburetor adjustment...................................... 6-11
Idle speed adjustment ...................................... 6-12
Throttle cable free play inspection.................... 6-12
Valve clearance adjustment ............................. 6-13
Tires ................................................................. 6-13
Wheels ............................................................. 6-15
Clutch lever free play adjustment ..................... 6-15
Rear brake pedal height adjustment ................ 6-17
Brake light switch adjustment........................... 6-17
Checking the front and rear brake pads ........... 6-18
Inspecting the brake fluid level ......................... 6-19
Brake fluid replacement.................................... 6-20
Drive chain slack check.................................... 6-20
Drive chain slack adjustment............................ 6-21

Drive chain lubrication.......................................6-21
Cable inspection and lubrication.......................6-22
Throttle cable and grip lubrication.....................6-22
Brake and shift pedal lubrication.......................6-22
Brake and clutch lever lubrication.....................6-23
Center and sidestand lubrication ......................6-23
Rear suspension lubrication..............................6-23
Front fork inspection .........................................6-24
Steering inspection ...........................................6-24
Wheel bearings.................................................6-25
Battery...............................................................6-25
Fuse replacement .............................................6-26
Headlight bulb replacement (for XJ600S).........6-27
Headlight bulb replacement (for XJ600N).........6-29
Front wheel removal .........................................6-31
Front wheel installation .....................................6-31
Rear wheel removal..........................................6-33
Rear wheel installation......................................6-34
Troubleshooting ................................................6-34
Troubleshooting chart .......................................6-35

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Содержание Diversion XJ600N

Страница 1: ...4BR 28199 E6 OWNER S MANUAL XJ600S ...

Страница 2: ...e the time to read this manual thoroughly so as to enjoy all your XJ600S XJ600NÕs advantages The ownerÕs 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 to keep your motorcycle in the best possible condition If you have any furth...

Страница 3: ...precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer l This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold l Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most curr...

Страница 4: ... Net layout8 layout_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE IMPORTANT MANUAL INFORMATION ...

Страница 5: ...00SN E6 English E EAU00008 XJ600S XJ600N OWNERÕS MANUAL 1999 by Yamaha Motor Co Ltd 1st Edition April 1999 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Страница 6: ...600SN E6 English E TOC 1 GIVE SAFETY THE RIGHT OF WAY 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX ...

Страница 7: ... Net layout8 layout_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E TOC ...

Страница 8: ...GIVE SAFETY THE RIGHT OF WAY Net layout8 layout_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E 1TOC GIVE SAFETY THE RIGHT OF WAY 1 1 ...

Страница 9: ...t their mental and physical best Under the influence of 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 proper...

Страница 10: ...yout8 layout_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E 2TOC Left view XJ600S 2 1 Right view XJ600S 2 2 Controls Instruments XJ600S 2 3 Left view XJ600N 2 4 Right view XJ600N 2 5 Controls Instruments XJ600N 2 6 ...

Страница 11: ..._XJ600SN E6 English E 2 frame Left view XJ600S EAU00026 1 Fuel cock page 3 13 2 Helmet holder page 3 15 3 Fuse box page 6 26 4 Luggage strap holders page 3 16 5 Seat lock page 3 14 6 Rear shock absorber spring preload adjusting ring page 3 15 7 Shift pedal page 3 10 ...

Страница 12: ...t_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E 2 frame Right view XJ600S 8 Tail brake light page 6 17 9 Storage compartment page 3 15 10 Seat page 3 14 11 Fuel tank page 3 11 12 Headlight page 6 27 13 Rear brake pedal page 3 11 ...

Страница 13: ...frame Controls Instruments XJ600S 14 Clutch lever page 3 9 15 Left handlebar switches page 3 7 16 Starter choke Ò Ó page 3 14 17 Speedometer page 3 6 18 Tachometer page 3 7 19 Right handlebar switches page 3 9 20 Front brake lever page 3 10 21 Throttle grip page 6 12 22 Main switch page 3 1 ...

Страница 14: ... E6 English E 2 frame Left view XJ600N 1 Steering lock page 3 3 2 Fuel cock page 3 13 3 Helmet holder page 3 15 4 Fuse box page 6 26 5 Luggage strap holders page 3 16 6 Seat lock page 3 14 7 Rear shock absorber spring preload adjusting ring page 3 15 8 Shift pedal page 3 10 ...

