Yamaha XJ600S User Manual

OWNER’S MANUAL

XJ600S

4BR-28199-E7

EAU03338

INTRODUCTION

Welcome to the Yamaha world of motorcycling!
As the owner of an XJ600S/XJ600N, you are benefiting from Yamaha’s vast experi-

ence and newest technology regarding the design and manufacture of high-quality
products, which have earned Yamaha a reputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all advantages of
your XJ600S/XJ600N. The owner’s manual does not only instruct you in how to
operate, inspect and maintain your motorcycle, but also in how to safeguard yourself
and others from trouble and injury.

In addition, the many tips given in this manual will help keep your motorcycle in the
best possible condition. If you have any further questions, do not hesitate to contact
your Yamaha dealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to put
safety first!

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

EAU00005

WARNING

CAUTION:

NOTE:

Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander, or a person insp ecting or repairing the motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage to the
motorcycle.

A NOTE provides key information to make procedures easier or clearer.

NOTE:

@

This manual should be considered a permanent part of this motorcycle and should remain

●

with it even if the motorcycle is subsequently sold.
Yamaha continually seeks advancements in product design and quality. Therefore, while

●

this manual contains the most current product information available at the time of printing,
there may be minor discrepancies between your motorcycle and this manual. If you have
any questions concerning this manual, please consult your Yamaha dealer.

@

IMPORTANT MANUAL INFORMATION

EW000002

WARNING

@

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.

@

IMPORTANT MANUAL INFORMATION

XJ600S/XJ600N

OWNER’S MANUAL

© 2000 by Yamaha Motor Co., Ltd.

1st Edition, May 2000

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

Printed in Japan.

EAU03337

EAU00009

TABLE OF CONTENTS

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

1

2

3

4

5

6

7

8

9

GIVE SAFETY THE RIGHT OF WAY

GIVE SAFETY THE RIGHT OF WAY ......................... ... ... ... ... .... ... ... . 1-1

1

1-

GIVE SAFETY THE RIGHT OF WAY

EAU00021

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and
freedom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.

1

Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motor cycle riders—more t han car drivers—must always be at their ment al
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 properly fitting helmet.
Optimum protective wear, however, should not encourage carelessness. Although full-coverage
helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will
always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to
take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,
predictably and defensively—avoiding all dangers, including those caused by others.

Enjoy your ride!

1-1

DESCRIPTION

Left view (XJ600S).............................................................................2-1

Right view (XJ600S)...........................................................................2-2

Controls and instruments (XJ600S)................................................... 2-3

Left view (XJ600N)............................................................................. 2-4

Right view (XJ600N) .......................................................................... 2-5

Controls and instruments (XJ600N)................................................... 2-6

2

2-

DESCRIPTION

Left view (XJ600S)

2

EAU00026

1.Fuel cock (page 3-11)

2.Helmet holder (page 3-13)

3.Fuse box (page 6-29)

4.Luggage strap holders (page 3-15)

5.Seat lock (page 3-12)

6.Rear shock absorber spring
preload adjusting ring (page 3-14)

7.Shift pedal (page 3-8)

2-1

Right view (XJ600S)

8.Tail/brake light

9.Storage compartment (page 3-13)

10.Seat (page 3-12)

11.Fuel tank (page 3-9)

12.Headlight (page 6-30)

13.Brake pedal (page 3-9)

DESCRIPTION

2

2-2

DESCRIPTION

Controls and instruments (XJ600S)

2

14.Clutch lever (page 3-7)

15.Left handlebar switches (page 3-6)

16.Starter (choke) lever (page 3-12)

17.Speedometer unit (page 3-4)

18.Tachometer (page 3-5)

19.Right handlebar switches (page 3-7)

20.Brake lever (page 3-8)

21.Throttle grip (page 6-13)

22.Main switch/steering lock (page 3-1)

2-3

Left view (XJ600N)

DESCRIPTION

2

1.Steering lock (page 3-3)

2.Fuel cock (page 3-11)

3.Helmet holder (page 3-13)

4.Fuse box (page 6-29)

5.Luggage strap holders (page 3-15)

6.Seat lock (page 3-12)

7.Rear shock absorber spring preload
adjusting ring (page 3-14)

8.Shift pedal (page 3-8)

2-4

DESCRIPTION

Right view (XJ600N)

2

9.Tail/brake light

10.Storage compartment (page 3-13)

11.Seat (page 3-12)

12.Fuel tank (page 3-9)

13.Headlight (page 6-30)

14.Brake pedal (page 3-9)

2-5

Controls and instruments (XJ600N)

15.Clutch lever (page 3-7)

16.Left handlebar switches (page 3-6)

17.Starter (choke) lever (page 3-12)

18.Speedometer unit (page 3-5)

19.Tachometer (page 3-5)

20.Right handlebar switches (page 3-7)

21.Brake lever (page 3-8)

22.Throttle grip (page 6-13)

23.Main switch (page 3-1)

DESCRIPTION

2

2-6

INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock .....................................3-1

Steering lock (for XJ600N)....................................3-3

Indicator lights .....................................................3-3

Speedometer unit (for XJ600S) ...........................3-4

Speedometer unit (for XJ600N) ...........................3-5

Tachometer .......................................................... 3-5

Handlebar switches .......................................... ...3-6

Clutch lever ..........................................................3-7

Shift pedal ............................................................3-8

Brake lever ..........................................................3-8

Brake pedal ..........................................................3-9

Fuel tank cap .......................................................3-9

Fuel ................................................................... 3-10

Fuel tank breather hose (for Germany only) ..... 3-10

Fuel cock ........................................................... 3-11

Starter (choke) lever .......................................... 3-12

Seat ................................ ...................... ............. 3- 12

Helmet holders .................................................. 3-13

Storage compartment .......... ... .......................... 3-1 3

Adjusting the shock absorber assembly ............ 3-14

Luggage strap holders ................................... ... 3-15

Sidestand .......................................................... 3-15

Ignition circuit cut-off system ............................. 3-16

3

3-

INSTRUMENT AND CONTROL FUNCTIONS

XJ600S XJ600N

3

EAU00027

EAU00029

Main switch/steering lock

The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.

EAU00036

ON

All electrical systems are supplied with
power, and the engine can be started.
The key cannot be removed.

EAU00038

OFF

All electrical systems are off. The key
can be removed.

3-1

EAU00040

LOCK (for XJ600S)

The steering is locked, and all electrical
systems are off. The key can be re­moved.

To lock the steering

1. Turn the handlebars all the way to
the left.

2. Push the key in from the “OFF” po­sition, and then turn it to “LOCK”
while still pushing it.

3. Remove the key.

To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.

INSTRUMENT AND CONTROL FUNCTIONS

CAUTION:

XJ600N

EW000016

WARNING

@

Never turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the motor­cycle is stopped before turning the
key to “OFF” or “LOCK”.

@

XJ600S

1. Push.

2. Turn.

EAU01590

(Parking) (for XJ600S)

The steering is locked, and the taillight
and auxiliary light are 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 “ ”.

ECA00043

CAUTION:

@

Do not use the parking position for
an extended length of time, other­wise the battery may discharge.

@

3

1. Push.

2. Release.

3. Turn.

EAU00055

P (Parking) (for XJ600N)

The taillight and auxiliary light are on,
but all other electrical systems are off.
The key can be removed.
The key must be pushed in, and then
released before it can be turned to “P”.

ECA00043

@

Do not use the parking position for
an extended length of time, other­wise the battery may discharge.

@

3-2

INSTRUMENT AND CONTROL FUNCTIONS

XJ600S

To unlock the steering

1. Open the steering lock cover, and
then insert the key.

2. Push the key in, turn it 1/8 turn
counterclockwise so that it moves
out, and then release it.

3. Remove the key, and then close

3

the lock cover.

1. Steering lock 1. Left turn indicator light “ ”

EAU02934

Steering lock (for XJ600N)

2. High beam indicator light “ ”

3. Right turn indicator light “ ”

4. Neutral indicator light “ ”

5. Oil level warning light “ ”

To lock the steering

1. Turn the handlebar all the way to

Indicator and warning lights

right.

2. Open the steering lock cover, and
then insert the key.

3. Turn the key 1/8 turn counter­clockwise, push it in while turning
the handlebar slightly to the left,
and then turn the key 1/8 turn

Turn signal indicator lights
“ ” / “ ”

The corresponding indicator light flash­es when the turn signal switch is
pushed to the left or right.

clockwise.

4. Check that the steering is locked,
remove the key, and then close
the lock cover.

3-3

Neutral indicator light “ ”

This indicator light comes on when the
transmission is in the neutral position.

EAU03034

EAU03299

EAU00061

INSTRUMENT AND CONTROL FUNCTIONS

XJ600S

XJ600N

1. Neutral indicator light “ ”

2. Left turn indicator light “ ”

3. Right turn indicator light “ ”

4. High beam indicator light “ ”

5. Oil level warning light “ ”

EAU00063

High beam indicator light “ ”

This indicator light comes on when the
high beam of the headlight is switched
on.

EAU03201

Oil level warning light “ ”

This warning light comes on when the
engine oil level is low.
The electrical circuit of the warning light
can be checked according to the fol­lowing procedure.

1. Set the engine stop switch to “ ”
and turn the key to “ON”.

2. Shift the transmission into the neu­tral position or pull the clutch lever.

3. Push the start switch. If the warn­ing light does not come on while
pushing the start switch, have a
Yamaha dealer check the electri­cal circuit.

NOTE:

@

Even if the oil level is sufficient, the
warning light may flicker when riding on
a slope or during sudden acceleration
or deceleration, but this is not a mal­function.

