4BR-28199-E6 XJ600S OWNER’S MANUAL · manual contains the most current product information...

4BR-28199-E6

OWNER’S MANUAL

XJ600S

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Welcome to the Yamaha world of motorcycling!

As the owner of a XJ600S/XJ600N, you are benefiting from YamahaÕs vast experiencein and newest technology for the design and the 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 yourXJ600S/XJ600NÕs advantages. The ownerÕs manual does not only instruct you in howto operate, inspect and maintain your motorcycle, but also in how to safeguard yourselfand others from trouble and injury.

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

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

INTRODUCTION

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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.

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

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

l This manual should be considered a permanent part of this motorcycle and should remain with iteven if the motorcycle is subsequently sold.

l Yamaha continually seeks advancements in product design and quality. Therefore, while thismanual contains the most current product information available at the time of printing, there maybe minor discrepancies between your motorcycle and this manual. If there is any question con-cerning this manual, please consult your Yamaha dealer.

CAUTION:

IMPORTANT MANUAL INFORMATION

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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THISMOTORCYCLE.

IMPORTANT MANUAL INFORMATION

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XJ600S/XJ600NOWNERÕS MANUAL

© 1999 by Yamaha Motor Co., Ltd.1st Edition, April 1999

All rights reserved. Any reprinting orunauthorized use without the written

permission of Yamaha Motor Co., Ltd.is expressly prohibited.

Printed in Japan.

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TABLE OF CONTENTS

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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

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GIVE SAFETY THE RIGHT OF WAY

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

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1-1

GIVE SAFETY THE RIGHT OF WAY

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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 ig-nore the laws of physics.

Regular care and maintenance are essential for preserving your motorcycleÕs value and operating condi-tion. Moreover, what is true for the motorcycle is also true for the rider: good performance depends on be-ing in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of thequestion. Motorcycle riders Ð more than car drivers Ð must always be at their mental and physical best.Under the influence of even small amounts of alcohol, there is a tendency to take dangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers.Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materialswith protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear,however, should not encourage carelessness. Though full-coverage helmets and suits, in particular, cre-ate an illusion of total safety and protection, motorcyclists will always be vulnerable. Riders who lack criti-cal self-control run the risk of going too fast and are apt to take chances. This is even more dangerous inwet weather. The good motorcyclist rides safely, predictably and defensively Ð avoiding all dangers, in-cluding those caused by others.

Enjoy your ride!

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DESCRIPTION


Left view (XJ600S) ............................................................................. 2-1Right view (XJ600S)........................................................................... 2-2Controls/Instruments (XJ600S) .......................................................... 2-3Left view (XJ600N)............................................................................. 2-4Right view (XJ600N) .......................................................................... 2-5Controls/Instruments (XJ600N).......................................................... 2-6

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2-1

DESCRIPTION


Left view (XJ600S)

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1. Fuel cock (page 3-13)2. Helmet holder (page 3-15)3. Fuse box (page 6-26)4. Luggage strap holders (page 3-16)5. Seat lock (page 3-14)

6. Rear shock absorber spring preload adjusting ring (page 3-15)

7. Shift pedal (page 3-10)

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DESCRIPTION


Right view (XJ600S)

8. Tail/brake light (page 6-17)9. Storage compartment (page 3-15)

10. Seat (page 3-14)11. Fuel tank (page 3-11)12. Headlight (page 6-27)13. Rear brake pedal (page 3-11)

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DESCRIPTION


Controls/Instruments (XJ600S)

14. Clutch lever (page 3-9)15. Left handlebar switches (page 3-7)16. Starter (choke) Ò Ó (page 3-14)17. Speedometer (page 3-6)18. Tachometer (page 3-7)19. Right handlebar switches (page 3-9)20. Front brake lever (page 3-10)21. Throttle grip (page 6-12)22. Main switch (page 3-1)

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DESCRIPTION


Left view (XJ600N)

1. Steering lock (page 3-3)2. Fuel cock (page 3-13)3. Helmet holder (page 3-15)4. Fuse box (page 6-26)5. Luggage strap holders (page 3-16)

6. Seat lock (page 3-14)7. Rear shock absorber spring preload

adjusting ring (page 3-15)8. Shift pedal (page 3-10)

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DESCRIPTION


Right view (XJ600N)

9. Tail/brake light (page 6-17)10. Storage compartment (page 3-15)11. Seat (page 3-14)12. Fuel tank (page 3-11)13. Headlight (page 6-27)14. Rear brake pedal (page 3-11)

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DESCRIPTION


Controls/Instruments (XJ600N)

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

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INSTRUMENT AND CONTROL FUNCTIONS


Main switch......................................................... 3-1Steering lock (for XJ600N) ................................ 3-3Indicator lights .................................................... 3-3Oil level indicator circuit check ........................... 3-5Speedometer (for XJ600S)................................. 3-6Speedometer (for XJ600N) ................................ 3-6Tachometer ........................................................ 3-7Handlebar switches ............................................ 3-7Clutch lever ........................................................ 3-9Shift pedal ........................................................ 3-10Front brake lever .............................................. 3-10Rear brake pedal .............................................. 3-11

Fuel tank cap ....................................................3-11Fuel ...................................................................3-12Fuel tank breather hose (for Germany only) .....3-12Fuel cock...........................................................3-13Starter (choke) Ò Ó .........................................3-14Seat...................................................................3-14Helmet holders..................................................3-15Storage compartment .......................................3-15Rear shock absorber adjustment ......................3-15Luggage strap holders ......................................3-16Sidestand..........................................................3-17Sidestand/clutch switch operation check ..........3-17

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Main switchThe main switch controls the ignitionand lighting systems. Its operation isdescribed below.

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ONElectrical circuits are switched on. Theengine can be started. The key cannotbe removed in this position.

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OFFAll electrical circuits are switched off.The key can be removed in this posi-tion.

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LOCK (for XJ600S)The steering is locked in this positionand all electrical circuits are switchedoff. The key can be removed in this po-sition. To lock the steering, turn thehandlebars all the way to the left. Whilepushing the key into the main switch,turn it from ÒOFFÓ to ÒLOCKÓ and re-move it. To release the lock, turn thekey to ÒOFFÓ while pushing.

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1. Push2. Turn

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Never turn the key to ÒOFFÓ orÒLOCKÓ when the motorcycle ismoving. The electrical circuits willbe switched off which may result inloss of control or an accident. Besure the motorcycle is stopped be-fore turning the key to ÒOFFÓ orÒLOCKÓ.

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(Parking) (for XJ600S)The steering is locked in this position,and the taillight and auxiliary light comeon but all other circuits are off. The keycan be removed in this position.To use the parking position, first lockthe steering, then turn the key to Ò Ó.Do not use this position for an extend-ed length of time as the battery maydischarge.

1. Push2. Release3. Turn

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P (Parking) (for XJ600N)The taillight and auxiliary light come onbut all other circuits are off. With thekey at ÒOFFÓ, push it into the mainswitch and release it. Then turn it coun-terclockwise to ÒPÓ, and remove it. (Donot use this position for an extendedlength of time as the battery may dis-charge.) To cancel the parking, turn thekey clockwise.

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1. Steering lock

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Steering lock (for XJ600N)To lock the steeringTurn the handlebars all the way to theright and open the steering lock cover.Insert the key and turn it 1/8 turn coun-terclockwise. Then, push the key in whileturning the handlebars slightly to the leftand turn the key 1/8 turn clockwise.Check that the steering is locked, re-move the key and close the lock cover.

To unlock the steeringInsert the key, push it in and turn it 1/8turn counterclockwise so that it movesout. Then, release and remove the key.

00 00 0 1

0 0 0 0

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45

21XJ600S

1. Left turn indicator light Ò Ó2. High beam indicator light Ò Ó3. Right turn indicator light Ò Ó4. Neutral indicator light Ò Ó5. Oil level indicator light Ò Ó

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Indicator lightsEAU00058

Turn indicator lights Ò Ó / Ò ÓThe corresponding indicator flasheswhen the turn switch is moved to theleft or right.

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Neutral indicator light Ò ÓThis indicator comes on when thetransmission is in neutral.

1. Neutral indicator light Ò Ó2. Left turn indicator light Ò Ó3. Right turn indicator light Ò Ó4. High beam indicator light Ò Ó5. Oil level indicator light Ò Ó

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High beam indicator light Ò ÓThis indicator comes on when theheadlight high beam is used.

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Oil level indicator light Ò ÓThis indicator comes on when the oillevel is low. This light circuit can bechecked by the procedure on page 3-5.

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EC000000

CAUTION:

Do not run the motorcycle until youknow it has sufficient engine oil.

NOTE:Even if the oil is filled to the specifiedlevel, the indicator light may flickerwhen riding on a slope or during sud-den acceleration or deceleration, butthis is normal.

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Oil level indicator circuit check

Turn the main switch to ÒONÓ and the engine stop switch to Ò Ó.

Oil level indicator light does not come on.

Oil level indicator light comes on.

Check engine oil level.

Oil level indicator light comes on.

Oil level indicator light does not come on.

Engine oil level and electrical circuit are OK.Go ahead with riding.

Put the transmission in neutral or apply the clutch lever, then push the start switch.

Oil level is OK.

Supplyengine oil.

Oil level is low.

Ask a Yamaha dealer to inspect electrical circuit.

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3

40

1

2

34

5

12

XJ600S

1. Speedometer2. Odometer3. Trip odometer4. Reset button

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Speedometer (for XJ600S)The speedometer shows riding speed.This speedometer is equipped with anodometer and trip odometer. The tripodometer can be reset to Ò0Ó with thereset button. Use the trip odometer toestimate how far you can ride on a tankof fuel. This information will enable youto plan fuel stops in the future.

