XJ600S Diversion Uso e Manutenzione

OWNER’S MANUAL
XJ600S
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2001 · 6 - 0.3 × 1 CR 4BR-28199-E8
(E)
E_5GK_Consumer.fm Page 11 Wednesday, June 13, 2001 1:03 PM
E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM
EAU03338
INTRODUCTION
Welcome to the Yamaha world of motorcycling!
As the owner of an XJ600S/XJ600N, you are benefiting from Yamaha’s vast experi-
ence and newest technology regarding the design and manufacture of high-quality
products, which have earned Yamaha a reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of
your XJ600S/XJ600N. The owner’s manual does not only instruct you in how to
operate, inspect and maintain your motorcycle, but also in how to safeguard yourself
and others from trouble and injury.
In addition, the many tips given in this manual will help keep your motorcycle in the
best possible condition. If you have any further questions, do not hesitate to contact
your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put
safety first!
IMPORTANT MANUAL INFORMATION EAU00005
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING 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.
CAUTION: 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.
NOTE:
@
● This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while
this manual contains the most current product information available at the time of printing,
there may be minor discrepancies between your motorcycle and this manual. If you have
any questions concerning this manual, please consult your Yamaha dealer.
@
IMPORTANT MANUAL INFORMATION

EW000002
@
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.
@
IMPORTANT MANUAL INFORMATION
EAU03337
XJ600S/XJ600N
OWNER’S MANUAL
© 2001 by Yamaha Motor Co., Ltd.
1st Edition, April 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
EAU00009
TABLE OF CONTENTS
1 GIVE SAFETY THE RIGHT OF WAY 1
2 DESCRIPTION 2
3 INSTRUMENT AND CONTROL FUNCTIONS 3
4 PRE-OPERATION CHECKS 4
5 OPERATION AND IMPORTANT RIDING POINTS 5
6 PERIODIC MAINTENANCE AND MINOR REPAIR 6
7 MOTORCYCLE CARE AND STORAGE 7
8 SPECIFICATIONS 8
9 CONSUMER INFORMATION 9
INDEX
GIVE SAFETY THE RIGHT OF WAY
GIVE SAFETY THE RIGHT OF WAY ................................................ 1-1
1
GIVE SAFETY THE RIGHT OF WAY

1-
EAU00021
Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and
freedom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
1
Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders—more than car drivers—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 materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.
Optimum protective wear, however, should not encourage carelessness. Although full-coverage
helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will
always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to
take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,
predictably and defensively—avoiding all dangers, including those caused by others.
Enjoy your ride!
1-1
DESCRIPTION
Left view (XJ600S) ............................................................................. 2-1

Right view (XJ600S)........................................................................... 2-2
Controls and instruments (XJ600S) ................................................... 2-3
Left view (XJ600N) ............................................................................. 2-4
2
Right view (XJ600N) .......................................................................... 2-5
Controls and instruments (XJ600N) ................................................... 2-6
DESCRIPTION
2-
EAU00026
Left view (XJ600S)
1. Fuel cock (page 3-11) 6. Shock absorber assembly

2. Helmet holder (page 3-13) spring preload adjusting ring (page 3-14)
3. Fuse box (page 6-29) 7. Shift pedal (page 3-8)
4. Luggage strap holders (page 3-15)
5. Seat lock (page 3-12)
2-1
DESCRIPTION
Right view (XJ600S)
8. Tail/brake light
9. Storage compartment (page 3-14)
10. Seat (page 3-12)
11. Fuel tank (page 3-9)
12. Headlight (page 6-30)
13. Brake pedal (page 3-9)
2-2
DESCRIPTION
Controls and instruments (XJ600S)
14. Clutch lever (page 3-7)

15. Left handlebar switches (page 3-6)
16. Starter (choke) lever (page 3-12)
17. Speedometer unit (page 3-4)
18. Tachometer (page 3-5)
19. Right handlebar switches (page 3-7)
20. Brake lever (page 3-8)
21. Throttle grip (page 6-13)
22. Main switch/steering lock (page 3-1)
2-3
DESCRIPTION
Left view (XJ600N)
1. Steering lock (page 3-3) 6. Seat lock (page 3-12)

2. Fuel cock (page 3-11) 7. Shock absorber assembly spring
3. Helmet holder (page 3-13) preload adjusting ring (page 3-14)
4. Fuse box (page 6-29) 8. Shift pedal (page 3-8)
5. Luggage strap holders (page 3-15)
2-4
DESCRIPTION
Right view (XJ600N)
9. Tail/brake light
10. Storage compartment (page 3-13)
11. Seat (page 3-12)
12. Fuel tank (page 3-9)
13. Headlight (page 6-30)
14. Brake pedal (page 3-9)
2-5
DESCRIPTION
Controls and instruments (XJ600N)
15. Clutch lever (page 3-7)

16. Left handlebar switches (page 3-6)
17. Starter (choke) lever (page 3-12)
18. Speedometer unit (page 3-5)
19. Tachometer (page 3-5)
20. Right handlebar switches (page 3-7)
21. Brake lever (page 3-8)
22. Throttle grip (page 6-13)
23. Main switch (page 3-1)
2-6
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock .....................................3-1 Fuel ................................................................... 3-10

Steering lock (for XJ600N)....................................3-3 Fuel tank breather hose (for Germany only) ..... 3-11
Indicator and warning lights ................................3-3 Fuel cock ........................................................... 3-11
Speedometer unit (for XJ600S) ...........................3-4 Starter (choke) lever .......................................... 3-12
Speedometer unit (for XJ600N) ...........................3-5 Seat ................................................................... 3-12
Tachometer ..........................................................3-5 Helmet holders .................................................. 3-13
3
Handlebar switches .............................................3-6 Storage compartment ....................................... 3-14
Clutch lever ..........................................................3-7 Adjusting the shock absorber assembly ............ 3-14
Shift pedal ............................................................3-8 Luggage strap holders ...................................... 3-15
Brake lever ..........................................................3-8 Sidestand .......................................................... 3-15
Brake pedal ..........................................................3-9 Ignition circuit cut-off system ............................. 3-16
Fuel tank cap .......................................................3-9

3-
EAU00027
XJ600S XJ600N
EAU00029 EAU00038 EAU00040
Main switch/steering lock OFF LOCK (for XJ600S)

The main switch/steering lock controls All electrical systems are off. The key The steering is locked, and all electrical
the ignition and lighting systems, and is can be removed. systems are off. The key can be re-
used to lock the steering. The various moved.
positions are described below.
To lock the steering
EAU00036 1. Turn the handlebars all the way to
ON the left.
All electrical systems are supplied with 2. Push the key in from the “OFF” po-
power, and the engine can be started. sition, and then turn it to “LOCK”
The key cannot be removed. while still pushing it.
3. Remove the key.
To unlock the steering

Push the key in, and then turn it to
“OFF” while still pushing it.
3-1

EW000016
XJ600S XJ600N
@
WARNING
Never turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the motor- 3
cycle is stopped before turning the
1. Push. 1. Push.
key to “OFF” or “LOCK”. 2. Turn. 2. Release.
@
3. Turn.
EAU01590
(Parking) (for XJ600S) EAU00055
The steering is locked, and the taillight P (Parking) (for XJ600N)

and auxiliary light are on, but all other The taillight and auxiliary light are on,
electrical systems are off. The key can but all other electrical systems are off.
be removed. The key can be removed.
The steering must be locked before the The key must be pushed in, and then
key can be turned to “ ”. released before it can be turned to “P”.
ECA00043
ECA00043
CAUTION: CAUTION:
@
@
Do not use the parking position for Do not use the parking position for
an extended length of time, other- an extended length of time, other-
wise the battery may discharge. wise the battery may discharge.
@
@
3-2

To unlock the steering XJ600S
1. Open the steering lock cover, and
then insert the key.
2. Push the key in, turn it 1/8 turn
counterclockwise so that it moves
out, and then release it.
3. Remove the key, and then close
3 the lock cover.
1. Steering lock 1. Left turn signal indicator light “ ”
2. High beam indicator light “ ”
EAU02934
3. Right turn signal indicator light “ ”
Steering lock (for XJ600N) 4. Neutral indicator light “ ”
5. Oil level warning light “ ”
To lock the steering EAU03034
1. Turn the handlebar all the way to Indicator and warning lights
right.
2. Open the steering lock cover, and EAU04121
Turn signal indicator lights “ ”

then insert the key.
and “ ”
3. Turn the key 1/8 turn counter-
The corresponding indicator light flash-
clockwise, push it in while turning
es when the turn signal switch is
the handlebar slightly to the left,
pushed to the left or right.
and then turn the key 1/8 turn
clockwise. EAU00061
4. Check that the steering is locked, Neutral indicator light “ ”
remove the key, and then close This indicator light comes on when the
the lock cover. transmission is in the neutral position.
3-3

XJ600N 1. Set the engine stop switch to “ ” XJ600S
and turn the key to “ON”.
2. Shift the transmission into the neu-
tral position or pull the clutch lever.
3. Push the start switch. If the warn-
ing light does not come on while
pushing the start switch, have a
Yamaha dealer check the electri- 3
cal circuit.
1. Neutral indicator light “ ” 1. Speedometer
2. Left turn signal indicator light “ ” 2. Odometer
3. Right turn signal indicator light “ ”
NOTE:
@
3. Tripmeter
4. High beam indicator light “ ” Even if the oil level is sufficient, the 4. Tripmeter reset button
5. Oil level warning light “ ” warning light may flicker when riding on EAU00094
EAU00063 a slope or during sudden acceleration Speedometer unit (for XJ600S)

High beam indicator light “ ” or deceleration, but this is not a mal- The speedometer unit is equipped with
This indicator light comes on when the function. a speedometer, an odometer and a
high beam of the headlight is switched @
tripmeter. The speedometer shows

on. riding speed. The odometer shows the
EAU03201
total distance traveled. The tripmeter
Oil level warning light “ ” shows the distance traveled since it
This warning light comes on when the was last set to zero with the reset but-
engine oil level is low. ton. The tripmeter can be used to esti-
The electrical circuit of the warning light mate the distance that can be traveled
can be checked according to the fol- with a full tank of fuel. This information
lowing procedure. will enable you to plan future fuel stops.
3-4

XJ600N XJ600S XJ600N
3
1. Speedometer 1. Tachometer 1. Tachometer
2. Odometer 2. Tachometer red zone (except for CH, A) 2. Tachometer red zone (except for CH, A)
3. Tripmeter 3. Tachometer red zone (for CH, A) 3. Tachometer red zone (for CH, A)
4. Tripmeter reset knob EAU00101*
EAU00095 Tachometer
Speedometer unit (for XJ600N) The electric tachometer allows the rider
The speedometer unit is equipped with to monitor the engine speed and keep it
a speedometer, an odometer and a within the ideal power range.
tripmeter. The speedometer shows EC000003*
riding speed. The odometer shows the CAUTION:

@
total distance traveled. The tripmeter Do not operate the engine in the ta-
shows the distance traveled since it chometer red zone.
was last set to zero with the reset knob. Red zone: 9,500 r/min and above
The tripmeter can be used to estimate (except for CH, A)
the distance that can be traveled with a 8,500 r/min and above
full tank of fuel. This information will en- (for CH, A)
able you to plan future fuel stops. @
3-5