@

3

1. Speedometer

2. Odometer

3. Tripmeter

4. Reset button

EAU00094

Speedometer unit (for XJ600S)

The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset but­ton. The tripmeter can be used to esti­mate the distance that can be traveled
with a full tank of fuel. This information
will enable you to plan future fuel stops.

3-4

INSTRUMENT AND CONTROL FUNCTIONS

XJ600N

XJ600N

3

1. Speedometer

2. Odometer

3. Tripmeter

4. Reset knob

Speedometer unit (for XJ600N)

The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset knob.
The tripmeter can be used to estimate
the distance that can be traveled with a
full tank of fuel. This information will en­able you to plan future fuel stops.

EAU00095

XJ600S

1. Tachometer

2. Red zone (except for CH, A)

3. Red zone (for CH, A)

EAU00101

Tachometer

The electric tachometer allows the rider
to monitor the engine speed and keep it
within the ideal power range.

CAUTION:

@

Do not operate the engine in the ta­chometer red zone.
Red zone: 9,500 r/min and above

(except for CH, A)
8,500 r/min and above
(for CH, A)

@

EC000003*

1. Tachometer

2. Red zone (except for CH, A)

3. Red zone (for CH, A)

3-5

INSTRUMENT AND CONTROL FUNCTIONS

1. Dimmer switch

2. Pass switch “PASS”

3. Hazard switch “ ”

4. Turn signal switch

5. Horn switch “ ”

EAU00118

Handlebar switches

EAU00120

Pass switch “PASS”

Press this switch to flash the headlight.

EAU00121

Dimmer switch

Set this switch to “ ” for the high
beam and to “ ” for the low beam.

EAU00144

Hazard switch “ ”

With the key in the “ON” or “P” position,
use this switch to turn on the hazard
light (simultaneous flashing of all turn
signal lights).
The hazard light is used in case of an
emergency or to warn other drivers
when your motorcycle is stopped
where it might be a traffic hazard.

EC000006

CAUTION:

@

Do not use the hazard light for an ex­tended length of time, otherwise the
battery may discharge.

@

EAU00127

Turn signal switch

To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When
released, the switch returns to the cen­ter position. To cancel the turn signal
lights, push the switch in after it has re­turned to the center position.

EAU00129

Horn switch “ ”

Press this switch to sound the horn.

3

3-6

INSTRUMENT AND CONTROL FUNCTIONS

Start switch “ ”

Push this switch to crank the engine
with the starter.

CAUTION:

@

See page 5-1 for starting instruc­tions prior to starting the engine.

3

@

EAU00143

EC000005

1. Engine stop switch

2. Light switch

3. Start switch “ ”

EAU00138

Engine stop switch

Set this switch to “ ” to stop the en­gine in case of an emergency, such as
when the motorcycle overturns or
when the throttle cable is stuck.

EAU00134

Light switch

Set this switch to “ ” to turn on the
auxiliary light, meter lighting and tail­light. Set the switch to “ ” to turn on
the headlight also.

1. Clutch lever

EAU00152

Clutch lever

The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle­bar 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 igni­tion circuit cut-off system. (See page
3-16 for an explanation of the ignition
circuit cut-off system.)

3-7

INSTRUMENT AND CONTROL FUNCTIONS

3

1. Shift pedal 1. Brake lever

EAU00157

2. Position adjusting nut

Shift pedal

The shift pedal is located on the left
side of the engine and is used in com­bination with the clutch lever when
shifting the gears of the 6-speed con­stant-mesh transmission equipped on
this motorcycle.

Brake lever

The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle­bar grip.

3-8

EAU00160

1. Brake lever position adjusting nut

2. Properly aligned marks

The brake lever is equipped with a po­sition adjusting nut. To adjust the dis­tance between the brake lever and the
handlebar grip, turn the adjusting nut
while holding the lever pushed away
from the handlebar grip. Make sure that
the mark “ ” on the adjusting nut is
aligned with the mark “ ” on the brake
lever.

INSTRUMENT AND CONTROL FUNCTIONS

NOTE:

WARNING

@

The fuel tank cap cannot be closed un­less the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked.

@

EWA00025

3

1. Brake pedal 1. Fuel tank cap lock cover

EAU00162

2. Unlock.

Brake pedal

The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.

Fuel tank cap

To open the fuel tank cap

Open the fuel tank cap lock cover, in­sert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be re­leased and the fuel tank cap can be
opened.

To close the fuel tank cap

1. Push the fuel tank cap into position
with the key inserted in the lock.

2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.

3-9

@

Make sure that the fuel tank cap is
properly closed before riding.

@

EAU02935

1. Fuel tank filler tube

2. Fuel level

EAU01183

Fuel

Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown in the illustra­tion.

W ARNING

@

Do not overfill the fuel tank, oth-

●

erwise it may overflow when the
fuel warms up and expands.
Avoid spilling fuel on the hot

●

engine.

@

EW000130

INSTRUMENT AND CONTROL FUNCTIONS

EAU00185

CAUTION:

@

Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfac­es or plastic parts.

@

Recommended fuel:

Regular unleaded gasoline with a
research octane number of 91 or
higher

Fuel tank capacity:

Total amount:

17.0 L

Reserve amount:

3.5 L

NOTE:

@

If knocking (or pinging) occurs, use
gasoline of a different brand or with a
higher octane grade.

@

EAU00191

1. Fuel tank breather hose

Fuel tank breather hose
(for Germany only)

Before operating the motorcycle:

Check the fuel tank breather hose

●

connection.
Check the fuel tank breather hose

●

for cracks or damage, and replace
it if damaged.
Make sure that the end of the fuel

●

tank breather hose is not blocked
and clean it if necessary.

3

EAU00196

3-10

INSTRUMENT AND CONTROL FUNCTIONS

Prime position

Normal position

3

1. Arrow mark positioned over “ON”

Fuel cock

The fuel cock supplies fuel from the
tank to the carburetors while also filter­ing it.
The fuel cock lever positions are ex­plained as follows and shown in the il­lustrations.

ON

With the fuel cock lever in this position,
fuel flows to the carburetors when the
engine is running. Turn the fuel cock le­ver to this position when starting the
engine and riding.

EAU00207

Reserve position

1. Arrow mark positioned over “RES”

RES

This indicates reserve. With the fuel
cock lever in this position, the fuel re­serve is made available. Quickly turn
the fuel cock lever to this position if you
run out of fuel while riding, otherwise
the engine may stall and will have to be
primed (see “PRI”). After turning the
fuel cock lever to “RES”, refuel as soon
as possible and be sure to turn the fuel
cock lever back to “ON”!

1. Arrow mark positioned over “PRI”

PRI

This indicates prime. With the fuel cock
lever in this position, the engine can be
“primed”. Turn the fuel cock lever to
this position when the engine has been
allowed to run out of fuel. This sends
fuel directly to the carburetors, which
will make starting easier. After the en­gine has started, be sure to turn the le­ver to “ON” (or “RES” if you have not
refueled yet).

3-11

INSTRUMENT AND CONTROL FUNCTIONS

NOTE:

3

1. Starter (choke) lever 1. Unlock. 1. Projection (× 2)

Starter (choke) lever

EAU02976

Seat

EAU02925

Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the lever in direction a to turn on
the starter (choke).

To remove the seat

Insert the key into the seat lock, turn it
counterclockwise, and then pull the

seat off.
Move the lever in direction b to turn off
the starter (choke).

3-12

2. Seat holder

To install the seat

Insert the projections on the front of the
seat into the seat holder, push the rear
of the seat down to lock it in place, and
then remove the key.

@

Make sure that the seat is properly se­cured before riding.

@

INSTRUMENT AND CONTROL FUNCTIONS

WARNING

@

Never ride with a helmet attached to
a helmet holder, since the helmet
may hit objects, causing loss of
control and possibly an accident.

@

EWA00015

3

1. Helmet holder (× 2) 1. Strap for U-LOCK (× 2)

EAU02936

Helmet holders

The helmet holders are located under
the seat.

To release a helmet from a helmet
holder

Remove the seat, remove the helmet
from the helmet holder, and then install
the seat.

Storage compartment

This storage compartment is designed
to hold a genuine Yamaha U-LOCK.
(Other locks may not fit.) When placing

To secure a helmet to a helmet holder

1. Remove the seat. (See page 3-12
for seat removal and installation
procedures.)

2. Attach the helmet to the helmet
holder, and then securely install
the seat.

a U-LOCK in the storage compartment,
securely fasten it with the straps. When
the U-LOCK is not in the storage com­partment, be sure to secure the straps
to prevent losing them.
When storing the owner’s manual or
other documents in the storage com­partment, be sure to wrap them in a
plastic bag so that they will not get wet.
When washing the motorcycle, be
careful not to let any water enter the
storage compartment.

3-13

EAU01688

WARNING

1. Spring preload adjusting ring

2. Position indicator

EAU00295

Adjusting the shock absorber
assembly

This shock absorber assembly is
equipped with a spring preload adjust­ing ring.

CAUTION:

@

Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.

@

EC000015

INSTRUMENT AND CONTROL FUNCTIONS

@

This shock absorber contains high­ly pressurized nitrogen gas. For
proper handling, read and under­stand the following information be­fore handling the shock absorber.
The manufacturer cannot be held re-

1. Special wrench

Adjust the spring preload as follows.
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction a. To de­crease the spring preload and thereby
soften the suspension, turn the adjust­ing ring in direction b.

NOTE:

@

Align the appropriate notch in the ad­justing ring with the position indicator
on the shock absorber.