1. Speedometer2. Odometer3. Trip odometer4. Reset knob

EAU00095

Speedometer (for XJ600N)The speedometer shows riding speed.This speedometer is equipped with anodometer and trip odometer. The tripodometer can be reset to Ò0Ó with thereset knob. Use the trip odometer toestimate how far you can ride on a tankof fuel. This information will enable youto plan fuel stops in the future.

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0

1

2

34 8

9

10

11

5 6 7

21 3

XJ600S

1. Tachometer2. Red zone (except for CH, A)3. Red zone (for CH, A)

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TachometerThis model is equipped with an electrictachometer so the rider can monitor theengine speed and keep it within theideal power range.

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CAUTION:

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

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

1. Tachometer2. Red zone (except for CH, A)3. Red zone (for CH, A)

1. Pass switch ÒPASSÓ2. Dimmer switch3. Hazard switch Ò Ó4. Turn signal switch5. Horn switch Ò Ó

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Handlebar switches

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Pass switch ÒPASSÓPress the switch to operate the passinglight.

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Dimmer switchTurn the switch to Ò Ó for the highbeam and to Ò Ó for the low beam.

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Hazard switch Ò ÓThe hazard switch should be turned onunder emergency or hazardous condi-tions. All turn signal lights will flash si-multaneously when this switch isturned on with the main switch in theÒONÓ or ÒPÓ position.

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CAUTION:

The battery can discharge from ex-tended use, making it difficult to op-erate the starter.

NOTE:Turn on the hazard switch to warn oth-er drivers if your motorcycle must bestopped where it might be a traffic haz-ard.

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Turn signal switchTo signal a right-hand turn, push theswitch to Ò Ó. To signal a left-handturn, push the switch to Ò Ó. Once theswitch is released it will return to thecenter position. To cancel the signal,push the switch in after it has returnedto the center position.

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Horn switch Ò ÓPress the switch to sound the horn.

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1. Engine stop switch2. Lights switch3. Start switch Ò Ó

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Engine stop switchThe engine stop switch is a safety de-vice for use in an emergency such aswhen the motorcycle overturns or iftrouble occurs in the throttle system.Turn the switch to Ò Ó to start the en-gine. In case of emergency, turn theswitch to Ò Ó to stop the engine.

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Lights switchTurning the light switch to Ò Ó,turns on the auxiliary light, meter lightsand taillight. Turning the light switch toÒ Ó, turns the headlight on also.

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Start switch Ò ÓThe starter motor cranks the enginewhen pushing the start switch.

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CAUTION:

See starting instructions prior tostarting the engine.

1. Clutch lever

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Clutch leverThe clutch lever is located on the lefthandlebar, and the ignition circuit cut-off system is incorporated in the clutchlever holder. Pull the clutch lever to thehandlebar to disengage the clutch, andrelease the lever to engage the clutch.The lever should be pulled rapidly andreleased slowly for smooth clutch oper-ation. (Refer to the engine starting pro-cedures for a description of the ignitioncircuit cut-off system.)

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1. Shift pedal

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Shift pedalThis motorcycle is equipped with a con-stant-mesh 6-speed transmission.The shift pedal is located on the leftside of the engine and is used in com-bination with the clutch when shifting.

1. Front brake lever2. Position adjusting nut

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Front brake leverThe front brake lever is located on theright handlebar and is equipped with aposition adjuster. To activate the frontbrake, pull the lever toward the handle-bar.

1. Position adjusting nut2. Proper position

To adjust the front brake lever position,turn the adjusting nut while pulling thelever forward. Make sure the mark Ò Óon the adjusting nut is aligned with themark Ò Ó on the lever.

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1. Rear brake pedal

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Rear brake pedalThe rear brake pedal is on the rightside of the motorcycle. Press down onthe brake pedal to apply the rear brake.

1. Lock cover2. Open

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Fuel tank capTo openOpen the lock cover. Insert the key andturn it 1/4 turn clockwise. The lock willbe released and the cap can beopened.

To closePush the tank cap into position with thekey inserted. To remove the key, turn itcounterclockwise to the original posi-tion. Then, close the lock cover.

NOTE:This tank cap cannot be closed unlessthe key is in the lock. The key cannotbe removed if the cap is not lockedproperly.

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Be sure the cap is properly installedand locked in place before riding themotorcycle.

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1. Filler tube2. Fuel level

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FuelMake sure there is sufficient fuel in thetank. Fill the fuel tank to the bottom ofthe filler tube as shown in the illustra-tion.

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Do not overfill the fuel tank. Avoidspilling fuel on the hot engine. Donot fill the fuel tank above the bot-tom of the filler tube or it may over-flow when the fuel heats up later andexpands.

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CAUTION:

Always wipe off spilled fuel immedi-ately with a dry and clean soft cloth.Fuel may deteriorate painted surfac-es or plastic parts.

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NOTE:If knocking or pinging occurs, use a dif-ferent brand of gasoline or higher oc-tane grade.

Recommended fuel:Regular unleaded gasoline witha research octane number of 91or higher.

Fuel tank capacity:Total:

17.0 LReserve:

3.5 L

1. Fuel tank breather hose

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Fuel tank breather hose (for Germany only)This model is equipped with a fuel tankbreather hose. Before using this motor-cycle, be sure to:l Check hose connection.l Check hose for cracks or damage.

Replace if damaged.l Make sure the end of the hose is

not blocked. Clean it if necessary.

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1. Arrow mark positioned over ÒONÓ

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Fuel cockThe fuel cock supplies fuel from thetank to the carburetors while also filter-ing it.The fuel cock has three positions,which should be set as illustrated.

ONWith the fuel cock in this position, fuelflows to the carburetors when the en-gine is running. Set the fuel cock to thisposition when starting the engine andfor riding.

1. Arrow mark positioned over ÒRESÓ

RESThis stands for ÒreserveÓ. If you arerunning out of fuel while riding with thefuel cock in the ÒONÓ position, quicklyturn the lever to this position. Other-wise the engine may die and will haveto be primed (see ÒPRIÓ below). Afterturning the lever to ÒRESÓ, fill the tankat the first opportunity and be sure toset the fuel cock back to ÒONÓ!

1. Arrow mark positioned over ÒPRIÓ

PRIThis stands for ÒprimeÓ. If the enginehas been allowed to run out of fuel, turnthe lever to the ÒPRIÓ position to sendfuel directly to the carburetors. This willmake starting easier. However, be sureto turn the lever to the ÒONÓ position (orÒRESÓ if you have not refuelled yet) af-ter the engine has started.

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1. Starter (choke) Ò Ó

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Starter (choke) Ò ÓStarting a cold engine requires a richerair-fuel mixture. A separate starter cir-cuit supplies this mixture.Move in direction a to turn on thestarter (choke).Move in direction b to turn off thestarter (choke).

1. Open

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SeatTo removeInsert the key in the lock and turn itcounterclockwise.

1. Projection (´ 2)2. Seat holder

To installInsert the projections on the front of theseat into the seat holder, then pushdown on the seat.

NOTE:Make sure that the seat is securely fit-ted.

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1. Helmet holder (´ 2)

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Helmet holdersThe helmet holders are under the seat.Remove the seat and hook the helmetson the helmet holders. Then, install theseat and lock it.

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Never ride with helmets in the hel-met holders. The helmets may hitobjects, causing loss of control andpossibly an accident.

1. Strap for U-LOCK (´ 2)

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Storage compartmentThis compartment is designed to storea genuine Yamaha U-LOCK. (Otherlocks may not fit.)Be sure the lock is fastened securelywith the straps when storing it in thecompartment.To prevent losing the straps, be sure tosecure them even when a U-LOCK isnot being stored in the compartment.When storing this OwnerÕs manual orother documents in the compartment,be sure to put them in a vinyl bag sothey do not get wet. When washing themotorcycle, be careful not to flood thiscompartment with water.

1. Spring preload adjusting ring2. Position indicator

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Rear shock absorber adjustmentThis shock absorber is equipped with aspring preload adjusting ring. Adjustspring preload as follows. Turn the ad-justing ring in direction a to increasespring preload and in direction b to de-crease spring preload. Make sure thatthe appropriate notch in the adjustingring is aligned with the position indica-tor on the rear shock absorber.

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1. Special wrench

HardStan-dard

Soft

Adjustingposition

7 6 5 4 3 2 1

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This shock absorber contains high-ly pressurized nitrogen gas. Readand understand the following infor-mation before handling the shockabsorber. The manufacturer cannotbe held responsible for propertydamage or personal injury that mayresult from improper handling.l Do not tamper with or attempt

to open the cylinder assembly.l Do not subject the shock ab-

sorber to an open flame or otherhigh heat source. This maycause the unit to explode due toexcessive gas pressure.

l Do not deform or damage thecylinder in any way. Cylinderdamage will result in poordamping performance.

l Take your shock absorber to aYamaha dealer for any service.

1. Luggage strap holder (´ 4)

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Luggage strap holdersThis motorcycle is equipped with fourluggage strap holders. There is a hold-er on each passenger footrest bracketand below each side of the seat.

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SidestandThis model is equipped with an ignitioncircuit cut-off system. The motorcyclemust not be ridden when the sidestandis down. The sidestand is located onthe left side of the frame. (Refer topage 5-1 for an explanation of this sys-tem.)

EW000044

This motorcycle must not be operat-ed with the sidestand in the downposition. If the stand is not properlyretracted, it could contact theground and distract the operator, re-sulting in a possible loss of control.Yamaha has designed into this mo-torcycle a lockout system to assistthe operator in fulfilling the respon-sibility of retracting the sidestand.Please check carefully the operatinginstructions listed below and if thereis any indication of a malfunction,return the motorcycle to a Yamahadealer immediately for repair.

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Sidestand/clutch switch operation checkCheck the operation of the sidestandswitch and clutch switch against the in-formation below.