Страница 15: ...t_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E 2 frame Right view XJ600N 9 Tail brake light page 6 17 10 Storage compartment page 3 15 11 Seat page 3 14 12 Fuel tank page 3 11 13 Headlight page 6 27 14 Rear brake pedal page 3 11 ...

Страница 16: ...frame Controls Instruments XJ600N 15 Clutch lever page 3 9 16 Left handlebar switches page 3 7 17 Starter choke Ò Ó page 3 14 18 Speedometer page 3 6 19 Tachometer page 3 7 20 Right handlebar switches page 3 9 21 Front brake lever page 3 10 22 Throttle grip page 6 12 23 Main switch page 3 1 ...

Страница 17: ... Net layout8 layout_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E 2 frame ...

Страница 18: ...3 6 Speedometer for XJ600N 3 6 Tachometer 3 7 Handlebar switches 3 7 Clutch lever 3 9 Shift pedal 3 10 Front brake lever 3 10 Rear brake pedal 3 11 Fuel tank cap 3 11 Fuel 3 12 Fuel tank breather hose for Germany only 3 12 Fuel cock 3 13 Starter choke Ò Ó 3 14 Seat 3 14 Helmet holders 3 15 Storage compartment 3 15 Rear shock absorber adjustment 3 15 Luggage strap holders 3 16 Sidestand 3 17 Sidest...

Страница 19: ... started The key cannot be removed in this position EAU00038 OFF All electrical circuits are switched off The key can be removed in this posi tion EAU00040 LOCK for XJ600S The steering is locked in this position and all electrical circuits are switched off The key can be removed in this po sition To lock the steering turn the handlebars all the way to the left While pushing the key into the main s...

Страница 20: ... the taillight and auxiliary light come on but all other circuits are off The key can be removed in this position To use the parking position first lock the steering then turn the key to Ò Ó Do not use this position for an extend ed length of time as the battery may discharge 1 Push 2 Release 3 Turn EAU00055 P Parking for XJ600N The taillight and auxiliary light come on but all other circuits are ...

Страница 21: ...0 0 1 0 0 0 0 3 4 5 2 1 XJ600S 1 Left turn indicator light Ò Ó 2 High beam indicator light Ò Ó 3 Right turn indicator light Ò Ó 4 Neutral indicator light Ò Ó 5 Oil level indicator light Ò Ó EAU00056 Indicator lights EAU00058 Turn indicator lights Ò Ó Ò Ó The corresponding indicator flashes when the turn switch is moved to the left or right EAU00061 Neutral indicator light Ò Ó This indicator comes ...

Страница 22: ...J600SN E6 English E 3 frame EC000000 CAUTION Do not run the motorcycle until you know it has sufficient engine oil NOTE Even if the oil is filled to the specified level the indicator light may flicker when riding on a slope or during sud den acceleration or deceleration but this is normal ...

Страница 23: ...level indicator light does not come on Oil level indicator light comes on Check engine oil level Oil level indicator light comes on Oil level indicator light does not come on Engine oil level and electrical circuit are OK Go ahead with riding Put the transmission in neutral or apply the clutch lever then push the start switch Oil level is OK Supply engine oil Oil level is low Ask a Yamaha dealer t...

Страница 24: ... reset to Ò0Ó with the reset button Use the trip odometer to estimate how far you can ride on a tank of fuel This information will enable you to plan fuel stops in the future 1 Speedometer 2 Odometer 3 Trip odometer 4 Reset knob EAU00095 Speedometer for XJ600N The speedometer shows riding speed This speedometer is equipped with an odometer and trip odometer The trip odometer can be reset to Ò0Ó wi...

Страница 25: ... speed and keep it within the ideal power range EC000003 CAUTION Do not operate in the red zone Red zone 9 500 r min and above except for CH A 8 500 r min and above for CH A 1 Tachometer 2 Red zone except for CH A 3 Red zone for CH A 1 Pass switch ÒPASSÓ 2 Dimmer switch 3 Hazard switch Ò Ó 4 Turn signal switch 5 Horn switch Ò Ó EAU00118 Handlebar switches EAU00120 Pass switch ÒPASSÓ Press the swit...