EAU03826 EAU03889
Hazard switch “ ” Turn signal switch “ / ”

With the key in the “ON” or “P” position, To signal a right-hand turn, push this
use this switch to turn on the hazard switch to “ ”. To signal a left-hand
light (simultaneous flashing of all turn turn, push this switch to “ ”. When
signal lights). released, the switch returns to the cen-
The hazard light is used in case of an ter position. To cancel the turn signal
emergency or to warn other drivers lights, push the switch in after it has re-
3
when your motorcycle is stopped turned to the center position.
1. Dimmer switch “ / ” where it might be a traffic hazard.
2. Pass switch “PASS” EC000006 EAU00129
3. Hazard switch “ ”
CAUTION: Horn switch “ ”
4. Turn signal switch “ / ” _
Press this switch to sound the horn.
5. Horn switch “ ” Do not use the hazard light for an ex-
EAU00118 tended length of time, otherwise the
Handlebar switches battery may discharge.
_
EAU00120
Pass switch “PASS”

Press this switch to flash the headlight.
EAU03888
Dimmer switch “ / ”
Set this switch to “ ” for the high
beam and to “ ” for the low beam.
3-6

EAU00143
Start switch “ ”
Push this switch to crank the engine
with the starter.
EC000005
CAUTION:
@
See page 5-1 for starting instruc-

tions prior to starting the engine.
3 @
1. Engine stop switch “ / ” 1. Clutch lever

2. Light switch “ / / ”
EAU00152
3. Start switch “ ”
Clutch lever
The clutch lever is located at the left
EAU03890
Engine stop switch “ / ” handlebar grip. To disengage the

Set this switch to “ ” before starting clutch, pull the lever toward the handle-
the engine. Set this switch to “ ” to bar grip. To engage the clutch, release
stop the engine in case of an emergen- the lever. The lever should be pulled
cy, such as when the motorcycle over- rapidly and released slowly for smooth
turns or when the throttle cable is clutch operation.
stuck. The clutch lever is equipped with a
clutch switch, which is part of the igni-
EAU03898 tion circuit cut-off system. (See page
Light switch “ / / ” 3-16 for an explanation of the ignition
Set this switch to “ ” to turn on the circuit cut-off system.)
auxiliary light, meter lighting and tail-
light. Set the switch to “ ” to turn on
the headlight also. Set the switch to
“ ” to turn off all the lights.
3-7
3
1. Shift pedal 1. Brake lever 1. Brake lever position adjusting nut
2. Brake lever position adjusting nut 2. Properly aligned marks
EAU00157
Shift pedal EAU00160

The brake lever is equipped with a po-
The shift pedal is located on the left Brake lever sition adjusting nut. To adjust the dis-
side of the engine and is used in com- The brake lever is located at the right tance between the brake lever and the
bination with the clutch lever when handlebar grip. To apply the front handlebar grip, turn the adjusting nut
shifting the gears of the 6-speed con- brake, pull the lever toward the handle- while holding the lever pushed away
stant-mesh transmission equipped on bar grip. from the handlebar grip. Make sure that
this motorcycle. the mark “ ” on the adjusting nut is
aligned with the mark “ ” on the brake
lever.
3-8

NOTE:
@
The fuel tank cap cannot be closed un-

less the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked.
@
EWA00025
@
WARNING
3 Make sure that the fuel tank cap is
1. Brake pedal 1. Fuel tank cap lock cover properly closed before riding.
@
2. Unlock.
EAU00162
Brake pedal EAU02935
The brake pedal is on the right side of Fuel tank cap

the motorcycle. To apply the rear
brake, press down on the brake pedal. To open the fuel tank cap
Open the fuel tank cap lock cover, in-
sert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be re-
leased and the fuel tank cap can be
opened.
To close the fuel tank cap

1. Push the fuel tank cap into position
with the key inserted in the lock.
2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
3-9

EAU00185
Your Yamaha engine has been de-
CAUTION: signed to use regular unleaded gaso-
@
Immediately wipe off spilled fuel line with a research octane number of
with a clean, dry, soft cloth, since 91 or higher. If knocking (or pinging)
fuel may deteriorate painted surfac- occurs, use a gasoline of a different
es or plastic parts. brand or premium unleaded fuel. Use
of unleaded fuel will extend spark plug
@
EAU04202
life and reduce maintenance costs. 3

Recommended fuel:
1. Fuel tank filler tube
2. Fuel level
REGULAR UNLEADED
GASOLINE ONLY
EAU03753
Fuel Fuel tank capacity:

Total amount:
Make sure that there is sufficient fuel in
17.0 L
the tank. Fill the fuel tank to the bottom
Reserve amount:
of the filler tube as shown.
EW000130 3.5 L
_
WARNING ECA00102
● Do not overfill the fuel tank, oth- CAUTION:

erwise it may overflow when the _
Use only unleaded gasoline. The

fuel warms up and expands. use of leaded gasoline will cause se-
● Avoid spilling fuel on the hot
vere damage to the engine internal
engine. parts such as valves, piston rings,
_
exhaust system, etc.

_
3-10

ON: Normal position RES: Reserve position
3
1. Fuel tank breather hose 1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES”
EAU00196 EAU00207
RES
Fuel tank breather hose Fuel cock This indicates reserve. With the fuel
(for Germany only) The fuel cock supplies fuel from the cock lever in this position, the fuel re-
Before operating the motorcycle: tank to the carburetors while also filter- serve is made available. Quickly turn
● Check the fuel tank breather hose ing it. the fuel cock lever to this position if you
connection. The fuel cock lever positions are ex- run out of fuel while riding, otherwise
● Check the fuel tank breather hose plained as follows and shown in the il- the engine may stall and will have to be
for cracks or damage, and replace lustrations. primed (see “PRI”). After turning the
it if damaged. fuel cock lever to “RES”, refuel as soon
● Make sure that the end of the fuel ON as possible and be sure to turn the fuel
tank breather hose is not blocked With the fuel cock lever in this position, cock lever back to “ON”!
and clean it if necessary. fuel flows to the carburetors when the
engine is running. Turn the fuel cock le-
ver to this position when starting the
engine and riding.
3-11

PRI: Prime position
3
1. Arrow mark positioned over “PRI” 1. Starter (choke) lever “ ” 1. Unlock.
PRI EAU03839 EAU02925
This indicates prime. With the fuel cock Starter (choke) lever “ ” Seat
lever in this position, the engine can be Starting a cold engine requires a richer
“primed”. Turn the fuel cock lever to air-fuel mixture, which is supplied by To remove the seat
this position when the engine has been the starter (choke). Insert the key into the seat lock, turn it
allowed to run out of fuel. This sends Move the lever in direction a to turn on counterclockwise, and then pull the
fuel directly to the carburetors, which the starter (choke). seat off.
will make starting easier. After the en- Move the lever in direction b to turn off
gine has started, be sure to turn the le- the starter (choke).
ver to “ON” (or “RES” if you have not
refueled yet).
3-12

EWA00015
@
WARNING
Never ride with a helmet attached to
a helmet holder, since the helmet
may hit objects, causing loss of
control and possibly an accident.
@
3 To release a helmet from a helmet

1. Projection (× 2) 1. Helmet holder (× 2) holder
2. Seat holder
EAU02936
Remove the seat, remove the helmet
To install the seat Helmet holders from the helmet holder, and then install
Insert the projections on the front of the The helmet holders are located under the seat.
seat into the seat holder, push the rear the seat.
of the seat down to lock it in place, and
then remove the key. To secure a helmet to a helmet holder
1. Remove the seat. (See page 3-12
NOTE:
@
for seat removal and installation
Make sure that the seat is properly se- procedures.)
cured before riding. 2. Attach the helmet to the helmet
@
holder, and then securely install

the seat.
3-13
3
1. Strap for U-LOCK (× 2) 1. Spring preload adjusting ring 1. Special wrench
2. Position indicator
EAU01688
Adjust the spring preload as follows.
Storage compartment EAU00295
To increase the spring preload and
This storage compartment is designed Adjusting the shock absorber
thereby harden the suspension, turn
to hold a genuine Yamaha U-LOCK. assembly the adjusting ring in direction a. To de-
(Other locks may not fit.) When placing This shock absorber assembly is crease the spring preload and thereby
a U-LOCK in the storage compartment, equipped with a spring preload adjust- soften the suspension, turn the adjust-
securely fasten it with the straps. When ing ring.
EC000015
ing ring in direction b.
the U-LOCK is not in the storage com-
partment, be sure to secure the straps CAUTION: NOTE:
@
@
to prevent losing them. Never attempt to turn an adjusting Align the appropriate notch in the ad-
When storing the owner’s manual or mechanism beyond the maximum justing ring with the position indicator
other documents in the storage com- or minimum settings. on the shock absorber.
@
@
partment, be sure to wrap them in a CI-10E
plastic bag so that they will not get wet. Setting
When washing the motorcycle, be Minimum (soft) 1
careful not to let any water enter the Standard 3
storage compartment. Maximum (hard) 7
3-14

EAU00315 EAU00330
Left Right Sidestand
@
WARNING
This shock absorber contains high- The sidestand is located on the left side
ly pressurized nitrogen gas. For of the frame. Raise the sidestand or
proper handling, read and under- lower it with your foot while holding the
stand the following information be- motorcycle upright.
fore handling the shock absorber.
NOTE:
The manufacturer cannot be held re-
@
3 The built-in sidestand switch is part of

sponsible for property damage or the ignition circuit cut-off system, which
1. Luggage strap holder (× 4)
personal injury that may result from cuts the ignition in certain situations.
EAU01398
improper handling. (See further down for an explanation of
● Do not tamper with or attempt to
Luggage strap holders
There are four luggage strap holders: the ignition circuit cut-off system.)
open the gas cylinder. @
one on each passenger footrest brack-

● Do not subject the shock ab-
et and one below each side of the seat.
sorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.
● Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping per-
formance.
● Always have a Yamaha dealer
service the shock absorber.
@
3-15

EW000044 EAU03741 EW000046
WARNING Ignition circuit cut-off system WARNING

@ _
The motorcycle must not be ridden The ignition circuit cut-off system (com- ● The vehicle must be placed on
with the sidestand down, or if the prising the sidestand switch, clutch the centerstand during this in-
sidestand cannot be properly switch and neutral switch) has the fol- spection.
moved up (or does not stay up), oth- lowing functions. ● If a malfunction is noted, have a
erwise the sidestand could contact ● It prevents starting when the trans- Yamaha dealer check the sys-
the ground and distract the opera- mission is in gear and the side- tem before riding. 3
tor, resulting in a possible loss of stand is up, but the clutch lever is _
control. Yamaha’s ignition circuit not pulled.

cut-off system has been designed to ● It prevents starting when the trans-
assist the operator in fulfilling the mission is in gear and the clutch
responsibility of raising the side- lever is pulled, but the sidestand is
stand before starting off. Therefore, still down.
check this system regularly as de- ● It cuts the running engine when
scribed below and have a Yamaha the transmission is in gear and the
dealer repair it if it does not function sidestand is moved down.
properly. Periodically check the operation of the
@
ignition circuit cut-off system according
to the following procedure.
3-16

CD-01E
With the engine turned off: NOTE:

1. Move the sidestand down. This check is most reliable if performed with
2. Make sure that the engine stop switch is set to “ ”. a warmed-up engine.
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective.
3 YES NO The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
The sidestand switch may be defective.
YES NO The motorcycle should not be ridden until
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The clutch switch may be defective.
YES NO The motorcycle should not be ridden until
The system is OK. The motorcycle can be ridden.
3-17
PRE-OPERATION CHECKS
Pre-operation check list ..................................................................... 4-1
4
4-
EAU01114
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list

ITEM CHECKS PAGE
Front brake • Check operation, fluid level and fluid leakage. 6-19–6-21
Rear brake • Fill with DOT 4 brake fluid if necessary. 6-18–6-21
4 • Check operation, condition and free play.
Clutch 6-17–6-18
• Adjust if necessary.
• Make sure that operation is smooth.
Throttle grip and housing • Check free play. 6-13, 6-24
• If necessary, have Yamaha dealer make adjustment or lubricate.
• Check oil level.
Engine oil 6-7–6-10
• Fill with oil if necessary.
• Check chain slack and condition.
Drive chain 6-21–6-23
• Adjust if necessary.
Wheels and tires • Check tire pressure, wear and damage. 6-14–6-17
• Check smooth operation.
Control and meter cables 6-23
• Lubricate if necessary.
Brake and shift pedal • Check smooth operation.
6-24
shafts • Lubricate if necessary.
Brake and clutch lever • Check smooth operation.
6-25
pivots • Lubricate if necessary.
Center and sidestand • Check smooth operation.
6-25
pivots • Lubricate if necessary.
4-1
ITEM CHECKS PAGE
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners —
• Tighten if necessary.
• Check fuel level.
Fuel 3-9–3-10
• Fill with fuel if necessary.
Lights, signals and
• Check proper operation. —
switches
NOTE:
_
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. 4
_
EWA00033
_
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle.
_
4-2
OPERATION AND IMPORTANT RIDING POINTS
Starting a cold engine ....................................................................... 5-1

Starting a warm engine ..................................................................... 5-2
Shifting .............................................................................................. 5-3
Recommended shift points (for Switzerland only) ............................. 5-3
Tips for reducing fuel consumption ................................................... 5-4
Engine break-in ................................................................................. 5-4
Parking .............................................................................................. 5-5
5

5-
EAU00372
EAU00373 EAU00381*
NOTE:
WARNING Starting a cold engine @
When the transmission is in the neutral

@
● Become thoroughly familiar In order for the ignition circuit cut-off position, the neutral indicator light
with all operating controls and system to enable starting, one of the should be on, otherwise have a
their functions before riding. following conditions must be met: Yamaha dealer check the electrical
Consult a Yamaha dealer re- ● The transmission is in the neutral circuit.
garding any control or function position. @
4. Turn the starter (choke) on and

that you do not thoroughly ● The transmission is in gear with
completely close the throttle. (See
understand. the clutch lever pulled and the
page 3-12 for starter (choke) oper-
● Never start the engine or oper- sidestand up.
EW000054 ation.)
ate it in a closed area for any
WARNING 5. Start the engine by pushing the
length of time. Exhaust fumes @
start switch.
5 ● Before starting the engine,
are poisonous, and inhaling
them can cause loss of con- check the function of the igni- NOTE:
@
sciousness and death within a tion circuit cut-off system ac- If the engine fails to start, release the
short time. Always make sure cording to the procedure start switch, wait a few seconds, and
that there is adequate ventila- described on page 3-17. then try again. Each starting attempt
● Never ride with the sidestand should be as short as possible to pre-
tion.
● Before starting out, make sure
down. serve the battery. Do not crank the en-
@
that the sidestand is up. If the 1. Turn the fuel cock lever to “ON”. gine more than 10 seconds on any one
sidestand is not raised com- 2. Turn the key to “ON” and make attempt.
@
pletely, it could contact the sure that the engine stop switch is
ground and distract the opera- set to “ ”.
tor, resulting in a possible loss 3. Shift the transmission into the neu-
of control. tral position.
@
5-1

EC000034 ECA00045 EAU01258
CAUTION: CAUTION: Starting a warm engine

@ @
The oil level warning light should For maximum engine life, never ac- Follow the same procedure as for start-
come on when the start switch is celerate hard when the engine is ing a cold engine with the exception
pushed, and it should go off when cold! that the starter (choke) is not required
the start switch is released. If the oil @
when the engine is warm.
7. When the engine is warm, turn the
level warning light flickers or re-
starter (choke) off.
mains on after starting, immediately
stop the engine, and then check the NOTE:
@
engine oil level and the vehicle for The engine is warm when it responds
oil leakage. If necessary, add engine normally to the throttle with the starter
oil, and then check the warning light (choke) turned off.
@ 5
again. If the warning light does not
come on when pushing the start
switch, or if it does not go off after
starting with sufficient engine oil,
have a Yamaha dealer check the
electrical circuit.
@
6. After starting the engine, move the

starter (choke) lever back halfway.
5-2

EC000048 EAU02937
CAUTION: Recommended shift points

(for Switzerland only)
@
● Even with the transmission in

the neutral position, do not The recommended shift points during
coast for long periods of time acceleration are shown in the table
with the engine off, and do not below.
CF-02E
tow the motorcycle for long dis- Shift point
tances. The transmission is (km/h)
properly lubricated only when 1st → 2nd 20
1. Shift pedal 2nd → 3rd 30
N. Neutral position
the engine is running. Inade-
3rd → 4th 40
quate lubrication may damage
EAU00423 4th → 5th 50
Shifting the transmission. 5th → 6th 60
5
● Always use the clutch while
Shifting gears lets you control the
changing gears to avoid dam- NOTE:
amount of engine power available for @
aging the engine, transmission, When shifting down two gears at a

starting off, accelerating, climbing hills,
and drive train, which are not time, reduce the speed accordingly
etc.
designed to withstand the (e.g., down to 35 km/h when shifting
The gear positions are shown in the
shock of forced shifting. from 5th to 3rd gear).
illustration. @
@
NOTE:
@
To shift the transmission into the neu-

tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
@
5-3

EAU00424 EAU00436 EAU00440*
Tips for reducing fuel Engine break-in 0–150 km

consumption There is never a more important period ● Avoid prolonged operation above
Fuel consumption depends largely on in the life of your engine than the period 5,000 r/min.
between 0 and 1,000 km. For this rea- ● After every hour of operation, stop
your riding style. Consider the following
tips to reduce fuel consumption: son, you should read the following ma- the engine, and then let it cool for
● Thoroughly warm up the engine. terial carefully. five to ten minutes.
Since the engine is brand new, do not ● Vary the engine speed from time
● Turn the starter (choke) off as
soon as possible. put an excessive load on it for the first to time. Do not operate the engine
● Shift up swiftly, and avoid high en- 1,000 km. The various parts in the en- at one set throttle position.
gine speeds during acceleration. gine wear and polish themselves to the
● Do not rev the engine while shift- correct operating clearances. During 150–500 km
this period, prolonged full-throttle oper- ● Avoid prolonged operation above 5
ing down, and avoid high engine
speeds with no load on the engine. ation or any condition that might result 6,000 r/min.
● Turn the engine off instead of let- in engine overheating must be avoided. ● Rev the engine freely through the
ting it idle for an extended length gears, but do not use full throttle at
of time (e.g., in traffic jams, at traf- any time.
fic lights or at railroad crossings).
5-4

500–1,000 km EAU00460
● Avoid prolonged full-throttle oper-

Parking
ation. When parking, stop the engine, and
● Avoid prolonged operation above then remove the key from the main
7,000 r/min. switch.
EW000058
EC000052*
CAUTION: @
WARNING
● Since the engine and exhaust
@
After 1,000 km of operation, the en-

gine oil must be changed and the oil system can become very hot,
filter cartridge replaced. park in a place where pedestri-
@ ans or children are not likely to
touch them.
5 1,000 km and beyond ● Do not park on a slope or on
The vehicle can now be operated soft ground, otherwise the
normally. motorcycle may overturn.
EC000053 @
CAUTION:
@
● Keep the engine speed out of

the tachometer red zone.
● If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the
vehicle.
@
5-5
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ....................................................6-1 Checking and lubricating the throttle grip and
Periodic maintenance and lubrication chart .........6-2 cable ............................................................... 6-24
Removing and installing the panel .......................6-5 Checking and lubricating the brake and shift
Checking the spark plugs ....................................6-6 pedals ............................................................. 6-24
Engine oil and oil filter cartridge ..........................6-7 Checking and lubricating the brake and clutch
levers ............................................................... 6-25
Cleaning the air filter element ............................6-10
Checking and lubricating the centerstand and
Adjusting the carburetors ...................................6-12
sidestand ......................................................... 6-25
Adjusting the engine idling speed ......................6-13
Lubricating the rear suspension ........................ 6-25
Adjusting the throttle cable free play ..................6-13
Checking the front fork ...................................... 6-26
Adjusting the valve clearance ............................6-14
Checking the steering ....................................... 6-26
Tires ...................................................................6-14
Checking the wheel bearings ............................ 6-27
Cast wheels .......................................................6-17
Battery ............................................................... 6-27 6
Adjusting the clutch lever free play ....................6-17
Replacing the fuses .......................................... 6-29
Adjusting the brake pedal position .....................6-18
Replacing the headlight bulb (for XJ600S)......... 6-30
Adjusting the rear brake light switch ..................6-19
Replacing the headlight bulb (for XJ600N) ........ 6-31
Checking the front and rear brake pads .............6-19
Front wheel ....................................................... 6-33
Checking the brake fluid level ............................6-20
Rear wheel ........................................................ 6-35
Changing the brake fluid ....................................6-21
Troubleshooting ................................................. 6-36
Drive chain slack ................................................6-21
Troubleshooting chart ........................................ 6-37
Lubricating the drive chain .................................6-23
Checking and lubricating the cables ..................6-23

6-
EAU00462
EAU00464 EW000063
Safety is an obligation of the owner. WARNING

Periodic inspection, adjustment and lu- @
Modifications not approved by

brication will keep your vehicle in the
Yamaha may cause loss of perfor-
safest and most efficient condition pos-
mance and render the vehicle un-
sible. The most important points of in-
safe for use. Consult a Yamaha
spection, adjustment, and lubrication
dealer before attempting any chang-
are explained on the following pages.
es.
The intervals given in the periodic @
maintenance and lubrication chart 1. Owner’s tool kit

should be simply considered as a gen- EAU00469
eral guide under normal riding condi- Owner’s tool kit

tions. However, DEPENDING ON THE The service information included in this
WEATHER, TERRAIN, GEOGRAPHI- manual and the tools provided in the
6 CAL LOCATION, AND INDIVIDUAL owner’s tool kit are intended to assist
USE, THE MAINTENANCE INTER- you in the performance of preventive
VALS MAY NEED TO BE SHORT- maintenance and minor repairs. How-
ENED. ever, additional tools such as a torque
EW000060
wrench may be necessary to perform
@
WARNING certain maintenance work correctly.
If you are not familiar with motor-
cycle maintenance work, have a NOTE:
@
If you do not have the tools or experi-

Yamaha dealer do it for you.
@ ence required for a particular job, have
a Yamaha dealer perform it for you.
@
6-1