@

CI-01E

Setting1234567

Minimum

(soft)

Stan-

dard

Maximum (hard)

sponsible for property damage or
personal injury that may result from
improper handling.

Do not tamper with or attempt to

●

open the gas cylinder.
Do not subject the shock ab-

●

sorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.
Do not deform or damage the

●

gas cylinder in any way, as this
will result in poor damping per­formance.
Always have a Yamaha dealer

●

service the shock absorber.

@

EAU00315

3

3-14

INSTRUMENT AND CONTROL FUNCTIONS

WARNING

Left

3

1. Luggage strap holder (× 4)

Luggage strap holders

There are four luggage strap holders:
one on each passenger footrest brack­et and one below each side of the seat.

Right

EAU01398

EAU00330

Sidestand

The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
motorcycle upright.

NOTE:

@

The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)

@

EW000044

@

The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up), oth­erwise the sidestand could contact
the ground and distract the opera­tor, resulting in a possible loss of
control. Yamaha’s ignition circuit
cut-off system has been designed to
assist the operator in fulfilling the
responsibility of raising the side­stand before starting off. Therefore,
check this system regularly as de­scribed below and have a Yamaha
dealer repair it if it does not function
properly.

@

3-15

INSTRUMENT AND CONTROL FUNCTIONS

EAU00332

Ignition circuit cut-off system

The ignition circuit cut-off system (com­prising the sidestand switch, clutch
switch and neutral switch) has the fol­lowing functions.

It prevents starting when the trans-

●

mission is in gear and the side­stand is up, but the clutch lever is
not pulled.
It prevents starting when the trans-

●

mission is in gear and the clutch
lever is pulled, but the sidestand is
still down.
It cuts the running engine when

●

the sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.

WARNING

@

The vehicle must be placed on

●

the centerstand during this in­spection.
If a malfunction is noted, have a

●

Yamaha dealer check the sys­tem before riding.

@

EW000046

3

3-16

INSTRUMENT AND CONTROL FUNCTIONS

CD-01E

With the engine turned off:

1. Move the sidestand down.

2. Make sure that the engine stop switch is set to “ ”.

3. Turn the key to “ON”.

4. Shift the transmission into the neutral position.

5. Push the start switch.

Does the engine start?

3

With the engine still running:

6. Move the sidestand up.

7. Keep the clutch lever pulled.

8. Shift the transmission into gear.

9. Move the sidestand down.

Does the engine stall?

YES

YES NO

After the engine has stalled:

10. Move the sidestand up.

11. Keep the clutch lever pulled.

12. Push the start switch.

Does the engine start?

YES NO

The system is OK.

The motorcycle can be ridden.

NO

NOTE:

This check is most reliable if performed with
a warmed-up engine.

The neutral switch may be defective.

The motorcycle should not be ridden

checked by a Yamaha dealer.

The sidestand switch may be defective.

The motorcycle should not be ridden

checked by a Yamaha dealer.

The clutch switch may be defective.

The motorcycle should not be ridden

checked by a Yamaha dealer.

until

until

until

3-17

PRE-OPERATION CHECKS

Pre-operation check list ....... ... ... .......................................... ... ...........4-1

4

4-

PRE-OPERATION CHECKS

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec­tion, to check the following points before each ride.

Pre-operation check list

ITEM CHECKS PAGE
Front brake
Rear brake

4

Clutch

Throttle grip and housing

Engine oil

Drive chain

Wheels and tires

Control and meter cables
Brake and shift pedal

shafts
Brake and clutch lever

pivots
Center and sidestand

pivots

• Check operation, fluid level and fluid leakage.

• Fill with DOT 4 brake fluid if necessary.

• Check operation, condition and free play.

• Adjust if necessary.

• Check smooth operation.

• Lubricate if necessary.

• Check oil level.

• Fill with oil if necessary.

• Check chain slack and condition.

• Adjust if necessary.

• Check tire pressure, wear and damage.

• Check smooth operation.

• Lubricate if necessary.

• Check smooth operation.

• Lubricate if necessary.

• Check smooth operation.

• Lubricate if necessary.

• Check smooth operation.

• Lubricate if necessary.

6-19–6-21
6-18–6-21

6-17–6-18

6-13, 6-24

6-7–6-10

6-21–6-23

6-14–6-17,

6-33–6-36

6-23

6-24

6-25

6-25

EAU01114

EAU03328

4-1

PRE-OPERATION CHECKS

ITEM CHECKS PAGE

Chassis fasteners

Fuel
Lights, signals and

switches

NOTE:

@

• Make sure that all nuts, bolts and screws are properly tightened.

• Tighten if necessary.

• Check fuel level.

• Fill with fuel if necessary.

• Check proper operation. —

Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.

@

WARNING

@

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle.

@

—

3-9–3-10

EWA00033

4

4-2

OPERATION AND IMPORTANT RIDING POINTS

Starting a cold engine ....................................................................... 5-1

Starting a warm engine ..................................................................... 5-2

Shifting .............................................................................................. 5-3

Recommended shift points (for Switzerland only) ............................. 5-3

Tips for reducing fuel consumption ................................................... 5-4

Engine break-in .................................................................................5-4

Parking .............................................................................................. 5-5

5

5-

NOTE:

NOTE:

OPERATION AND IMPORTANT RIDING POINTS

EAU00372

WARNING

@

● Become thoroughly familiar

with all operating controls and
their functions before riding.
Consult a Yamaha dealer re­garding any control or function
that you do not thoroughly
understand.

● Never start the engine or oper-

ate it in a closed area for any

5

length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con­sciousness and death within a
short time. Always make sure
that there is adequate ventila­tion.

● Before starting out, make sure

that the sidestand is up. If the
sidestand is not raised com­pletely, it could contact the
ground and distract the opera­tor, resulting in a possible loss
of control.

@

EAU00373

EAU00381

Starting a cold engine

In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral

●

position.
The transmission is in gear with

●

the clutch lever pulled and the
sidestand up.

WARNING

@

● Before starting the engine,

check the function of the igni­tion circuit cut-off system ac­cording to the procedure
described on page 3-16.

● Never ride with the sidestand

down.

@

1. Turn the fuel cock lever to “ON”.

2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.

3. Shift the transmission into the neu­tral position.

EW000054

@

When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.

@

4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-12 for starter (choke) oper­ation.)

5. Start the engine by pushing the
start switch.

@

If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre­serve the battery. Do not crank the en­gine more than 10 seconds on any one
attempt.

@

5-1

OPERATION AND IMPORTANT RIDING POINTS

EC000034

CAUTION:

@

The oil level warning light should
come on when the start switch is
pushed, and it should go off when
the start switch is released. If the oil
level warning light flickers or re­mains on after starting, immediately
stop the engine, and then check the
engine oil level and the vehicle for
oil leakage. If necessary, add engine
oil, and then check the warning light
again. If the warning light does not
come on when pushing the start
switch, or if it does not go off after
starting with sufficient engine oil,
have a Yamaha dealer check the
electrical circuit.

@

6. After starting the engine, move the
starter (choke) knob/lever back
halfway.

ECA00045

CAUTION:

@

For maximum engine life, never ac­celerate hard when the engine is
cold!

@

7. When the engine is warm, turn the
starter (choke) off.

NOTE:

@

The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.

@

EAU01258

Starting a warm engine

Follow the same procedure as for start­ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.

5

5-2

OPERATION AND IMPORTANT RIDING POINTS

NOTE:

1. Shift pedal
N. Neutral position

Shifting

5

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
illustration.

NOTE:

@

To shift the transmission into the neu­tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.

@

EAU00423

CAUTION:

@

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 dis­tances. The transmission is
properly lubricated only when
the engine is running. Inade­quate lubrication may damage
the transmission.
Always use the clutch while

●

changing gears to avoid dam­aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.

@

EC000048

EAU02937

Recommended shift points
(for Switzerland only)

The recommended shift points during
acceleration are shown in the table
below.

CF-02E

1st → 2nd
2nd → 3rd
3rd → 4th
4th → 5th
5th → 6th

@

When shifting down two gears at a
time, reduce the speed accordingly
(e.g., down to 35 km/h when shifting
from 5th to 3rd gear).

@

Shift point

(km/h)

20
30
40
50
60

5-3

OPERATION AND IMPORTANT RIDING POINTS

EAU00424

Tips for reducing fuel
consumption

Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Thoroughly warm up the engine.

●

Turn the starter (choke) off as

●

soon as possible.
Shift up swiftly, and avoid high en-

●

gine speeds during acceleration.
Do not rev the engine while shift-

●

ing down, and avoid high engine
speeds with no load on the engine.
Turn the engine off instead of let-

●

ting it idle for an extended length
of time (e.g., in traffic jams, at traf­fic lights or at railroad crossings).

EAU00436

Engine break-in

There is never a more important period
in the life of your engine than the period
between 0 and 1,000 km. For this rea­son, you should read the following ma­terial carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,000 km. The various parts in the en­gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full-throttle oper­ation or any condition that might result
in engine overheating must be avoided.

0–150 km

Avoid prolonged operation above

●

5,000 r/min.
After every hour of operation, stop

●

the engine, and then let it cool for
five to ten minutes.
Vary the engine speed from time

●

to time. Do not operate the engine
at one set throttle position.

150–500 km

Avoid prolonged operation above

●

6,000 r/min.
Rev the engine freely through the

●

gears, but do not use full throttle at
any time.

EAU00440

5

5-4

OPERATION AND IMPORTANT RIDING POINTS

500–1,000 km

Avoid prolonged full-throttle oper-

●

ation.
Avoid prolonged operation above

●

7,000 r/min.