Страница 26: ...CAUTION The battery can discharge from ex tended use making it difficult to op erate the starter NOTE Turn on the hazard switch to warn oth er drivers if your motorcycle must be stopped where it might be a traffic haz ard EAU00127 Turn signal switch To signal a right hand turn push the switch to Ò Ó To signal a left hand turn push the switch to Ò Ó Once the switch is released it will return to the...

Страница 27: ... auxiliary light meter lights and taillight Turning the light switch to Ò Ó turns the headlight on also EAU00143 Start switch Ò Ó The starter motor cranks the engine when pushing the start switch EC000005 CAUTION See starting instructions prior to starting the engine 1 Clutch lever EAU00152 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut off system is in...

Страница 28: ...m bination with the clutch when shifting 1 Front brake lever 2 Position adjusting nut EAU00160 Front brake lever The front brake lever is located on the right handlebar and is equipped with a position adjuster To activate the front brake pull the lever toward the handle bar 1 Position adjusting nut 2 Proper position To adjust the front brake lever position turn the adjusting nut while pulling the ...

Страница 29: ...ank cap To open Open the lock cover Insert the key and turn it 1 4 turn clockwise The lock will be released and the cap can be opened To close Push the tank cap into position with the key inserted To remove the key turn it counterclockwise to the original posi tion Then close the lock cover NOTE This tank cap cannot be closed unless the key is in the lock The key cannot be removed if the cap is no...

Страница 30: ...85 CAUTION Always wipe off spilled fuel immedi ately with a dry and clean soft cloth Fuel may deteriorate painted surfac es or plastic parts EAU00191 NOTE If knocking or pinging occurs use a dif ferent brand of gasoline or higher oc tane grade Recommended fuel Regular unleaded gasoline with a research octane number of 91 or higher Fuel tank capacity Total 17 0 L Reserve 3 5 L 1 Fuel tank breather ...

Страница 31: ...positioned over ÒRESÓ RES This stands for ÒreserveÓ If you are running out of fuel while riding with the fuel cock in the ÒONÓ position quickly turn the lever to this position Other wise the engine may die and will have to be primed see ÒPRIÓ below After turning the lever to ÒRESÓ fill the tank at the first opportunity and be sure to set the fuel cock back to ÒONÓ 1 Arrow mark positioned over ÒPRI...

Страница 32: ...e A separate starter cir cuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke 1 Open EAU02925 Seat To remove Insert the key in the lock and turn it counterclockwise 1 Projection 2 2 Seat holder To install Insert the projections on the front of the seat into the seat holder then push down on the seat NOTE Make sure that the se...

Страница 33: ...h the straps when storing it in the compartment To prevent losing the straps be sure to secure them even when a U LOCK is not being stored in the compartment When storing this OwnerÕs manual or other documents in the compartment be sure to put them in a vinyl bag so they do not get wet When washing the motorcycle be careful not to flood this compartment with water 1 Spring preload adjusting ring 2...

Страница 34: ...jury that may result from improper handling l Do not tamper with or attempt to open the cylinder assembly l Do not subject the shock ab sorber to an open flame or other high heat source This may cause the unit to explode due to excessive gas pressure l Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance l Take your shock absorber to a Yamaha deal...

Страница 35: ...gned into this mo torcycle a lockout system to assist the operator in fulfilling the respon sibility of retracting the sidestand Please check carefully the operating instructions listed below and if there is any indication of a malfunction return the motorcycle to a Yamaha dealer immediately for repair EAU00332 Sidestand clutch switch operation check Check the operation of the sidestand switch and...

Страница 36: ...PRE OPERATION CHECKS Net layout8 layout_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E 4TOC Pre operation check list 4 1 ...

Страница 37: ... level and fluid leakage Fill with DOT 4 or DOT 3 brake fluid if necessary 6 18 6 20 Rear brake 6 17 6 20 Clutch Check operation condition and free play Adjust if necessary 6 15 6 16 Throttle grip and housing Check for smooth operation Lubricate if necessary 6 12 6 22 Engine oil Check oil level Fill with oil if necessary 6 7 6 9 Drive chain Check chain slack and condition Adjust if necessary 6 20 ...

