Yamaha Diver 510N XJ6S, Owner'S Manual

Page 1: ...DIC183 XJ6S XJ6SA OWNER S MANUAL Read this manual carefully before operating this vehicle 36C 28199 E1 ...

Page 2: ...ion record No Contents Date To change contact person and integrate type designation 9 Jun 2005 Date of issue 1 Aug 2002 Place of issue Shizuoka Japan R TTE Directive 1999 5 EC EN300 330 2 v1 1 1 2001 6 EN60950 1 2001 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC is in compliance with following norm s or documents Kind of equipment IMMOBILIZER Type designation 5SL 00 Hereby dec...

Page 3: ...ry 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 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur re...

Page 4: ...ey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP U36CE1E0 book Page 1 T...

Page 5: ...MANUAL 2009 by Yamaha Motor Co Ltd 1st edition July 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U36CE1E0 book Page 2 Thursday July 30 2009 11 32 AM ...

Page 6: ... ADJUSTMENT 6 1 Owner s tool kit 6 1 Periodic maintenance chart for the emission control system 6 2 General maintenance and lubrication chart 6 3 Removing and installing cowlings and panels 6 7 Checking the spark plugs 6 9 Engine oil and oil filter cartridge 6 10 Coolant 6 13 Replacing the air filter element 6 17 Adjusting the engine idling speed 6 18 Checking the throttle cable free play 6 19 Val...

Page 7: ...acing a turn signal light bulb 6 37 Replacing the license plate light bulb 6 37 Auxiliary light bulb 6 38 Front wheel XJ6S 6 38 Rear wheel XJ6S 6 40 Troubleshooting 6 42 Troubleshooting charts 6 43 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U36CE1E0 book Page 2 Thursday July 30 2009 11 32 AM ...

Page 8: ...assenger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ...

Page 9: ...d contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Always wear protective clothing that covers your legs ankles and feet The eng...

Page 10: ... as evenly as possi ble on both sides of the motorcycle to minimize imbalance or instabili ty Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pre...

Page 11: ...rk area can create instability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may becom...

Page 12: ...justing screw page 6 18 3 Seat lock page 3 18 4 Main fuse page 6 33 5 Fuse box page 6 33 6 Owner s tool kit page 6 1 7 Storage compartment page 3 20 8 Shift pedal page 3 13 9 Engine oil filter cartridge page 6 10 10 Engine oil drain bolt page 6 10 U36CE1E0 book Page 1 Thursday July 30 2009 11 32 AM ...

Page 13: ...fluid reservoir page 6 24 4 Engine oil filler cap page 6 10 5 Radiator cap page 6 13 6 Coolant reservoir page 6 13 7 Coolant drain bolt page 6 14 8 Engine oil dipstick page 6 10 9 Brake pedal page 3 14 10 Shock absorber assembly spring preload adjusting ring page 3 21 U36CE1E0 book Page 2 Thursday July 30 2009 11 32 AM ...

Page 14: ...13 2 Left handlebar switches page 3 12 3 Main switch steering lock page 3 2 4 Multi function meter unit page 3 8 5 Front brake fluid reservoir page 6 24 6 Right handlebar switches page 3 12 7 Throttle grip page 6 19 8 Brake lever page 3 14 U36CE1E0 book Page 3 Thursday July 30 2009 11 32 AM ...

Page 15: ...EDIATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep the c...

Page 16: ...e place and only use it for code re registering EAU38530 ON All electrical circuits are supplied with power the meter lighting taillight li cense plate light and auxiliary light come on and the engine can be start ed The key cannot be removed TIP The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls EAU10661 OFF All el...

Page 17: ...he key in and then turn it to OFF while still pushing it EAU34341 Parking The steering is locked and the taillight license plate light and auxiliary light are on The hazard lights and turn signal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked before the key can be turned to NOTICE ECA11020 Do not use the parking position for an e...

Page 18: ...ed with a self diagnosis device for the oil level detection circuit If a problem is detected in the oil level detection circuit the following cycle will be repeated until the malfunction is corrected The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU11427 Coolant temperature warning light This warning light comes o...