CAUTION:

@

After 1,000 km of operation, the en­gine oil must be changed and the oil
filter cartridge/element replaced.

@

1,000 km and beyond

5

The vehicle can now be operated
normally.

CAUTION:

@

Keep the engine speed out of

●

the tachometer red zone.
If any engine trouble should oc-

●

cur during the engine break-in
period, immediately have a
Yamaha dealer check the
vehicle.

@

EC000052

EC000053

EAU00460

Parking

When parking, stop the engine, and
then remove the key from the main
switch.

WARNING

@

Since the engine and exhaust

●

system can become very hot,
park in a place where pedestri­ans or children are not likely to
touch them.
Do not park on a slope or on

●

soft ground, otherwise the
motorcycle may overturn.

@

EW000058

5-5

PERIODIC MAINTENANCE AND MINOR REPAIR

Owner’s tool kit ....................................................6-1

Periodic maintenance and lubrication chart .........6-2

Removing and installing the panel .......................6-5

Checking the spark plugs ....................................6-6

Engine oil and oil filter car tridge .......... .... ... ... ... ...6-7

Cleaning the air filter element ............................6-10

Adjusting the carburetors ...................................6-12

Adjusting the engine idling speed ......................6-13

Adjusting the throttle cable free play ..................6-13

Adjusting the valve clearance ............................6-14

Tires .................................. ............................. .... 6-14

Wheels .............................. ............................. .... 6-17

Adjusting the clutch lever free play ....................6-17

Adjusting the brake pedal position .....................6-18

Adjusting the rear brake light switch ..................6-19

Checking the front and rear brake pads .............6-19

Checking the brake fluid level ............................6-20

Changing the brake fluid ....................................6-21

Drive chain slack ................................................6-21

Lubricating the drive chain .......................... ... ... .6-23

Checking and lubricating the cables ..................6-23

Checking and lubricating the throttle grip and

cable ............................................................... 6-24

Checking and lubricating the brake and

shift pedals ...................................................... 6-24

Checking and lubricating the brake and

clutch levers .................................................... 6-25

Checking and lubricating the centerstand and

sidestand ............................ ....................... ...... 6-25

Lubricating the rear suspension ........................ 6-25

Checking the front fork ...................................... 6-26

Checking the steering ....................................... 6-26

Checking the wheel bearings ............................ 6-27

Battery ........ .... ................................................... 6-27

Replacing the fuses .......................................... 6-29

Replacing a headlight bulb (for XJ600S)............ 6-30

Replacing the headlight bulb (for XJ600N) ........ 6-31

Front wheel ....................................................... 6-33

Rear wheel ........................................................ 6-35

Troubleshooting ................. ................................ 6-36

Troubleshooting chart . .... ... ... ... .... ...................... 6-37

6

6-

WARNING

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00462

Safety is an obligation of the owner.
Periodic inspection, adjustment and lu­brication will keep your vehicle in the
safest and most efficient condition pos­sible. The most important points of in­spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen­eral guide under normal riding condi­tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI­CAL LOCATION, AND INDIVIDUAL

6

USE, THE MAINTENANCE INTER­VALS MAY NEED TO BE SHORT­ENED.

WARNING

@

If you are not familiar with motor­cycle maintenance work, have a
Yamaha dealer do it for you.

@

EAU00464

EW000060

1. Tool kit

EAU00469

Owner’s tool kit

The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How­ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.

NOTE:

@

If you do not have the tools or experi­ence required for a particular job, have
a Yamaha dealer perform it for you.

@

EW000063

@

Modifications not approved by
Yamaha may cause loss of perfor­mance and render the vehicle un­safe for use. Consult a Yamaha
dealer before attempting any chang­es.

@

6-1

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance and lubrication chart

NOTE:

The annual checks must be performed every year, except if a kilometer-base d maintenance is performed instead .

●

From 50,000 km, repeat the maintenance intervals starting from 10,000 km.

●

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and t echni-

●

cal skills.

CP-01ECP-01E

NO. ITEM CHECK OR MAINTENANCE JOB

Fuel line • Check fuel hoses and vacuum hose for cracks or damage. √√√√ √

1

*

Fuel filter • Check condition. √√

2

*

• Check condition.

3 Spark plugs

Valves

4

*

5 Air filter element

6Clutch

Front brake

7

*

Rear brake

8

*

Brake hoses

9

*

• Clean and regap.

• Replace. √√

• Check valve clearance.

•Adjust.

•Clean. √√

• Replace. √√

• Check operation.

•Adjust.

• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)

• Replace brake pads. Whenever worn to the limit

• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)

• Replace brake pads. Whenever worn to the limit

• Check for cracks or damage. √√√√ √

• Replace. (See NOTE on page 6-4.) Every 4 years

6-2

ODOMETER READING (×1,000 km)

1 10203040

√√

Every 20,000 km

√√√√√

√√√√√ √

√√√√√ √

EAU03540

Annual

check

6

PERIODIC MAINTENANCE AND MINOR REPAIR

NO. ITEM CHECK OR MAINTENANCE JOB

10*Wheels • Check runout and for damage. √√√√

• Check tread depth and for damage.

11

Tires

*

12

Wheel bearings • Check bearing for looseness or damage. √√√√

*

Swingarm

13

*

14 Drive chain

15

Steering bearings

*

16

Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √√√√ √

6

*

17 Sidestand/centerstand

Sidestand switch • Check operation. √√√√√ √

18

*

Front fork • Check operation and for oil leakage. √√√√

19

*

Rear shock absorber

20

*

assembly
Rear suspension relay

arm and connecting arm

21

*

pivoting points

22

Carburetors

*

23 Engine oil • Change. √√√√√ √
24 Engine oil filter cartridge •Replace. √√√

• Replace if necessary.

• Check air pressure.

• Correct if necessary.

• Check operation and for excessive play. √√√√

• Lubricate with molybdenum disulfide grease. Every 50,000 km

• Check chain slack.

• Make sure that the rear wheel is properly aligned.

• Clean and lubricate.

• Check bearing play and steering for roughness. √√√√√

• Lubricate with lithium-soap-based grease Every 20,000 km

• Check operation.

• Lubricate.

• Check operation and shock absorber for oil leakage . √√√√

• Check operation. √√√√

• Lubricate with molybdenum disulfide grease. √√

• Check starter (choke) operation.

• Adjust engine idling speed and synchronization.

ODOMETER READING (×1,000 km)

1 10203040

√√√√

Every 1,000 km and after washing
the motorcycle or riding in the rain.

√√√√ √

√√√√√ √

Annual

check

6-3

PERIODIC MAINTENANCE AND MINOR REPAIR

NO. ITEM CHECK OR MAINTENANCE JOB

Front and rear brake

25

*

switches

26 Moving parts and cables •Lubricate. √√√√ √

Lights, signals and

27

*

switches

NOTE:

_

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

●

Hydraulic brake service

●

• Check operation. √√√√√ √

• Check operation.

• Adjust headlight beam.

ODOMETER READING (×1,000 km)

1 10203040

√√√√√ √

Annual

check

EAU03884

• Regularly check 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.

_

6

6-4

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Panel A 1. Screw (× 2)

EAU01777

Removing and installing the
panel

The panel shown above needs to be

6

removed to perform some of the main­tenance jobs described in this chapter.
Refer to this section each time the pan­el needs to be removed and installed.

Panel A

To remove the panel

1. Remove the seat. (See page 3-12
for seat removal and installation
procedures.)

2. Remove the screws, and then
slide the panel as shown to re­lease it.

EAU02926

6-5

To install the panel

1. Place the panel in the original po­sition, and then install the screws.

2. Install the seat.

PERIODIC MAINTENANCE AND MINOR REPAIR

The porcelain insulator around the cen­ter electrode of each spark plug should
be a medium-to-light tan (the ideal col­or when the motorcycle is ridden nor­mally), and all spark plugs installed in
the engine should have the same color.
If any spark plug shows a distinctly dif­ferent color, the engine could be defec-

a. Spark plug gap

EAU01880

Checking the spark plugs

The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte­nance and lubrication chart. In addition,
the condition of the spark plugs can re­veal the condition of the engine.

tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.

Specified spark plug:

CR8E (NGK) or
U24ESR-N (DENSO)

Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.

6

6-6

Spark plug gap:

0.7–0.8 mm

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

NOTE:

Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.

Tightening torque:

Spark plug:

12.5 Nm (1.25 m·kg)

NOTE:

@

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark

6

plug should be tightened to the speci­fied torque as soon as possible.

@

1. Engine oil level window

2. Maximum level mark

3. Minimum level mark

EAU02938

Engine oil and oil filter
cartridge

The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car­tridge replaced at the intervals speci­fied in the periodic maintenance and
lubrication chart.

To check the engine oil level

1. Place the motorcycle on the cen­terstand.

@

Make sure that the motorcycle is posi­tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading.

@

2. Start the engine, warm it up for
several minutes, and then turn it
off.

3. Wait a few minutes until the oil set­tles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.

@

The engine oil should be between the
minimum and maximum level marks.

@

4. If the engine oil is below the mini­mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.

6-7

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

1. Engine oil filler cap 1. Engine oil drain bolt 1. Oil filter cartridge

To change the engine oil (with or
without oil filter cartridge replace­ment)

3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.

1. Start the engine, warm it up for

NOTE:

several minutes, and then turn it
off.

2. Place an oil pan under the engine

@

Skip steps 4–6 if the oil filter cartridge is
not being replaced.