EW000046

l Be sure to use the centerstandduring this inspection.

l If improper operation is noted,consult a Yamaha dealer.

TURN MAIN SWITCH TO ÒONÓ AND ENGINE STOP SWITCH TO Ò Ó.

TRANSMISSION IS IN GEAR AND SIDESTAND IS UP.

PULL IN CLUTCH LEVER ANDPUSH START SWITCH.

ENGINE WILL START.

SIDESTAND IS DOWN.

ENGINE WILL STALL.

SIDESTAND SWITCH IS OK.

CLUTCH SWITCH IS OK.

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PRE-OPERATION CHECKS


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

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Owners are personally responsible for their vehicleÕs condition. Your motorcycleÕs vital functions can start to deterioratequickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak orloss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual in-spection, you check the following points before each ride.

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PRE-OPERATION CHECK LIST

ITEM CHECKS PAGE

Front brake ¥ Check operation, fluid level and fluid leakage.¥ Fill with DOT 4 (or DOT 3) brake fluid if necessary.

6-18 ~ 6-20

Rear brake 6-17 ~ 6-20

Clutch ¥ Check operation, condition and free play.¥ Adjust if necessary. 6-15 ~ 6-16

Throttle grip and housing ¥ Check for smooth operation.¥ Lubricate if necessary. 6-12, 6-22

Engine oil ¥ Check oil level.¥ Fill with oil if necessary. 6-7 ~ 6-9

Drive chain ¥ Check chain slack and condition.¥ Adjust if necessary. 6-20 ~ 6-21

Wheels and tires ¥ Check tire pressure, wear and damage. 6-13 ~ 6-15,6-31 ~ 6-34

Control and meter cables ¥ Check for smooth operation. ¥ Lubricate if necessary. 6-22

Brake and shift pedal shafts

¥ Check for smooth operation. ¥ Lubricate if necessary. 6-22

Brake and clutch lever pivots


Center and sidestand pivots


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

If any item in the PRE-OPERATION CHECK is not working properly, have it inspected and repaired before operatingthe motorcycle.

Chassis fasteners ¥ Make sure that all nuts, bolts and screws are properly tightened.¥ Tighten if necessary. Ñ

Fuel tank ¥ Check fuel level.¥ Fill with fuel if necessary. 3-11 ~ 3-12

Lights, signals and switches ¥ Check for proper operation. 3-7 ~ 3-9,

6-27 ~ 6-30

ITEM CHECKS PAGE

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OPERATION AND IMPORTANT RIDING POINTS


Starting the engine ............................................................................. 5-1Starting a warm engine ...................................................................... 5-4Shifting ............................................................................................... 5-4Recommended shift points (for Switzerland only).............................. 5-5Tips for reducing fuel consumption .................................................... 5-5Engine break-in .................................................................................. 5-5Parking ............................................................................................... 5-6

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l Before riding this motorcycle,become thoroughly familiarwith all operating controls andtheir functions. Consult aYamaha dealer regarding anycontrol or function that you donot thoroughly understand.

l Never start your engine or let itrun for any length of time in aclosed area. The exhaust fumesare poisonous and can causeloss of consciousness anddeath within a short time. Al-ways operate your motorcyclein an area with adequate ventila-tion.

l Before starting out, always besure the sidestand is up. Failureto retract the sidestand com-pletely can result in a seriousaccident when you try to turn acorner.

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Starting the engine

NOTE:This motorcycle is equipped with an ig-nition circuit cut-off system. The enginecan be started only under one of thefollowing conditions:l The transmission is in neutral.l The sidestand is up, the transmis-

sion is in gear and the clutch is dis-engaged.

The motorcycle must not be riddenwhen the sidestand is down.

EW000054

Before going through the followingsteps, check the function of thesidestand switch and clutch switch.(Refer to page 3-17.)

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TURN THE MAIN SWITCH TO ÒONÓ AND THE ENGINE STOP SWITCH TO Ò Ó.

IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN,

PUSH THE START SWITCH. ENGINE WILL START.

RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR.

IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP,

PULL IN THE CLUTCH LEVER AND PUSH THE START SWITCH. ENGINE WILL START.

MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN.

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1. Turn the fuel cock to ÒONÓ.2. Turn the main switch to ÒONÓ and

the engine stop switch to Ò Ó.3. Shift transmission into neutral.

NOTE:When the transmission is in neutral, theneutral indicator light should be on. Ifthe light does not come on, ask aYamaha dealer to inspect it.

4. Turn on the starter (choke) andcompletely close the throttle grip.

5. Start the engine by pushing thestart switch.

NOTE:If the engine fails to start, release thestart switch, wait a few seconds, thentry again. Each attempt should be asshort as possible to preserve the bat-tery. Do not crank the engine morethan 10 seconds on any one attempt.

EC000034

CAUTION:

The oil level indicator light shouldcome on when the start switch ispushed and should go off when thestart switch is released. If the indica-tor light flickers or remains on, im-mediately stop the engine andcheck the engine oil level and for oilleakage. If necessary, fill the enginewith oil and check to see that the oillevel indicator light goes off. If thelight does not go off even with suffi-cient oil in the crankcase or the lightdoes not come on when pushing thestart switch, consult a Yamahadealer.

6. After starting the engine, move thestarter (choke) halfway back.

NOTE:For maximum engine life, never accel-erate hard with a cold engine!

7. After the engine is warm, turn offthe starter (choke) completely.

NOTE:The engine is warm when it respondsnormally to the throttle with the starter(choke) turned off.

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5-4



EAU01258

Starting a warm engineThe starter (choke) is not requiredwhen the engine is warm.

EC000046

CAUTION:

See the ÒEngine break-inÓ sectionprior to operating the motorcycle forthe first time.

1. Shift pedalN. Neutral

EAU00423

ShiftingThe transmission lets you control theamount of power you have available ata given speed for starting, accelerating,climbing hills, etc. The use of the shiftpedal is shown in the illustration.To shift into neutral, depress the shiftpedal repeatedly until it reaches theend of its travel, then raise the pedalslightly.

EC000048

CAUTION:

l Do not coast for long periodswith the engine off, and do nottow the motorcycle a long dis-tance. Even with gears in neu-tral, the transmission is onlyproperly lubricated when theengine is running. Inadequatelubrication may damage thetransmission.

l Always use the clutch whenchanging gears. The engine,transmission, and driveline arenot designed to withstand theshock of forced shifting andcan be damaged by shiftingwithout using the clutch.

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EAU02937

Recommended shift points (for Switzerland only)The recommended shift points areshown in the table below.

NOTE:When shifting two gears down from 5thto 3rd, bring your motorcycle to aspeed of 35 km/h.

Acceleration shift point(km/h)

1st ® 2nd2nd ® 3rd3rd ® 4th4th ® 5th5th ® 6th

2030405060

EAU00424

Tips for reducing fuel consumptionYour motorcycleÕs fuel consumptiondepends to a large extent on yourriding style. The following tips can helpreduce fuel consumption:l Warm up the engine before riding.l Turn off the starter (choke) as

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

gine speeds during acceleration.l Do not double-clutch or rev the en-

gine while shifting down and avoidhigh engine speeds with no loadon the engine.

l Turn off the engine instead of let-ting it idle for an extended lengthof time, i.e. in traffic jams, at trafficlights or railroad crossings.

EAU00436

Engine break-inThere is never a more important periodin the life of your motorcycle than theperiod between zero and 1,000 km. Forthis reason we ask that you carefullyread the following material. Becausethe engine is brand new, you must notput an excessive load on it for the first1,000 km. The various parts in the en-gine wear and polish themselves to thecorrect operating clearances. Duringthis period, prolonged full throttle oper-ation, or any condition which might re-sult in excessive heating of the engine,must be avoided.

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EAU00440

0 ~ 150 kmAvoid operation above 5,000 r/min.Stop the engine and let it cool for 5 to10 minutes after every hour of opera-tion. Vary the speed of the motorcyclefrom time to time. Do not operate it atone set throttle position.

150 ~ 500 kmAvoid prolonged operation above6,000 r/min. Rev the motorcycle freelythrough the gears, but do not use fullthrottle at any time.

500 ~ 1,000 kmAvoid prolonged full throttle operation.Avoid cruising speeds in excess of7,000 r/min.

EC000052

CAUTION:

After 1,000 km of operation, be sureto replace the engine oil and oil fil-ter.

1,000 km and beyondFull throttle can be used.

EC000053

CAUTION:

l Never let engine speeds enterthe red zone.

l If any engine trouble should oc-cur during the break-in period,consult a Yamaha dealer imme-diately.

EAU00460

ParkingWhen parking the motorcycle, stop theengine and remove the ignition key.

EW000058

The exhaust system is hot. Park themotorcycle in a place where pedes-trians or children are not likely totouch the motorcycle. Do not parkthe motorcycle on a slope or softground; the motorcycle may over-turn.

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PERIODIC MAINTENANCE AND MINOR REPAIR


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

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

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EAU00464

Periodic inspection, adjustment and lu-brication will keep your motorcycle inthe safest and most efficient conditionpossible. Safety is an obligation of themotorcycle owner. The maintenanceand lubrication schedule chart shouldbe considered strictly as a guide togeneral maintenance and lubricationintervals. YOU MUST TAKE INTOCONSIDERATION THAT WEATHER,TERRAIN, GEOGRAPHICAL LOCA-TIONS, AND A VARIETY OF INDIVID-UAL USES ALL TEND TO DEMANDTHAT EACH OWNER ALTER THISTIME SCHEDULE TO SHORTER IN-TERVALS TO MATCH THE ENVI-RONMENT. The most important pointsof motorcycle inspection, adjustment,and lubrication are explained in the fol-lowing pages.

