Operation Manual

PERIODIC MAINTENANCE AND MINOR REPAIR

Owner’s tool kit ....................................................6-1

Periodic maintenance and lubrication chart .........6-2

Removing and installing the panel .......................6-5

Checking the spark plugs ....................................6-6

Engine oil and oil filter cartridge ..........................6-7

Cleaning the air filter element ............................6-10

Adjusting the carburetors ...................................6-12

Adjusting the engine idling speed ......................6-13

Adjusting the throttle cable free play ..................6-13

Adjusting the valve clearance ............................6-14

Tires ...................................................................6-14

Cast wheels .......................................................6-17

Adjusting the clutch lever free play ....................6-17

Adjusting the brake pedal position .....................6-18

Adjusting the rear brake light switch ..................6-19

Checking the front and rear brake pads .............6-19

Checking the brake fluid level ............................6-20

Changing the brake fluid ....................................6-21

Drive chain slack ................................................6-21

Lubricating the drive chain .................................6-23

Checking and lubricating the cables ..................6-23

Checking and lubricating the throttle grip and

cable ............................................................... 6-24

Checking and lubricating the brake and shift

pedals ............................................................. 6-24

Checking and lubricating the brake and clutch

levers ............................................................... 6-25

Checking and lubricating the centerstand and

sidestand ......................................................... 6-25

Lubricating the rear suspension ........................ 6-25

Checking the front fork ...................................... 6-26

Checking the steering ....................................... 6-26

Checking the wheel bearings ............................ 6-27

Battery ............................................................... 6-27

Replacing the fuses .......................................... 6-29

Replacing the headlight bulb (for XJ600S)......... 6-30

Replacing the headlight bulb (for XJ600N) ........ 6-31

Front wheel ....................................................... 6-33

Rear wheel ........................................................ 6-35

Troubleshooting ................................................. 6-36

Troubleshooting chart ........................................ 6-37

E_4br.book Page 1 Wednesday, July 25, 2001 1:40 PM