OWNER’S MANUAL XJ900S YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 . 7 - 0.
E_5GK_Consumer.
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM INTRODUCTION EAU03338 Welcome to the Yamaha world of motorcycling! As the owner of an XJ900S, 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 XJ900S.
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM 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_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
E_4km.book Page 3 Tuesday, August 28, 2001 9:51 AM IMPORTANT MANUAL INFORMATION EAU04229 XJ900S OWNER’S MANUAL ©2001 by Yamaha Motor Co., Ltd. 1st edition, June 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
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E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY ................................................
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM 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_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM DESCRIPTION Left view ............................................................................................. 2-1 Right view........................................................................................... 2-2 Controls and instruments ...................................................................
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM DESCRIPTION EAU00026 2- Left view 2 1. Headlight 2. Helmet holder 3. Seat lock 4. Grab bar 5. Luggage strap holders 6. Final gear case 7. Shock absorber assembly spring preload adjusting ring 8.
E_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM DESCRIPTION Right view 2 9. Tail/brake light 10. Grab bar 11. Fuse box 12. Main fuse 13. Seat 14. Owner’s tool kit 15. Air filter element 16. Front fork spring preload adjusting bolt 17. Engine oil level check window 18.
E_4km.book Page 3 Tuesday, August 28, 2001 9:51 AM DESCRIPTION Controls and instruments 2 1. Clutch lever 2. Left handlebar switches 3. Starter (choke) lever 4. Speedometer unit 5. Tachometer 6. Fuel gauge 7. Clock 8. Right handlebar switches 9. Brake lever 10. Throttle grip 11.
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock .....................................3-1 Indicator and warning lights ................................3-2 Speedometer unit ................................................3-3 Tachometer ..........................................................3-4 Self-diagnosis device ...........................................3-4 Fuel gauge ...........................................................3-5 Clock ....
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00027 3- 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. EAU00036 ON All electrical systems are supplied with power, and the engine can be started. The key cannot be removed. EAU00040 LOCK The steering is locked, and all electrical systems are off. The key can be removed.
E_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM INSTRUMENT AND CONTROL FUNCTIONS EAU04356 EAU03680 (Parking) The steering is locked, the taillight and auxiliary light are on, and the hazard light can be turned on, but all other electrical systems are off. The key can be removed. The steering must be locked before the key can be turned to “ ”. Fuel level warning light “ ” This warning light comes on when the fuel level drops below approximately 5 L. When this occurs, refuel as soon as possible.
E_4km.book Page 3 Tuesday, August 28, 2001 9:51 AM INSTRUMENT AND CONTROL FUNCTIONS EAU03201 3 1. 2. 3. 4. 5. 6. Left turn signal indicator light “ Fuel level warning light “ ” Neutral indicator light “ ” High beam indicator light “ ” Oil level warning light “ ” Right turn signal indicator light “ ” ” EAU00061 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position.
E_4km.book Page 4 Tuesday, August 28, 2001 9:51 AM INSTRUMENT AND CONTROL FUNCTIONS EAU01559 Self-diagnosis device This model is equipped with a self-diagnosis device for the following electrical circuits: ● throttle position sensor ● ignition system If any of those circuits are defective, the tachometer will repeatedly display the following error code: 1. Tachometer 2.
E_4km.book Page 5 Tuesday, August 28, 2001 9:51 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00109 Anti-theft alarm (optional) This motorcycle can be equipped with an optional anti-theft alarm by a Yamaha dealer. Contact a Yamaha dealer for more information. 3 1. Fuel gauge EAU00110 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank. The needle moves towards “E” (Empty) as the fuel level decreases. When the needle reaches “E”, approximately 5 L of fuel remain in the fuel tank.
E_4km.book Page 6 Tuesday, August 28, 2001 9:51 AM INSTRUMENT AND CONTROL FUNCTIONS 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. EAU03888 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. EC000006 CAUTION: Do not use the hazard light for an extended length of time, otherwise the battery may discharge. _ 1. 2. 3. 4. 5.