Страница 38: ...nd the added safety it assures is more than worth the time involved If any item in the PRE OPERATION CHECK 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 Ñ Fuel tank Check fuel level Fill with fuel if necessary 3 11 3 12 Lights signals and switches Check fo...

Страница 39: ... Net layout8 layout_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E 4 frame ...

Страница 40: ...8 layout_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E 5TOC Starting the engine 5 1 Starting a warm engine 5 4 Shifting 5 4 Recommended shift points for Switzerland only 5 5 Tips for reducing fuel consumption 5 5 Engine break in 5 5 Parking 5 6 ...

Страница 41: ...ays operate your motorcycle in an area with adequate ventila tion l Before starting out always be sure the sidestand is up Failure to retract the sidestand com pletely can result in a serious accident when you try to turn a corner EAU00381 Starting the engine NOTE This motorcycle is equipped with an ig nition circuit cut off system The engine can be started only under one of the following conditio...

Страница 42: ...O ÒONÓ AND THE ENGINE STOP SWITCH TO Ò Ó IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN PUSH THE START SWITCH ENGINE WILL START RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP PULL IN THE CLUTCH LEVER AND PUSH THE START SWITCH ENGINE WILL START MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN ...

Страница 43: ...ank the engine more than 10 seconds on any one attempt EC000034 CAUTION The oil level indicator light should come on when the start switch is pushed and should go off when the start switch is released If the indica tor light flickers or remains on im mediately stop the engine and check the engine oil level and for oil leakage If necessary fill the engine with oil and check to see that the oil leve...

Страница 44: ...ting climbing hills etc The use of the shift pedal is shown in the illustration To shift into neutral depress the shift pedal repeatedly until it reaches the end of its travel then raise the pedal slightly EC000048 CAUTION l Do not coast for long periods with the engine off and do not tow the motorcycle a long dis tance Even with gears in neu tral the transmission is only properly lubricated when ...

Страница 45: ...ble l Shift up swiftly and avoid high en gine speeds during acceleration l Do not double clutch or rev the en gine while shifting down and avoid high engine speeds with no load on the engine l Turn off the engine instead of let ting it idle for an extended length of time i e in traffic jams at traffic lights or railroad crossings EAU00436 Engine break in There is never a more important period in t...

Страница 46: ...0 km Avoid prolonged full throttle operation Avoid cruising speeds in excess of 7 000 r min EC000052 CAUTION After 1 000 km of operation be sure to replace the engine oil and oil fil ter 1 000 km and beyond Full throttle can be used EC000053 CAUTION l Never let engine speeds enter the red zone l If any engine trouble should oc cur during the break in period consult a Yamaha dealer imme diately EAU...

Страница 47: ... Net layout8 layout_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E 5 frame ...

Страница 48: ...d rear brake pads 6 18 Inspecting the brake fluid level 6 19 Brake fluid replacement 6 20 Drive chain slack check 6 20 Drive chain slack adjustment 6 21 Drive chain lubrication 6 21 Cable inspection and lubrication 6 22 Throttle cable and grip lubrication 6 22 Brake and shift pedal lubrication 6 22 Brake and clutch lever lubrication 6 23 Center and sidestand lubrication 6 23 Rear suspension lubric...

Страница 49: ...adjustment and lubrication are explained in the fol lowing pages EW000060 If you are not familiar with motor cycle service this work should be done by a Yamaha dealer EAU00462 1 Tool kit EAU00469 Tool kit The service information included in this manual is intended to provide you the owner with the necessary information for completing some of your own pre ventive maintenance and minor re pairs The ...

Страница 50: ...if necessary Ö Ö Ö 4 Valves Check valve clearance Adjust if necessary Every 24 000 km or 24 months whichever comes first 5 Air filter Clean or replace if necessary Ö Ö 6 Clutch Check operation Adjust or replace cable Ö Ö Ö 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Correct accordingly Replace brake pads if necessary Ö Ö Ö 8 Rear brake Check operati...

Страница 51: ...ate with lithium soap base grease every 24 000 km or 24 months whichever comes first Ö Ö 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Ö Ö 16 Sidestand centerstand Check operation Lubricate and repair if necessary Ö Ö 17 Sidestand switch Check operation Replace if necessary Ö Ö Ö 18 Front fork Check operation and for oil leakage Correct a...