@

2. Oil filter wrench

4. Remove the oil filter cartridge with
an oil filter wrench.

@

An oil filter wrench is available at a
Yamaha dealer.

@

to collect the used oil.

6-8

6

PERIODIC MAINTENANCE AND MINOR REPAIR

1. O-ring 1. Torque wrench

5. Apply a thin coat of engine oil to
the O-ring of the new oil filter car­tridge.

NOTE:

@

6

Make sure that the O-ring is properly
seated.

@

6. Install the new oil filter cartridge,
and then tighten it to the specified
torque with a torque wrench.

Tightening torque:

Oil filter cartridge:

17 Nm (1.7 m·kg)

7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.

8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.

Recommended engine oil:

See page 8-1.

Oil quantity:

Without oil filter cartridge
replacement:

2.3 L
With oil filter cartridge
replacement:

2.6 L
Total amount (dry engine):

3.1 L

Tightening torque:

Engine oil drain bolt:

43 Nm (4.3 m·kg)

6-9

PERIODIC MAINTENANCE AND MINOR REPAIR

EC000072

CAUTION:

@

In order to prevent clutch slip-

●

page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a higher
grade than “CD”. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.
Make sure that no foreign mate-

●

rial enters the crankcase.

@

9. 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.

NOTE:

@

After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient.

@

EC000067

CAUTION:

@

If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal­er check the vehicle.

@

10. Turn the engine off, and then
check the oil level and correct it if
necessary.

1. Screw

EAU02928

Cleaning the air filter element

The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre­quently if you are riding in unusually
wet or dusty areas.

1. Remove the seat. (See page 3-12
for seat removal and installation
procedures.)

2. Turn the fuel cock lever to “ON”,
and then remove the fuel cock le­ver by removing the screw.

6

6-10

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Fuel hose

2. Vacuum hose

3. Fuel tank drain hose

3. Disconnect the hoses shown.

6

4. Remove the fuel tank by removing
the bolts.

6-11

1. Screw (× 4)

5. Remove the air filter case cover by
removing the screws.

6. Pull the air filter element out.

PERIODIC MAINTENANCE AND MINOR REPAIR

CAUTION:

1. Air filter element

7. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.

8. Insert the air filter element into the
air filter case.

EC000082

CAUTION:

@

Make sure that the air filter ele-

●

ment is properly seated in the
air filter case.
The engine should never be op-

●

erated without the air filter ele­ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.

@

9. Install the air filter case cover by
installing the screws.

10. Install the fuel tank by installing the
bolts.

11. Connect the hoses.

12. Install the fuel cock lever by install­ing the screw.

13. Install the seat.

EAU00630

Adjusting the carburetors

The carburetors are important parts of
the engine and require very sophisti­cated adjustment. Therefore, most car­buretor adjustments should be left to a
Yamaha dealer, who has the neces­sary professional knowledge and expe­rience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.

EC000095

@

The carburetors have been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl­edge may result in poor perfor­mance of or damage to the engine.

@

6

6-12

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00632

Adjusting the engine idling
speed

The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.

1. Start the engine and warm it up for
several minutes at 1,000–
2,000 r/min while occasionally rev­ving it to 4,000–5,000 r/min.

NOTE:

@

The engine is warm when it quickly re-

6

sponds to the throttle.

@

1. Throttle stop screw

2. Check the engine idling speed
and, if necessary, adjust it to spec­ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di­rection a. To decrease the engine
idling speed, turn the screw in di­rection b.

Engine idling speed:

1,200 – 1,300 r/min

a. Throttle cable free play

EAU00635

Adjusting the throttle cable
free play

The throttle cable free play should
measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.

NOTE:

@

If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.

@

6-13

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00637

Adjusting the 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.

EAU03362

Tires

To maximize the performance, durabil­ity, and safe operation of your motor­cycle, note the following points
regarding the specified tires.

Tire air pressure

The tire air pressure should be
checked and, if necessary, adjusted
before each ride.

WARNING

@

The tire air pressure must be

●

checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
The tire air pressure must be

●

adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car­go, and accessories approved
for this model.

@

EW000082

CE-01E

Load* Front Rear

Up to 90 kg

90 kg–maximum

High-speed riding

CE-07E

Maximum load*

* Total weight of rider, passenger, cargo and

accessories

Tire air pressure

(measured on cold tires)

200 kPa

2.00 kg/cm

2.00 bar
200 kPa

2.00 kg/cm

2.00 bar
200 kPa

2.00 kg/cm

2.00 bar

2

2

2

XJ600S: 184 kg
XJ600N: 187 kg

225 kPa

2.25 kg/cm

2.25 bar
250 kPa

2.50 kg/cm

2.50 bar
250 kPa

2.50 kg/cm

2.50 bar

2

2

2

6

6-14

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

WARNING

@

Because loading has an enormous
impact on the handling, braking,
performance and safety characteris­tics of your motorcycle, you should
keep the following precautions in
mind.

NEVER OVERLOAD THE

●

MOTORCYCLE! Operation of an
overloaded motorcycle may re­sult in tire damage, loss of con­trol, or severe injury. Make sure
that the total weight of rider,

6

passenger, cargo, and accesso­ries does not exceed the speci­fied maximum load for the
vehicle.
Do not carry along loosely

●

packed items, which can shift
during a ride.
Securely pack the heaviest

●

items close to the center of the
motorcycle and distribute the
weight evenly on both sides.

EWA00012

Adjust the suspension and tire

●

air pressure with regard to the
load.
Check the tire condition and air

●

pressure before each ride.

@

1. Side wall
a. Tire tread depth

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
replace the tire immediately.

CE-08E

Minimum tire tread depth
(front and rear)

@

1.6 mm

The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.

@

6-15

PERIODIC MAINTENANCE AND MINOR REPAIR

WARNING

WARNING

@

Have a Yamaha dealer replace

●

excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta­bility and can lead to loss of
control.
The replacement of all wheel-

●

and brake-related parts, includ­ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl­edge and experience.

@

EW000079

Tire information

This motorcycle is equipped with tube
tires.

EW000078

WARNING

@

The front and rear tires should

●

be of the same make and de­sign, otherwise the handling
characteristics of the motor­cycle cannot be guaranteed.
After extensive tests, only the

●

tires listed below have been ap­proved for this model by
Yamaha Motor Co., Ltd.

@

CE-10E

FRONT

Manufacturer Size Type

DUNLOP 110/80-17 57H D103FA
MICHELIN 110/80-17 57H MACADAM 50

REAR

Manufacturer Size Type

DUNLOP 130/70-18 63H D103A
MICHELIN 130/70-18 63H MACADAM 50

@

Have a Yamaha dealer replace

●

excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta­bility and can lead to loss of
control.
The replacement of all wheel-

●

and brake-related parts, includ­ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl­edge and experience.

@

EAU00683

6

6-16

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00687

Wheels

To maximize the performance, durabil­ity, and safe operation of your motor­cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked

●

for cracks, bends or warpage 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 deformed or cracked
wheel must be replaced.

6

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 han­dling characteristics, and a short­ened tire life.
Ride at moderate speeds after

●

changing a tire since the tire sur­face must first be “broken in” for it
to develop its optimal characteris­tics.

1. Clutch lever free play locknut

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

Adjusting the clutch lever free
play

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

1. Loosen the locknut at the clutch le­ver.

2. To increase the clutch lever free
play, turn the adjusting bolt in di­rection a. To decrease the clutch
lever free play, turn the adjusting
bolt in direction b.

EAU00694

1. Clutch lever cable

2. Clutch lever free play adjusting nut

3. Locknut

3. If the specified clutch lever free
play could be obtained as de­scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.

4. Fully turn the adjusting bolt at the
clutch lever in direction a to loos­en the clutch cable.

5. Loosen the locknut at the crank­case.

6. To increase the clutch lever free
play, turn the adjusting nut in di­rection a. To decrease the clutch
lever free play, turn the adjusting
nut in direction b.

6-17

PERIODIC MAINTENANCE AND MINOR REPAIR

WARNING

7. Tighten the locknut at the clutch
lever and the crankcase.

a. Distance between brake pedal and footrest

EAU00712

Adjusting the brake pedal
position

The top of the brake pedal should be
positioned approximately 40 mm below
the top of the footrest as shown. Peri­odically check the brake pedal position
and, if necessary, have a Yamaha
dealer adjust it.

EW000109

@

A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be­fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident.

@

6

6-18

PERIODIC MAINTENANCE AND MINOR REPAIR

Front

EAU00721

Checking the front and rear
brake pads

The front and rear brake pads must be
checked for wear at the intervals spec­ified in the periodic maintenance and
lubrication chart.

1. Brake light switch

2. Brake light switch adjusting nut

Adjusting the rear brake light
switch

The rear brake light switch, which is ac-

6

tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting 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. To
make the brake light come on later,
turn the adjusting nut in direction b.

EAU00713

1. Wear indicator groove (× 2)

EAU00725

Front brake pads

Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with­out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
indicator groove has almost disap­peared, have a Yamaha dealer replace
the brake pads as a set.

6-19

PERIODIC MAINTENANCE AND MINOR REPAIR

Rear

Rear

1. Wear indicator groove (× 2)

Rear brake pads

Each rear brake pad is provided with a
wear indicator, which allows you to
check the brake pad wear without hav­ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicator while applying the
brake. If a brake pad has worn to the
point that the wear indicator almost
touches the brake disc, have a
Yamaha dealer replace the brake pads
as a set.

EAU00728

Front

1. Minimum level mark

EAU03196

Checking the brake fluid level

Insufficient brake fluid may allow air to
enter the brake system, possibly caus­ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu­id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys­tem for leakage.