EAU03685
Periodic maintenance and lubrication chart

NOTE:
_
● The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
● From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_
CP-01ECP-01E
ODOMETER READING (×1,000 km) Annual

NO. ITEM CHECK OR MAINTENANCE JOB
1 10 20 30 40 check
1 * Fuel line • Check fuel hoses and vacuum hose for cracks or damage. √ √ √ √ √
2 * Fuel filter • Check condition. √ √
• Check condition.
√ √
3 Spark plugs • Clean and regap.
6
• Replace. √ √
• Check valve clearance.
4 * Valves Every 20,000 km
• Adjust.
• Clean. √ √
5 Air filter element
• Replace. √ √
• Check operation.
6 Clutch √ √ √ √ √
• Adjust.
• Check operation, fluid level and vehicle for fluid leakage.
√ √ √ √ √ √
7 (See NOTE on page 6-4.)
* Front brake
• Replace brake pads. Whenever worn to the limit
• Check operation, fluid level and vehicle for fluid leakage.
√ √ √ √ √ √
8 (See NOTE on page 6-4.)
* Rear brake
• Replace brake pads. Whenever worn to the limit
6-2

1 10 20 30 40 check
• Check for cracks or damage. √ √ √ √ √
9 * Brake hoses • Replace. (See NOTE on page 6-4.) Every 4 years
10 * Wheels • Check runout and for damage. √ √ √ √
• Check tread depth and for damage.
• Replace if necessary.
11 * Tires √ √ √ √ √
• Check air pressure.
• Correct if necessary.
12 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √
• Check operation and for excessive play. √ √ √ √
13 * Swingarm • Lubricate with lithium-soap-based grease. Every 50,000 km
• Check chain slack.
Every 1,000 km and after washing
14 Drive chain • Make sure that the rear wheel is properly aligned.
the motorcycle or riding in the rain.
• Clean and lubricate.
6 • Check bearing play and steering for roughness. √ √ √ √ √
15 * Steering bearings • Lubricate with lithium-soap-based grease Every 20,000 km
16 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √
• Check operation.
17 Sidestand/centerstand √ √ √ √ √
• Lubricate.
18 * Sidestand switch • Check operation. √ √ √ √ √ √
19 * Front fork • Check operation and for oil leakage. √ √ √ √
Shock absorber
20 * • Check operation and shock absorber for oil leakage. √ √ √ √
assembly
Rear suspension relay • Check operation. √ √ √ √
21 * arm and connecting arm • Lubricate with lithium-soap-based grease.
pivoting points √ √
6-3

1 10 20 30 40 check
• Check starter (choke) operation.
22 * Carburetors √ √ √ √ √ √
• Adjust engine idling speed and synchronization.
• Change. √ √ √ √ √ √
23 Engine oil
• Check oil level and vehicle for oil leakage. √ √ √ √ √ √
24 Engine oil filter cartridge • Replace. √ √ √
Front and rear brake
25 * switches • Check operation. √ √ √ √ √ √
26 Moving parts and cables • Lubricate. √ √ √ √ √

Lights, signals and • Check operation.
27 * switches √ √ √ √ √ √
• Adjust headlight beam.
EAU03884
NOTE:
_
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 6
● Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
• Replace the brake hoses every four years and if cracked or damaged.
_
6-4
1. Panel A 1. Screw (× 2)
EAU01777 EAU02926
Removing and installing the Panel A

panel
The panel shown above needs to be To remove the panel
6 removed to perform some of the main- 1. Remove the seat. (See page 3-12
tenance jobs described in this chapter. for seat removal and installation
Refer to this section each time the pan- procedures.)
el needs to be removed and installed. 2. Remove the screws, and then
slide the panel as shown to re-
lease it.
6-5

The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal col-
or when the motorcycle is ridden nor-
mally), and all spark plugs installed in
the engine should have the same color.
If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
a. Spark plug gap
problems yourself. Instead, have a
To install the panel EAU01880
Yamaha dealer check the motorcycle.
1. Place the panel in the original po- Checking the spark plugs
If a spark plug shows signs of electrode
sition, and then install the screws. The spark plugs are important engine
erosion and excessive carbon or other
2. Install the seat. components, which should be checked
deposits, it should be replaced.
periodically, preferably by a Yamaha 6
dealer. Since heat and deposits will
Specified spark plug:
cause any spark plug to slowly erode,
CR8E (NGK) or
they should be removed and checked
U24ESR-N (DENSO)
in accordance with the periodic mainte-
nance and lubrication chart. In addition, Before installing a spark plug, the spark
the condition of the spark plugs can re- plug gap should be measured with a
veal the condition of the engine. wire thickness gauge and, if necessary,
adjusted to specification.
Spark plug gap:

0.7–0.8 mm
6-6

Clean the surface of the spark plug NOTE:
_
gasket and its mating surface, and then Make sure that the motorcycle is posi-
wipe off any grime from the spark plug tioned straight up when checking the oil
threads. level. A slight tilt to the side can result in
a false reading.
_
Tightening torque: 2. Start the engine, warm it up for

Spark plug: several minutes, and then turn it
12.5 Nm (1.25 m·kgf) off.
1. Engine oil level check window 3. Wait a few minutes until the oil set-
NOTE:
@
2. Maximum level mark tles, and then check the oil level
If a torque wrench is not available when 3. Minimum level mark through the check window located
installing a spark plug, a good estimate EAU04185 at the bottom-right side of the
of the correct torque is 1/4–1/2 turn Engine oil and oil filter crankcase.
past finger tight. However, the spark
cartridge
6 plug should be tightened to the speci- NOTE:
The engine oil level should be checked _
fied torque as soon as possible. The engine oil should be between the
@
before each ride. In addition, the oil
must be changed and the oil filter car- minimum and maximum level marks.
_
tridge replaced at the intervals speci- 4. If the engine oil is below the mini-
fied in the periodic maintenance and mum level mark, add sufficient oil
lubrication chart. of the recommended type to raise
it to the correct level.
To check the engine oil level
1. Place the motorcycle on the cen-
terstand.
6-7
1. Engine oil filler cap 1. Engine oil drain bolt 1. Oil filter cartridge
2. Oil filter wrench
To change the engine oil (with or 3. Remove the engine oil filler cap
without oil filter cartridge replace- and drain bolt to drain the oil from 4. Remove the oil filter cartridge with
ment) the crankcase. an oil filter wrench.
1. Start the engine, warm it up for
NOTE: NOTE:
several minutes, and then turn it _
_
6
Skip steps 4–6 if the oil filter cartridge is An oil filter wrench is available at a
off. Yamaha dealer.
not being replaced.
2. Place an oil pan under the engine _
_
to collect the used oil.
6-8

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

See page 8-1.
Oil quantity:
Without oil filter cartridge
1. O-ring 1. Torque wrench
replacement:
5. Apply a thin coat of engine oil to 6. Install the new oil filter cartridge 2.3 L
the O-ring of the new oil filter car- with an oil filter wrench, and then With oil filter cartridge
tridge. tighten it to the specified torque replacement:
with a torque wrench. 2.6 L
6 NOTE:
_
Total amount (dry engine):

Make sure that the O-ring is properly
Tightening torque: 3.1 L
seated.
_
Oil filter cartridge:
17 Nm (1.7 m·kgf)
7. Install the engine oil drain bolt, and

then tighten it to the specified
torque.
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
6-9

EC000072 EC000067
CAUTION: CAUTION:
_ _
● In order to prevent clutch slip- If the oil level warning light flickers
page (since the engine oil also or remains on, immediately turn the
lubricates the clutch), do not engine off and have a Yamaha deal-
mix any chemical additives with er check the vehicle.
the oil or use oils of a higher _
10. Turn the engine off, and then

grade than “CD”. In addition, do
check the oil level and correct it if
not use oils labeled “ENERGY
necessary. 1. Screw
CONSERVING II” or higher.
EAU02928*
● Make sure that no foreign mate-
Cleaning the air filter element
rial enters the crankcase.
_ The air filter element should be cleaned
9. Start the engine, and then let it idle at the intervals specified in the periodic
for several minutes while checking maintenance and lubrication chart. 6
it for oil leakage. If oil is leaking, Clean the air filter element more fre-
immediately turn the engine off quently if you are riding in unusually
and check for the cause. wet or dusty areas.
1. Remove the seat. (See page 3-12
NOTE:
_
for seat removal and installation

After the engine is started, the engine
procedures.)
oil level warning light should go off if the
2. Turn the fuel cock lever to “ON”,
oil level is sufficient.
_ and then remove the fuel cock le-
ver by removing the screw.
6-10
1. Fuel hose 1. Screw (× 4)

2. Vacuum hose
3. Fuel tank drain hose 4. Remove the fuel tank by removing 5. Remove the air filter case cover by
the bolts. removing the screws.
3. Disconnect the hoses shown.
6. Pull the air filter element out.
6-11

EC000082* EAU00630
CAUTION: Adjusting the carburetors

@
● Make sure that the air filter ele- The carburetors are important parts of
ment is properly seated in the the engine and require very sophisti-
air filter case. cated adjustment. Therefore, most car-
● The engine should never be op- buretor adjustments should be left to a
erated without the air filter ele- Yamaha dealer, who has the neces-
ment installed, otherwise the sary professional knowledge and expe-
pistons and/or cylinders may rience. The adjustment described in
1. Air filter element the following section, however, may be
become excessively worn.
7. Lightly tap the air filter element to @
serviced by the owner as part of routine
9. Install the air filter case cover by maintenance.
remove most of the dust and dirt,
installing the screws. EC000095
and then blow the remaining dirt
10. Install the fuel tank by installing the CAUTION:
out with compressed air as shown. @
bolts. The carburetors have been set and 6

If the air filter element is damaged,
11. Connect the hoses. extensively tested at the Yamaha
replace it.
12. Install the fuel cock lever by install- factory. Changing these settings
8. Insert the air filter element into the
ing the screw. without sufficient technical knowl-
air filter case.
13. Install the seat. edge may result in poor perfor-
mance of or damage to the engine.
@
6-12

EAU00632
Adjusting the engine idling

speed
The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Start the engine and warm it up for
1. Throttle stop screw a. Throttle cable free play
several minutes at 1,000–
2,000 r/min while occasionally rev- 2. Check the engine idling speed EAU00635
ving it to 4,000–5,000 r/min. and, if necessary, adjust it to spec- Adjusting the throttle cable
ification by turning the throttle stop free play
NOTE:
@
screw. To increase the engine The throttle cable free play should
6 The engine is warm when it quickly re- measure 3–5 mm at the throttle grip.
idling speed, turn the screw in di-
sponds to the throttle.
@
rection a. To decrease the engine Periodically check the throttle cable
idling speed, turn the screw in di- free play and, if necessary, have a
rection b. Yamaha dealer adjust it.
Engine idling speed:

