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In addition, the many tips given in this manual will help to 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!
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.
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IMPORTANT MANUAL INFORMATION EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
EAA30002 TABLE OF CONTENTS 1 GIVE SAFETY THE RIGHT OF WAY 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE-OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX...
GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY..........1-1...
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GIVE SAFETY THE RIGHT OF WAY 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 ig- nore the laws of physics. Regular care and maintenance are essential for preserving your motorcycleÕs value and operating condi- tion.
DESCRIPTION Left view (XJ600S) ................2-1 Right view (XJ600S)................2-2 Controls/Instruments (XJ600S) ............2-3 Left view (XJ600N)................2-4 Right view (XJ600N) ................2-5 Controls/Instruments (XJ600N)............2-6...
INSTRUMENT AND CONTROL FUNCTIONS EAU00027 EAU00028 EAU00038 EAU00040 Main switch LOCK (for XJ600S) The steering is locked in this position All electrical circuits are switched off. The main switch controls the ignition and all electrical circuits are switched The key can be removed in this posi- and lighting systems.
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INSTRUMENT AND CONTROL FUNCTIONS EAU01590 (Parking) (for XJ600S) The steering is locked in this position, and the taillight and auxiliary light come on but all other circuits are off. The key can be removed in this position. To use the parking position, first lock the steering, then turn the key to Ò...
INSTRUMENT AND CONTROL FUNCTIONS XJ600S 0 0 0 0 1. Steering lock 1. Left turn indicator light Ò Ó 1. Neutral indicator light Ò Ó 2. High beam indicator light Ò Ó 2. Left turn indicator light Ò Ó EAU02934 3.
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INSTRUMENT AND CONTROL FUNCTIONS EC000000 CAUTION: Do not run the motorcycle until you know it has sufficient engine oil. NOTE: Even if the oil is filled to the specified level, the indicator light may flicker when riding on a slope or during sud- den acceleration or deceleration, but this is normal.
Oil level indicator light Oil level Oil level comes on. does not come on. is OK. is low. Ask a Yamaha dealer to Engine oil level and Supply inspect electrical circuit. electrical circuit are OK. engine oil. Go ahead with riding.
INSTRUMENT AND CONTROL FUNCTIONS XJ600S 1. Speedometer 1. Speedometer 2. Odometer 2. Odometer 3. Trip odometer 3. Trip odometer 4. Reset button 4. Reset knob EAU00094 EAU00095 Speedometer (for XJ600S) Speedometer (for XJ600N) The speedometer shows riding speed. The speedometer shows riding speed. This speedometer is equipped with an This speedometer is equipped with an odometer and trip odometer.
INSTRUMENT AND CONTROL FUNCTIONS XJ600S 1. Tachometer 1. Tachometer 1. Pass switch ÒPASSÓ 2. Red zone (except for CH, A) 2. Red zone (except for CH, A) 2. Dimmer switch 3. Red zone (for CH, A) 3. Red zone (for CH, A) 3.
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INSTRUMENT AND CONTROL FUNCTIONS EAU00144 EAU00127 Hazard switch Ò Ó Turn signal switch The hazard switch should be turned on To signal a right-hand turn, push the under emergency or hazardous condi- switch to Ò Ó. To signal a left-hand tions.
INSTRUMENT AND CONTROL FUNCTIONS EAU00134 Lights switch Turning the light switch to Ò Ó, turns on the auxiliary light, meter lights and taillight. Turning the light switch to Ò Ó, turns the headlight on also. EAU00143 Start switch Ò Ó The starter motor cranks the engine 1.
INSTRUMENT AND CONTROL FUNCTIONS 1. Shift pedal 1. Front brake lever 1. Position adjusting nut 2. Position adjusting nut 2. Proper position EAU00157 Shift pedal To adjust the front brake lever position, EAU00160 Front brake lever This motorcycle is equipped with a con- turn the adjusting nut while pulling the The front brake lever is located on the stant-mesh 6-speed transmission.
