Yamaha · Yamaha shaft-drive air-cooled (XS750/850/1100, XJ, Virago 1976-2007)

XJ550 / XJ600 Seca / Maxim (chain)

Library entry covers 1981-1997

20 factory 41 guideline

Published source

Yamaha XJ600S 1992 Service Manual (Yamaha Motor Co.), Periodic Maintenance/Lubrication pp.3-1 to 3-2

Factory service manual. Covers 1992 XJ600S Seca II service manual, chart in km, mi and months.

Open the source

61 items for a 1981 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Two or more carburetors
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

1981 Yamaha XJ550 / XJ600 Seca / Maxim (chain)

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain: check slack and alignment, clean and lube. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: every 300 mi (500 km)

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

On the road: every 1,000 mi

1 item

Check road kit: plugs, points file, master link, tube patches, wire, tape

Pre-ride / on the road

Guideline

On the road: every 4,000 mi or 6 months

1 item

Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Factory

Manual: Chassis fittings and fasteners: check. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: dealer item; first at 600 mi

Every 1,000 mi or 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Guideline

Wet-cell batteries on old machines need regular topping up, more in hot weather.

Every 1,500 mi or 6 months

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.

Every 2,000 mi or 12 months

1 item

Lubricate control cables and lever pivots

Controls and cables

Guideline

Every 3,000 mi or 12 months

9 items

Check engine mounting bolts and plates

Engine

Guideline
Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Adjust clutch pushrod / clutch adjuster

Primary and gearbox

Guideline
Check chain guard, chain oiler (if fitted), rear chain case

Final drive

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering damper (friction or hydraulic)

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline

Every 4,000 mi or 6 months

11 items

Change engine oil

Engine

Factory

Manual: Engine oil: replace. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: first at 600 mi (1,000 km); row partly under the site watermark
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plugs: check, clean or replace. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: first at 600 mi (1,000 km)
Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter: clean, replace if necessary. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2
Replace fuel lines

Fuel and air

Factory

Manual: Fuel hose and vacuum pipe: check. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: dealer item
Synchronize carburetors

Fuel and air

Factory

Manual: Carburetor: check idle speed, synchronization and starter. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: dealer item; first at 600 mi
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch: check operation, adjust. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Center and sidestand, sidestand switch: check. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: first at 600 mi
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Front forks and rear shock: check operation and leakage. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: dealer item
Check brake pads and discs

Brakes

Factory

Manual: Brake: check operation and fluid leakage. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: dealer item
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings: check. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: dealer item
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Wheels: check balance, damage and runout. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: dealer item

Every 4,000 mi or 12 months

1 item

Replace spark plugs

Engine

Guideline

Every 5,000 mi or 2 years

1 item

Check cylinder head bolt torque

Engine

Guideline

Air-cooled iron and alloy engines can lose head bolt tension; follow your manual's sequence and whether it is done hot or cold.

Every 6,000 mi or 12 months

4 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,000 mi or 2 years

2 items

Check engine breather and oil return

Engine

Guideline
Check valve clearances (shim adjusted)

Engine

Guideline

Every 8,000 mi or 12 months

2 items

Replace oil filter

Engine

Factory

Manual: Engine oil filter: replace. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: dealer item; first at 600 mi (1,000 km)
Replace fuel filter

Fuel and air

Factory

Manual: Fuel filter: check, replace if necessary. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: dealer item

Every 10,000 mi or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 10,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 12,000 mi or 2 years

1 item

Replace air filter element

Fuel and air

Guideline

Every 15,000 mi or 5 years

1 item

Inspect clutch plates and springs

Primary and gearbox

Guideline

Every 16,000 mi or 2 years

3 items

Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance: check and adjust. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: dealer item
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings: repack. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: dealer item; check at 600 mi and every 8,000 mi
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Rear arm pivot: repack. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: dealer item; check every 8,000 mi; molybdenum disulfide grease

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

4 items

Inspect fuel tank for rust, sealer failure, leaks

Fuel and air

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Factory

Manual: Brake caliper and master cylinder seals: replace. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: replace the oil seals every two years; replace fluid whenever the cylinders are taken apart

Every 4 years

2 items

Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hoses: replace. Factory: Periodic maintenance/lubrication pp.3-1 to 3-2: every four years, or if cracked or damaged
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.