1,200 – 1,300 r/min
NOTE:
@
If the specified idling speed cannot be

obtained as described above, have a
Yamaha dealer make the adjustment.
@
6-13

EAU00637 EAU03362 CE-01E
Tire air pressure
Adjusting the valve clearance Tires (measured on cold tires)
The valve clearance changes with use, To maximize the performance, durabil- Load* Front Rear
resulting in improper air-fuel mixture ity, and safe operation of your motor- 200 kPa 225 kPa
Up to 90 kg (2.00 kgf/cm2, (2.25 kgf/cm2,
and/or engine noise. To prevent this cycle, note the following points 2.00 bar) 2.25 bar)
from occurring, the valve clearance regarding the specified tires. 200 kPa 250 kPa
must be adjusted by a Yamaha dealer 90 kg–maximum (2.00 kgf/cm2, (2.50 kgf/cm2,
2.00 bar) 2.50 bar)
at the intervals specified in the periodic Tire air pressure
200 kPa 250 kPa
maintenance and lubrication chart. The tire air pressure should be High-speed riding (2.00 kgf/cm2, (2.50 kgf/cm2,
checked and, if necessary, adjusted 2.00 bar) 2.50 bar)
CE-07E
before each ride.
XJ600S: 184 kg
EW000082 Maximum load*
XJ600N: 187 kg
@
WARNING * Total weight of rider, passenger, cargo and
● The tire air pressure must be accessories
checked and adjusted on cold 6

tires (i.e., when the temperature
of the tires equals the ambient
temperature).
● The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
@
6-14

EWA00012
● Adjust the suspension and tire
@
WARNING air pressure with regard to the
Because loading has an enormous load.
impact on the handling, braking, ● Check the tire condition and air
performance and safety characteris- pressure before each ride.
tics of your motorcycle, you should @
keep the following precautions in

mind.
● NEVER OVERLOAD THE
1. Tire sidewall
MOTORCYCLE! Operation of an a. Tire tread depth
overloaded motorcycle may re-
sult in tire damage, loss of con- Tire inspection
trol, or severe injury. Make sure The tires must be checked before each
that the total weight of rider, ride. If the center tread depth reaches
6 passenger, cargo, and accesso- the specified limit, if the tire has a nail
ries does not exceed the speci- or glass fragments in it, or if the side-
fied maximum load for the wall is cracked, have a Yamaha dealer
vehicle. replace the tire immediately.
CE-08E
● Do not carry along loosely Minimum tire tread depth
1.6 mm
packed items, which can shift (front and rear)
during a ride.
NOTE:
● Securely pack the heaviest
@
The tire tread depth limits may differ

items close to the center of the
from country to country. Always comply
motorcycle and distribute the
with the local regulations.
weight evenly on both sides. @
6-15

EW000079
Tire information EAU00683
@
WARNING This motorcycle is equipped with tube @
WARNING
● Have a Yamaha dealer replace tires. ● Have a Yamaha dealer replace
excessively worn tires. Besides EW000078 excessively worn tires. Besides
being illegal, operating the @
WARNING being illegal, operating the
motorcycle with excessively ● The front and rear tires should motorcycle with excessively
worn tires decreases riding sta- be of the same make and de- worn tires decreases riding sta-
bility and can lead to loss of sign, otherwise the handling bility and can lead to loss of
control. characteristics of the motor- control.
● The replacement of all wheel- cycle cannot be guaranteed. ● The replacement of all wheel-
and brake-related parts, includ- ● After extensive tests, only the and brake-related parts, includ-
ing the tires, should be left to a tires listed below have been ap- ing the tires, should be left to a
Yamaha dealer, who has the proved for this model by Yamaha dealer, who has the
necessary professional knowl- Yamaha Motor Co., Ltd. necessary professional knowl-
edge and experience. @
edge and experience. 6

CE-10E
@ FRONT @
Manufacturer Size Model

DUNLOP 110/80-17 57H D103FA
DUNLOP 110/80-17 M/C 57H D103FA
MICHELIN 110/80-17 57H MACADAM 50
MICHELIN 110/80-17 M/C 57H MACADAM 50
REAR
Manufacturer Size Model
DUNLOP 130/70-18 63H D103A
DUNLOP 130/70-18 M/C 63H D103A
MICHELIN 130/70-18 63H MACADAM 50
MICHELIN 130/70-18 M/C 63H MACADAM 50
6-16

EAU03773
Cast wheels
To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.
● The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re- 1. Locknut 1. Clutch lever cable
2. Clutch lever free play adjusting bolt 2. Clutch lever free play adjusting nut
place the wheel. Do not attempt c. Clutch lever free play 3. Locknut
even the smallest repair to the
wheel. A deformed or cracked
EAU00694
3. If the specified clutch lever free
Adjusting the clutch lever free play could be obtained as de-
wheel must be replaced.
play scribed above, tighten the locknut
6 ● The wheel should be balanced
The clutch lever free play should mea- and skip the rest of the procedure,
whenever either the tire or wheel
sure 2–3 mm as shown. Periodically otherwise proceed as follows.
has been changed or replaced. An
check the clutch lever free play and, if 4. Fully turn the adjusting bolt at the
unbalanced wheel can result in
poor performance, adverse han-
necessary, adjust it as follows. clutch lever in direction a to loos-
1. Loosen the locknut at the clutch le- en the clutch cable.
dling characteristics, and a short-
ver. 5. Loosen the locknut at the crank-
ened tire life.
2. To increase the clutch lever free case.
● Ride at moderate speeds after
play, turn the adjusting bolt in di- 6. To increase the clutch lever free
changing a tire since the tire sur-
rection a. To decrease the clutch play, turn the adjusting nut in di-
face must first be “broken in” for it
to develop its optimal characteris-
lever free play, turn the adjusting rection a. To decrease the clutch
bolt in direction b. lever free play, turn the adjusting
tics.
nut in direction b.
6-17

7. Tighten the locknut at the clutch EW000109
lever and the crankcase. @

WARNING
A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
a. Distance between brake pedal and footrest
the braking performance, which
EAU00712
may result in loss of control and an
Adjusting the brake pedal accident.
position @
The top of the brake pedal should be

positioned approximately 40 mm below 6
the top of the footrest as shown. Peri-
odically check the brake pedal position
and, if necessary, have a Yamaha
dealer adjust it.
6-18

EAU00721
Checking the front and rear Front

brake pads
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
1. Rear brake light switch 1. Brake pad wear indicator groove (× 2)

2. Rear brake light switch adjusting nut
EAU00725
EAU00713 Front brake pads

Adjusting the rear brake light Each front brake pad is provided with a
switch wear indicator groove, which allows
6 The rear brake light switch, which is ac- you to check the brake pad wear with-
tivated by the brake pedal, is properly out having to disassemble the brake.
adjusted when the brake light comes To check the brake pad wear, check
on just before braking takes effect. If the wear indicator groove. If a brake
necessary, adjust the brake light switch pad has worn to the point that the wear
as follows. indicator groove has almost disap-
Turn the adjusting nut while holding the peared, have a Yamaha dealer replace
rear brake light switch in place. To the brake pads as a set.
make the brake light come on earlier,
turn the adjusting nut in direction a. To
make the brake light come on later,
turn the adjusting nut in direction b.
6-19

Rear Front Rear
1. Brake pad wear indicator (× 2) 1. Minimum level mark 1. Minimum level mark
EAU00728 EAU03776
Observe these precautions:
Rear brake pads Checking the brake fluid level ● When checking the fluid level,
Each rear brake pad is provided with a Insufficient brake fluid may allow air to make sure that the top of the brake
wear indicator, which allows you to enter the brake system, possibly caus- fluid reservoir is level.
check the brake pad wear without having it to become ineffective. 6
● Use only the recommended quali-
ing to disassemble the brake. To check Before riding, check that the brake fluid ty brake fluid, otherwise the rubber
the brake pad wear, check the position is above the minimum level mark and seals may deteriorate, causing
of the wear indicator while applying the replenish if necessary. A low brake flu- leakage and poor braking perfor-
brake. If a brake pad has worn to the id level may indicate worn brake pads mance.
point that the wear indicator almost and/or brake system leakage. If the
touches the brake disc, have a brake level is low, be sure to check the Recommended brake fluid: DOT 4
Yamaha dealer replace the brake pads brake pads for wear and the brake sys-
as a set. tem for leakage. ● Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
6-20

● Be careful that water does not en- EAU03985*
ter the brake fluid reservoir when Changing the brake fluid
refilling. Water will significantly Have a Yamaha dealer change the
lower the boiling point of the fluid brake fluid at the intervals specified in
and may result in vapor lock. the NOTE after the periodic mainte-
● Brake fluid may deteriorate paint-
nance and lubrication chart. In addition,
ed surfaces or plastic parts. Al- have the oil seals of the brake master
ways clean up spilled fluid cylinders and calipers as well as the
immediately. brake hose replaced at the intervals
listed below or whenever they are dam- a. Drive chain slack
● As the brake pads wear, it is nor-
mal for the brake fluid level to aged or leaking. EAU00745
● Oil seals: Replace every two Drive chain slack

gradually go down. However, if the
years. The drive chain slack should be
brake fluid level goes down sud-
● Brake hose: Replace every four checked before each ride and adjusted
denly, have a Yamaha dealer
6 years. if necessary.
check the cause.
To check the drive chain slack

1. Place the motorcycle on the
centerstand.
2. Shift the transmission into the neu-
tral position.
3. Spin the rear wheel several times
to locate the tightest portion of the
drive chain.
4. Measure the drive chain slack as
shown.
6-21

NOTE:
Drive chain slack: _
Using the alignment marks on each

30–40 mm side of the swingarm, make sure that
5. If the drive chain slack is incorrect, both adjusting nuts are in the same po-
adjust it as follows. sition for proper wheel alignment.
_
EC000096
CAUTION:
_
Improper drive chain slack will over-

1. Axle nut load the engine as well as other vital
2. Locknut parts of the motorcycle and can lead
3. Drive chain slack adjusting nut to chain slippage or breakage. To
4. Alignment marks
prevent this from occurring, keep
EAU03752
the drive chain slack within the
To adjust the drive chain slack
specified limits.
1. Loosen the axle nut, then loosen _
6
the locknut at each end of the 3. Tighten the locknuts, and then
swingarm. tighten the axle nut to the specified
2. To tighten the drive chain, turn the torque.
adjusting nut at each end of the
swingarm in direction a. To loos- Tightening torque:
en the drive chain, turn the adjust- Axle nut:
ing nut at each end of the 105 Nm (10.5 m·kgf)
swingarm in direction b, and then
push the rear wheel forward.
6-22

EAU03006
2. Wipe the drive chain dry. EAU02962
Lubricating the drive chain 3. Thoroughly lubricate the drive Checking and lubricating the
The drive chain must be cleaned and chain with a special O-ring chain cables
lubricated at the intervals specified in lubricant. The operation of all control cables and
the periodic maintenance and lubrica- ECA00052 the condition of the cables should be
tion chart, otherwise it will quickly wear CAUTION: checked before each ride, and the ca-
@
out, especially when riding in dusty or Do not use engine oil or any other bles and cable ends should be lubricat-
wet areas. Service the drive chain as lubricants for the drive chain, as ed if necessary. If a cable is damaged
follows. they may contain substances that or does not move smoothly, have a
EC000097
could damage the O-rings. Yamaha dealer check or replace it.
CAUTION: @
The drive chain must be lubricated Recommended lubricant:

after washing the motorcycle or Engine oil
riding in the rain.
EW000112
6
@
1. Clean the drive chain with kero- WARNING

sene and a small soft brush. @
ECA00053
Damage to the outer sheath may in-
terfere with proper cable operation
CAUTION:
@
and will cause the inner cable to
To prevent damaging the O-rings,
rust. Replace a damaged cable as
do not clean the drive chain with
soon as possible to prevent unsafe
steam cleaners, high-pressure
conditions.
washers or inappropriate solvents. @
6-23