6-20

1. Minimum level mark

Observe these precautions:

When checking the fluid level,

●

make sure that the top of the mas­ter cylinder or brake fluid reservoir
is level.
Use only the recommended quali-

●

ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor­mance.

Recommended brake fluid: DOT 4

Refill with the same type of brake

●

fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.

6

PERIODIC MAINTENANCE AND MINOR REPAIR

Be careful that water does not en-

●

ter the master cylinder 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. Al­ways clean up spilled fluid
immediately.
As the brake pads wear, it is nor-

●

mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud­denly, have a Yamaha dealer

6

check the cause.

Changing the brake fluid

Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica­tion chart. In addition, have the oil seals
of the brake master cylinder and caliper
as well as the brake hose replaced at
the intervals listed below or whenever
they are damaged or leaking.

Oil seals: Replace every two

●

years.
Brake hose: Replace every four

●

years.

EAU03238

a. Drive chain slack

EAU00745

Drive chain slack

The drive chain slack should be
checked before each ride and adjusted
if necessary.

To check the drive chain slack

1. Place the motorcycle on the
centerstand.

2. Shift the transmission into the neu­tral position.

3. Spin the rear wheel several times
to locate the tightest portion of the
drive chain.

4. Measure the drive chain slack as
shown.

6-21

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

CAUTION:

Drive chain slack:

30–40 mm

5. If the drive chain slack is incorrect,
adjust it as follows.

1. Axle nut

2. Chain puller locknut

3. Drive chain slack adjusting nut

4. Alignment marks

EAU00762

To adjust the drive chain slack

1. Loosen the axle nut, then the
chain puller locknut at each end of
the swingarm.

2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction 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 forward.

@

Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po­sition for proper wheel alignment.

@

@

EC000096

Improper drive chain slack will over­load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.

@

3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque.

Tightening torque:

Axle nut:

105 Nm (10.5 m·kg)

6

6-22

PERIODIC MAINTENANCE AND MINOR REPAIR

WARNING

Lubricating the drive chain

The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica­tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.

CAUTION:

@

The drive chain must be lubricated
after washing the motorcycle or
riding in the rain.

@

6

1. Clean the drive chain with kero­sene and a small soft brush.

CAUTION:

@

To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents.

@

EAU03006

EC000097

ECA00053

2. Wipe the drive chain dry.

3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.

ECA00052

CAUTION:

@

Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.

@

EAU02962

Checking and lubricating the
cables

The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca­bles and cable ends should be lubricat­ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.

Recommended lubricant:

Engine oil

EW000112

@

Damage to the outer sheath may in­terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.

@

6-23

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU03209

Checking and lubricating the
throttle grip and cable

The operation of the throttle grip and
the condition of the throttle cable
should be checked before each ride,
and the cable should be lubricated or
replaced if necessary.

NOTE:

@

Since the throttle grip must be removed
to access the throttle cable end, the
throttle grip and the cable should al­ways be lubricated at the same time.

@

1. Remove the throttle grip by remov­ing the screws.

2. Disconnect the throttle cable, hold
it up, and then apply several drops
of oil to the cable end, allowing it to
trickle into the sheath.

3. Connect the throttle cable, and
then grease the inside of the throt­tle grip housing.

4. Grease the metal-to-metal contact
surface of the throttle grip, and
then install the grip by installing
the screws.

Recommended lubricant:

Throttle cable:

Engine oil

Throttle grip housing and grip:

Lithium-soap-based grease
(all-purpose grease)

6-24

EAU03370

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 lu­bricated if necessary.

Recommended lubricant:

Lithium-soap-based grease
(all-purpose grease)

6

PERIODIC MAINTENANCE AND MINOR REPAIR

Checking and lubricating the
brake and clutch levers

The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu­bricated if necessary.

Recommended lubricant:

Lithium-soap-based grease
(all-purpose grease)

6

EAU03164

EAU03371

Checking and lubricating the
centerstand and sidestand

The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to­metal contact surfaces should be lubri­cated if necessary.

WARNING

@

If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re­pair it.

@

Recommended lubricant:

Lithium-soap-based grease
(all-purpose grease)

EW000114

EAU00790

Lubricating the rear
suspension

The pivoting points of the rear suspen­sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.

Recommended lubricant:

Molybdenum disulfide grease

6-25

PERIODIC MAINTENANCE AND MINOR REPAIR

WARNING

EAU02939

Checking the front fork

The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main­tenance and lubrication chart.

To check the condition

WARNING

@

Securely support the motorcycle so
that there is no danger of it falling
over.

@

Check the inner tubes for scratches,
damage and excessive oil leakage.

EW000115

To check the operation

1. Place the motorcycle on a level
surface and hold it in an upright
position.

2. While applying the front brake,
push down hard on the handle­bars several times to check if the
front fork compresses and re­bounds smoothly.

EC000098

CAUTION:

@

If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re­pair it.

@

EAU00794

Checking the steering

Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol­lows at the intervals specified in the pe­riodic maintenance and lubrication
chart.

1. Place a stand under the engine to
raise the front wheel off the
ground.

EW000115

@

Securely support the motorcycle so
that there is no danger of it falling
over.

@

6

6-26

PERIODIC MAINTENANCE AND MINOR REPAIR

CAUTION:

WARNING

2. Hold the lower ends of the front
fork legs and try to move them for­ward and backward. If any free
play can be felt, have a Yamaha

6

dealer check or repair the steer­ing.

EAU01144

Checking the wheel bearings

The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica­tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.

EAU00800

Battery

This motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.

@

Never attempt to remove the battery
cell seals, as this would permanent­ly damage the battery.

@

@

Electrolyte is poisonous and

●

dangerous since it contains sul­furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al­ways shield your eyes when
working near batteries. In case
of contact, administer the fol­lowing FIRST AID.

EC000101

EW000116

6-27

PERIODIC MAINTENANCE AND MINOR REPAIR

CAUTION:

• EXTERNAL: Flush with plenty
of water.

• INTERNAL: Drink large quan­tities of water or milk and im­mediately call a physician.

• EYES: Flush with water for
15 minutes and seek prompt
medical attention.

Batteries produce explosive hy-

●

drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro­vide 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 bat­tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the motorcycle is equipped with op­tional electrical accessories.

To store the battery

1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.

2. If the battery will be stored for
more than two months, check it at
least once a month and fully
charge it if necessary.

3. Fully charge the battery before in­stallation.

4. After installation, make sure that
the battery leads are properly con­nected to the battery terminals.

@

Always keep the battery

●

charged. Storing a discharged
battery can cause permanent
battery damage.
To charge a sealed-type (MF)

●

battery, a special (constant­voltage) battery charger is re­quired. Using a conventional
battery charger will damage the
battery. If you do not have ac­cess to a sealed-type (MF) bat­tery charger, have a Yamaha
dealer charge your battery.

@

EC000102

6

6-28

PERIODIC MAINTENANCE AND MINOR REPAIR

CAUTION:

1. Fuse box 1. Main fuse

EAU01470

Replacing the fuses

The fuse box is located under the seat.
(See page 3-12 for seat removal and
installation procedures.)

6

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.

2. Ignition fuse

3. Signaling system fuse

4. Headlight fuse

5. Hazard fuse

6. Spare fuse (× 3)

Specified fuses:

Main fuse: 30 A
Ignition fuse: 10 A
Signaling system fuse: 15 A
Headlight fuse: 15 A
Hazard fuse: 10 A

EC000103

@

Do not use a fuse of a higher amper­age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.

@

3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.

4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.

6-29

PERIODIC MAINTENANCE AND MINOR REPAIR

CAUTION:

1. Headlight coupler

2. Headlight bulb cover

Replacing a headlight bulb
(for XJ600S)

This motorcycle is equipped with
quartz bulb headlights. If a headlight
bulb burns out, replace it as follows.

1. Disconnect the headlight coupler,

EAU00829

and then remove the headlight
bulb cover.

1. Headlight bulb holder 1. Do not touch this area.

2. Unhook the headlight bulb holder,
and then remove the defective

3. Place a new bulb into position, and
then secure it with the bulb holder.

bulb.

EW000119

WARNING

@

Headlight bulbs get very hot. There­fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.

@

@

Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af­fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner.

@

6-30

EC000105

6

PERIODIC MAINTENANCE AND MINOR REPAIR

4. Install the bulb cover, and then
connect the coupler.

5. Have a Yamaha dealer adjust the
headlight beam if necessary.

1. Screw (× 2) 1. Headlight coupler

EAU03188

Replacing the headlight bulb
(for XJ600N)

This motorcycle is equipped with a

6

quartz bulb headlight. If the headlight

2. Headlight bulb cover

2. Disconnect the headlight coupler,
and then remove the headlight unit
and bulb cover.

bulb burns out, replace it as follows.

1. Remove the headlight unit by re­moving the screws.

6-31

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Headlight bulb holder 1. Do not touch this area.

5. Install the bulb cover, and then
connect the coupler.

6. Install the headlight unit by install­ing the screws.

7. Have a Yamaha dealer adjust the
headlight beam if necessary.

3. Unhook the headlight bulb holder,
and then remove the defective
bulb.

EW000119

WARNING

@

Headlight bulbs get very hot. There­fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.

@

4. Place a new bulb into position, and
then secure it with the bulb holder.

EC000105

CAUTION:

@

Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af­fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner.