E_4km.book Page 7 Tuesday, August 28, 2001 9:51 AM 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 EAU03890 The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip.
E_4km.book Page 8 Tuesday, August 28, 2001 9:51 AM 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 5-speed constant-mesh transmission equipped on this motorcycle. 1. 2. 3. a. Brake lever Brake lever position adjusting nut Properly aligned marks Adjusting range 1.
E_4km.book Page 9 Tuesday, August 28, 2001 9:51 AM INSTRUMENT AND CONTROL FUNCTIONS 2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover. 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. @ 3 @ 1. Fuel tank cap lock cover 2. Unlock. EWA00025 EAU02935 Fuel tank cap WARNING Make sure that the fuel tank cap is properly closed before riding. 1.
E_4km.book Page 10 Tuesday, August 28, 2001 9:51 AM INSTRUMENT AND CONTROL FUNCTIONS ‘EAU00186 @ CAUTION: ● Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. ● For Germany only: Whenever replacement is necessary, use a fuel tank cap of the same special design as the original.
E_4km.book Page 11 Tuesday, August 28, 2001 9:51 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Fuel tank breather hose 1. Starter (choke) lever “ ” 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_4km.book Page 12 Tuesday, August 28, 2001 9:51 AM INSTRUMENT AND CONTROL FUNCTIONS EW000030 WARNING Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident. @ @ 1. Projection (× 2) 2. Seat holder 1. Helmet 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.
E_4km.book Page 13 Tuesday, August 28, 2001 9:51 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. U-LOCK 2. Strap (× 2) 1. Spring preload adjusting bolt EAU00285 EAU04292 Storage compartment This storage compartment is designed to hold an optional genuine Yamaha ULOCK. (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_4km.book Page 14 Tuesday, August 28, 2001 9:51 AM INSTRUMENT AND CONTROL FUNCTIONS EAU01671 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting ring. EC000015 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. 3 _ _ 1. Spring preload adjusting ring 2. Position indicator Adjust the spring preload as follows.
E_4km.book Page 15 Tuesday, August 28, 2001 9:51 AM 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_4km.book Page 16 Tuesday, August 28, 2001 9:51 AM 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_4km.book Page 17 Tuesday, August 28, 2001 9:51 AM 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_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM PRE-OPERATION CHECKS Pre-operation check list .....................................................................
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM 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_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM PRE-OPERATION CHECKS ITEM CHECKS Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. PAGE Wheels and tires • • • • Brake and shift pedals • Make sure that operation is smooth. • Lubricate pedal pivoting points if necessary. 6-25 Brake and clutch levers • Make sure that operation is smooth. • Lubricate lever pivoting points if necessary.
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E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM OPERATION AND IMPORTANT RIDING POINTS Starting the engine ............................................................................ 5-1 Starting a warm engine ..................................................................... 5-3 Shifting .............................................................................................. 5-3 Recommended shift points (for Switzerland only) .............................
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM 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_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM OPERATION AND IMPORTANT RIDING POINTS not go off after starting with sufficient engine oil, have a Yamaha dealer check the electrical circuit. ● If the fuel level warning light remains on after starting, stop the engine, and then check the fuel level. If necessary, refuel as soon as possible, and then check the warning light again.
E_4km.book Page 3 Tuesday, August 28, 2001 9:51 AM OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 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. 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.
E_4km.book Page 4 Tuesday, August 28, 2001 9:51 AM OPERATION AND IMPORTANT RIDING POINTS EAU02941 EAU00424 Recommended shift points (for Switzerland only) Tips for reducing fuel consumption The recommended shift points during acceleration are shown in the table below. 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.
E_4km.book Page 5 Tuesday, August 28, 2001 9:51 AM OPERATION AND IMPORTANT RIDING POINTS EAU04032* 0–1,000 km Avoid prolonged 5,000 r/min. 1,000–1,600 km Avoid prolonged 6,000 r/min. operation operation above EC000053 _ above EC000056* CAUTION: After 1,000 km of operation, the engine oil and final gear oil must be changed, and the oil filter cartridge replaced. CAUTION: ● Keep the engine speed out of the tachometer red zone.