EAU04034 EAU03370
Checking and lubricating the Checking and lubricating the

throttle grip and cable brake and shift pedals
The operation of the throttle grip should The operation of the brake and shift
be checked before each ride. In addi- pedals should be checked before each
tion, the cable should be lubricated or ride, and the pedal pivots should be lu-
replaced at the intervals specified in bricated if necessary.
the periodic maintenance chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
6-24

EAU03164 EAU03371 EAU00790
Checking and lubricating the Checking and lubricating the Lubricating the rear
brake and clutch levers centerstand and sidestand suspension
The operation of the brake and clutch The operation of the centerstand and The pivoting points of the rear suspen-
levers should be checked before each sidestand should be checked before sion must be lubricated at the intervals
ride, and the lever pivots should be lu- each ride, and the pivots and metal-to- specified in the periodic maintenance
bricated if necessary. metal contact surfaces should be lubri- and lubrication chart.
cated if necessary.
Recommended lubricant: EW000114
Lithium-soap-based grease @
WARNING Molybdenum disulfide grease
(all-purpose grease) If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it.
6 @
Lithium-soap-based grease
(all-purpose grease)
6-25

EAU02939 EAU00794
Checking the front fork Checking the steering

The condition and operation of the front Worn or loose steering bearings may
fork must be checked as follows at the cause danger. Therefore, the operation
intervals specified in the periodic main- of the steering must be checked as fol-
tenance and lubrication chart. lows at the intervals specified in the pe-
riodic maintenance and lubrication
To check the condition chart.
EW000115
1. Place a stand under the engine to
@
WARNING raise the front wheel off the
Securely support the motorcycle so To check the operation ground.
that there is no danger of it falling 1. Place the motorcycle on a level
EW000115
over. surface and hold it in an upright @

WARNING
@
position. Securely support the motorcycle so

Check the inner tubes for scratches,
2. While applying the front brake, that there is no danger of it falling 6
damage and excessive oil leakage.
push down hard on the handle- over.
@
bars several times to check if the

front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:
@
If any damage is found or the front

fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
@
6-26

EAU01144 EAU00800
Checking the wheel bearings Battery

The front and rear wheel bearings must This motorcycle is equipped with a
be checked at the intervals specified in sealed-type (MF) battery, which does
the periodic maintenance and lubrica- not require any maintenance. There is
tion chart. If there is play in the wheel no need to check the electrolyte or to
hub or if the wheel does not turn add distilled water.
smoothly, have a Yamaha dealer EC000101
check the wheel bearings. CAUTION:

@
Never attempt to remove the battery

2. Hold the lower ends of the front cell seals, as this would permanent-
fork legs and try to move them for- ly damage the battery.
@
ward and backward. If any free EW000116
play can be felt, have a Yamaha WARNING

6
@
dealer check or repair the steer- ● Electrolyte is poisonous and

ing. dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
6-27

• EXTERNAL: Flush with plenty To charge the battery EC000102
of water. Have a Yamaha dealer charge the bat- CAUTION:

@
• INTERNAL: Drink large quan- tery as soon as possible if it seems to ● Always keep the battery
tities of water or milk and im- have discharged. Keep in mind that the charged. Storing a discharged
mediately call a physician. battery tends to discharge more quickly battery can cause permanent
• EYES: Flush with water for if the motorcycle is equipped with op- battery damage.
15 minutes and seek prompt tional electrical accessories. ● To charge a sealed-type (MF)
medical attention. battery, a special (constant-
● Batteries produce explosive hy- To store the battery voltage) battery charger is re-
drogen gas. Therefore, keep 1. If the motorcycle will not be used quired. Using a conventional
sparks, flames, cigarettes, etc., for more than one month, remove battery charger will damage the
away from the battery and pro- the battery, fully charge it, and battery. If you do not have ac-
vide sufficient ventilation when then place it in a cool, dry place. cess to a sealed-type (MF) bat-
charging it in an enclosed 2. If the battery will be stored for tery charger, have a Yamaha
space. more than two months, check it at dealer charge your battery. 6
● KEEP THIS AND ALL BATTER- least once a month and fully
@
IES OUT OF THE REACH OF charge it if necessary.

CHILDREN. 3. Fully charge the battery before in-
@
stallation.
4. After installation, make sure that
the battery leads are properly con-
nected to the battery terminals.
6-28

EC000103
CAUTION:
@
Do not use a fuse of a higher amper-

age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
@
3. Turn the key to “ON” and turn on

1. Fuse box 1. Main fuse the electrical circuit in question to
EAU01470
2. Ignition fuse check if the device operates.
3. Signaling system fuse
Replacing the fuses 4. Headlight fuse
4. If the fuse immediately blows
The fuse box is located under the seat. 5. Hazard fuse again, have a Yamaha dealer
(See page 3-12 for seat removal and 6. Spare fuse (× 3) check the electrical system.
6 installation procedures.)
If a fuse is blown, replace it as follows. Specified fuses:
1. Turn the key to “OFF” and turn off Main fuse: 30 A
the electrical circuit in question. Ignition fuse: 10 A
2. Remove the blown fuse, and then Signaling system fuse: 15 A
install a new fuse of the specified Headlight fuse: 15 A
amperage. Hazard fuse: 10 A
6-29
1. Headlight coupler 1. Headlight bulb holder 1. Do not touch this area.

2. Headlight bulb cover
2. Unhook the headlight bulb holder, 3. Place a new headlight bulb into
EAU04136
and then remove the defective position, and then secure it with
Replacing the headlight bulb
bulb. the bulb holder.
(for XJ600S) EW000119 EC000105
This motorcycle is equipped with a WARNING CAUTION: 6

quartz bulb headlight. If the headlight
_ _
Headlight bulbs get very hot. There- Do not touch the glass part of the
bulb burns out, replace it as follows. fore, keep flammable products away headlight bulb to keep it free from
1. Disconnect the headlight coupler, from a lit headlight bulb, and do not oil, otherwise the transparency of
and then remove the bulb cover. touch the bulb until it has cooled the glass, the luminosity of the bulb,
down. and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
_
and fingerprints on the headlight

bulb using a cloth moistened with
alcohol or thinner.
_
6-30

4. Install the headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Screw (× 2) 1. Headlight coupler

2. Headlight bulb cover
EAU04189
Replacing the headlight bulb 2. Disconnect the headlight coupler,

(for XJ600N) and then remove the bulb cover.
This motorcycle is equipped with a
6 quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.
1. Remove the headlight unit by re-
moving the screws.
6-31

5. Install the headlight bulb cover,
and then connect the coupler.
6. Install the headlight unit by install-
ing the screws.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Headlight bulb holder 1. Do not touch this area.
3. Unhook the headlight bulb holder, 4. Place a new headlight bulb into
and then remove the defective position, and then secure it with
bulb. the bulb holder.
EW000119 EC000105
_
WARNING CAUTION: 6
_
Headlight bulbs get very hot. There- Do not touch the glass part of the
fore, keep flammable products away headlight bulb to keep it free from
from a lit headlight bulb, and do not oil, otherwise the transparency of
touch the bulb until it has cooled the glass, the luminosity of the bulb,
down. and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
_
and fingerprints on the headlight

bulb using a cloth moistened with
alcohol or thinner.
_
6-32
1. Speedometer cable 1. Front wheel axle

2. Front wheel axle pinch bolt
EAU00868 EAU04164
Front wheel ECA00047 To install the front wheel

CAUTION: 1. Install the speedometer gear unit
@
To remove the front wheel Do not pull the brake lever after the into the wheel hub so that the pro-
6
EW000122
brake caliper has been removed, jections mesh with the slots.
@
WARNING otherwise the brake pads will be 2. Lift the wheel up between the fork
● It is advisable to have a Yamaha forced shut. legs.
dealer service the wheel. @
4. Loosen the front wheel axle pinch NOTE:

● Securely support the motor- _
bolt. Make sure that the slot in the speedom-

cycle so that there is no danger
5. Pull the wheel axle out, and then eter gear unit fits over the retainer on
of it falling over.
@
remove the wheel. the fork leg.
1. Place the motorcycle on the cen- _
terstand. 3. Insert the wheel axle.

2. Disconnect the speedometer ca- 4. Take the motorcycle off the cen-
ble from the front wheel. terstand so that the front wheel is
3. Remove the brake calipers by re- on the ground.
moving the bolts.
6-33

Tightening torques:
Wheel axle:
58 Nm (5.8 m·kgf)
Front wheel axle pinch bolt:
40 Nm (4.0 m·kgf)
Brake caliper bolt:
19 Nm (1.9 m·kgf)
7. Connect the speedometer cable.

8. Push down hard on the handlebar
5. Install the brake calipers by install- several times to check for proper
ing the bolts.
fork operation.
NOTE:
_
Make sure that there is enough space 6

between the brake pads before install-
ing the brake calipers onto the brake
discs.
_
6. Tighten the wheel axle, then the

front wheel axle pinch bolt, and the
brake caliper bolts to the specified
torques.
6-34
1. Rear wheel axle nut 1. Brake torque rod bolt

2. Nut
EAU01480
4. While supporting the brake caliper
Rear wheel 3. Disconnect the brake torque rod bracket, pull the wheel axle out.
from the brake caliper bracket by 5. Push the wheel forward, and then
To remove the rear wheel removing the nut and the bolt. remove the drive chain from the
EW000122
6 rear sprocket.
@
WARNING
● It is advisable to have a Yamaha NOTE:
@
dealer service the wheel. The drive chain does not need to be
● Securely support the motor- disassembled in order to remove and
cycle so that there is no danger install the rear wheel.
@
of it falling over. 6. Remove the wheel.

