OWNER’S MANUAL XJ600S YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 · 6 - 0.
E_5GK_Consumer.
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM INTRODUCTION EAU03338 Welcome to the Yamaha world of motorcycling! As the owner of an XJ600S/XJ600N, you are benefiting from Yamaha’s vast experience 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.
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM 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! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
E_4br.book Page 3 Wednesday, July 25, 2001 1:40 PM IMPORTANT MANUAL INFORMATION EAU03337 XJ600S/XJ600N OWNER’S MANUAL © 2001 by Yamaha Motor Co., Ltd. 1st Edition, April 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
E_4br.
E_4br.
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY ................................................
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM GIVE SAFETY THE RIGHT OF WAY EAU00021 1- 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.
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM 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) .....................................
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM DESCRIPTION EAU00026 2- Left view (XJ600S) 2 1. Fuel cock 2. Helmet holder 3. Fuse box 4. Luggage strap holders 5. Seat lock 6. Shock absorber assembly spring preload adjusting ring 7.
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM DESCRIPTION Right view (XJ600S) 2 8. Tail/brake light 9. Storage compartment 10. Seat 11. Fuel tank 12. Headlight 13.
E_4br.book Page 3 Wednesday, July 25, 2001 1:40 PM DESCRIPTION Controls and instruments (XJ600S) 2 14. Clutch lever 15. Left handlebar switches 16. Starter (choke) lever 17. Speedometer unit 18. Tachometer 19. Right handlebar switches 20. Brake lever 21. Throttle grip 22.
E_4br.book Page 4 Wednesday, July 25, 2001 1:40 PM DESCRIPTION Left view (XJ600N) 2 1. Steering lock 2. Fuel cock 3. Helmet holder 4. Fuse box 5. Luggage strap holders 6. Seat lock 7. Shock absorber assembly spring preload adjusting ring 8.
E_4br.book Page 5 Wednesday, July 25, 2001 1:40 PM DESCRIPTION Right view (XJ600N) 2 9. Tail/brake light 10. Storage compartment 11. Seat 12. Fuel tank 13. Headlight 14.
E_4br.book Page 6 Wednesday, July 25, 2001 1:40 PM DESCRIPTION Controls and instruments (XJ600N) 2 15. Clutch lever 16. Left handlebar switches 17. Starter (choke) lever 18. Speedometer unit 19. Tachometer 20. Right handlebar switches 21. Brake lever 22. Throttle grip 23.
E_4br.
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock .....................................3-1 Steering lock (for XJ600N)....................................3-3 Indicator and warning lights ................................3-3 Speedometer unit (for XJ600S) ...........................3-4 Speedometer unit (for XJ600N) ...........................3-5 Tachometer ..........................................................3-5 Handlebar switches ...............
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00027 3- XJ600S XJ600N 3 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. EAU00038 EAU00040 OFF All electrical systems are off. The key can be removed. LOCK (for XJ600S) The steering is locked, and all electrical systems are off. The key can be removed.
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS 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 XJ600N @ 3 1. Push. 2. Turn.
E_4br.book Page 3 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS 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 the lock cover. 3 1. Steering lock XJ600S 1. 2. 3. 4. 5. EAU02934 Steering lock (for XJ600N) To lock the steering 1. Turn the handlebar all the way to right. 2.
E_4br.book Page 4 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS 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. XJ600N 1. 2. 3. 4. 5.
E_4br.book Page 5 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS XJ600N XJ600S XJ600N 3 1. 2. 3. 4. Speedometer Odometer Tripmeter Tripmeter reset knob 1. Tachometer 2. Tachometer red zone (except for CH, A) 3. Tachometer red zone (for CH, A) EAU00101* EAU00095 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.
E_4br.book Page 6 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS 1. 2. 3. 4. 5. Dimmer switch “ / Pass switch “PASS” Hazard switch “ ” Turn signal switch “ Horn switch “ ” ” EAU03826 EAU03889 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).