Страница 52: ...id Check the brake fluid level regularly and fill as required Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years Replace the brake hoses every four years or if cracked or damaged 21 Carburetors Check engine idling speed synchronization and starter operation Adjust if necessary Ö Ö Ö 22 Engine oil Check oil level and vehicle for oil leakage Correct ...

Страница 53: ...installation The panel illustrated needs to be re moved to perform some of the mainte nance described in this chapter Refer to this section each time the panel has to be removed or installed 1 Screw 2 EAU02926 Panel A To remove 1 Remove the seat See page 3 14 for seat removal and installation procedures 2 Remove the screws and slide it as shown to unhook it ...

Страница 54: ...olor at this point is a medium to light tan color for a motorcycle that is being ridden normal ly If one spark plug shows a distinctly different color there could be some thing wrong with the engine Do not attempt to diagnose such prob lems yourself Instead take the motor cycle to a Yamaha dealer The spark plugs should be periodically removed and inspected because heat and de posits will cause any...

Страница 55: ... Tightening torque Spark plug 12 5 Nm 1 25 mákg 1 Level window 2 Maximum level mark 3 Minimum level mark EAU02938 Engine oil Oil level inspection 1 Place the motorcycle on the cen terstand Warm up the engine for several minutes NOTE Be sure the motorcycle is positioned straight up when checking the oil level A slight tilt toward the side can result in false readings 1 Engine oil filler cap 2 With ...

Страница 56: ...the engine and remove the oil filler cap 3 Remove the drain bolt and drain the oil 1 Oil filter cartridge 2 Oil filter wrench 4 Remove the oil filter by using an oil filter wrench NOTE An oil filter wrench is available at a nearby Yamaha dealer 5 Install the drain bolt and tighten it to the specified torque Tightening torque Drain bolt 43 Nm 4 3 mákg 1 O ring 6 Apply a light coat of engine oil to ...

Страница 57: ...o not put in any chemical addi tives Engine oil also lubricates the clutch and additives could cause clutch slippage l Be sure no foreign material en ters the crankcase Recommended oil See page 8 1 Oil quantity Total amount 3 1 L Periodic oil change 2 3 L With oil filter replacement 2 6 L 9 Start the engine and warm it up for several minutes While warming up check for oil leakage If oil leakage is...

Страница 58: ...e cleaned at the specified intervals It should be cleaned more frequently if you are riding in un usually wet or dusty areas 1 Remove the seat See page 3 14 for seat removal and installation procedures 2 Turn the fuel cock lever to ÒONÓ Then remove the fuel cock lever by removing the screw 1 Fuel hose 2 Vacuum hose 3 Drain hose 3 Disconnect the hoses 4 Remove the fuel tank ...

Страница 59: ... Make sure the air filter is prop erly seated in the air filter case l The engine should never be run without the air filter installed Excessive piston and or cylin der wear may result EAU00630 Carburetor adjustment The carburetors are important parts of the engine and require very sophisti cated adjustment Most adjustments should be left to a Yamaha dealer who has the professional knowledge and e...

Страница 60: ...ly responds to the throttle 2 Set the idle to the specified engine speed by adjusting the throttle stop screw Turn the screw in di rection a to increase engine speed and in direction b to de crease engine speed NOTE If the specified idle speed cannot be obtained by performing the above ad justment consult a Yamaha dealer Standard idle speed 1 200 1 300 r min a Free play EAU00635 Throttle cable fre...

Страница 61: ...d adjust the tire pres sure before operating the motorcycle EW000082 Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature Tire infla tion pressure must be adjusted ac cording to total weight of cargo rider passenger and accessories fairing saddlebags etc if approved for this model and vehicle speed Maximum load XJ600S 184 kg XJ6...

Страница 62: ...ing saddlebags etc if approved for this model does not exceed the maximum load of the motorcycle Operation of an over loaded motorcycle could cause tire damage an accident or even injury a Tread depth 1 Side wall Tire inspection Always check the tires before operating the motorcycle If center tread depth reaches the limit as shown if the tire has a nail or glass fragments in it or if the side wall...