INSTRUMENT AND CONTROL FUNCTIONS NOTE: This tank cap cannot be closed unless the key is in the lock. The key cannot be removed if the cap is not locked properly. EW000023 Be sure the cap is properly installed 1. Rear brake pedal 1.
INSTRUMENT AND CONTROL FUNCTIONS EAU00185 CAUTION: Always wipe off spilled fuel immedi- ately with a dry and clean soft cloth. Fuel may deteriorate painted surfac- es or plastic parts. EAU00191 Recommended fuel: 1. Filler tube 1. Fuel tank breather hose Regular unleaded gasoline with 2.
INSTRUMENT AND CONTROL FUNCTIONS 1. Arrow mark positioned over ÒONÓ 1. Arrow mark positioned over ÒRESÓ 1. Arrow mark positioned over ÒPRIÓ EAU00207 Fuel cock This stands for ÒreserveÓ. If you are This stands for ÒprimeÓ. If the engine The fuel cock supplies fuel from the running out of fuel while riding with the has been allowed to run out of fuel, turn tank to the carburetors while also filter-...
INSTRUMENT AND CONTROL FUNCTIONS 1. Starter (choke) Ò Ó 1. Open 1. Projection (´ 2) 2. Seat holder EAU02976 EAU02925 Starter (choke) Ò Ó Seat To install Starting a cold engine requires a richer To remove Insert the projections on the front of the air-fuel mixture.
The helmet holders are under the seat. This compartment is designed to store adjustment Remove the seat and hook the helmets a genuine Yamaha U-LOCK. (Other This shock absorber is equipped with a on the helmet holders. Then, install the locks may not fit.) spring preload adjusting ring.
Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance. Take your shock absorber to a Yamaha dealer for any service. 3-16...
ENGINE STOP SWITCH TO Ò Ó. ground and distract the operator, re- sulting in a possible loss of control. Yamaha has designed into this mo- TRANSMISSION IS IN GEAR AND torcycle a lockout system to assist SIDESTAND IS UP. the operator in fulfilling the respon- sibility of retracting the sidestand.
PRE-OPERATION CHECKS EAU01114 Owners are personally responsible for their vehicleÕs condition. Your motorcycleÕs vital functions can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or loss of tire pressure could have serious consequences.
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PRE-OPERATION CHECKS ITEM CHECKS PAGE ¥ Make sure that all nuts, bolts and screws are properly tightened. Chassis fasteners Ñ ¥ Tighten if necessary. ¥ Check fuel level. Fuel tank 3-11 ~ 3-12 ¥ Fill with fuel if necessary. Lights, signals and 3-7 ~ 3-9, ¥...
The engine their functions. Consult can be started only under one of the Yamaha dealer regarding any following conditions: control or function that you do The transmission is in neutral. not thoroughly understand. The sidestand is up, the transmis-...
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OPERATION AND IMPORTANT RIDING POINTS TURN THE MAIN SWITCH TO ÒONÓ AND THE ENGINE STOP SWITCH TO Ò Ó. IF TRANSMISSION IS IN NEUTRAL AND IF TRANSMISSION IS IN GEAR AND SIDESTAND IS DOWN, SIDESTAND IS UP, PUSH THE START SWITCH. PULL IN THE CLUTCH LEVER AND PUSH THE ENGINE WILL START.
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Yamaha dealer to inspect it. leakage. If necessary, fill the engine with oil and check to see that the oil 4.
OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine CAUTION: The starter (choke) is not required Do not coast for long periods when the engine is warm. with the engine off, and do not EC000046 tow the motorcycle a long dis- CAUTION: tance.
OPERATION AND IMPORTANT RIDING POINTS EAU02937 EAU00424 EAU00436 Recommended shift points Tips for reducing fuel Engine break-in (for Switzerland only) consumption There is never a more important period in the life of your motorcycle than the The recommended shift points are Your motorcycleÕs fuel consumption period between zero and 1,000 km.
If any engine trouble should oc- motorcycle in a place where pedes- cur during the break-in period, trians or children are not likely to 150 ~ 500 km consult a Yamaha dealer imme- touch the motorcycle. Do not park Avoid prolonged operation above diately.