@

6-32

6

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

6

1. Speedometer cable 1. Front wheel axle

EAU00868

2. Front wheel axle pinch bolt

Front wheel

CAUTION:

To remove the front wheel

EW000122

WARNING

@

It is advisable to have a Yamaha

●

dealer service the wheel.
Securely support the motor-

●

cycle so that there is no danger
of it falling over.

@

1. Place the motorcycle on the cen­terstand.

2. Disconnect the speedometer ca­ble from the front wheel.

3. Remove the brake calipers by re­moving the bolts.

@

Do not pull the brake lever after the
brake caliper has been removed,
otherwise the brake pads will be
forced shut.

@

4. Loosen the front wheel axle pinch
bolt.

5. Pull the wheel axle out, and then
remove the wheel.

6-33

ECA00047

EAU03420

To install the front wheel

1. Install the speedometer gear unit
into the wheel hub so that the pro­jections mesh with the slots.

2. Lift the wheel up between the fork
legs.

@

Make sure that the slot in the speedom­eter gear unit fits over the retainer on
the fork leg.

@

3. Insert the wheel axle.

4. Take the motorcycle off the cen­terstand so that the front wheel is
on the ground.

5. Install the brake calipers by install­ing the bolts.

NOTE:

@

Make sure that there is enough space
between the brake pads before install­ing the brake calipers onto the brake
discs.

@

6. Tighten the front wheel axle pinch
bolt, then the wheel axle, and the
brake caliper bolts to the specified
torques.

PERIODIC MAINTENANCE AND MINOR REPAIR

Tightening torques:

Wheel axle:

58 Nm (5.8 m·kg)

Front wheel axle pinch bolt:

40 Nm (4.0 m·kg)

Brake caliper bolt:

19 Nm (1.9 m·kg)

7. Connect the speedometer cable.

8. Push down hard on the handlebar
several times to check for proper
fork operation.

6

6-34

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

CAUTION:

1. Rear wheel axle nut 1. Brake torque rod bolt

Rear wheel

To remove the rear wheel

6

@

●

●

@

1. Place the motorcycle on the

2. Remove the axle nut.

EAU01480

EW000122

WARNING

It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor­cycle so that there is no danger
of it falling over.

centerstand.

2. Nut

3. Disconnect the brake torque rod
from the brake caliper bracket by
removing the nut and the bolt.

6-35

4. While supporting the brake caliper
bracket, pull the wheel axle out.

5. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.

@

The drive chain does not need to be
disassembled in order to remove and
install the rear wheel.

@

6. Remove the wheel.

ECA00048

@

Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.

@

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01468

To install the rear wheel

1. Insert the wheel axle from the
right-hand side.

2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-21 for
drive chain slack adjustment pro­cedures.)

3. Install the axle nut and brake
torque rod bolt at the brake caliper
bracket.

4. Install the brake caliper by install­ing the bolts.

NOTE:

@

Make sure that there is enough space
between the brake pads before install­ing the brake caliper onto the brake
disc.

@

5. Take the motorcycle off the cen­terstand so that the rear wheel is
on the ground.

6. Tighten the axle nut and brake
torque rod bolt to the specified
torques.

Tightening torques:

Axle nut:

105 Nm (10.5 m·kg)

Brake torque rod bolt:

23 Nm (2.3 m·kg)

EAU01008

Troubleshooting

Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur­ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your­self. However, should your motorcycle
require 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 replace­ment 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.

6

6-36

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01297

Troubleshooting chart

EW000125

WARNING

@

Keep away open flames and do not smoke while checking or working on the fuel system.

@

1. Fuel

Check the fuel level in

There is enough fuel.

the fuel tank.

There is no fuel.

Check the compression.

Supply fuel.

The engine does not start.
Check the compression.

2. Compression

There is compression.

6

Operate the electric starter.

3. Ignition

Remove the spark plugs
and check the electrodes.

4. Battery

Operate the electric starter.

There is no compression.

Wet

Dry

The engine turns over
quickly.

The engine turns over
slowly.

Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.

Have a Yamaha dealer check the vehicle.

Check the ignition.

Have a Yamaha dealer
check the vehicle.

The battery is good.

Check the battery lead connections,
and charge the battery if necessary.

6-37

Open the throttle halfway and operate
the electric starter.

The engine does not start.
Check the battery.

The engine does not start.
Have a Yamaha dealer
check the vehicle.

MOTORCYCLE CARE AND STORAGE

Care .................................................................................................. 7-1

Storage ................................ ................... .................... ................... .... 7-4

7

7-

CAUTION:

MOTORCYCLE CARE AND STORAGE

EAU03430

Care

While the open design of a motorcycle
reveals the attractiveness of the tech­nology, it also makes it more vulnera­ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un­noticed on a car, however, it detracts
from the overall appearance of a
motorcycle. 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.

7

Before cleaning

1. Cover the muffler outlets with plas­tic bags 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 in­stalled.

3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod­ucts onto seals, gaskets, sprock­ets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.

Cleaning

ECA00010

@

● Avoid using strong acidic wheel

cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af­fected area any longer than in­structed. Also, thoroughly rinse
the area off with water, immedi­ately dry it, and then apply a
corrosion protection spray.

● Improper cleaning can damage

windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.

7-1

MOTORCYCLE CARE AND STORAGE

NOTE:

CAUTION:

Do not use any harsh chemical

●

products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re­movers or inhibitors, brake flu­id, antifreeze or electrolyte.
Do not use high-pressure wash-

●

ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar­eas: seals (of wheel and swing­arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments, switch­es and 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 wind­shield. Test the product on a
small hidden part of the wind­shield to make sure that it does
not leave any marks. If the wind­shield is scratched, use a quali­ty plastic polishing compound
after washing.

@

After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.

After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.

@

Salt sprayed on roads in the winter may
remain well into spring.

@

1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.

ECA00012

@

Do not use warm water since it in­creases the corrosive action of the
salt.

@

2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick­el-plated, surfaces to prevent cor­rosion.

7

7-2

MOTORCYCLE CARE AND STORAGE

CAUTION:

NOTE:

After cleaning

1. Dry the motorcycle with a chamois
or an absorbing cloth.

2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.

3. Use a chrome polish to shine
chrome, aluminum and stainless­steel parts, including the exhaust
system. (Even the thermally in­duced discoloring of stainless­steel exhaust systems can be re­moved through polishing.)

4. To prevent corrosion, it is recom­mended to apply a corrosion pro­tection spray on all metal,

7

including chrome- and nickel-plat­ed, surfaces.

5. Use spray oil as a universal clean­er to remove any remaining dirt.

6. Touch up minor paint damage
caused by stones, etc.

7. Wax all painted surfaces.

8. Let the motorcycle dry completely
before storing or covering it.

WARNING

@

Make sure that there is no oil or

●

wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac­etone, and wash the tires with
warm water and a mild deter­gent.
Before operating the motor-

●

cycle test its braking perfor­mance and cornering behavior.

@

EWA00001

ECA00013

@

Apply spray oil and wax spar-

●

ingly and make sure to wipe off
any excess.
Never apply oil or wax to any

●

rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing

●

compounds as they will wear
away the paint.

@

@

Consult a Yamaha dealer for advice on
what products to use.

@

7-3

MOTORCYCLE CARE AND STORAGE

W ARNING

Storage

Short-term

Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.

CAUTION:

@

Storing the motorcycle in a

●

poorly ventilated room or cover­ing it with a tarp, while it is still
wet, will allow water and humid­ity to seep in and cause rust.
To prevent corrosion, avoid

●

damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi­cals are stored.

@

ECA00014

Long-term

Before storing your motorcycle for
several months:

1. Follow all the instructions in the
“Care” section of this chapter.

2. Turn the fuel cock lever to “ON”.

3. Drain the carburetor float cham­bers by loosening the drain bolts;
this will prevent fuel deposits from
building up. Pour the drained fuel
into the fuel tank.

4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.

5. Perform the following steps to pro­tect the cylinders, piston rings, etc.
from corrosion.

a. Remove the spark plug caps and

spark plugs.

b. Pour a teaspoonful of engine oil

into each spark plug bore.

c. Install the spark plug caps onto the

spark plugs, and then place the
spark plugs on the cylinder head
so that the electrodes are 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.)

e. Remove the spark plug caps from

the spark plugs, and then install
the spark plugs and the spark plug
caps.

EWA00003

@

To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.

@

6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.

7

7-4

MOTORCYCLE CARE AND STORAGE

7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna­tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.

8. Cover the muffler outlets with plas­tic bags to prevent moisture from
entering them.

9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex­cessively cold or warm place (less

7

than 0 °C or more than 30 °C). For
more information on storing the
battery, see page 6-27.

NOTE:

@

Make any necessary repairs before
storing the motorcycle.

@

7-5

SPECIFICATIONS

Specifications .................................................................................... 8-1

Conversion table ............................................................................... 8-5

8

8-

CAUTION:

SPECIFICATIONS

Specifications

CS-01E

Model XJ600S/XJ600N
Dimensions

Overall length 2,170 mm
Overall width 735 mm
Overall height

XJ600S 1,205 mm

XJ600N 1,090 mm
Seat hight 770 mm
Wheelbase 1,445 mm
Ground clearance 150 mm
Minimum turning radius 2,700 mm

Basic weight (with oil and
full fuel tank)

XJ600S 213 kg

XJ600N 210 kg

Engine

8

Engine type Air-cooled 4-stroke, DOHC
Cylinder arrangement Forward-inclined parallel

Displacement 598 cm
Bore × Stroke 58.5 × 55.7 mm
Compression ratio 10:1
Starting system Electric starter
Lubrication system Wet sump

4-cylinder

EAU01038

Engine oil

Type

-20 -10 0

20 30

10

SAE 10W–30

SAE 10W–40

SAE 15W–40

SAE 20W–40

SAE 20W–50

40

50 ˚C

Recommended engine oil
classification API Service SE, SF, SG type or

higher

Be sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled
“Energy Conserving”) contain anti-friction additives which
will cause clutch and/or starter clutch slippage, resulting in
reduced component life and poor engine performance.