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR Owner’s tool kit ....................................................6-1 Periodic maintenance and lubrication chart .........6-2 Removing and installing cowlings ........................6-5 Checking the spark plugs ....................................6-7 Engine oil and oil filter cartridge ..........................6-8 Final gear oil ......................................................
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM 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_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM 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-03E NO.
E_4km.book Page 3 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR NO. 10 * Wheels 11 * Tires 12 * Wheel bearings 13 * Swingarm 14 * Steering bearings 15 * Chassis fasteners 16 6 ITEM 17 18 Sidestand, centerstand * Sidestand switch * Front fork Shock absorber CHECK OR MAINTENANCE JOB 10 20 30 40 • Check runout and for damage. √ √ √ √ • Check tread depth and for damage. • Replace if necessary. • Check air pressure. • Correct if necessary.
E_4km.book Page 4 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR NO. 25 ITEM Front and rear brake * switches CHECK OR MAINTENANCE JOB • Check operation. 26 Moving parts and cables • Lubricate. 27 Lights, signals and switches * • Check operation. • Adjust headlight beam.
E_4km.book Page 5 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling A 2. Cowling B 1. Cowling A 2. Screw (× 2) EAU01065 Removing and installing cowlings 6 The cowlings shown above need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling needs to be removed and installed. EAU03595 Cowling A To remove the cowling 1. Remove the seat. (See page 3-11 for seat removal and installation procedures.) 2.
E_4km.book Page 6 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Grab bar 2. Cowling B 1. Bolt (× 2) EAU03596 Cowling B To remove the cowling 1. Remove cowling A. (See page 6-5 for cowling removal and installation procedures.) 1. Screw (× 2) 2. Remove the grab bar by removing the bolts. 3. Remove the screws, and then pull the cowling off as shown. To install the cowling 1. Place the cowling in the original position, and then install the screws. 2.
E_4km.book Page 7 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01880 Checking the spark plugs 6 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.
E_4km.book Page 8 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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 plug should be tightened to the specified torque as soon as possible. @ @ EAU04261 Engine oil and oil filter cartridge The engine oil level should be checked before each ride.
E_4km.book Page 9 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil filler cap 6 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_4km.book Page 10 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Install the engine oil drain bolt, and then tighten it to the specified torque. ECA00105 _ Tightening torque: Engine oil drain bolt: 43 Nm (4.3 m·kgf) 1. O-ring 5. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure that the O-ring is properly seated. _ _ 6.
E_4km.book Page 11 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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. EAU03681 Final gear oil The final gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the motorcycle.
E_4km.book Page 12 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Final gear oil filler bolt 2. Correct oil level 3. Final gear oil drain bolt 2. Remove the oil filler bolt, and then check the oil level in the final gear case. NOTE: The oil level should be at the brim of the filler hole. To change the final gear oil 1. Place an oil pan under the final gear case to collect the used oil. 2. Remove the oil filler bolt and drain bolt to drain the oil from the final gear case. 3.
E_4km.book Page 13 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. 2. 3. 4. Fuel tank Fuel hose Fuel sender coupler Fuel cock lever 1. Bolt (× 2) EAU03597* Cleaning the air filter element 6 1. Screw (× 4) 3. Remove the fuel tank bolts. 4. Disconnect the fuel sender coupler, and then take the fuel tank off. The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart.
E_4km.book Page 14 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EC000082* @ 1. Air filter element 6. Pull the air filter element out. 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.
E_4km.book Page 15 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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.
E_4km.book Page 16 Tuesday, August 28, 2001 9:51 AM 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. a.
E_4km.book Page 17 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00658 CE-01E 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. Load* 6 @ WARNING ● The tire air pressure must be checked and adjusted on cold tires (i.e.
E_4km.book Page 18 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EW000079 @ 1. Tire sidewall 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. WARNING ● Have a Yamaha dealer replace excessively worn tires.