If you do not have necessary tools re- the safest and most efficient condition quired during a service operation, take possible. Safety is an obligation of the your motorcycle to a Yamaha dealer motorcycle owner. The maintenance for service. and lubrication schedule chart should...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 PERIODIC MAINTENANCE AND LUBRICATION EVERY 6,000 km 12,000 km INITIAL ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) 6 months 12 months (whichever (whichever comes first) comes first) ¥ Check fuel hoses and vacuum hose for cracks or damage. Fuel line Ö...
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PERIODIC MAINTENANCE AND MINOR REPAIR EVERY 6,000 km 12,000 km INITIAL ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) 6 months 12 months (whichever (whichever comes first) comes first) ¥ Check bearing for looseness or damage. Wheel bearings Ö Ö ¥ Replace if necessary. ¥...
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Engine oil filter cartridge ¥ Replace. Ö Ö * Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. EAU01792 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel A 1. Screw (´ 2) EAU01777 EAU02926 Panel removal and installation Panel A The panel illustrated needs to be re- To remove moved to perform some of the mainte- 1. Remove the seat. (See page 3-14 nance described in this chapter.
PERIODIC MAINTENANCE AND MINOR REPAIR Do not attempt to diagnose such prob- lems yourself. Instead, take the motor- cycle to a Yamaha dealer. The spark plugs should be periodically removed and inspected because heat and de- posits will cause any spark plug to slowly break down and erode.
PERIODIC MAINTENANCE AND MINOR REPAIR When installing a spark plug, the gas- ket surface should always be cleaned and a new gasket used. Any grime should be wiped off from the threads and the spark plug tightened to the specified torque. Tightening torque: Spark plug: 1.
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2. Stop the engine. Place an oil pan An oil filter wrench is available at a under the engine and remove the nearby Yamaha dealer. oil filler cap. 3. Remove the drain bolt and drain 5. Install the drain bolt and tighten it the oil.
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When installing the oil filter, tighten it to CAUTION: mains on, immediately stop the en- the proper torque by using a torque gine and consult with a Yamaha Do not put in any chemical addi- wrench. dealer. tives. Engine oil also lubricates...
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw 1. Fuel hose 2. Vacuum hose 4. Remove the fuel tank. EAU02928 3. Drain hose Air filter 3. Disconnect the hoses. The air filter should be cleaned at the specified intervals. It should be cleaned more frequently if you are riding in un- usually wet or dusty areas.
The carburetors are important parts of the engine and require very sophisti- cated adjustment. Most adjustments should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idle speed may be adjusted by the owner as part of routine maintenance.
1,000 to 2,000 r/min. Occasionally 5 mm at the throttle grip. If the free play rev the engine to 4,000 to is incorrect, ask a Yamaha dealer to 5,000 r/min. The engine is warm make this adjustment. when it quickly responds to the throttle.
(2.00 kg/cm (2.50 kg/cm should be left to a professional Always check and adjust the tire pres- Maximum load* 2.00 bar) 2.50 bar) Yamaha service technician. sure before operating the motorcycle. 200 kPa 250 kPa EW000082 High speed riding (2.00 kg/cm (2.50 kg/cm...
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CYCLE. Make sure the total weight the side wall is cracked, contact a regulations of your own country. of the cargo, rider, passenger, and Yamaha dealer immediately and have accessories (fairing, saddlebags, the tire replaced. etc. if approved for this model) does not exceed the maximum load of the motorcycle.
Yamaha dealer. Do not should be left to a Yamaha Service 1. Locknut attempt even small repairs to the 2. Adjusting bolt Technician. c. Free play wheel. If a wheel is deformed or cracked, it must be replaced.
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PERIODIC MAINTENANCE AND MINOR REPAIR 7. Turn the adjusting nut at the crankcase in direction a to in- crease free play or in direction b to decrease free play. 8. Tighten the locknut at the crank- case and the clutch lever. 1.
40 mm below the top of the justed when the brake light comes on footrest. If not, ask a Yamaha dealer to just before braking takes effect. To ad- adjust it.