E_4br.book Page 7 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00143 Start switch “ ” Push this switch to crank the engine with the starter. EC000005 CAUTION: See page 5-1 for starting instructions prior to starting the engine. @ 3 @ 1. Engine stop switch “ 2. Light switch “ / 3. Start switch “ ” / / ” ” 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.
E_4br.book Page 8 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Shift pedal EAU00157 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. 1. Brake lever 2. Brake lever position adjusting nut 1. Brake lever position adjusting nut 2.
E_4br.book Page 9 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS NOTE: 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 WARNING Make sure that the fuel tank cap is properly closed before riding. @ 3 1. Brake pedal EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 1.
E_4br.book Page 10 Wednesday, July 25, 2001 1:40 PM 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. @ @ EAU04202 Recommended fuel: REGULAR UNLEADED GASOLINE ONLY Fuel tank capacity: Total amount: 17.0 L Reserve amount: 3.5 L 1. Fuel tank filler tube 2. Fuel level EAU03753 Fuel Make sure that there is sufficient fuel in the tank.
E_4br.book Page 11 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS ON: Normal position RES: Reserve position 3 1. Fuel tank breather hose 1. Arrow mark positioned over “ON” EAU00196 Fuel tank breather hose (for Germany only) Before operating the motorcycle: ● Check the fuel tank breather hose connection. ● Check the fuel tank breather hose for cracks or damage, and replace it if damaged. ● Make sure that the end of the fuel tank breather hose is not blocked and clean it if necessary.
E_4br.book Page 12 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS PRI: Prime position 3 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.
E_4br.book Page 13 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS EWA00015 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. @ @ 3 1. Projection (× 2) 2. Seat holder 1. Helmet holder (× 2) 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.
E_4br.book Page 14 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Strap for U-LOCK (× 2) EAU01688 Storage compartment This storage compartment is designed to hold a genuine Yamaha U-LOCK. (Other locks may not fit.) When placing a U-LOCK in the storage compartment, securely fasten it with the straps. When the U-LOCK is not in the storage compartment, be sure to secure the straps to prevent losing them.
E_4br.book Page 15 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00315 WARNING 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 responsible for property damage or personal injury that may result from improper handling. ● Do not tamper with or attempt to open the gas cylinder.
E_4br.book Page 16 Wednesday, July 25, 2001 1:40 PM INSTRUMENT AND CONTROL FUNCTIONS EW000044 WARNING The motorcycle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), 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.
E_4br.book Page 17 Wednesday, July 25, 2001 1:40 PM 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 YES NOTE: This check is most reliable if performed with a warmed-up engine. ”. NO The neutral switch may be defective.
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM PRE-OPERATION CHECKS Pre-operation check list .....................................................................
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM PRE-OPERATION CHECKS EAU01114 4- 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.
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM PRE-OPERATION CHECKS ITEM CHECKS PAGE Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. • Tighten if necessary. Fuel • Check fuel level. • Fill with fuel if necessary. 3-9–3-10 Lights, signals and switches • Check proper operation. — — NOTE: Pre-operation checks should be made each time the motorcycle is used.
E_4br.
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM 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 .
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM OPERATION AND IMPORTANT RIDING POINTS EAU00372 5- EAU00373 @ 5 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 operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time.
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM OPERATION AND IMPORTANT RIDING POINTS EC000034 ECA00045 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.
E_4br.book Page 3 Wednesday, July 25, 2001 1:40 PM OPERATION AND IMPORTANT RIDING POINTS EC000048 @ 1. Shift pedal N. Neutral position EAU00423 5 Shifting Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration. 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.
E_4br.book Page 4 Wednesday, July 25, 2001 1:40 PM 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 engine speeds during acceleration. ● Do not rev the engine while shifting down, and avoid high engine speeds with no load on the engine.