E_4km.book Page 19 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● Always make sure that the valve caps are securely installed to prevent air pressure leakage. ● Use only the tire valves and valve cores listed below to avoid tire deflation during a high-speed ride. @ CE-10E FRONT 1. Tire air valve 2. Tire air valve core 3. Tire air valve cap with seal 6 Manufacturer Metzeler Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves.
E_4km.book Page 20 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03773 Cast 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.
E_4km.book Page 21 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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_4km.book Page 22 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR Rear Front 1. Brake pad wear indicator groove (× 3) 1. Brake pad wear indicator groove EAU01160 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. Each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake.
E_4km.book Page 23 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Minimum level mark 1. Minimum level mark EAU03294 Checking the brake fluid level 6 ● Rear Front 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.
E_4km.book Page 24 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03976 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking. ● Oil seals: Replace every two years.
E_4km.book Page 25 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03370 6 EAU03164 EAU03371 Checking and lubricating the brake and shift pedals Checking and lubricating the brake and clutch levers Checking and lubricating the centerstand and sidestand The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.
E_4km.book Page 26 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU04282 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 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.
E_4km.book Page 27 Tuesday, August 28, 2001 9:51 AM 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_4km.book Page 28 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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. 2. Hold the lower ends of the front fork legs and try to move them forward and backward.
E_4km.book Page 29 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR • 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. ● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN.
E_4km.book Page 30 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EC000102 @ @ CAUTION: keep the battery ● Always 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. 1. Fuse box 2.
E_4km.book Page 31 Tuesday, August 28, 2001 9:51 AM 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. _ _ 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 1. Headlight coupler 2. Bulb cover 1.
E_4km.book Page 32 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Do not touch this area. 1. Screw (× 2) 3. Place a new headlight bulb into position, and then secure it with the bulb holder. 1. Screw EAU01623 Replacing the tail/brake light bulb EAU03497 Replacing a turn signal light bulb 1. Remove the tail/brake light lens by removing the screws. 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3.
E_4km.book Page 33 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR Left 1. Speedometer cable EAU03598 Front wheel 1. Bolt (× 3) 2. Brake hose holder 3. Brake caliper 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. @ 1. Place the motorcycle on the centerstand. 2. Disconnect the speedometer cable from the front wheel. 1. Front wheel axle pinch bolt 2. Wheel axle 3.
E_4km.book Page 34 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 5. Install the brake hose holders by installing the bolts. 6. Take the motorcycle off the centerstand so that the front wheel is on the ground. 7. Tighten the wheel axle, then the front wheel axle pinch bolt and the brake caliper bolts to the specified torques. 1. Retainer 2. Lift the wheel up between the fork legs. EAU04360 To install the front wheel 1.
E_4km.book Page 35 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Rear wheel axle pinch bolt 1. Axle nut EAU04361 Rear wheel To remove the rear wheel 6 EW000122 _ 1. Remove the axle nut, and then loosen the rear wheel axle pinch bolt. 2. Place the motorcycle on the centerstand. 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. _ 6-35 1. 2. 3. 4. 5. 6.
E_4km.book Page 36 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR ECA00062 CAUTION: Do not push the brake pedal after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut. _ _ 1. Splines EAU04362 To install the rear wheel 1. Apply a light coating of lithiumsoap-based grease to the splines of the final gear case and wheel hub. 2. Install the wheel, brake caliper bracket, spacer and wheel axle. 3.
E_4km.book Page 37 Tuesday, August 28, 2001 9:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 8. Install the brake torque rod cotter pin. EW000124 WARNING Always use a new cotter pin. _ _ 6 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.
E_4km.book Page 38 Tuesday, August 28, 2001 9:51 AM 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.
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E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM MOTORCYCLE CARE AND STORAGE Care .................................................................................................. 7-1 Storage ..............................................................................................
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM MOTORCYCLE CARE AND STORAGE EAU03412 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_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM 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_4km.book Page 3 Tuesday, August 28, 2001 9:51 AM MOTORCYCLE CARE AND STORAGE 7 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. 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.) 3.