Page 19: ...adiator fan equipped vehi cles the radiator fan s automati cally switch on or off according to the coolant temperature in the ra diator If the engine overheats see page 6 43 for further instructions U36CE1E0 book Page 5 Thursday July 30 2009 11 32 AM ...

Page 20: ... ahead with riding 117 134 C 243 274 F Temperature display flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 6 43 Above 135 C Above 275 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 43 ABS ABS U36CE1E0 book Page 6 Thursday July 30 200...

Page 21: ...f the warning light comes on or flashes while riding have a Yamaha dealer check the brake system as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have a Yamaha dealer...

Page 22: ...to turn the key to ON be fore using the SELECT and RE SET buttons For the U K only To switch the speedometer and odometer trip meter displays between kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will swe...

Page 23: ...d TRIP B in the following order TRIP A TRIP B ODO TRIP A When the fuel amount in the fuel tank decreases to 3 2 L 0 85 US gal 0 70 Imp gal the left segment of the fuel meter will start flashing and the odometer display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point In that case push the SELECT button to switch the displa...

Page 24: ... electrical circuit Coolant temperature mode The coolant temperature display indi cates the temperature of the coolant NOTICE ECA10021 Do not continue to operate the en gine if it is overheating Self diagnosis device This model is equipped with a self diag nosis device for various electrical cir cuits If a problem is detected in any of those circuits the engine trouble warning light will come on a...

Page 25: ...off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start the engine take the vehicle the code re registering key and both standard keys to a Yamaha dealer and have the stan dard keys re registered If the display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle NOTICE ECA11590 If the display indicates an ...

Page 26: ...itch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12711 Start switch Push this switch to crank the engine with the starter See page 5 1 for start ing instructions prior to starting the en gine EAU44710 The engine tro...

Page 27: ...0 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 23 EAU12870 Shift pedal The...

Page 28: ...Anti lock Brake System features a dual electronic con trol system which acts on the front and rear brakes independently The ABS is monitored by an ECU which will have recourse to manual braking if a mal function occurs WARNING EWA10090 The ABS performs best on long braking distances On certain rough or gravel roads the braking distance may be longer with than without the ABS Therefore always keep ...

Page 29: ... any type of magnets including magnetic pick up tools magnetic screwdrivers etc away from the front and rear wheel hubs otherwise the magnetic rotors equipped in the wheel hubs may be damaged result ing in improper performance of the ABS system EAU13074 Fuel tank cap 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 lo...

Page 30: ...tion such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any spilled fuel immedi ately NO...

Page 31: ...of a different brand or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance costs EAU39451 Fuel tank breather overflow hose Before operating the motorcycle Check the fuel tank breather over flow hose connection Check the fuel tank breather over flow hose for cracks or damage and replace it if damaged Make sure that the end of the fuel tank breather overfl...

Page 32: ...ust sys tem has cooled down before do ing any maintenance work Do not allow the engine to idle more than a few minutes Long idling can cause a build up of heat NOTICE ECA10701 Use only unleaded gasoline The use of leaded gasoline will cause unre pairable damage to the catalytic converter EAU32980 Seat To remove the seat 1 Insert the key into the seat lock and then turn it counterclockwise 2 While ...

Page 33: ...he helmet strap as shown and then hook the cable loop over the helmet holder 3 Place the helmet on the right side of the vehicle and then install the seat WARNING Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident EWA10161 To release the helmet from the hel met holder Remove the seat remove the helmet holding cab...

Page 34: ... hicle When storing the Owner s Manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the vehicle be careful not to let any water enter the storage compartment EAU46830 Handlebar position The handlebars can be adjusted to one of two positions to suit the rider s pref erence Have a Yamaha dealer adjust the position of ...

Page 35: ...load and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench and exten sion bar included in the owner s tool kit to make the adjustment WARNING EWA10221 ...

Page 36: ...e holding the vehicle upright TIP The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See page 3 23 for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could ...

Page 37: ...ission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure U...

Page 38: ...clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden YES NO YES NO YES NO The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be w...

Page 39: ... points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Check the fuel tank breather overflow hose for obstructions cracks or damage and check the hose connection 3 16 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 10 Coolant Check coolant level in reservoir If necessary ad...