EW000060

If you are not familiar with motor-cycle service, this work should bedone by a Yamaha dealer.

EAU00462

1. Tool kit

EAU00469

Tool kitThe service information included in thismanual is intended to provide you, theowner, with the necessary informationfor completing some of your own pre-ventive maintenance and minor re-pairs. The tools provided in the ownerÕstool kit are to assist you in the perfor-mance of periodic maintenance. How-ever, some other tools such as a torquewrench are also necessary to performthe maintenance correctly.

NOTE:If you do not have necessary tools re-quired during a service operation, takeyour motorcycle to a Yamaha dealerfor service.

EW000063

Modifications to this motorcycle notapproved by Yamaha may causeloss of performance, and render itunsafe for use. Consult a Yamahadealer before attempting any chang-es.

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EAU00473

PERIODIC MAINTENANCE AND LUBRICATION

NO. ITEM CHECKS AND MAINTENANCE JOBS INITIAL(1,000 km)

EVERY

6,000 km or

6 months(whichevercomes first)

12,000 km or


1 * Fuel line ¥ Check fuel hoses and vacuum hose for cracks or damage. ¥ Replace if necessary. Ö Ö

2 * Fuel filter ¥ Check condition. ¥ Replace if necessary. Ö

3 Spark plugs ¥ Check condition. ¥ Clean, regap or replace if necessary. Ö Ö Ö

4 * Valves ¥ Check valve clearance. ¥ Adjust if necessary.

Every 24,000 km or 24 months(whichever comes first)

5 Air filter ¥ Clean or replace if necessary. Ö Ö

6 Clutch ¥ Check operation. ¥ Adjust or replace cable. Ö Ö Ö

7 * Front brake

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

¥ Correct accordingly.¥ Replace brake pads if necessary.

Ö Ö Ö

8 * Rear brake

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

¥ Correct accordingly.¥ Replace brake pads if necessary.

Ö Ö Ö

9 * Wheels ¥ Check balance, runout and for damage. ¥ Rebalance or replace if necessary. Ö Ö

10 * Tires

¥ Check tread depth and for damage.¥ Replace if necessary.¥ Check air pressure.¥ Correct if necessary.

Ö Ö

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11 * Wheel bearings ¥ Check bearing for looseness or damage.¥ Replace if necessary. Ö Ö

12 * Swingarm

¥ Check swingarm pivoting point for play.¥ Correct if necessary. ¥ Lubricate with molybdenum disulfide grease every 24,000 km or

24 months (whichever comes first).

Ö Ö

13 Drive chain

¥ Check chain slack.¥ Adjust if necessary. Make sure that the rear wheel is properly

aligned.¥ Clean and lubricate.

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

14 * Steering bearings

¥ Check bearing play and steering for roughness.¥ Correct accordingly. ¥ Lubricate with lithium soap base grease every 24,000 km or

24 months (whichever comes first).

Ö Ö

15 * Chassis fasteners ¥ Make sure that all nuts, bolts and screws are properly tightened.¥ Tighten if necessary. Ö Ö

16 Sidestand/centerstand ¥ Check operation.¥ Lubricate and repair if necessary. Ö Ö

17 * Sidestand switch ¥ Check operation.¥ Replace if necessary. Ö Ö Ö

18 * Front fork ¥ Check operation and for oil leakage. ¥ Correct accordingly. Ö Ö

19 *Rear shock absorber assembly

¥ Check operation and shock absorber for oil leakage. ¥ Replace shock absorber assembly if necessary. Ö Ö

20 *Rear shock absorber assembly pivoting points

¥ Check operation. ¥ Lubricate with molybdenum disulfide grease every 24,000 km or

24 months (whichever comes first).Ö Ö


EVERY

6,000 km or


12,000 km or


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6-4



* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.

EAU01792

NOTE:l The air filter needs more frequent service if you are riding in unusually wet or dusty areas.l Hydraulic brake system

¥ When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level regularlyand fill as required.

¥ Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.¥ Replace the brake hoses every four years or if cracked or damaged.

21 * Carburetors ¥ Check engine idling speed, synchronization and starter operation. ¥ Adjust if necessary. Ö Ö Ö

22 Engine oil¥ Check oil level and vehicle for oil leakage. ¥ Correct if necessary.¥ Change. (Warm engine before draining.)

Ö Ö Ö

23 Engine oil filter cartridge ¥ Replace. Ö Ö


EVERY

6,000 km or


12,000 km or


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6-5



1. Panel A

EAU01777

Panel removal and installationThe panel illustrated needs to be re-moved to perform some of the mainte-nance described in this chapter. Referto this section each time the panel hasto be removed or installed.

1. Screw (´ 2)

EAU02926

Panel ATo remove

1. Remove the seat. (See page 3-14for seat removal and installationprocedures.)

2. Remove the screws and slide it asshown to unhook it.

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6-6



To install1. Place in the original position and

install the screws.2. Install the seat.

a. Spark plug gap

EAU01880

Spark plug inspectionThe spark plug is an important enginecomponent and should be inspectedperiodically, preferably by a Yamahadealer. The condition of the spark plugcan indicate the condition of the en-gine.Normally, all spark plugs from thesame engine should have the samecolor on the white insulator around thecenter electrode. The ideal color at thispoint is a medium-to-light tan color for amotorcycle that is being ridden normal-ly. If one spark plug shows a distinctlydifferent color, there could be some-thing wrong with the engine.

Do not attempt to diagnose such prob-lems yourself. Instead, take the motor-cycle to a Yamaha dealer. The sparkplugs should be periodically removedand inspected because heat and de-posits will cause any spark plug toslowly break down and erode. If elec-trode erosion becomes excessive, or ifcarbon and other deposits are exces-sive, the spark plug should be replacedwith the specified plug.

Before installing any spark plug, mea-sure the electrode gap with a wirethickness gauge and adjust it to speci-fication.

Specified spark plug:CR8E (NGK) or U24ESR-N(DENSO)

Spark plug gap:0.7 ~ 0.8 mm

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When installing a spark plug, the gas-ket surface should always be cleanedand a new gasket used. Any grimeshould be wiped off from the threadsand the spark plug tightened to thespecified torque.

NOTE:If a torque wrench is not available wheninstalling a spark plug, a good estimateof the correct torque is 1/4 to 1/2 turnpast finger tight. The spark plug shouldbe tightened to the specified torque assoon as possible.

Tightening torque:Spark plug:

12.5 Nm (1.25 mákg)1. Level window2. Maximum level mark3. Minimum level mark

EAU02938

Engine oilOil level inspection

1. Place the motorcycle on the cen-terstand. Warm up the engine forseveral minutes.

NOTE:Be sure the motorcycle is positionedstraight up when checking the oil level.A slight tilt toward the side can result infalse readings.

1. Engine oil filler cap

2. With the engine stopped, checkthe oil level through the level win-dow located at the lower part ofthe right side crankcase cover.

NOTE:Wait a few minutes until the oil levelsettles before checking.

3. The oil level should be betweenthe maximum and minimummarks. If the level is low, fill the en-gine with sufficient oil to reach thespecified level.

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1. Engine oil drain bolt

Engine oil and oil filter cartridge re-placement

1. Warm up the engine for severalminutes.

2. Stop the engine. Place an oil panunder the engine and remove theoil filler cap.

3. Remove the drain bolt and drainthe oil.

1. Oil filter cartridge2. Oil filter wrench

4. Remove the oil filter by using an oilfilter wrench.

NOTE:An oil filter wrench is available at anearby Yamaha dealer.

5. Install the drain bolt and tighten itto the specified torque.

Tightening torque:Drain bolt:

43 Nm (4.3 mákg)

1. O-ring

6. Apply a light coat of engine oil tothe O-ring of the new oil filter.

NOTE:Make sure the O-ring is seated proper-ly.

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6-9



1. Torque wrench

7. Install the new oil filter and tightenit to the specified torque with an oilfilter wrench.

NOTE:When installing the oil filter, tighten it tothe proper torque by using a torquewrench.

Tightening torque:Oil filter:

17 Nm (1.7 mákg)

8. Fill the engine with sufficient oil toreach the specified level. Installthe oil filler cap and tighten it.

EC000066

CAUTION:

l Do not put in any chemical addi-tives. Engine oil also lubricatesthe clutch and additives couldcause clutch slippage.

l Be sure no foreign material en-ters the crankcase.

Recommended oil:See page 8-1.

Oil quantity:Total amount:

3.1 LPeriodic oil change:

2.3 LWith oil filter replacement:

2.6 L

9. Start the engine and warm it up forseveral minutes. While warmingup, check for oil leakage. If oilleakage is found, stop the engineimmediately and check for thecause.

NOTE:After the engine is started, the oil levelindicator light should go off if the oil is atthe specified level.

EC000067

CAUTION:

If the indicator light flickers or re-mains on, immediately stop the en-gine and consult with a Yamahadealer.

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6-10



1. Screw

EAU02928

Air filterThe air filter should be cleaned at thespecified intervals. It should be cleanedmore frequently if you are riding in un-usually wet or dusty areas.

1. Remove the seat. (See page 3-14for seat removal and installationprocedures.)

2. Turn the fuel cock lever to ÒONÓ.Then, remove the fuel cock leverby removing the screw.

1. Fuel hose2. Vacuum hose3. Drain hose

3. Disconnect the hoses.

4. Remove the fuel tank.

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6-11



1. Screw (´ 4)

5. Remove the air filter case cover byremoving the screws.

6. Pull out the air filter.

7. Tap the air filter lightly to removemost of the dust and dirt. Blow outthe remaining dirt with com-pressed air as shown. If the air fil-ter is damaged, replace it.

8. Reassemble by reversing the re-moval procedure.

EC000082

CAUTION:

l Make sure the air filter is prop-erly seated in the air filter case.

l The engine should never be runwithout the air filter installed.Excessive piston and/or cylin-der wear may result.