EAU00725 Front brake ALMOST in contact with the disc plate, A wear indicator groove is provided on ask a Yamaha dealer to replace the each brake pad. This indicator allows pads. checking of brake pad wear without disassembling the brake. Inspect the groove.
Insufficient brake fluid may let air enter leakage and poor brake perfor- Have a Yamaha dealer check the the brake system, possibly causing the mance. cause if the brake fluid level goes brakes to become ineffective.
EAU00742 Brake fluid replacement The brake fluid should be replaced only by trained Yamaha service personnel. Have the Yamaha dealer replace the following components during periodic maintenance or when they are dam- aged or leaking: oil seals (every two years) brake hoses (every four years) a.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00769 Drive chain lubrication each side of the swingarm. Use these marks to align the rear The chain consists of many parts which wheel. work with each other. If the chain is not maintained properly, it will wear out EC000096 CAUTION: quickly.
Lubricate the cables and cable ends. If a suitable all-purpose grease. a cable does not operate smoothly, ask a Yamaha dealer to replace it. Recommended lubricant: Engine oil 6-22...
Molybdenum disulfide grease Recommended lubricant: Check to see that the center and side- Engine oil stand move up and down smoothly. Recommended lubricant: Engine oil EW000114 If the center and/or sidestand does not move smoothly, consult a Yamaha dealer. 6-23...
Therefore it is not dangerous, causing severe burns, smoothly, have a Yamaha dealer in- necessary to check the electrolyte or fill etc. It contains sulfuric acid. Avoid spect the wheel bearings.
Always make sure the connec- see if the electrical device operates. If improper rating can cause extensive tions are correct when reinstall- the fuse immediately blows again, con- electrical system damage and pos- ing the battery. sult a Yamaha dealer. sibly a fire. 6-26...
PERIODIC MAINTENANCE AND MINOR REPAIR Specified fuses: Main fuse: 30 A Ignition fuse: 10 A Signaling system fuse: 15 A Headlight fuse: 15 A Hazard light fuse: 10 A 1. Connector 1. Bulb holder 2. Bulb holder cover 2. Unhook the bulb holder and re- EAU00829 move the defective bulb.
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PERIODIC MAINTENANCE AND MINOR REPAIR 4. Install the bulb holder cover and the headlight connector. If a headlight beam adjustment is necessary, ask a Yamaha dealer to make adjustment. 1. DonÕt touch 3. Put a new bulb into position and secure it in place with the bulb holder.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (´ 2) 1. Connector (´ 2) 1. Bulb holder 2. Bulb cover 3. Turn the bulb holder counterclock- EAU00833 Headlight bulb replacement 2. Remove connectors, wise to remove it and remove the (for XJ600N) headlight unit and then the bulb defective bulb.
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PERIODIC MAINTENANCE AND MINOR REPAIR 5. Install the bulb cover, connectors and headlight unit. Ask a Yamaha dealer to adjust the headlight beam if necessary. 1. DonÕt touch 4. Put a new bulb into position and secure it in place with the bulb holder.
Do not depress the brake lever when wheel hub and the speedometer the disc and caliper are separated. gear unit are installed with the pro- It is advisable to have a Yamaha jections meshed into the slots. dealer service the wheel. 4. Loosen the pinch bolt.
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PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Wheel axle: 58 Nm (5.8 mákg) Pinch bolt: 40 Nm (4.0 mákg) Caliper bolt: 19 Nm (1.9 mákg) 7. Install the speedometer cable. 3. Install the wheel axle and let the motorcycle down. 4.
5. Push the wheel forward and re- EW000122 by removing the nut. move the drive chain. 6. Remove the wheel assembly. It is advisable to have a Yamaha dealer service the wheel. NOTE: Securely support the motor- Do not depress the brake pedal...
If your motorcycle requires any repair, disc. bring it to a Yamaha dealer. The skilled 5. Take the motorcycle off the cen- technicians at a Yamaha dealership terstand. have the tools, experience, and know- 6.
Remove spark plugs and check electrodes. Engine doesnÕt start, go to battery Dry. Ask a Yamaha dealer to inspect. check. 4. Battery Engine turns over Battery good. quickly. Engine doesnÕt start, ask a Yamaha Use the electric starter.