Страница 63: ... in a wheel consult a Yamaha dealer Do not attempt even small repairs to the wheel If a wheel is deformed or cracked it must be replaced l Tires and wheels should be bal anced whenever either one is changed or replaced Failure to have a wheel balanced can result in poor performance adverse han dling characteristics and short ened tire life l Ride at moderate speeds after changing a tire since the ...

Страница 64: ...nnot be ob tained proceed with the following steps 4 Loosen the locknut at the clutch le ver 5 Turn the adjusting bolt at the clutch lever in direction a to loos en the cable 6 Loosen the locknut at the crank case side 7 Turn the adjusting nut at the crankcase in direction a to in crease free play or in direction b to decrease free play 8 Tighten the locknut at the crank case and the clutch lever ...

Страница 65: ...e is operated Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident Have a Yamaha dealer inspect and bleed the system if necessary 1 Brake light switch 2 Adjusting nut EAU00713 Brake light switch adjustment The rear brake light switch is activated by the brake pedal and is properly ad justed when the brake light comes on just before br...

Страница 66: ... wear indicator groove is provided on each brake pad This indicator allows checking of brake pad wear without disassembling the brake Inspect the groove If the groove has almost disap peared ask a Yamaha dealer to re place the pads 1 Wear indicator 2 EAU00728 Rear brake Apply the brake and inspect the wear indicator If the wear indicator is ALMOST in contact with the disc plate ask a Yamaha dealer...

Страница 67: ...ars 1 Minimum level mark l Use only the designated quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor brake perfor mance NOTE If DOT 4 is not available DOT 3 can be used Recommended brake fluid DOT 4 l Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance l Be careful that water does ...

Страница 68: ...maintenance or when they are dam aged or leaking l oil seals every two years l brake hoses every four years a Chain slack EAU00745 Drive chain slack check NOTE Spin the wheel several times and find the tightest position of the chain Check and or adjust the chain slack while itÕs in this tightest position Inspect the drive chain when the motor cycle is on the centerstand Check the slack at the posi...

Страница 69: ...hin the specified limits 3 After adjusting tighten the lock nuts Then tighten the axle nut to the specified torque Tightening torque Axle nut 105 Nm 10 5 mákg EAU00769 Drive chain lubrication The chain consists of many parts which work with each other If the chain is not maintained properly it will wear out quickly Therefore the chain must be serviced regularly This service is es pecially necessar...

Страница 70: ...rate smoothly ask a Yamaha dealer to replace it Recommended lubricant Engine oil EAU00773 Throttle cable and grip lubrication The throttle twist grip assembly should be greased at the time that the cable is lubricated since the grip must be re moved to get at the end of the throttle cable After removing the screws hold the end of the cable up in the air and put in several drops of lubricant With t...

Страница 71: ...lubricant Engine oil EAU02965 Center and sidestand lubrication Lubricate the pivoting and mating joints Check to see that the center and side stand move up and down smoothly EW000114 If the center and or sidestand does not move smoothly consult a Yamaha dealer Recommended lubricant Engine oil EAU00790 Rear suspension lubrication Lubricate the pivoting parts Recommended lubricant Molybdenum disulfi...

Страница 72: ...ard on the handle bars several times and check if the fork rebounds smoothly EC000098 CAUTION If any damage or unsmooth move ment is found with the front fork consult a Yamaha dealer EAU00794 Steering inspection Periodically inspect the condition of the steering Worn out or loose steering bearings may be dangerous Place a stand under the engine to raise the front wheel off the ground Hold the lowe...

Страница 73: ...the battery tends to discharge more quickly so be sure to recharge it periodically EC000101 CAUTION Never try to remove the sealing caps of the battery cells The battery will be damaged EW000116 Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing ANTIDOTE l EXTERNAL Flush with water l INTERNAL Drink large quanti...

Страница 74: ...r Yamaha dealer l Always make sure the connec tions are correct when reinstall ing the battery 1 Fuse box EAU01470 Fuse replacement The fuse box is located under the seat See page 3 14 for seat removal and installation procedures If any fuse is blown turn off the main switch and the switch of the circuit in question Install a new fuse of specified amperage Turn on the switches and see if the elect...