EAU00630

Carburetor adjustmentThe carburetors are important parts ofthe engine and require very sophisti-cated adjustment. Most adjustmentsshould be left to a Yamaha dealer whohas the professional knowledge andexperience to do so. However, the idlespeed may be adjusted by the owneras part of routine maintenance.

EC000095

CAUTION:

The carburetors were set at theYamaha factory after many tests. Ifthey are changed, poor engine per-formance and damage may result.

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6-12



1. Throttle stop screw

EAU00632

Idle speed adjustment1. Start the engine and warm it up for

a few minutes at approximately1,000 to 2,000 r/min. Occasionallyrev the engine to 4,000 to5,000 r/min. The engine is warmwhen it quickly responds to thethrottle.

2. Set the idle to the specified enginespeed by adjusting the throttlestop screw. Turn the screw in di-rection a to increase enginespeed and in direction b to de-crease engine speed.

NOTE:If the specified idle speed cannot beobtained by performing the above ad-justment, consult a Yamaha dealer.

Standard idle speed:1,200 ~ 1,300 r/min

a. Free play

EAU00635

Throttle cable free play inspectionThere should be a free play of 3 ~5 mm at the throttle grip. If the free playis incorrect, ask a Yamaha dealer tomake this adjustment.

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6-13



EAU00637

Valve clearance adjustmentThe correct valve clearance changeswith use, resulting in improper fuel/airsupply or engine noise. To prevent this,the valve clearance must be adjustedregularly. This adjustment however,should be left to a professionalYamaha service technician.

EAU00647

TiresTo ensure maximum performance,long service, and safe operation, notethe following:

Tire air pressureAlways check and adjust the tire pres-sure before operating the motorcycle.

EW000082

Tire inflation pressure should bechecked and adjusted when thetemperature of the tire equals theambient air temperature. Tire infla-tion pressure must be adjusted ac-cording to total weight of cargo,rider, passenger, and accessories(fairing, saddlebags, etc. if approvedfor this model), and vehicle speed.

Maximum load* XJ600S: 184 kg XJ600N: 187 kg

Cold tire pressure Front Rear

Up to 90 kg*200 kPa

(2.00 kg/cm2,2.00 bar)

225 kPa(2.25 kg/cm2,

2.25 bar)

90 kg load ~Maximum load*

200 kPa(2.00 kg/cm2,

2.00 bar)

250 kPa(2.50 kg/cm2,

2.50 bar)

High speed riding200 kPa

(2.00 kg/cm2,2.00 bar)

250 kPa(2.50 kg/cm2,

2.50 bar)

* Load is the total weight of cargo, rider, passengerand accessories.

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6-14



EW000083

Proper loading of your motorcycleis important for several characteris-tics of your motorcycle, such ashandling, braking, performance andsafety. Do not carry loosely packeditems that can shift. Securely packyour heaviest items close to thecenter of the motorcycle, and dis-tribute the weight evenly from sideto side. Properly adjust the suspen-sion for your load, and check thecondition and pressure of your tires.NEVER OVERLOAD YOUR MOTOR-CYCLE. Make sure the total weightof the cargo, rider, passenger, andaccessories (fairing, saddlebags,etc. if approved for this model) doesnot exceed the maximum load of themotorcycle. Operation of an over-loaded motorcycle could cause tiredamage, an accident, or even injury.

a. Tread depth1. Side wall

Tire inspectionAlways check the tires before operatingthe motorcycle. If center tread depthreaches the limit as shown, if the tirehas a nail or glass fragments in it, or ifthe side wall is cracked, contact aYamaha dealer immediately and havethe tire replaced.

NOTE:These limits may be different by regula-tion from country to country. If so, con-form to the limits specified by theregulations of your own country.

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

Minimum tire tread depth (front and rear)

1.6 mm

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EAU00683

Operating the motorcycle with ex-cessively worn tires decrease ridingstability and can lead to loss of con-trol. Have excessively worn tires re-placed by a Yamaha dealerimmediately. Brakes, tires, and re-lated wheel parts replacementshould be left to a Yamaha ServiceTechnician.

EAU00687

WheelsTo ensure maximum performance,long service, and safe operation, notethe following:l Always inspect the wheels before

a ride. Check for cracks, bends, orwarpage of the wheels. If any ab-normal condition exists in a wheel,consult a Yamaha dealer. Do notattempt even small repairs to thewheel. If a wheel is deformed orcracked, it must be replaced.

l Tires and wheels should be bal-anced whenever either one ischanged or replaced. Failure tohave a wheel balanced can resultin poor performance, adverse han-dling characteristics, and short-ened tire life.

l Ride at moderate speeds afterchanging a tire since the tire sur-face must first be broken in for it todevelop its optimal characteristics.

1. Locknut2. Adjusting boltc. Free play

EAU00694

Clutch lever free play adjustmentThe clutch lever free play should be ad-justed to 2 ~ 3 mm.

1. Loosen the locknut at the clutch le-ver.

2. Turn the adjusting bolt at theclutch lever in direction a to in-crease free play or in direction bto decrease free play.

3. Tighten the locknut at the clutchlever.

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1. Clutch lever cable2. Adjusting nut3. Locknut

If the specified free play cannot be ob-tained, proceed with the followingsteps.

4. Loosen the locknut at the clutch le-ver.

5. Turn the adjusting bolt at theclutch lever in direction a to loos-en the cable.

6. Loosen the locknut at the crank-case side.

7. Turn the adjusting nut at thecrankcase in direction a to in-crease free play or in direction bto decrease free play.

8. Tighten the locknut at the crank-case and the clutch lever.

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a. Pedal height

EAU00712

Rear brake pedal height adjustmentThe top of the brake pedal should bepositioned 40 mm below the top of thefootrest. If not, ask a Yamaha dealer toadjust it.

EW000109

A soft or spongy feeling in the brakepedal can indicate the presence ofair in the brake system. This airmust be removed by bleeding thebrake system before the motorcycleis operated. Air in the system willcause greatly diminished brakingcapability and can result in loss ofcontrol and an accident. Have aYamaha dealer inspect and bleedthe system if necessary.

1. Brake light switch2. Adjusting nut

EAU00713

Brake light switch adjustmentThe rear brake light switch is activatedby the brake pedal and is properly ad-justed when the brake light comes onjust before braking takes effect. To ad-just the rear brake light switch, hold theswitch body so it does not rotate whileturning the adjusting nut. Turn the ad-justing nut in direction a to make thebrake light come on earlier. Turn theadjusting nut in direction b to make thebrake light come on later.

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1. Wear indicator groove (´ 2)

EAU00721

Checking the front and rear brake pads

EAU00725

Front brakeA wear indicator groove is provided oneach brake pad. This indicator allowschecking of brake pad wear withoutdisassembling the brake. Inspect thegroove. If the groove has almost disap-peared, ask a Yamaha dealer to re-place the pads.

1. Wear indicator (´ 2)

EAU00728

Rear brakeApply the brake and inspect the wearindicator. If the wear indicator isALMOST in contact with the disc plate,ask a Yamaha dealer to replace thepads.

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6-19



1. Minimum level mark

EAU00732

Inspecting the brake fluid levelInsufficient brake fluid may let air enterthe brake system, possibly causing thebrakes to become ineffective.Before riding, check that the brake fluidis above the minimum level and fillwhen necessary.Observe these precautions:l When checking the fluid level,

make sure the top of the mastercylinder is level by turning the han-dlebars.

1. Minimum level mark

l Use only the designated qualitybrake fluid. Otherwise, the rubberseals may deteriorate, causingleakage and poor brake perfor-mance.

NOTE:If DOT 4 is not available, DOT 3 can beused.

Recommended brake fluid: DOT 4

l Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor brake performance.

l Be careful that water does not en-ter the master cylinder when refill-ing. Water will significantly lowerthe boiling point of the fluid andmay result in vapor lock.

l Brake fluid may deteriorate paint-ed surfaces or plastic parts. Al-ways clean up spilled fluidimmediately.

l Have a Yamaha dealer check thecause if the brake fluid level goesdown.

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EAU00742

Brake fluid replacementThe brake fluid should be replaced onlyby trained Yamaha service personnel.Have the Yamaha dealer replace thefollowing components during periodicmaintenance or when they are dam-aged or leaking:l oil seals (every two years)l brake hoses (every four years) a. Chain slack

EAU00745

Drive chain slack check

NOTE:Spin the wheel several times and findthe tightest position of the chain. Checkand/or adjust the chain slack while itÕsin this tightest position.

Inspect the drive chain when the motor-cycle is on the centerstand. Check theslack at the position shown in the illus-tration. Normal slack is approximately30 ~ 40 mm. If the slack exceeds40 mm, adjust.

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1. Axle nut2. Locknut3. Adjusting nut4. Alignment marks

EAU00762

Drive chain slack adjustment1. Loosen the axle nut.2. Loosen the locknuts on each side.

To tighten the chain, turn the chainadjusting nuts in direction a. Toloosen the chain, turn the adjust-ing nuts in direction b and pushthe wheel forward. Turn each ad-justing nut exactly the sameamount to maintain correct axlealignment. There are marks on

each side of the swingarm. Usethese marks to align the rearwheel.

EC000096

CAUTION:

Too little chain slack will overloadthe engine and other vital parts.Keep the slack within the specifiedlimits.