MOTORCYCLE CARE AND STORAGE EAU01517 Care Before cleaning Cleaning 1. Cover up the muffler outlets with After normal use The exposure of its technology makes plastic bags. Remove dirt with warm water, a neutral a motorcycle charming but also vul- 2.
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MOTORCYCLE CARE AND STORAGE ECA00010 Do not use any harsh chemical For motorcycles equipped with CAUTION: products on plastic parts. Be a windshield: Do not use strong Avoid using strong acidic wheel sure to avoid using cloths or cleaners or hard sponges as cleaners, especially on spoked sponges which have been in they will cause dulling or...
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MOTORCYCLE CARE AND STORAGE EWA00001 After cleaning 1. Clean your motorcycle with cold water and soap after the engine 1. Dry the motorcycle with a chamois Make sure that there is no oil or wax has cooled down. or an absorbing cloth. on the brakes and tires.
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ÒOFFÓ position: Turn the fuel cock NOTE: To prevent corrosion, avoid to ÒOFFÓ. Consult a Yamaha dealer for advice on damp cellars, stables (because 4. Fill up the fuel tank and add fuel what products to use. of the presence of ammonia)
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MOTORCYCLE CARE AND STORAGE c. Install the spark plug caps onto the 7. Check and, if necessary, correct spark plugs and place the spark the tire air pressure, then raise the plugs on the cylinder head so that motorcycle so that both of its the electrodes are grounded.
SPECIFICATIONS Specifications ..................8-1 HOW TO USE THE CONVERSION TABLE ........8-5...
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SPECIFICATIONS EAU01038 Specifications Model XJ600S / XJ600N Engine oil Dimensions Type -20û -10û 0û 10û 20û 30û 40û 50ûC Overall length 2,170 mm SAE 10W/30 Overall width 735 mm Overall height SAE 10W/40 XJ600S 1,205 mm SAE 15W/40 XJ600N 1,090 mm SAE 20W/40 Seat hight 770 mm...
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SPECIFICATIONS Air filter Dry type element Operation Left foot operation Fuel Gear ratio Type Regular unleaded gasoline 2.733 Fuel tank capacity 17.0 L 1.778 Reserve amount 3.5 L 1.333 Carburetor 1.074 Type´quantity BDS28 ´ 4 0.913 Manufacturer MIKUNI 0.821 Spark plug Chassis Type/Manufacturer CR8E / NGK...
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SPECIFICATIONS Maximum load* Brakes XJ600S 184 kg Front XJ600N 187 kg Type Dual disc brake Air pressure (cold tire) Operation Right hand operation Up to 90 kg load* Fluid DOT 4 or DOT 3 Front 200 kPa (2.00 kg/cm , 2.00 bar) Rear Rear 225 kPa (2.25 kg/cm...
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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 Type YTX9-BS, GTX9-BS Headlight fuse 15 A Voltage, capacity 12 V, 8 AH Hazard light fuse 10 A Headlight type...
SPECIFICATIONS EAU01064 HOW TO USE THE CONVERSION TABLE CONVERSION TABLE All specification data in this manual are listed in SI and METRIC TO IMPERIAL METRIC UNITS. Metric unit Multiplier Imperial unit Use this table to convert METRIC unit data to IMPERIAL mákg 7.233 ftálb...
CONSUMER INFORMATION Identification number records............. 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...
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is sto- len. 1. KEY IDENTIFICATION 1.
Record the infor- vided. mation on this label in the space pro- vided. This information will be needed to order spare parts from your Yamaha The vehicle identification number is dealer. used to identify your motorcycle and may be used to register your motor- cycle with the licensing authority in your state.
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INDEX Helmet holders ........3-15 High beam indicator light ....... 3-3 Air filter ..........6-10 Front brake lever ......... 3-10 Horn switch ..........3-8 Front fork inspection ......6-24 Front wheel installation ......6-31 Battery ..........6-25 Front wheel removal ......6-31 Identification number records ....