E_4br.book Page 5 Wednesday, July 25, 2001 1:40 PM OPERATION AND IMPORTANT RIDING POINTS 500–1,000 km ● Avoid prolonged full-throttle operation. ● Avoid prolonged operation above 7,000 r/min. EAU00460 Parking When parking, stop the engine, and then remove the key from the main switch. EW000058 EC000052* CAUTION: After 1,000 km of operation, the engine oil must be changed and the oil filter cartridge replaced. @ @ 5 1,000 km and beyond The vehicle can now be operated normally.
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM 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 cartridge ..........................6-7 Cleaning the air filter element ............................6-10 Adjusting the carburetors ..........
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462 6- EAU00464 6 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.
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03685 Periodic maintenance and lubrication chart NOTE: ● The annual checks must be performed every year, except if a kilometer-based 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 technical skills. _ _ CP-01ECP-01E NO.
E_4br.book Page 3 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING (×1,000 km) 1 10 √ • Check for cracks or damage. 20 30 40 Annual check √ √ √ √ 9 * Brake hoses 10 * Wheels • Check runout and for damage. √ √ √ √ 11 * Tires • Check tread depth and for damage. • Replace if necessary. • Check air pressure. • Correct if necessary. √ √ √ √ 12 * Wheel bearings • Check bearing for looseness or damage.
E_4br.book Page 4 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR NO. ODOMETER READING (×1,000 km) 1 10 20 30 40 Annual check • Check starter (choke) operation. • Adjust engine idling speed and synchronization. √ √ √ √ √ √ • Change. √ √ √ √ √ √ • Check oil level and vehicle for oil leakage. √ √ √ √ √ √ ITEM CHECK OR MAINTENANCE JOB 22 * Carburetors 23 Engine oil 24 Engine oil filter cartridge • Replace.
E_4br.book Page 5 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel A 1. Screw (× 2) EAU01777 Removing and installing the panel 6 The panel shown above needs to be 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. EAU02926 Panel A To remove the panel 1. Remove the seat. (See page 3-12 for seat removal and installation procedures.) 2.
E_4br.book Page 6 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR a. Spark plug gap To install the panel 1. Place the panel in the original position, and then install the screws. 2. Install the seat. EAU01880 Checking the spark plugs The spark plugs are important engine components, which should be checked periodically, preferably by a Yamaha dealer.
E_4br.book Page 7 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. NOTE: 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. _ _ Tightening torque: Spark plug: 12.5 Nm (1.
E_4br.book Page 8 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil filler cap To change the engine oil (with or without oil filter cartridge replacement) 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil. 1. Engine oil drain bolt 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase.
E_4br.book Page 9 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR 8. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap. 1. O-ring 5. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. 6 NOTE: Make sure that the O-ring is properly seated. 1. Torque wrench 6. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench.
E_4br.book Page 10 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR _ EC000072 EC000067 CAUTION: ● In order to prevent clutch slippage (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 material enters the crankcase.
E_4br.book Page 11 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Fuel hose 2. Vacuum hose 3. Fuel tank drain hose 3. Disconnect the hoses shown. 1. Screw (× 4) 4. Remove the fuel tank by removing the bolts. 6 6-11 5. Remove the air filter case cover by removing the screws. 6. Pull the air filter element out.
E_4br.book Page 12 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR EC000082* @ 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. CAUTION: ● Make sure that the air filter element is properly seated in the air filter case.
E_4br.book Page 13 Wednesday, July 25, 2001 1:40 PM 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. 1. Throttle stop screw 2.
E_4br.book Page 14 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 EAU03362 Adjusting the valve clearance Tires 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.
E_4br.book Page 15 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● Adjust the suspension and tire air pressure with regard to the load. ● Check the tire condition and air pressure before each ride. EWA00012 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.
E_4br.book Page 16 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000079 @ @ 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 wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.
E_4br.book Page 17 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03773 Cast wheels 6 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.
E_4br.book Page 18 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Tighten the locknut at the clutch lever and the crankcase. EW000109 WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident. @ a.
E_4br.book Page 19 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00721 Checking the front and rear brake pads Front The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. 1. Rear brake light switch 2. Rear brake light switch adjusting nut 1.