3. After adjusting, tighten the lock-nuts. Then tighten the axle nut tothe specified torque.

Tightening torque:Axle nut:

105 Nm (10.5 mákg)

EAU00769

Drive chain lubricationThe chain consists of many parts whichwork with each other. If the chain is notmaintained properly, it will wear outquickly. Therefore, the chain must beserviced regularly. This service is es-pecially necessary when riding in dustyareas. This motorcycle is equippedwith a sealed type chain. Steam clean-ing, high-pressure washes, and sol-vents can damage chain so do not usethese for cleaning it. Use only keroseneto clean the drive chain. Wipe it dry,and thoroughly lubricate it with SAE 30~ 50W motor oil. Do not use any otherlubricants on the drive chain. They maycontain solvents that could damage thesealed chain.

EC000097

CAUTION:

Be sure to oil the chain after wash-ing the motorcycle or riding in therain.

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EAU02962

Cable inspection and lubrication

EW000112

Damage to the outer housing of ca-bles may lead to internal rusting andinterfere with the cable movement.Replace damaged cables as soon aspossible to prevent unsafe condi-tions.

Lubricate the cables and cable ends. Ifa cable does not operate smoothly, aska Yamaha dealer to replace it.

Recommended lubricant:Engine oil

EAU00773

Throttle cable and grip lubricationThe throttle twist grip assembly shouldbe greased at the time that the cable islubricated, since the grip must be re-moved to get at the end of the throttlecable. After removing the screws, holdthe end of the cable up in the air andput in several drops of lubricant. Withthe throttle grip disassembled, coat themetal surface of the grip assembly witha suitable all-purpose grease.

EAU02984

Brake and shift pedal lubricationLubricate the pivoting parts.


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EAU02985

Brake and clutch lever lubricationLubricate the pivoting parts.


EAU02965

Center and sidestand lubricationLubricate the pivoting and matingjoints.Check to see that the center and side-stand move up and down smoothly.

EW000114

If the center and/or sidestand doesnot move smoothly, consult aYamaha dealer.


EAU00790

Rear suspension lubricationLubricate the pivoting parts.

Recommended lubricant:Molybdenum disulfide grease

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EAU02939

Front fork inspectionVisual check

EW000115

Securely support the motorcycle sothere is no danger of it falling over.

Check for scratches or damage on theinner tube and excessive oil leakagefrom the front fork.

Operation check1. Place the motorcycle on a level

place.2. Hold the motorcycle in an upright

position and apply the front brake.3. Push down hard on the handle-

bars several times and check if thefork rebounds smoothly.

EC000098

CAUTION:

If any damage or unsmooth move-ment is found with the front fork,consult a Yamaha dealer.

EAU00794

Steering inspectionPeriodically inspect the condition of thesteering. Worn out or loose steeringbearings may be dangerous. Place astand under the engine to raise thefront wheel off the ground. Hold thelower end of the front forks and try tomove them forward and backward. Ifany free play can be felt, ask a Yamahadealer to inspect and adjust the steer-ing. Inspection is easier if the frontwheel is removed.

EW000115

Securely support the motorcycle sothere is no danger of it falling over.

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6-25



EAU01144

Wheel bearingsIf there is play in the front or rear wheelhub or if the wheel does not turnsmoothly, have a Yamaha dealer in-spect the wheel bearings.

EAU00800

BatteryThis motorcycle is equipped with asealed-type battery. Therefore it is notnecessary to check the electrolyte or fillthe battery with distilled water.l If the battery seems to have dis-

charged, consult a Yamaha deal-er.

l If the motorcycle is equipped withoptional electrical accessories, thebattery tends to discharge morequickly, so be sure to recharge itperiodically.

EC000101

CAUTION:

Never try to remove the sealing capsof the battery cells. The battery willbe damaged.

EW000116

Battery electrolyte is poisonous anddangerous, causing severe burns,etc. It contains sulfuric acid. Avoidcontact with skin, eyes or clothing.ANTIDOTE:l EXTERNAL: Flush with water.l INTERNAL: Drink large quanti-

ties of water or milk. Follow withmilk of magnesia, beaten egg,or vegetable oil. Call a physi-cian immediately.

l EYES: Flush with water for15 minutes and get promptmedical attention.

Batteries produce explosive gases.Keep sparks, flame, cigarettes etc.,away. Ventilate when charging orusing in an enclosed space. Alwaysshield your eyes when working nearbatteries. KEEP OUT OF REACH OFCHILDREN.

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6-26



Battery storageWhen the motorcycle is not used for amonth or longer, remove the battery,fully charge it and store it in a cool, dryplace.

EC000102

CAUTION:

l Completely recharge the bat-tery before storing. Storing adischarged battery can causepermanent battery damage.

l Use a battery charger designedfor a sealed-type (MF) battery.Using a conventional batterycharger will cause battery dam-age. If you do not have a sealed-type battery charger, contactyour Yamaha dealer.

l Always make sure the connec-tions are correct when reinstall-ing the battery.

1. Fuse box

EAU01470

Fuse replacementThe fuse box is located under the seat.(See page 3-14 for seat removal andinstallation procedures.)If any fuse is blown, turn off the mainswitch and the switch of the circuit inquestion. Install a new fuse of specifiedamperage. Turn on the switches andsee if the electrical device operates. Ifthe fuse immediately blows again, con-sult a Yamaha dealer.

1. Main fuse2. Ignition fuse3. Signaling system fuse4. Headlight fuse5. Hazard light fuse6. Spare fuse (´ 3)

EC000103

CAUTION:

Do not use fuses of higher amper-age rating than those recommend-ed. Substitution of a fuse ofimproper rating can cause extensiveelectrical system damage and pos-sibly a fire.

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6-27



Specified fuses:Main fuse: 30 AIgnition fuse: 10 ASignaling system fuse: 15 AHeadlight fuse: 15 AHazard light fuse: 10 A

1. Connector2. Bulb holder cover

EAU00829

Headlight bulb replacement (for XJ600S)This motorcycle is equipped with aquartz bulb headlight.If a headlight bulb burns out, replace itas follows:

1. Remove the headlight connectorand the bulb holder cover.

1. Bulb holder

2. Unhook the bulb holder and re-move the defective bulb.

EW000119

Keep flammable products and yourhands away from a bulb while it ison, as it is hot. Do not touch a bulbuntil it cools down.

R

6-28



1. DonÕt touch

3. Put a new bulb into position andsecure it in place with the bulbholder.

EC000105

CAUTION:

Avoid touching the glass part of abulb. Keep it free from oil; other-wise, the transparency of the glass,life of the bulb, and luminous fluxwill be adversely affected. If oil getson a bulb, thoroughly clean it with acloth moistened with alcohol or lac-quer thinner.

4. Install the bulb holder cover andthe headlight connector.If a headlight beam adjustment isnecessary, ask a Yamaha dealerto make adjustment.

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6-29



1. Screw (´ 2)

EAU00833

Headlight bulb replacement (for XJ600N)This motorcycle is equipped with aquartz bulb headlight.If the headlight bulb burns out, replacethe bulb as follows:

1. Remove the headlight unit screws.

1. Connector (´ 2)2. Bulb cover

2. Remove the connectors, theheadlight unit and then the bulbcover.

1. Bulb holder

3. Turn the bulb holder counterclock-wise to remove it and remove thedefective bulb.

EW000119

Keep flammable products and yourhands away from a bulb while it ison, as it is hot. Do not touch a bulbuntil it cools down.

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6-30



1. DonÕt touch

4. Put a new bulb into position andsecure it in place with the bulbholder.

EC000105

CAUTION:

Avoid touching the glass part of abulb. Keep it free from oil; other-wise, the transparency of the glass,life of the bulb, and luminous fluxwill be adversely affected. If oil getson a bulb, thoroughly clean it with acloth moistened with alcohol or lac-quer thinner.

5. Install the bulb cover, connectorsand headlight unit. Ask a Yamahadealer to adjust the headlightbeam if necessary.

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6-31



1. Speedometer cable

EAU00868

Front wheel removalEW000122

l It is advisable to have a Yamahadealer service the wheel.

l Securely support the motor-cycle so there is no danger of itfalling over.

1. Place the motorcycle on the cen-terstand.

2. Remove the speedometer cablefrom the front wheel side.

3. Remove the calipers.

1. Wheel axle2. Pinch bolt

NOTE:Do not depress the brake lever whenthe disc and caliper are separated.

4. Loosen the pinch bolt.5. Remove the wheel axle. Make

sure the motorcycle is properlysupported.

EAU01469

Front wheel installation1. Install the speedometer gear unit

into the wheel hub. Make sure thewheel hub and the speedometergear unit are installed with the pro-jections meshed into the slots.

2. Lift up the wheel between the frontfork legs. Make sure the slot in thespeedometer gear unit fits overthe stopper on the front fork outertube.

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6-32



3. Install the wheel axle and let themotorcycle down.

4. Install the calipers and caliperbolts. Make sure there is enoughgap between the brake pads be-fore installing the calipers onto thebrake discs.

5. Push down hard on the handle-bars several times to check forproper fork operation.

6. Tighten the wheel axle, pinch boltand caliper bolts to the specifiedtorque.

7. Install the speedometer cable.

Tightening torque:Wheel axle:

58 Nm (5.8 mákg)Pinch bolt:

40 Nm (4.0 mákg)Caliper bolt:

19 Nm (1.9 mákg)

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6-33



1. Axle nut

EAU01480

Rear wheel removalEW000122

l It is advisable to have a Yamahadealer service the wheel.

l Securely support the motor-cycle so there is no danger of itfalling over.

1. Place the motorcycle on the cen-terstand.

2. Remove the axle nut.

1. Brake torque rod bolt2. Nut

3. Remove the brake torque rod boltby removing the nut.

4. While supporting the brake cali-per, pull out the wheel axle.

5. Push the wheel forward and re-move the drive chain.

6. Remove the wheel assembly.

NOTE:l Do not depress the brake pedal

when the disc and caliper are sep-arated.

l You do not have to disassemblethe chain in order to remove or in-stall the rear wheel.