Page 40: ... play and lubricate cable and grip housing 6 19 6 28 Control cables Make sure that operation is smooth Lubricate if necessary 6 28 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 6 26 6 27 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 19 6 22 Brake and shift pedals Make sure that opera...

Page 41: ...tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle 3 22 ITEM CHECKS PAGE U36CE1E0 book Page 3 Thursday July 30 2009 11 32 AM ...

Page 42: ...ine auto stop system The engine stops automatically if left idling for 20 minutes In this case the multi function meter unit indi cates error code 70 but this is not a malfunction Push the start switch to clear the error code and to restart the engine EAU44727 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The tra...

Page 43: ...engine more than 10 seconds on any one at tempt EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration TIP 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 NOTIC...

Page 44: ...fully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17093 0 1000 km 0 600 mi Avoid prolonged operation above 5800 r min NOTICE...

Page 45: ...d exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not park near grass or other flammable materials which might catch fire U36CE1E0 book Page 4 Thursday July 30 2009 11 32 AM ...

Page 46: ...ith vehicle ser vice have a Yamaha dealer perform service WARNING EWA15121 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to deat...

Page 47: ... Periodic maintenance chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 24000 mi 4 Fuel injection Adjust e...

Page 48: ...e brake pads Whenever worn to the limit 4 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout and for damage 7 Tires Check tread depth and for dam age Replace if necessary Check air pressure Correct if necessary 8 Wheel bearings Check bearing for loose...

Page 49: ...ned 13 Brake lever pivot shaft Lubricate with silicone grease 14 Brake pedal pivot shaft Lubricate with lithium soap based grease 15 Clutch lever pivot shaft Lubricate with lithium soap based grease 16 Shift pedal pivot shaft Lubricate with lithium soap based grease 17 Sidestand center stand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil lea...

Page 50: ...Replace 23 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 24 Front and rear brake switches Check operation 25 Moving parts and cables Lubricate 26 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 27 Lights signals and switches Check operation Adjust ...

Page 51: ...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 U36CE1E0 book Page 6 Thursday July 30 2009 11 32 AM ...

Page 52: ... moved and installed EAU46770 Panel A To remove the panel Remove the bolt and the quick fasten er and then take the panel off To install the panel Place the panel in the original position and then install the bolt and the quick fastener EAU47880 Panels B and C To remove one of the panels 1 Remove the bolts 1 Cowling A 2 Cowling B 1 2 1 Panel A 2 Cowling C 1 Panel B 2 Panel C 2 1 2 1 1 Panel A 2 Bo...

Page 53: ...e the cowling Remove the bolts and then take the cowling off To install the cowling Place the cowling in the original posi tion and then install the bolts EAU47581 Cowlings B and C To remove one of the cowlings 1 Remove panel B if removing cowl ing B or panel C if removing cowl ing C 2 Remove the quick fastener and the bolts and then take the cowl ing off 1 Panel B 2 Bolt 1 Projection 2 1 1 1 Cowl...

Page 54: ...cation chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally and all spark plugs installed in the en gine should have the same color If any spark plug shows a distinctly different color the engine could be o...

Page 55: ...checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on the center stand A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes unti...

Page 56: ...6 7 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap the engine oil drain bolt and its gasket to drain the oil from the crankcase TIP Skip steps 5 7 if the oil filter cartridge is not being replaced 5 Remove the oil filter cartridge with an oil filter wrench 1 Engine oil dipstick 2 ...

Page 57: ...on any parts after the engine and exhaust sys tem have cooled down NOTICE ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial ...

Page 58: ... level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU47560 To check the coolant level 1 Place the vehicle on the center stand TIP The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when che...

Page 59: ...ent of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10472 5 Route the coolant reservoir breath er hose through the guide as shown EAU47573 To change the coolant 1 Place the vehicle on the center stand 2 Remove cowlings A and C See page 6 7 3 Place a container under the engine to collect the used coolant 4 Remove the radiator cap retaining bolt radia...

Page 60: ... the cool ing system with clean tap water 10 Install the coolant drain bolt and its new gasket and then tighten the bolt to the specified torque 11 Install the coolant reservoir and its cover by placing them in the origi nal position and then installing the bolts 12 Pour the specified amount of the recommended coolant into the ra diator and reservoir 1 Coolant reservoir cap 2 Coolant reservoir bre...