Страница 75: ...onnector 2 Bulb holder cover EAU00829 Headlight bulb replacement for XJ600S This motorcycle is equipped with a quartz bulb headlight If a headlight bulb burns out replace it as follows 1 Remove the headlight connector and the bulb holder cover 1 Bulb holder 2 Unhook the bulb holder and re move the defective bulb EW000119 Keep flammable products and your hands away from a bulb while it is on as it ...

Страница 76: ...105 CAUTION Avoid touching the glass part of a bulb Keep it free from oil other wise the transparency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on a bulb thoroughly clean it with a cloth moistened with alcohol or lac quer thinner 4 Install the bulb holder cover and the headlight connector If a headlight beam adjustment is necessary ask a Yamaha dealer t...

Страница 77: ...eadlight If the headlight bulb burns out replace the bulb as follows 1 Remove the headlight unit screws 1 Connector 2 2 Bulb cover 2 Remove the connectors the headlight unit and then the bulb cover 1 Bulb holder 3 Turn the bulb holder counterclock wise to remove it and remove the defective bulb EW000119 Keep flammable products and your hands away from a bulb while it is on as it is hot Do not touc...

Страница 78: ... holder EC000105 CAUTION Avoid touching the glass part of a bulb Keep it free from oil other wise the transparency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on a bulb thoroughly clean it with a cloth moistened with alcohol or lac quer thinner 5 Install the bulb cover connectors and headlight unit Ask a Yamaha dealer to adjust the headlight beam if neces...

Страница 79: ...from the front wheel side 3 Remove the calipers 1 Wheel axle 2 Pinch bolt NOTE Do not depress the brake lever when the disc and caliper are separated 4 Loosen the pinch bolt 5 Remove the wheel axle Make sure the motorcycle is properly supported EAU01469 Front wheel installation 1 Install the speedometer gear unit into the wheel hub Make sure the wheel hub and the speedometer gear unit are installe...

Страница 80: ...per bolts Make sure there is enough gap between the brake pads be fore installing the calipers onto the brake discs 5 Push down hard on the handle bars several times to check for proper fork operation 6 Tighten the wheel axle pinch bolt and caliper bolts to the specified torque 7 Install the speedometer cable Tightening torque Wheel axle 58 Nm 5 8 mákg Pinch bolt 40 Nm 4 0 mákg Caliper bolt 19 Nm ...

Страница 81: ...nger of it falling over 1 Place the motorcycle on the cen terstand 2 Remove the axle nut 1 Brake torque rod bolt 2 Nut 3 Remove the brake torque rod bolt by removing the nut 4 While supporting the brake cali per pull out the wheel axle 5 Push the wheel forward and re move the drive chain 6 Remove the wheel assembly NOTE l Do not depress the brake pedal when the disc and caliper are sep arated l Yo...

Страница 82: ...ening torque Axle nut 105 Nm 10 5 mákg Brake torque rod bolt 23 Nm 2 3 mákg EAU01008 Troubleshooting Although Yamaha motorcycles receive a rigid inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The trouble shooting chart describes a quick easy procedure for making checks ...

Страница 83: ...Compression There is compression No compression Go to ignition check Ask a Yamaha dealer to inspect Remove spark plugs and check electrodes 3 Ignition Wet Dry Wipe clean with dry cloth and correct spark gap or replace spark plugs Ask a Yamaha dealer to inspect Engine doesnÕt start go to battery check Open throttle half way and start the engine Use the electric starter 4 Battery Engine turns over q...

Страница 84: ...MOTORCYCLE CARE AND STORAGE Net layout8 layout_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E 7TOC Care 7 1 Storage 7 4 ...

Страница 85: ...e the following cleaning and storing precautions Before cleaning 1 Cover up the muffler outlets with plastic bags 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 g...

Страница 86: ... electrolyte l Do not use high pressure wash ers or steam jet cleaners since they cause water seepage and deterioration in the following ar eas seals of wheel bearings swingarm bearings forks and brakes electric components couplers connectors instru ments switches and lights breather hoses and vents l For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they wil...

Страница 87: ... stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all even chrome and nickel plated metal surfaces 5 Use spray oil as a universal clean er to remove any remaining dirt 6 Touch up minor paint damage caused ...