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6-34



EAU01468

Rear wheel installation1. Install the wheel assembly and in-

sert the axle.2. Install and adjust the drive chain.

(See page 6-20 for details aboutadjusting the drive chain slack.)

3. Install the axle nut.4. Install the caliper and caliper bolts.

Make sure there is enough gapbetween the brake pads before in-stalling the caliper onto the brakedisc.

5. Take the motorcycle off the cen-terstand.

6. Tighten the axle nut and braketorque rod bolt to the specifiedtorques.

Tightening torque:Axle nut:

105 Nm (10.5 mákg)Brake torque rod bolt:

23 Nm (2.3 mákg)

EAU01008

TroubleshootingAlthough Yamaha motorcycles receivea rigid inspection before shipment fromthe factory, trouble may occur duringoperation.Any problem in the fuel, compression,or ignition systems can cause poorstarting and loss of power. The trouble-shooting chart describes a quick, easyprocedure for making checks.If your motorcycle requires any repair,bring it to a Yamaha dealer. The skilledtechnicians at a Yamaha dealershiphave the tools, experience, and know-how to properly service your motor-cycle. Use only genuine Yamaha partson your motorcycle. Imitation parts maylook like Yamaha parts, but they are of-ten inferior. Consequently, they have ashorter service life and can lead to ex-pensive repair bills.

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6-35



EAU01297

Troubleshooting chartEW000125

Never check the fuel system while smoking or in the vicinity of an open flame.

Check if there is fuel in the fuel tank.

1. FuelEnough fuel.

No fuel.

Go to compression check.

Supply fuel.

Use the electric starter.

2. CompressionThere is compression.

No compression.

Go to ignition check.

Ask a Yamaha dealer to inspect.

Remove spark plugs and check electrodes.

3. IgnitionWet.

Dry.

Wipe clean with dry cloth and correct spark gap or replace spark plugs.

Ask a Yamaha dealer to inspect. Engine doesnÕt start, go to battery check.

Open throttle half-way and startthe engine.

Use the electric starter.

4. BatteryEngine turns over quickly.

Engine turns over slowly.

Battery good.

Check connections or recharge.

Engine doesnÕt start, ask a Yamaha dealer to inspect.

Engine doesnÕt start, go to compression check.

R

MOTORCYCLE CARE AND STORAGE


Care ................................................................................................... 7-1Storage............................................................................................... 7-4

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7-1



CareThe exposure of its technology makesa motorcycle charming but also vul-nerable. Although high-quality compo-nents are used, they are not all rust-resistant. While a rusty exhaust pipemay remain unnoticed on a car, itdoes look unattractive on a motor-cycle. Frequent and proper care, how-ever, will keep your motorcyclelooking good, extend its life and main-tain its performance. Moreover, thewarranty states that the vehicle mustbe properly taken care of. For all thesereasons, it is recommended that youobserve the following cleaning andstoring precautions.

Before cleaning1. Cover up the muffler outlets with

plastic bags.2. Make sure that all caps and covers

as well as all electrical couplersand connectors, including thespark plug caps, are tightly in-stalled.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply such prod-ucts onto seals, gaskets, sprock-ets, the drive chain and wheelaxles. Always rinse the dirt anddegreaser off with water.

CleaningAfter normal useRemove dirt with warm water, a neutraldetergent and a soft clean sponge,then rinse with plenty of clean water.Use a tooth or bottle brush for hard-to-reach parts. Tougher dirt and insectswill come off more easily if the area iscovered with a wet cloth for a few min-utes before cleaning.

EAU01517

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7-2



ECA00010

CAUTION:

l Avoid using strong acidic wheelcleaners, especially on spokedwheels. If you do use suchproducts for hard-to-removedirt, do not leave it on any long-er than instructed, then thor-oughly rinse it off with water,immediately dry the area andapply a corrosion protectionspray.

l Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Useonly a soft, clean cloth orsponge with mild detergent andwater to clean plastic.

l Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abrasivecleaning products, solvent orthinner, fuel (gasoline), rust re-movers or inhibitors, brake flu-id, antifreeze or electrolyte.

l Do not use high-pressure wash-ers or steam-jet cleaners sincethey cause water seepage anddeterioration in the following ar-eas: seals (of wheel bearings,swingarm bearings, forks andbrakes), electric components(couplers, connectors, instru-ments, switches and lights),breather hoses and vents.

l For motorcycles equipped witha windshield: Do not use strongcleaners or hard sponges asthey will cause dulling orscratching. Some cleaningcompounds for plastic mayleave scratches on the wind-shield. Test the product on asmall hidden part of the wind-shield to make sure they do notleave any marks. If the wind-shield is scratched, use a quali-ty plastic polishing compoundafter washing.

After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on theroads in the winter are extremely corro-sive in combination with water, carryout the following steps after each ridein the rain, near the sea or on salt-sprayed roads. (Salt sprayed in thewinter may remain on the roads wellinto spring.)

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7-3



1. Clean your motorcycle with coldwater and soap after the enginehas cooled down.

ECA00012

CAUTION:

Do not use warm water since it in-creases the corrosive action of thesalt.

2. Be sure to apply a corrosion pro-tection spray on all (even chrome-and nickel-plated) metal surfacesto prevent corrosion.

After cleaning1. Dry the motorcycle with a chamois

or an absorbing cloth.2. Immediately dry the drive chain

and lubricate it to prevent it fromrusting.

3. Use a chrome polish to shinechrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermally in-duced discoloring of stainless-steel exhaust systems can be re-moved through polishing.)

4. To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all (even chrome-and nickel-plated) metal surfaces.

5. Use spray oil as a universal clean-er to remove any remaining dirt.

6. Touch up minor paint damagecaused by stones, etc.

7. Wax all painted surfaces.8. Let the motorcycle dry completely

before storing it or covering it.

EWA00001

Make sure that there is no oil or waxon the brakes and tires. If neces-sary, clean the brake discs and lin-ings with a regular brake disccleaner or acetone, and wash thetires with warm water and mild soap.Then, carefully test the motorcyclefor its braking performance and cor-nering behavior.

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7-4



ECA00013

CAUTION:

l Apply spray oil and wax spar-ingly and wipe off any excess.

l Never apply oil or wax on rub-ber and plastic parts, but treatthem with a suitable care prod-uct.

l Avoid using abrasive polishingcompounds as they wear awaythe paint.

NOTE:Consult a Yamaha dealer for advice onwhat products to use.

StorageShort-termAlways store your motorcycle in a cool,dry place and, if necessary, protect itagainst dust with a porous cover.

ECA00014

CAUTION:

l Storing the motorcycle in apoorly ventilated room or cov-ering it with a tarp while it is stillwet will allow water and humidi-ty to seep in and cause rust.

l To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi-cals are stored.

Long-termBefore storing your motorcycle for sev-eral months:

1. Follow all the instructions in theÒCareÓ section of this chapter.

2. Drain the carburetor float cham-bers by loosening the drain bolts;this will prevent fuel deposits frombuilding up. Pour the drained fuelinto the fuel tank.

3. Only for motorcycles equippedwith a fuel cock which has anÒOFFÓ position: Turn the fuel cockto ÒOFFÓ.

4. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and thefuel from deteriorating.

5. Perform the following steps to pro-tect the cylinders, piston rings, etc.from corrosion.

a. Remove the spark plug caps andspark plugs.

b. Pour a teaspoonful of engine oilinto each spark plug bore.

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7-5



c. Install the spark plug caps onto thespark plugs and place the sparkplugs on the cylinder head so thatthe electrodes are grounded. (Thiswill limit sparking during the nextstep.)

d. Turn the engine over several timeswith the starter. (This will coat thecylinder walls with oil.)

e. Remove the spark plug caps fromthe spark plugs, install the sparkplugs and then the spark plugcaps.

EWA00003

When turning the engine over, besure to ground the spark plug elec-trodes to prevent damage or injuryfrom sparking.

6. Lubricate all control cables andthe pivoting points of all levers andpedals as well as of the side-stand/centerstand.

7. Check and, if necessary, correctthe tire air pressure, then raise themotorcycle so that both of itswheels are off the ground. Alterna-tively, turn the wheels a little everymonth in order to prevent the tiresfrom becoming degraded in onespot.

8. Cover up the muffler outlets withplastic bags to prevent moisturefrom entering.

9. Remove the battery and fullycharge it. Store it in a cool, dryplace and recharge it once amonth. Do not store the battery inan excessively cold or warm place(less than 0ûC or more than 30ûC).For more information, see ÒBatterystorageÓ in the chapter ÒPERIOD-IC MAINTENANCE AND MINORREPAIRSÓ.

NOTE:Make any necessary repairs beforestoring the motorcycle.

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SPECIFICATIONS


Specifications ..................................................................................... 8-1HOW TO USE THE CONVERSION TABLE ...................................... 8-5

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8-1

SPECIFICATIONS


Specifications

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

Engine type Air-cooled 4-stroke, DOHC

Cylinder arrangement Forward-inclined parallel 4-cyclinder

Displacement 598 cm3

Bore ´ Stroke 58.5 ´ 55.7 mm

Compression ratio 10:1

Starting system Electric starter

Lubrication system Wet sump

Engine oil

Type

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

higher

Quantity

Periodic oil change 2.3 L

With oil Þlter replacement 2.6 L

Total amount 3.1 L

-20û -10û 0û 10û 20û 30û 40û 50ûC

SAE 10W/30

SAE 15W/40

SAE 20W/40

SAE 20W/50

SAE 10W/40

CAUTION:

Be sure to use motor oils that do not contain anti-frictionmodifiers. Passenger car motor oils (often labeledÒEnergy ConservingÓ) contain anti-friction additives whichwill cause clutch and/or starter clutch slippage, resulting inreduced component life and poor engine performance.