Page 61: ...en install the cap 18 Route the coolant reservoir breath er hose through the guide as shown 19 Start the engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system 20 Install the cowlings Antifreeze water mixture ratio 1 1 Recommended antifreeze High quality ethylene glycol anti freeze containing corrosion inhibi tors for aluminum engi...

Page 62: ...E Make sure that the air filter element is properly seated in the air filter case The engine should never be operated without the air filter element installed otherwise the piston s and or cylinder s may become excessively worn ECA10481 7 Install the air filter case cover by in stalling the screws 8 Place the fuel tank in its original position Make sure that the fuel hoses are properly connected a...

Page 63: ...art The engine should be warm before making this adjustment Check the engine idling speed and if necessary adjust it to specification by turning the idle adjusting screw To in crease the engine idling speed turn the screw in direction a To decrease the engine idling speed turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make...

Page 64: ...t EAU21772 Tires To maximize the performance durabil ity and safe operation of your motorcy cle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10501 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire air pressur...

Page 65: ...ity and can lead to loss of control The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience Tire information Tire air pressure measured on cold tires 0 90 kg 0 198 lb Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi XJ6S 90 189 kg 198 417 lb XJ6SA 90 184 kg 198 406 lb Fr...

Page 66: ...h speed tires Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for app...

Page 67: ...EAU47590 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the clutch le ver free play and if necessary adjust it as follows To increase the clutch lever free play turn the clutch lever free play adjusting bolt at the clutch lever in direction a To decrease the clutch lever free play turn the adjusting bolt in dire...

Page 68: ...lding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU36503 Brake light switches XJ6SA The brake light which is activated by the brake pedal and brake lever should come on just before braking takes ef fect If necessary have a Yamaha deal er adjust the br...

Page 69: ...rn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pads Check each rear brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 1 5 mm 0 06 in have a Yamaha dealer replace the brake pads as a set EAU39371 Checking the brake fluid level Front b...

Page 70: ... braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the bra...

Page 71: ...he drive chain slack adjusting nut at each end of the swingarm in direc tion a To loosen the drive chain turn the adjusting nut at each end of the swingarm in direction b and then push the rear wheel for ward NOTICE Improper drive chain slack will overload the en gine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the d...

Page 72: ...e motorcycle riding in the rain or riding in wet areas 1 Clean the drive chain with kero sene and a small soft brush NOTICE To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inap propriate solvents ECA11121 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or a...

Page 73: ...le to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EWA10721 EAU23112 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated by a Yamaha dealer at the intervals speci fied in the periodic maintenance chart EAU44272 Checking and lubricating the brake and sh...

Page 74: ...er The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease U36CE1E0 book Page 29 Thursday July 30 2009 11 32 AM ...

Page 75: ...s not move up and down smoothly have a Yamaha dealer check or re pair it Otherwise the centerstand or sidestand could contact the ground and distract the operator resulting in a possible loss of control EAUM1651 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Recommended lubrica...

Page 76: ... several times to check if the front fork compresses and rebounds smoothly NOTICE ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU45511 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenan...

Page 77: ...rns 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 EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Theref...

Page 78: ...y is turned to OFF then discon nect the negative lead before disconnecting the positive lead ECA16302 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals NOTICE ECA16530 Always kee...

Page 79: ...Ignition fuse 5 Signaling system fuse 6 Backup fuse for clock and immobilizer sys tem 7 Fuel injection system fuse 8 Radiator fan fuse 1 2 3 4 5 6 7 8 1 Starter relay cover 2 Main fuse 3 Spare main fuse 4 Fuse box 2 4 3 1 1 Taillight fuse 2 ABS control unit fuse 3 ABS solenoid fuse 4 ABS motor fuse 5 Spare fuse 6 Headlight fuse 7 Ignition fuse 8 Signaling system fuse 9 Backup fuse for clock and im...

Page 80: ...ss part of the headlight bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bul...