@
ECA00048
1. Place the motorcycle on the
CAUTION:
centerstand. @
Do not apply the brake after the

2. Remove the axle nut.
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
@
6-35

EAU01468 EAU01008
To install the rear wheel Tightening torques: Troubleshooting

1. Insert the wheel axle from the Axle nut: Although Yamaha motorcycles receive
right-hand side. 105 Nm (10.5 m·kgf) a thorough inspection before shipment
2. Install the drive chain onto the rear Brake torque rod bolt: from the factory, trouble may occur dur-
sprocket, and then adjust the drive 23 Nm (2.3 m·kgf) ing operation. Any problem in the fuel,
chain slack. (See page 6-21 for compression, or ignition systems, for
drive chain slack adjustment pro- example, can cause poor starting and
cedures.) loss of power.
3. Install the axle nut and brake The following troubleshooting chart
torque rod bolt at the brake caliper represents a quick and easy procedure
bracket. for checking these vital systems your-
4. Install the brake caliper by install- self. However, should your motorcycle
ing the bolts. require any repair, take it to a Yamaha
dealer, whose skilled technicians have 6
NOTE:
@
the necessary tools, experience, and

Make sure that there is enough space
know-how to service the motorcycle
between the brake pads before install-
properly.
ing the brake caliper onto the brake
Use only genuine Yamaha replace-
disc.
@ ment parts. Imitation parts may look
5. Take the motorcycle off the cen- like Yamaha parts, but they are often
terstand so that the rear wheel is inferior, have a shorter service life and
on the ground. can lead to expensive repair bills.
6. Tighten the axle nut and brake
torque rod bolt to the specified
torques.
6-36

EAU01297
Troubleshooting chart
EW000125
@
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
@
1. Fuel
There is enough fuel. Check the compression.
Check the fuel level in
the fuel tank.
The engine does not start.
There is no fuel. Supply fuel.
Check the compression.
2. Compression
There is compression. Check the ignition.
Operate the electric starter.
6 There is no compression.
Have a Yamaha dealer
check the vehicle.
3. Ignition Wipe off with a dry cloth and correct the Open the throttle halfway and operate
Wet
spark plug gaps, or replace the spark plugs. the electric starter.
Remove the spark plugs
and check the electrodes.
The engine does not start.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
4. Battery The engine turns over

The battery is good.
quickly. The engine does not start.
Operate the electric starter. Have a Yamaha dealer
The engine turns over Check the battery lead connections, check the vehicle.
slowly. and charge the battery if necessary.
6-37
MOTORCYCLE CARE AND STORAGE
Care .................................................................................................. 7-1

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

7-
EAU03430
Care Before cleaning Cleaning

While the open design of a motorcycle 1. Cover the muffler outlets with plas- ECA00010
reveals the attractiveness of the tech- tic bags after the engine has CAUTION:
@
nology, it also makes it more vulnera- cooled down. ● Avoid using strong acidic wheel
ble. Rust and corrosion can develop 2. Make sure that all caps and covers cleaners, especially on spoked
even if high-quality components are as well as all electrical couplers wheels. If such products are
used. A rusty exhaust pipe may go un- and connectors, including the used on hard-to-remove dirt, do
noticed on a car, however, it detracts spark plug caps, are tightly in- not leave the cleaner on the af-
from the overall appearance of a stalled. fected area any longer than in-
motorcycle. Frequent and proper care 3. Remove extremely stubborn dirt, structed. Also, thoroughly rinse
does not only comply with the terms of like oil burnt onto the crankcase, the area off with water, immedi-
the warranty, but it will also keep your with a degreasing agent and a ately dry it, and then apply a
motorcycle looking good, extend its life brush, but never apply such prod- corrosion protection spray.
and optimize its performance. ucts onto seals, gaskets, sprock- ● Improper cleaning can damage
ets, the drive chain and wheel windshields, cowlings, panels
axles. Always rinse the dirt and and other plastic parts. Use
7 degreaser off with water. only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
7-1

● Do not use any harsh chemical ● For motorcycles equipped with After riding in the rain, near the sea or
products on plastic parts. Be a windshield: Do not use strong on salt-sprayed roads
sure to avoid using cloths or cleaners or hard sponges as Since sea salt or salt sprayed on roads
sponges which have been in they will cause dulling or during winter are extremely corrosive in
contact with strong or abrasive scratching. Some cleaning combination with water, carry out the
cleaning products, solvent or compounds for plastic may following steps after each ride in the
thinner, fuel (gasoline), rust re- leave scratches on the wind- rain, near the sea or on salt-sprayed
movers or inhibitors, brake flu- shield. Test the product on a roads.
id, antifreeze or electrolyte. small hidden part of the wind-
● Do not use high-pressure wash- shield to make sure that it does NOTE:
@
Salt sprayed on roads in the winter may

ers or steam-jet cleaners since not leave any marks. If the wind-
remain well into spring.
they cause water seepage and shield is scratched, use a quali- @
deterioration in the following ar- ty plastic polishing compound 1. Clean the motorcycle with cold
eas: seals (of wheel and swing- after washing. water and a mild detergent, after
arm bearings, fork and brakes), @
the engine has cooled down.
ECA00012
electric components (couplers,
After normal use CAUTION:
connectors, instruments, switch- 7
Remove dirt with warm water, a mild @
es and lights), breather hoses Do not use warm water since it in-
detergent, and a soft, clean sponge,
and vents. creases the corrosive action of the
and then rinse thoroughly with clean
salt.
water. Use a toothbrush or bottlebrush @
for hard-to-reach areas. Stubborn dirt 2. After drying the motorcycle, apply
and insects will come off more easily if a corrosion protection spray on all
the area is covered with a wet cloth for metal, including chrome- and nick-
a few minutes before cleaning. el-plated, surfaces to prevent cor-
rosion.
7-2

After cleaning EWA00001 ECA00013
1. Dry the motorcycle with a chamois @

WARNING CAUTION:
@
or an absorbing cloth. ● Make sure that there is no oil or ● Apply spray oil and wax spar-
2. Immediately dry the drive chain wax on the brakes or tires. If ingly and make sure to wipe off
and lubricate it to prevent it from necessary, clean the brake any excess.
rusting. discs and brake linings with a ● Never apply oil or wax to any
3. Use a chrome polish to shine regular brake disc cleaner or ac- rubber and plastic parts, but
chrome, aluminum and stainless- etone, and wash the tires with treat them with a suitable care
steel parts, including the exhaust warm water and a mild deter- product.
system. (Even the thermally in- gent. ● Avoid using abrasive polishing
duced discoloring of stainless- ● Before operating the motor- compounds as they will wear
steel exhaust systems can be re- cycle test its braking perfor- away the paint.
moved through polishing.) mance and cornering behavior. @
4. To prevent corrosion, it is recom-

@
NOTE:
@
mended to apply a corrosion pro- Consult a Yamaha dealer for advice on

tection spray on all metal, what products to use.
@
7 including chrome- and nickel-plat-

ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
7-3

Storage Long-term c. Install the spark plug caps onto the
Before storing your motorcycle for spark plugs, and then place the
Short-term several months: spark plugs on the cylinder head
Always store your motorcycle in a cool, 1. Follow all the instructions in the so that the electrodes are ground-
dry place and, if necessary, protect it “Care” section of this chapter. ed. (This will limit sparking during
against dust with a porous cover. 2. Turn the fuel cock lever to “ON”. the next step.)
ECA00014 3. Drain the carburetor float cham- d. Turn the engine over several times
CAUTION: bers by loosening the drain bolts; with the starter. (This will coat the
@
● Storing the motorcycle in a this will prevent fuel deposits from cylinder walls with oil.)
poorly ventilated room or cover- building up. Pour the drained fuel e. Remove the spark plug caps from
ing it with a tarp, while it is still into the fuel tank. the spark plugs, and then install
wet, will allow water and humid- 4. Fill up the fuel tank and add fuel the spark plugs and the spark plug
ity to seep in and cause rust. stabilizer (if available) to prevent caps.
● To prevent corrosion, avoid the fuel tank from rusting and the EWA00003
damp cellars, stables (because fuel from deteriorating. @

WARNING
of the presence of ammonia) 5. Perform the following steps to pro- To prevent damage or injury from
and areas where strong chemi- tect the cylinders, piston rings, etc. sparking, make sure to ground the 7
cals are stored. from corrosion. spark plug electrodes while turning
@
a. Remove the spark plug caps and the engine over.
@
spark plugs. 6. Lubricate all control cables and

b. Pour a teaspoonful of engine oil the pivoting points of all levers and
into each spark plug bore. pedals as well as of the sidestand/
centerstand.
7-4

7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlets with plas-
tic bags to prevent moisture from
entering them.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place (less
7 than 0 °C or more than 30 °C). For
more information on storing the
battery, see page 6-27.
NOTE:
@
Make any necessary repairs before

storing the motorcycle.
@
7-5
SPECIFICATIONS
Specifications .................................................................................... 8-1

Conversion table ............................................................................... 8-5
8
SPECIFICATIONS
8-
EAU01038
Specifications
CS-01E
Model XJ600S/XJ600N Engine oil
Dimensions Type
-20 -10 0 10 20 30 40 50 ˚C
Overall length 2,170 mm
Overall width 735 mm SAE 10W-30
Overall height SAE 10W-40

XJ600S 1,205 mm SAE 15W-40
XJ600N 1,090 mm SAE 20W-40
Seat height 770 mm
SAE 20W-50
Wheelbase 1,445 mm
Ground clearance 150 mm Recommended engine oil
classification API Service SE, SF, SG type or
Minimum turning radius 2,700 mm
higher
Basic weight (with oil and
full fuel tank) CAUTION:
XJ600S 213 kg Be sure to use motor oils that do not contain anti-friction
XJ600N 210 kg modifiers. Passenger car motor oils (often labeled
“ENERGY CONSERVING II”) contain anti-friction additives
Engine which will cause clutch and/or starter clutch slippage, result-
8 Engine type Air-cooled 4-stroke, DOHC ing in reduced component life and poor engine performance.
Cylinder arrangement Forward-inclined parallel
4-cylinder Quantity
3 Without oil filter cartridge
Displacement 598 cm
replacement 2.3 L
Bore × Stroke 58.5 × 55.7 mm
With oil filter cartridge
Compression ratio 10:1
replacement 2.6 L
Starting system Electric starter
Total amount (dry engine) 3.1 L
Lubrication system Wet sump
8-1
SPECIFICATIONS
Air filter Dry type element Operation Left foot
Fuel Gear ratio
Type REGULAR UNLEADED 1st 2.733
GASOLINE ONLY
2nd 1.778
Fuel tank capacity 17.0 L
3rd 1.333
Reserve amount 3.5 L 4th 1.074
Carburetor
5th 0.913
Manufacturer MIKUNI
6th 0.821
Model × quantity BDS28 × 4 Chassis
Spark plug
Frame type Double cradle
Model/Manufacturer CR8E / NGK
Caster angle 25°
U24ESR-N / DENSO Trail 97 mm
Gap 0.7–0.8 mm
Tire
Clutch type Wet, multiple-disc Front
Transmission
Type Tubeless tire
Primary reduction system Spur gear
Size 110/80-17 57H
Primary reduction ratio 2.225 110/80-17 M/C 57H
Secondary reduction system Chain drive 8
Manufacturer/model MICHELIN / MACADAM 50
Secondary reduction ratio 3.000 (except for CH, A)
DUNLOP / D103FA
2.875 (for CH, A) Rear
Number of drive chain
Type Tubeless tire
sprocket teeth (rear/front) 48/16 (except for CH, A)
Size 130/70-18 63H
46/16 (for CH, A)
130/70-18 M/C 63H
Transmission type Constant mesh 6-speed
Manufacturer/model MICHELIN / MACADAM 50
DUNLOP / D103A
8-2
SPECIFICATIONS
Maximum load* Brakes
XJ600S 184 kg Front
XJ600N 187 kg Type Dual disc brake
Tire air pressure (measured on Operation Right hand
cold tires)
Fluid DOT 4
Up to 90 kg* Rear
Front 200 kPa (2.00 kgf/cm2, 2.00 bar)
Type Single disc brake
Rear 225 kPa (2.25 kgf/cm2, 2.25 bar)
Operation Right foot
90 kg–maximum* Fluid DOT 4
Front 200 kPa (2.00 kgf/cm2, 2.00 bar)
Suspension
Rear 250 kPa (2.50 kgf/cm2, 2.50 bar)
Front Telescopic fork
High-speed riding Rear Swingarm (monocross suspen-
Front 200 kPa (2.00 kgf/cm2, 2.00 bar) sion)
Rear 250 kPa (2.50 kgf/cm2, 2.50 bar) Spring/shock absorbers
* Total weight of rider, passenger, cargo and accessories Front Coil spring / oil damper
Wheels Rear Coil spring / gas-oil damper
Front Wheel travel
8 Type Cast wheel Front 140 mm
Size 17 × MT 2.50 Rear 110 mm
Rear Electrical systems
Type Cast wheel Ignition system Transistorized coil ignition
Size 18 × MT 3.50
8-3
SPECIFICATIONS
Charging system Fuses
Type A.C. magneto Main fuse 30 A
Standard output 14 V, 20 A @ 5,000 r/min Ignition fuse 10 A
Battery Signaling system fuse 15 A
Model YTX9-BS Headlight fuse 15 A
Voltage, capacity 12 V, 8 Ah Hazard fuse 10 A
Headlight type Quartz bulb (halogen)
Bulb voltage, wattage × quantity
Headlight 12 V, 60/55 W × 1
Auxiliary light 12 V, 4 W × 1 (except for GB,
IRL)
12 V, 3.4 W × 1 (for GB, IRL)
Tail/brake light 12 V, 5/21 W × 1
Turn signal light 12 V, 21 W × 4
Meter lighting
XJ600S 12 V, 1.7 W × 3
XJ600N 14 V, 3 W × 2
12 V, 1.7 W × 2 8
Neutral indicator light 12 V, 3.4 W × 1
High beam indicator light 12 V, 3.4 W × 1
Oil level warning light
XJ600S 12 V, 3.4 W × 1
XJ600N 14 V, 3 W × 1
Turn signal indicator light 12 V, 3.4 W × 2
8-4
SPECIFICATIONS
EAU03941
Conversion table
CS-03E
Conversion table
All specification data in this manual are listed in SI and METRIC SYSTEM TO IMPERIAL SYSTEM
METRIC UNITS. Metric unit Conversion factor Imperial unit
m·kgf × 7.233 ft·lb
m·kgf × 86.794 in·lb
Use this table to convert METRIC unit values to IMPERIAL Torque
cm·kgf × 0.0723 ft·lb
unit values. cm·kgf × 0.8679 in·lb
kg × 2.205 lb
Weight
g × 0.03527 oz
Example:
Speed km/h × 0.6214 mi/h
METRIC VALUE CONVERSION IMPERIAL VALUE km × 0.6214 mi