EAU01038

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8-2

SPECIFICATIONS


Air filter Dry type element

Fuel

Type Regular unleaded gasoline

Fuel tank capacity 17.0 L

Reserve amount 3.5 L

Carburetor

Type´quantity BDS28 ´ 4

Manufacturer MIKUNI

Spark plug

Type/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 operation

Gear ratio

1st 2.733

2nd 1.778

3rd 1.333

4th 1.074

5th 0.913

6th 0.821

Chassis

Frame type Double cradle

Caster 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

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8-3

SPECIFICATIONS


Maximum load*

XJ600S 184 kg

XJ600N 187 kg

Air pressure (cold tire)

Up to 90 kg load*

Front 200 kPa (2.00 kg/cm2, 2.00 bar)

Rear 225 kPa (2.25 kg/cm2, 2.25 bar)

90 kg load ~ maximum load*


Rear 250 kPa (2.50 kg/cm2, 2.50 bar)

High speed riding


Rear 250 kPa (2.50 kg/cm2, 2.50 bar)

* Load is total weight of cargo, rider, passenger and accessories.

Wheels

Front

Type Cast

Size 17 ´ MT 2.50

Rear

Type Cast

Size 18 ´ MT 3.50

Brakes

Front

Type Dual disc brake

Operation Right hand operation

Fluid DOT 4 or DOT 3

Rear

Type Single disc brake

Operation Right foot operation

Fluid DOT 4 or DOT 3

Suspension

Front

Type Telescopic fork

Rear

Type Swingarm (monocross suspension)

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 T.C.I. (digital)

R

8-4

SPECIFICATIONS


Charging system

Type A.C. magneto

Standard output 14 V, 20 A @ 5,000 r/min

Battery

Type YTX9-BS, GTX9-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 light

XJ600S 12 V, 1.7 W ´ 3

XJ600N 14 V, 3 W ´ 2

12 V, 1.7 W ´ 2

Neutral indicator light 12 V, 3.4 W ´ 1

High beam indicator light 12 V, 3.4 W ´ 1

Oil level indicator light

XJ600S 12 V, 3.4 W ´ 1

XJ600N 14 V, 3 W ´ 1

Turn indicator light 12 V, 3.4 W ´ 2

Fuses

Main fuse 30 A

Ignition fuse 10 A

Signaling system fuse 15 A

Headlight fuse 15 A

Hazard light fuse 10 A

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8-5

SPECIFICATIONS


EAU01064

HOW TO USE THE CONVERSION TABLEAll specification data in this manual are listed in SI andMETRIC UNITS. Use this table to convert METRIC unit data to IMPERIALunit data.Ex.

METRIC MULTIPLIER IMPERIAL

**mm ´ 0.03937 = **in

2 mm ´ 0.03937 = 0.08 in

CONVERSION TABLE

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

Torque

mákgmákgcmákgcmákg

7.23386.7940.07230.8679

ftálbinálbftálbinálb

Weight kgg

2.2050.03527

lboz

Speed km/hr 0.6214 mph

Distance

kmmmcmmm

0.62143.2811.0940.39370.03937

miftydinin

Volume /Capacity

cc (cm3)cc (cm3)lt (liter)lt (liter)

0.035270.061020.87990.2199

oz (IMP liq.)cuáinqt (IMP liq.)gal (IMP liq.)

Misc.kg/mmkg/cm2

Centigrade (°C)

55.99714.22349/5 + 32

lb/inpsi (lb/in2)Fahrenheit (°F)

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CONSUMER INFORMATION


Identification number records............................................................. 9-1Key identification number (for XJ600S).............................................. 9-1Key identification number (for XJ600N) ............................................. 9-1Vehicle identification number ............................................................. 9-2Model label......................................................................................... 9-2

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9-1



EAU02944

Identification number recordsRecord the key identification number,vehicle identification number and mod-el label information in the spaces pro-vided for assistance when orderingspare parts from a Yamaha dealer orfor reference in case the vehicle is sto-len.

1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATION NUMBER:

3. MODEL LABEL INFORMATION:

EAU01039

1. Key identification number

EAU01041

Key identification number (for XJ600S)The key identification number isstamped on the key tag. Record thisnumber in the space provided and useit for reference when obtaining a newkey.

1. Key identification number

EAU01042

Key identification number (for XJ600N)The key identification number isstamped on the key. Record this num-ber in the space provided and use it forreference when obtaining a new key.

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9-2



1. Vehicle identification number

EAU01043

Vehicle identification numberThe vehicle identification number isstamped into the steering head pipe.Record this number in the space pro-vided.

The vehicle identification number isused to identify your motorcycle andmay be used to register your motor-cycle with the licensing authority inyour state.

1. Model label

EAU01050

Model labelThe model label is affixed to the frameunder the seat. (See page 3-14 for seatremoval procedures.) Record the infor-mation on this label in the space pro-vided. This information will be neededto order spare parts from your Yamahadealer.

L

INDEX

/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/EEIX.frame

AAir filter .................................................6-10

BBattery ..................................................6-25Brake and clutch lever lubrication ........6-23Brake and shift pedal lubrication ..........6-22Brake fluid replacement ........................6-20Brake light switch adjustment ...............6-17

CCable inspection and lubrication ..........6-22Carburetor adjustment ..........................6-11Care ........................................................7-1Center and sidestand lubrication ..........6-23Checking the front and rear brake

pads ...................................................6-18Clutch lever ............................................3-9Clutch lever free play adjustment .........6-15Controls/Instruments (XJ600N) ..............2-6Controls/Instruments (XJ600S) ..............2-3

DDimmer switch ........................................3-7Drive chain lubrication ..........................6-21Drive chain slack adjustment ................6-21Drive chain slack check ........................6-20

EEngine break-in ......................................5-5Engine oil ................................................6-7Engine stop switch .................................3-9

FFront brake lever ................................. 3-10Front fork inspection ............................ 6-24Front wheel installation ........................ 6-31Front wheel removal ............................ 6-31Fuel ...................................................... 3-12Fuel cock ............................................. 3-13Fuel tank breather hose

(for Germany only) ............................ 3-12Fuel tank cap ....................................... 3-11Fuse replacement ................................ 6-26

GGive safety the right of way ................... 1-1

HHandlebar switches ............................... 3-7

Dimmer switch ................................. 3-7Engine stop switch ........................... 3-9Hazard switch .................................. 3-8Horn switch ...................................... 3-8Lights switch .................................... 3-9Pass switch ...................................... 3-7Start switch ...................................... 3-9Turn signal switch ............................ 3-8

Hazard switch ........................................ 3-8Headlight bulb replacement

(for XJ600N) ...................................... 6-29Headlight bulb replacement

(for XJ600S) ...................................... 6-27

Helmet holders ..................................... 3-15High beam indicator light ....................... 3-3Horn switch ............................................ 3-8

IIdentification number records ................ 9-1Idle speed adjustment .......................... 6-12Indicator lights ........................................ 3-3

High beam indicator light .................. 3-3Neutral indicator light ....................... 3-3Oil level indicator light ...................... 3-3Turn indicator lights .......................... 3-3

Inspecting the brake fluid level ............ 6-19

KKey identification number

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

(for XJ600S) ........................................ 9-1

LLeft view (XJ600N) ................................ 2-4Left view (XJ600S) ................................. 2-1Lights switch .......................................... 3-9Luggage strap holders ......................... 3-16

MMain switch ............................................ 3-1Model label ............................................ 9-2

NNeutral indicator light ............................. 3-3

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INDEX

/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9156_XJ600SN-E6/English/EEIX.frame

OOil level indicator circuit check .............. 3-5Oil level indicator light ............................ 3-3

PPanel A .................................................. 6-5Panel removal and installation ............... 6-5Parking .................................................. 5-6Pass switch ............................................ 3-7Periodic maintenance and lubrication .... 6-2Pre-operation check list ......................... 4-1

RRear brake pedal ................................. 3-11Rear brake pedal height adjustment .... 6-17Rear shock absorber adjustment ......... 3-15Rear suspension lubrication ................ 6-23Rear wheel installation ........................ 6-34Rear wheel removal ............................. 6-33Recommended shift points

(for Switzerland only) .......................... 5-5Right view (XJ600N) .............................. 2-5Right view (XJ600S) .............................. 2-2

SSeat ..................................................... 3-14Shift pedal ............................................ 3-10Shifting ................................................... 5-4Sidestand ............................................. 3-17Sidestand/clutch switch operation

check ................................................. 3-17

Spark plug inspection ............................ 6-6Specifications ......................................... 8-1Speedometer (for XJ600N) .................... 3-6Speedometer (for XJ600S) .................... 3-6Start switch ............................................ 3-9Starter (choke) Ò Ó ............................ 3-14Starting a warm engine .......................... 5-4Starting the engine ................................. 5-1Steering inspection .............................. 6-24Steering lock (for XJ600N) ..................... 3-3Storage ................................................... 7-4Storage compartment .......................... 3-15

TTachometer ............................................ 3-7Throttle cable and grip lubrication ........ 6-22Throttle cable free play inspection ....... 6-12Tips for reducing fuel consumption ........ 5-5Tires ..................................................... 6-13Tool kit ................................................... 6-1Troubleshooting ................................... 6-34Troubleshooting chart .......................... 6-35Turn indicator lights ............................... 3-3Turn signal switch .................................. 3-8

VValve clearance adjustment ................. 6-13Vehicle identification number ................. 9-2

WWheel bearings .................................... 6-25Wheels ................................................. 6-15

PRINTED IN JAPAN99 · 4 - 0.3 × 1 CR

(E)

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

4BR-28199-E6 XJ600S OWNER’S MANUAL · manual contains the most current product information...

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Transcript of 4BR-28199-E6 XJ600S OWNER’S MANUAL · manual contains the most current product information...