Page 81: ...over and then connect the coupler 6 Install the cowling 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU47020 Replacing the tail brake light bulb 1 Remove the seat See page 3 18 2 Remove the socket together with the bulb by turning it counter clockwise 3 Remove the burnt out bulb by pull ing it out 1 Do not touch the glass part of the bulb 1 Headlight bulb cover 2 Headlight couple...

Page 82: ...a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw NOTICE Do not over tighten the screw otherwise the lens may break ECA11191 EAU24312 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the socket together with the bulb by pulling it out 1 Tail brake light bulb 2 Tail ...

Page 83: ...c trical circuit or replace the bulb EAU44790 Front wheel XJ6S WARNING EWA14840 For the ABS model have a Yamaha dealer remove and install the wheel EAU42641 To remove the front wheel WARNING EWA10821 To avoid injury securely support the vehicle so there is no danger of it falling over 1 Place the vehicle on the center stand 2 Loosen the front wheel axle pinch bolt then the wheel axle and the brake...

Page 84: ...ake pads before install ing the brake calipers onto the brake discs 4 Take the motorcycle off the center stand so that the front wheel is on the ground and then put the side stand down 5 Tighten the wheel axle the front wheel axle pinch bolt and the brake caliper bolts to the specified torques 6 Push down hard on the handlebar several times to check for proper fork operation 1 Wheel axle 2 Front w...

Page 85: ...the motorcycle on the cen terstand 4 Remove the axle nut 5 Push the wheel forward and then remove the drive chain from the rear sprocket TIP The drive chain does not need to be disassembled in order to remove and install the rear wheel 6 While supporting the brake caliper and slightly lifting the wheel pull the wheel axle out TIP A rubber mallet may be useful to tap the wheel axle out 1 Axle nut 2...

Page 86: ...d into the slot in the brake caliper bracket Make sure that there is enough space between the brake pads be fore installing the wheel 2 Install the drive chain onto the rear sprocket 3 Install the axle nut 4 Take the motorcycle off the center stand so that the rear wheel is on the ground and then put the side stand down 5 Adjust the drive chain slack See page 6 26 6 Tighten the axle nut and then t...

Page 87: ...quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills WARNING EWA15141 When checking the fuel system do not smoke and ...

Page 88: ...amaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engi...

Page 89: ...hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the...

Page 90: ...utlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always...

Page 91: ...ild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corros...

Page 92: ...tic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU26181 Storage Short term Always s...

Page 93: ...rk plugs and then install the spark plugs and the spark plug caps 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 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 f...

Page 94: ...64 US qt 2 20 Imp qt With oil filter cartridge replacement 2 80 L 2 96 US qt 2 46 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 00 L 2 11 US qt 1 76 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 17 3 L 4 57 US...

Page 95: ...t 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi Loading condition XJ6S 90 189 kg 198 417 lb XJ6SA 90 184 kg 198 406 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi High speed riding Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT4 50 Front...

Page 96: ...t 12 V 5 0 W 1 Meter lighting LED Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED ABS warning light XJ6SA LED Immobilizer system indicator light LED Fuses Main fuse 30 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 7 5 A Ignition fuse 1...

Page 97: ...tion number is stamped into the steering head pipe Record this number in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area EAU26480 Model label The model label is affixed to the frame under the seat See page 3 18 Record the information on this label in the space provid...

Page 98: ...3 Fuel tank breather overflow hose 3 17 Fuel tank cap 3 15 Fuses replacing 6 33 H Handlebar position adjusting 3 20 Handlebar switches 3 12 Hazard switch 3 13 Headlight bulb replacing 6 35 Helmet holder 3 19 High beam indicator light 3 4 Horn switch 3 12 I Identification numbers 9 1 Ignition circuit cut off system 3 23 Immobilizer system 3 1 Immobilizer system indicator light 3 7 Indicator and war...

Page 99: ...al indicator light 3 4 Turn signal light bulb replacing 6 37 Turn signal switch 3 12 V Valve clearance 6 19 Vehicle identification number 9 1 W Wheel bearings checking 6 32 Wheel front XJ6S 6 38 Wheel rear XJ6S 6 40 Wheels 6 22 U36CE1E0 book Page 2 Thursday July 30 2009 11 32 AM ...

Page 100: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 101: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 102: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2009 08 0 3 1 CR E DIC183 ...