m × 3.281 ft
FACTOR Distance m × 1.094 yd
cm × 0.3937 in
2 mm × 0.03937 = 0.08 in mm × 0.03937 in
cc (cm3) × 0.03527 oz (IMP liq.)
Volume, cc (cm3) × 0.06102 cu·in
Capacity L (liter) × 0.8799 qt (IMP liq.)
L (liter) × 0.2199 gal (IMP liq.)
kgf/mm × 55.997 lb/in
Miscellaneous kgf/cm2 × 14.2234 psi (lb/in2)
8 °C × 1.8 + 32 °F
8-5
CONSUMER INFORMATION
Identification numbers ....................................................................... 9-1

Key identification number (for XJ600S) .............................................. 9-1
Key identification number (for XJ600N).............................................. 9-1
Vehicle identification number ............................................................. 9-2
Model label ........................................................................................ 9-2
9
9-
EAU01039
EAU02944
Identification numbers XJ600S XJ600N

Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehi-
cle is stolen.
1. Key identification number 1. Key identification number
1. KEY IDENTIFICATION NUMBER: EAU01041 EAU01042
CA-02E Key identification number Key identification number

(for XJ600S) (for XJ600N)
The key identification number is The key identification number is
stamped into the key tag. Record this stamped into the key. Record this num-
2. VEHICLE IDENTIFICATION number in the space provided and use ber in the space provided and use it for
NUMBER: it for reference when ordering a new reference when ordering a new key.
CA-02E key.
9
3. MODEL LABEL INFORMATION:
CA-01E
9-1
1. Vehicle identification number 1. Model label

EAU01043 EAU01050
Vehicle identification number Model label

The vehicle identification number is The model label is affixed to the frame
stamped into the steering head pipe. under the seat. (See page 3-12 for seat
Record this number in the space pro- removal and installation procedures.)
vided. Record the information on this label in
the space provided. This information
NOTE:
@
will be needed when ordering spare
The vehicle identification number is
parts from a Yamaha dealer.
used to identify your motorcycle and
may be used to register your motor-
cycle with the licensing authority in 9
your area.
@
9-2
INDEX
10-
A D I
Air filter element, cleaning ......................6-10 Dimmer switch......................................... 3-6 Identification numbers ..............................9-1
Drive chain, lubricating .......................... 6-23 Idling speed, adjusting ...........................6-13
B
Drive chain slack ................................... 6-21 Ignition circuit cut-off system ..................3-16
Battery ...................................................6-27
Checking.......................................... 6-21 Indicator and warning lights......................3-3
Brake and clutch levers, checking and
Adjusting .......................................... 6-22
lubricating ............................................6-25 K
Brake and shift pedals, checking and E Key identification number (for XJ600N) ....9-1
lubricating ............................................6-24 Engine break-in ....................................... 5-4 Key identification number (for XJ600S) ....9-1
Brake fluid, changing .............................6-21 Engine oil and oil filter cartridge ............... 6-7
L
Brake fluid level, checking......................6-20 Engine stop switch................................... 3-7
Light switch ..............................................3-7
Brake lever...............................................3-8
F Luggage strap holders ...........................3-15
Brake light switch (rear), adjusting .........6-19
Front fork, checking ............................... 6-26
Brake pads, checking.............................6-19 M
Fuel ....................................................... 3-10
Brake pedal..............................................3-9 Main switch/steering lock .........................3-1
Fuel cock............................................... 3-11
Brake pedal position, adjusting ..............6-18 Model label ..............................................9-2
Fuel consumption, tips for reducing ......... 5-4
C Fuel tank breather hose N
Cables, checking and lubricating............6-23 (Germany only) ................................... 3-11 Neutral indicator light ...............................3-3
Carburetors, adjusting............................6-12 Fuel tank cap........................................... 3-9
O
Care.........................................................7-1 Fuses, replacing .................................... 6-29
Oil level warning light ...............................3-4
Centerstand and sidestand,
H
checking and lubricating ......................6-25 P
Handlebar switches ................................. 3-6
Clutch lever..............................................3-7 Panel, removing and installing..................6-5
Hazard switch.......................................... 3-6
Clutch lever free play, adjusting .............6-17 Parking.....................................................5-5
Headlight bulb, replacing (for XJ600S)... 6-30
Conversion table......................................8-5 Part locations ...........................................2-1
Headlight bulb, replacing (for XJ600N) .. 6-31
Pass switch..............................................3-6
Helmet holders ...................................... 3-13
Periodic maintenance and lubrication
High beam indicator light ......................... 3-4
chart ......................................................6-2
Horn switch ............................................. 3-6
Pre-operation check list............................4-1
INDEX
S T
Safety information.................................... 1-1 Tachometer............................................. 3-5
Seat....................................................... 3-12 Throttle cable free play, adjusting.......... 6-13
Shifting .................................................... 5-3 Throttle grip and cable, checking and
Shift pedal ............................................... 3-8 lubricating ........................................... 6-24
Shift points (for Switzerland only)............. 5-3 Tires...................................................... 6-14
Shock absorber assembly, adjusting ..... 3-14 Tool kit .................................................... 6-1
Sidestand .............................................. 3-15 Troubleshooting .................................... 6-36
Spark plugs, checking ............................. 6-6 Troubleshooting chart ........................... 6-37
Specifications .......................................... 8-1 Turn signal indicator lights....................... 3-3
Speedometer unit (for XJ600N) ............... 3-5 Turn signal switch ................................... 3-6
Speedometer unit (for XJ600S) ............... 3-4
V
Starter (choke) lever .............................. 3-12
Valve clearance, adjusting .................... 6-14
Starting a cold engine .............................. 5-1
Vehicle identification number................... 9-2
Starting a warm engine............................ 5-2
Start switch.............................................. 3-7 W
Steering, checking ................................. 6-26 Wheel bearings, checking ..................... 6-27
Steering lock (for XJ600N)....................... 3-3 Wheel (front)............................................6-33
Storage.................................................... 7-4 Installing.............................................6-33
Storage compartment ............................ 3-14 Removing...........................................6-33
Suspension (rear), lubricating ................ 6-25 Wheel (rear).............................................6-35
Installing.............................................6-36
Removing...........................................6-35
Wheels.................................................. 6-17
OWNER’S MANUAL
XJ600S
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2001 · 6 - 0.3 × 1 CR 4BR-28199-E8
(E)

XJ600S Diversion Uso e Manutenzione

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OWNER’S MANUAL

Welcome to the Yamaha world of motorcycling!

IMPORTANT MANUAL INFORMATION EAU00005

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

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

IMPORTANT MANUAL INFORMATION

IMPORTANT MANUAL INFORMATION

1 GIVE SAFETY THE RIGHT OF WAY 1

3 INSTRUMENT AND CONTROL FUNCTIONS 3

5 OPERATION AND IMPORTANT RIDING POINTS 5

6 PERIODIC MAINTENANCE AND MINOR REPAIR 6

7 MOTORCYCLE CARE AND STORAGE 7

GIVE SAFETY THE RIGHT OF WAY

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

GIVE SAFETY THE RIGHT OF WAY

Enjoy your ride!

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

Left view (XJ600S)

1. Fuel cock (page 3-11) 6. Shock absorber assembly

14. Clutch lever (page 3-7)

1. Steering lock (page 3-3) 6. Seat lock (page 3-12)

15. Clutch lever (page 3-7)

INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock .....................................3-1 Fuel ................................................................... 3-10

INSTRUMENT AND CONTROL FUNCTIONS

EAU00029 EAU00038 EAU00040

Main switch/steering lock OFF LOCK (for XJ600S)

To unlock the steering

INSTRUMENT AND CONTROL FUNCTIONS

(Parking) (for XJ600S) EAU00055

The steering is locked, and the taillight P (Parking) (for XJ600N)

INSTRUMENT AND CONTROL FUNCTIONS

Turn signal indicator lights “ ”

INSTRUMENT AND CONTROL FUNCTIONS

EAU00063 a slope or during sudden acceleration Speedometer unit (for XJ600S)

tripmeter. The speedometer shows

INSTRUMENT AND CONTROL FUNCTIONS

riding speed. The odometer shows the CAUTION:

INSTRUMENT AND CONTROL FUNCTIONS

Hazard switch “ ” Turn signal switch “ / ”

Pass switch “PASS”

INSTRUMENT AND CONTROL FUNCTIONS

See page 5-1 for starting instruc-

1. Engine stop switch “ / ” 1. Clutch lever

Engine stop switch “ / ” handlebar grip. To disengage the

INSTRUMENT AND CONTROL FUNCTIONS

Shift pedal EAU00160

INSTRUMENT AND CONTROL FUNCTIONS

The fuel tank cap cannot be closed un-

Brake pedal EAU02935

The brake pedal is on the right side of Fuel tank cap

To close the fuel tank cap

INSTRUMENT AND CONTROL FUNCTIONS

life and reduce maintenance costs. 3

Fuel Fuel tank capacity:

● Do not overfill the fuel tank, oth- CAUTION:

Use only unleaded gasoline. The

exhaust system, etc.