Страница 88: ...r and humidi ty to seep in and cause rust l To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 Follow all the instructions in the ÒCareÓ section of this chapter 2 Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits...

Страница 89: ...parking 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 7 Check and if necessary correct the tire air pressure then raise 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 from becoming degraded in one spot 8 Cover up the muffler outl...

Страница 90: ...SPECIFICATIONS Net layout8 layout_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E 8TOC Specifications 8 1 HOW TO USE THE CONVERSION TABLE 8 5 ...

Страница 91: ...linder Displacement 598 cm3 Bore Stroke 58 5 55 7 mm Compression ratio 10 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classiÞcation API Service SE SF SG type or higher Quantity Periodic oil change 2 3 L With oil Þlter replacement 2 6 L Total amount 3 1 L 20û 10û 0û 10û 20û 30û 40û 50ûC SAE 10W 30 SAE 15W 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 ...

Страница 92: ...r Primary reduction ratio 2 225 Secondary reduction system 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 operation 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 ...

Страница 93: ...2 2 00 bar Rear 250 kPa 2 50 kg cm2 2 50 bar Load is total weight of cargo rider passenger and accessories Wheels Front Type Cast Size 17 MT 2 50 Rear Type Cast Size 18 MT 3 50 Brakes Front Type Dual disc brake Operation Right hand operation Fluid DOT 4 or DOT 3 Rear Type Single disc brake Operation Right foot operation Fluid DOT 4 or DOT 3 Suspension Front Type Telescopic fork Rear Type Swingarm ...

Страница 94: ...ight 12 V 60 55 W 1 Auxiliary light 12 V 4 W 1 except for GB IRL 12 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 light 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 indicator light XJ600S 12 V 3 4 W 1 XJ600N 14 V 3 W 1 Turn indicator light 12 V 3 4 W 2 Fuses Main fu...

Страница 95: ...0 03937 in 2 mm 0 03937 0 08 in CONVERSION TABLE METRIC TO IMPERIAL Metric unit Multiplier Imperial unit Torque mákg mákg cmákg cmákg 7 233 86 794 0 0723 0 8679 ftálb inálb ftálb inálb Weight kg g 2 205 0 03527 lb oz Speed km hr 0 6214 mph 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 lt liter lt liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq ...

Страница 96: ...t8 layout_G2 work Imai_work OM PS AA9156_XJ600SN E6 English E 9TOC Identification number records 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 ...

Страница 97: ...e vehicle is sto len 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION EAU01039 1 Key identification number EAU01041 Key identification number for XJ600S The key identification number is stamped on the key tag Record this number in the space provided and use it for reference when obtaining a new key 1 Key identification number EAU01042 Key identification number ...

Страница 98: ...s number in the space pro vided The vehicle identification number is used to identify your motorcycle and may be used to register your motor cycle with the licensing authority in your state 1 Model label EAU01050 Model label The model label is affixed to the frame under the seat See page 3 14 for seat removal procedures Record the infor mation on this label in the space pro vided This information ...

Страница 99: ... 31 Front wheel removal 6 31 Fuel 3 12 Fuel cock 3 13 Fuel tank breather hose for Germany only 3 12 Fuel tank cap 3 11 Fuse replacement 6 26 G Give safety the right of way 1 1 H Handlebar switches 3 7 Dimmer switch 3 7 Engine stop switch 3 9 Hazard switch 3 8 Horn switch 3 8 Lights switch 3 9 Pass switch 3 7 Start switch 3 9 Turn signal switch 3 8 Hazard switch 3 8 Headlight bulb replacement for X...

Страница 100: ...ight view XJ600S 2 2 S Seat 3 14 Shift pedal 3 10 Shifting 5 4 Sidestand 3 17 Sidestand clutch switch operation check 3 17 Spark plug inspection 6 6 Specifications 8 1 Speedometer for XJ600N 3 6 Speedometer for XJ600S 3 6 Start switch 3 9 Starter choke Ò Ó 3 14 Starting a warm engine 5 4 Starting the engine 5 1 Steering inspection 6 24 Steering lock for XJ600N 3 3 Storage 7 4 Storage compartment 3...

Страница 101: ...PRINTED IN JAPAN 99 4 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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