E_4br.book Page 20 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR Rear Front 1. Brake pad wear indicator (× 2) Rear 1. Minimum level mark EAU00728 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.
E_4br.book Page 21 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● 6 Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. ● Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. ● As the brake pads wear, it is normal for the brake fluid level to gradually go down.
E_4br.book Page 22 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: 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. Drive chain slack: 30–40 mm _ 5. If the drive chain slack is incorrect, adjust it as follows. _ EC000096 CAUTION: 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.
E_4br.book Page 23 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. EAU03006 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.
E_4br.book Page 24 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU04034 EAU03370 Checking and lubricating the throttle grip and cable Checking and lubricating the brake and shift pedals The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.
E_4br.book Page 25 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03164 EAU00790 Checking and lubricating the centerstand and sidestand Lubricating the rear suspension The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. 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.
E_4br.book Page 26 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02939 EAU00794 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 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.
E_4br.book Page 27 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 6 EAU00800 Checking the wheel bearings Battery 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. This motorcycle is equipped with a sealed-type (MF) battery, which does not require any maintenance.
E_4br.book Page 28 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR • 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 hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space.
E_4br.book Page 29 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR EC000103 CAUTION: 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. @ @ 1. Fuse box EAU01470 Replacing the fuses 6 The fuse box is located under the seat. (See page 3-12 for seat removal and installation procedures.) If a fuse is blown, replace it as follows. 1.
E_4br.book Page 30 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Headlight coupler 2. Headlight bulb cover 1. Headlight bulb holder 2. Unhook the headlight bulb holder, and then remove the defective bulb. EAU04136 Replacing the headlight bulb (for XJ600S) This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Disconnect the headlight coupler, and then remove the bulb cover. 1. Do not touch this area. 3.
E_4br.book Page 31 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR 4. Install the headlight bulb cover, and then connect the coupler. 5. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Screw (× 2) EAU04189 Replacing the headlight bulb (for XJ600N) 6 This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the screws. 6-31 1. Headlight coupler 2.
E_4br.book Page 32 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR 5. Install the headlight 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. 1. Headlight bulb holder 1. Do not touch this area. 4. Place a new headlight bulb into position, and then secure it with the bulb holder. 3. Unhook the headlight bulb holder, and then remove the defective bulb.
E_4br.book Page 33 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Speedometer cable EAU00868 1. Front wheel axle 2. Front wheel axle pinch bolt Front wheel EAU04164 ECA00047 CAUTION: Do not pull the brake lever after the brake caliper has been removed, otherwise the brake pads will be forced shut. @ To remove the front wheel EW000122 6 @ WARNING ● It is advisable to have a Yamaha dealer service the wheel.
E_4br.book Page 34 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torques: Wheel axle: 58 Nm (5.8 m·kgf) Front wheel axle pinch bolt: 40 Nm (4.0 m·kgf) Brake caliper bolt: 19 Nm (1.9 m·kgf) 5. Install the brake calipers by installing the bolts. 7. Connect the speedometer cable. 8. Push down hard on the handlebar several times to check for proper fork operation.
E_4br.book Page 35 Wednesday, July 25, 2001 1:40 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Rear wheel axle nut EAU01480 Rear wheel 1. Brake torque rod bolt 2. Nut 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. 3. Disconnect the brake torque rod from the brake caliper bracket by removing the nut and the bolt.
E_4br.book Page 36 Wednesday, July 25, 2001 1:40 PM 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.
E_4br.book Page 37 Wednesday, July 25, 2001 1:40 PM 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 There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start.
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM MOTORCYCLE CARE AND STORAGE Care .................................................................................................. 7-1 Storage ..............................................................................................
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM MOTORCYCLE CARE AND STORAGE EAU03430 7- 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.
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM MOTORCYCLE CARE AND STORAGE ● 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.
E_4br.book Page 3 Wednesday, July 25, 2001 1:40 PM MOTORCYCLE CARE AND STORAGE 7 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.