E_4km.book Page 4 Tuesday, August 28, 2001 9:51 AM 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_4km.book Page 5 Tuesday, August 28, 2001 9:51 AM MOTORCYCLE CARE AND STORAGE 7 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/ centerstand. 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.
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM SPECIFICATIONS Specifications .................................................................................... 8-1 Conversion table ...............................................................................
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E_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM SPECIFICATIONS Final gear oil Type Quantity Air filter Operation Hypoid gear oil SAE 80 (API GL4) or multi-grade hypoid gear oil SAE 80W-90 Left foot Gear ratio 0.2 L Dry element Fuel Type REGULAR UNLEADED GASOLINE ONLY 1st 2.188 2nd 1.500 3rd 1.154 4th 0.933 5th 0.
E_4km.book Page 3 Tuesday, August 28, 2001 9:51 AM SPECIFICATIONS Manufacturer/ model Maximum load* Brakes Dunlop / K505 Front Metzeler / ME55A Type Bridgestone / G602 Operation Right hand 205 kg Fluid DOT 4 Type Single disc brake Tire air pressure (measured on cold tires) Rear up to 90 kg* Front Rear 225 kPa (2.25 kgf/cm2, 2.25 bar) 250 kPa (2.50 kgf/cm2, 2.50 bar) Front 250 kPa (2.50 kgf/cm2, 2.50 bar) Rear 290 kPa (2.90 kgf/cm2, 2.90 bar) 250 kPa (2.50 kgf/cm2, 2.
E_4km.book Page 4 Tuesday, August 28, 2001 9:51 AM SPECIFICATIONS Voltage, capacity Headlight type 12 V, 12 Ah Quartz bulb (halogen) Bulb voltage, wattage × quantity Headlight 12 V, 60/55 W × 1 Tail/brake light 12 V, 5/21 W × 1 Auxiliary light 12 V, 4 W × 1 Turn signal light 12 V, 21 W × 4 Meter lighting 12 V, 3.4 W × 4 Neutral indicator light 12 V, 3.4 W × 1 High beam indicator light 12 V, 3.4 W × 1 Oil level warning light 12 V, 3.4 W × 1 Turn signal indicator light 12 V, 3.
E_4km.book Page 5 Tuesday, August 28, 2001 9:51 AM SPECIFICATIONS EAU03941 Conversion table Conversion table METRIC SYSTEM TO IMPERIAL SYSTEM CS-03E Metric unit All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit values to IMPERIAL unit values. CONVERSION FACTOR 2 mm × 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 × 3.281 × 1.094 × 0.3937 × 0.
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM CONSUMER INFORMATION Identification numbers ....................................................................... 9-1 Key identification number .................................................................. 9-1 Vehicle identification number ............................................................. 9-1 Model label ........................................................................................
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM CONSUMER INFORMATION EAU01039 9- EAU02944 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 1. KEY IDENTIFICATION NUMBER: CA-02E 2.
E_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM CONSUMER INFORMATION 1. Model label EAU01050 Model label The model label is affixed to the frame under the seat. (See page 3-11 for seat removal and installation procedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
E_4km.book Page 1 Tuesday, August 28, 2001 9:51 AM INDEX 10- A Air filter element, cleaning ......................6-13 Anti-theft alarm ........................................3-5 B Battery ...................................................6-29 Brake and clutch levers, checking and lubricating ............................................6-25 Brake and shift pedals, checking and lubricating ............................................6-25 Brake fluid, changing .............................
E_4km.book Page 2 Tuesday, August 28, 2001 9:51 AM INDEX Starting a warm engine............................ 5-3 Starting the engine .................................. 5-1 Start switch.............................................. 3-7 Steering, checking ................................. 6-27 Storage.................................................... 7-4 Storage compartment ............................ 3-13 T Tachometer ............................................. 3-4 Tail/brake light bulb, replacing ....
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OWNER’S MANUAL XJ900S YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 . 7 - 0.