Quantity

3

Without oil filter cartridge
replacement 2.3 L

With oil filter cartridge
replacement 2.6 L

Total amount (dry engine) 3.1 L

8-1

SPECIFICATIONS

Air filter Dry type element
Fuel

Type Regular unleaded gasoline
Fuel tank capacity 17.0 L
Reserve amount 3.5 L

Carburetor

Manufacturer MIKUNI
Model × quantity BDS28 × 4

Spark plug

Model/Manufacturer CR8E / NGK

U24ESR-N / DENSO

Gap 0.7–0.8 mm

Clutch type Wet, multiple-disc
Transmission

Primary reduction system Spur gear
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
Gear ratio

1st 2.733
2nd 1.778
3rd 1.333
4th 1.074
5th 0.913
6th 0.821

Chassis

Frame type Double cradle
Caster angle 25°
Trail 97 mm

Tire

Front

Type Tubeless
Size 110/80-17 57H
Manufacturer/model MICHELIN / MACADAM 50

DUNLOP / D103FA

Rear

Type Tubeless
Size 130/70-18 63H
Manufacturer/model MICHELIN / MACADAM 50

DUNLOP / D103A

8

8-2

SPECIFICATIONS

Maximum load*

XJ600S 184 kg
XJ600N 187 kg

Tire air pressure (measured on
cold tires)

Up to 90 kg*

2

Front 200 kPa (2.00 kg/cm
Rear 225 kPa (2.25 kg/cm

90 kg maximum*

Front 200 kPa (2.00 kg/cm
Rear 250 kPa (2.50 kg/cm

High-speed riding

Front 200 kPa (2.00 kg/cm
Rear 250 kPa (2.50 kg/cm

* Total weight of rider, passenger, cargo and accessories

Wheels

Front

8

Rear

Type Cast wheel
Size 17 × MT 2.50

Type Cast wheel
Size 18 × MT 3.50

, 2.00 bar)

2

, 2.25 bar)

2

, 2.00 bar)

2

, 2.50 bar)

2

, 2.00 bar)

2

, 2.50 bar)

Brakes

Front

Type Dual disc brake
Operation Right hand
Fluid DOT 4

Rear

Type Single disc brake
Operation Right foot
Fluid DOT 4

Suspension

Front Telescopic fork
Rear Swingarm (monocross suspen-

sion)

Spring/shock absorbers

Front Coil spring / oil damper
Rear Coil spring / gas-oil damper

Wheel travel

Front 140 mm
Rear 110 mm

Electrical systems

Ignition system Transistorized coil ignition

8-3

SPECIFICATIONS

Charging system

Type A.C. magneto
Standard output 14 V, 20 A @ 5,000 r/min

Battery

Model YTX9-BS
Voltage, capacity 12 V, 8 Ah

Headlight type Quartz bulb (halogen)
Bulb voltage, wattage × quantity

Headlight 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 lighting

XJ600S 12 V, 1.7 W × 3
XJ600N 14 V, 3 W × 2

12 V, 1.7 W × 2
Neutral indicator light 12 V, 3.4 W × 1
High beam indicator light 12 V, 3.4 W × 1
Oil level warning light

XJ600S 12 V, 3.4 W × 1
XJ600N 14 V, 3 W × 1

Turn signal indicator light 12 V, 3.4 W × 2

Fuses

Main fuse 30 A
Ignition fuse 10 A
Signaling system fuse 15 A
Headlight fuse 15 A
Hazard fuse 10 A

8

8-4

SPECIFICATIONS

Conversion table

CS-02E

All specification data in this manual are listed in SI and
METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL
unit data.
Example

METRIC MULTIPLIER IMPERIAL

** mm × 0.03937 = ** in

2 mm × 0.03937 = 0.08 in

8

EAU01064

Conversion table

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

m·kg

Torque

Weight
Speed km/h 0.6214 mi/h

Distance

Volume,
Capacity

Miscellaneous

m·kg
cm·kg
cm·kg

kg
g

km
m
m
cm
mm

3

cc (cm

)

3

)

cc (cm
L (liter)
L (liter)

kg/mm

2

kg/cm
Centigrade (°C)

7.233

86.794

0.0723

0.8679

2.205

0.03527

0.6214

3.281

1.094

0.3937

0.03937

0.03527

0.06102

0.8799

0.2199

55.997

14.2234
9/5 + 32

ft·lb
in·lb
ft·lb
in·lb

lb
oz

mi
ft
yd
in
in

oz (IMP liq.)
cu·in
qt (IMP liq.)
gal (IMP liq.)

lb/in
psi (lb/in
Fahrenheit (°F)

2

)

8-5

CONSUMER INFORMATION

Identification numbers ......................................... .............................. 9-1

Key identification number (for XJ600S).............................................. 9-1

Key identification number (for XJ600N)..............................................9-1

Vehicle identification number ..... .... ... ... ... ... ........................................ 9-2

Model label ........................................................................................ 9-2

9

9-

XJ600N

CONSUMER INFORMATION

EAU01039

Identification numbers

Record the key identification number,
vehicle identification number and mod­el label information in the spaces pro­vided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehi­cle is stolen.

1. KEY IDENTIFICATION NUMBER:

CA-02E

2. VEHICLE IDENTIFICATION
NUMBER:

CA-02E

9

3. MODEL LABEL INFORMATION:

CA-01E

EAU02944

XJ600S

1. Key identification number

EAU01041

Key identification number
(for XJ600S)

The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new
key.

1. Key identification number

EAU01042

Key identification number
(for XJ600N)

The key identification number is
stamped into the key. Record this num­ber in the space provided and use it for
reference when ordering a new key.

9-1

1. Vehicle identification number 1. Model label

EAU01043

Vehicle identification number

The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro­vided.

Model label

The model label is affixed to the frame
under the seat. (See page 3-12 for seat
removal and installation procedures.)
Record the information on this label in
the space provided. This information

NOTE:

@

The vehicle identification number is
used to identify your motorcycle and

will be needed when ordering spare
parts from a Yamaha dealer.

may be used to register your motor­cycle with the licensing authority in
your area.

@

CONSUMER INFORMATION

EAU01050

9

9-2

10-

INDEX

A

Air filter element, c leaning......................6-10

B

Battery...................................................6-27

Brake and clutch levers, checking and

lubricating............................................6-25

Brake and shift pedals, checking and

lubricati n g............................................6-24

Brake fluid, changing .............................6-21

Brake fluid level, checking......................6-20

Brake leve r ...............................................3-8

Brake light sw i tc h ( r ear ) , a dj us t in g.........6-19

Brake pads, checking.............................6-19

Brake peda l ..............................................3-9

Brake pedal p o sition, adjustin g..............6-18

C

Cables, ch e cking and lubricating............6-23

Carbureto r s, adjusting............................6-12

Care.........................................................7-1

Centerstand and sidestand, checking

and lubric a t ing.....................................6-25

Clutch lev e r..............................................3-7

Clutch lev e r f r e e play, adjus t i n g.............6-17

Controls an d instruments ( XJ600N).........2-6

Controls an d instruments ( XJ600S)..........2-3

Conversion table......................................8-5

D

Dimmer swi t ch.........................................3-6

Drive chai n , lubricating...........................6-23

Drive chain slack...................................6-21

Adjusting.......................................... 6-22

Checking..........................................6-21

E

Engine bre ak-in.......................................5-4

Engine oil and oil filt e r cartridge............... 6-7

Engine sto p sw i t ch...................................3-7

F

Front fork, checking...............................6-26

Front whee l...........................................6-33

Installing........................................... 6-33

Removing.........................................6-33

Fuel....................................................... 3-10

Fuel cock...............................................3-11

Fuel consumption, tips for r educ i ng.........5-4

Fuel tank breather hose

(Germany on ly )................................... 3-10

Fuel tank cap...........................................3-9

Fuses, repl a cing.................................... 6-29

H

Handlebar switc hes.................................3-6

Hazard swi t c h..........................................3-6

Headlight bulb, replacing (for XJ600N)..6-31
Headlight bulb, replacing (for XJ600S) ..6-30

Helmet hold er s......................................3-13

High beam i n dicator ligh t.........................3-4

Horn switc h.............................................3-6

I

Identification nu mber s.............................9-1

Idling spe ed, adjusting........................... 6-13

Ignition ci r cuit cut-off system..................3-16

Indicator l i ghts..........................................3-3

K

Key identif ication numbe r ( f or XJ600N)....9-1

Key identif ication numbe r ( f or XJ600S)....9-1

L

Left view ( XJ600N)...................................2-4

Left view ( XJ600S)...................................2-1

Light switch..............................................3-7

Luggage strap holders...........................3-15

N

Neutral indica t or li gh t...............................3-3

M

Main switch /steering lock .........................3-1

Maintenance and lubrication, periodic......6-2

Model label..............................................9-2

O

Operation.................................................5-1

Oil level wa r ning light...............................3-4

P

Pass switc h..............................................3-6

Panel, removing and installing..................6-5

Parking.....................................................5-5

Part locations...........................................2-1

Pre-operat i o n check list............................4-1

R

Rear wheel.............................................6-35

Installing...........................................6-36

Removing.........................................6-35