E_4br.book Page 4 Wednesday, July 25, 2001 1:40 PM MOTORCYCLE CARE AND STORAGE Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA00014 @ @ 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.
E_4br.book Page 5 Wednesday, July 25, 2001 1:40 PM 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.
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM SPECIFICATIONS Specifications .................................................................................... 8-1 Conversion table ...............................................................................
E_4br.
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM SPECIFICATIONS Air filter Dry type element Operation Fuel Gear ratio Type REGULAR UNLEADED GASOLINE ONLY Fuel tank capacity 17.0 L Reserve amount 3.5 L Carburetor Manufacturer MIKUNI Model × quantity BDS28 × 4 Model/Manufacturer CR8E / NGK Gap 0.7–0.8 mm U24ESR-N / DENSO 2nd 1.778 3rd 1.333 4th 1.074 5th 0.913 6th 0.
E_4br.book Page 3 Wednesday, July 25, 2001 1:40 PM SPECIFICATIONS Maximum load* Brakes XJ600S 184 kg XJ600N 187 kg Front Type Tire air pressure (measured on cold tires) Up to 90 kg* Operation Right hand Fluid DOT 4 Type Single disc brake Rear Front 200 kPa (2.00 kgf/cm2, 2.00 bar) Rear 225 kPa (2.25 kgf/cm2, 2.25 bar) 90 kg–maximum* Front 200 kPa (2.00 kgf/cm2, 2.00 bar) Rear 250 kPa (2.50 kgf/cm2, 2.50 bar) High-speed riding Front 200 kPa (2.00 kgf/cm2, 2.00 bar) Rear 250 kPa (2.
E_4br.book Page 4 Wednesday, July 25, 2001 1:40 PM SPECIFICATIONS Charging system Fuses Type A.C. magneto Main fuse 30 A Standard output 14 V, 20 A @ 5,000 r/min Ignition fuse 10 A Signaling system fuse 15 A Model YTX9-BS Headlight fuse 15 A Voltage, capacity 12 V, 8 Ah Hazard fuse 10 A Battery 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.
E_4br.book Page 5 Wednesday, July 25, 2001 1:40 PM SPECIFICATIONS EAU03941 Conversion table CS-03E Conversion table All specification data in this manual are listed in SI and METRIC UNITS. METRIC SYSTEM TO IMPERIAL SYSTEM Metric unit Use this table to convert METRIC unit values to IMPERIAL unit values. Example: METRIC VALUE 2 mm CONVERSION FACTOR × 0.03937 Torque ft·lb in·lb ft·lb in·lb Weight kg g × 2.205 × 0.03527 lb oz Speed km/h × 0.6214 mi/h Distance km m m cm mm × 0.6214 × 3.
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM 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 .....................................................
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM CONSUMER INFORMATION EAU01039 9- EAU02944 Identification numbers XJ600S XJ600N 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 1. KEY IDENTIFICATION NUMBER: CA-02E 2. VEHICLE IDENTIFICATION NUMBER: CA-02E 9 1.
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM CONSUMER INFORMATION 1. Vehicle identification number 1. Model label EAU01043 EAU01050 Vehicle identification number Model label The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided. 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.
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM INDEX 10- A D I Air filter element, cleaning ......................6-10 Dimmer switch......................................... 3-6 Drive chain, lubricating .......................... 6-23 Drive chain slack ................................... 6-21 Checking.......................................... 6-21 Adjusting .......................................... 6-22 Identification numbers ..............................9-1 Idling speed, adjusting ...........
E_4br.book Page 2 Wednesday, July 25, 2001 1:40 PM INDEX S T Safety information.................................... 1-1 Seat....................................................... 3-12 Shifting .................................................... 5-3 Shift pedal ............................................... 3-8 Shift points (for Switzerland only)............. 5-3 Shock absorber assembly, adjusting ..... 3-14 Sidestand .............................................. 3-15 Spark plugs, checking ...........
E_5GK_Consumer.
E_5GK_Consumer.
OWNER’S MANUAL XJ600S YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 · 6 - 0.
