Yamaha XT500E Owner'S Manual Download Page 59 | Manualshive

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6-21

PERIODIC MAINTENANCE AND MINOR REPAIR

6

EAU00696

Adjusting the brake lever
free play

Brake lever free play, adjusting

The brake lever free play should
measure 2–5 mm as shown.
Periodically check the brake lever
free play and, if necessary, adjust it
as follows.

1. Loosen the locknut at the brake

lever.

2. To increase the brake lever free

play, turn the adjusting bolt in
direction

a

. To decrease the

brake lever free play, turn the
adjusting bolt in direction

b

.

1

2

b

a

c

1.

Locknut

2.

Adjusting bolt

c.

Free play

EAU00712

Adjusting the brake pedal
position

Brake pedal position, adjusting

The top of the brake pedal should be
positioned approximately 12 mm
below the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary,
have a Yamaha dealer adjust it.

a

a.

Brake pedal position

3. Tighten the locknut.

EW000099

w

8

After adjusting the brake lever
free play, check the free play
and make sure that the brake
is working properly.

8

A soft or spongy feeling in the
brake lever 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 before operating the
motorcycle. Air in the
hydraulic system will diminish
the braking performance,
which may result in loss of
control and an accident.

4PT-E7 (English) 6/29/01 9:13 AM Page 58

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Summary of Contents for XT500E

Page 1: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 7 0 9 1 E 4PT 28199 E7 OWNER S MANUAL YAMAHA MOTOR CO LTD XT600E XT500E ...

Page 2: ... so as to enjoy all advantages of your XT500E XT600E 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 you...

Page 3: ...n to avoid damage to the motorcycle A NOTE provides key information to make procedures easier or clearer Q w cC NOTE NOTE 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold 8 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product infor...

Page 4: ...IMPORTANT MANUAL INFORMATION EW000002 w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE 4PT E7 English 6 29 01 9 13 AM Page 3 ...

Page 5: ...Yamaha Motor Co Ltd 1st edition June 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EAU04229 4PT E7 English 6 29 01 9 13 AM Page 4 ...

Page 6: ...N 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 9 8 7 6 5 4 3 2 1 4PT E7 English 6 29 01 9 13 AM Page 5 ...

Page 7: ...4PT E7 English 6 29 01 9 13 AM Page 6 ...

Page 8: ...Q GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY 1 1 1 4PT E7 English 6 29 01 9 13 AM Page 7 ...

Page 9: ...ce 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 passen gers 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 pro tective wear howeve...

Page 10: ...DESCRIPTION Left view 2 1 Right view 2 2 Controls and instruments 2 3 2 4PT E7 English 6 29 01 9 13 AM Page 9 ...

Page 11: ... page 3 8 3 Battery page 6 31 4 Owner s tool kit page 6 1 5 Helmet holder page 3 10 6 Shock absorber spring preload adjusting nut page 3 10 7 Fuse page 6 32 8 Starter choke knob page 3 9 9 Shift pedal page 3 5 1 2 3 4 5 6 7 8 9 Left view 4PT E7 English 6 29 01 9 13 AM Page 10 ...

Page 12: ... DESCRIPTION 2 10 Air filter element page 6 13 11 Oil filter element page 6 11 12 Engine oil filler cap page 6 10 13 Brake pedal page 3 5 6 21 10 11 13 12 Right view 4PT E7 English 6 29 01 9 13 AM Page 11 ...

Page 13: ...Speedometer unit page 3 2 4 Main switch steering lock page 3 1 5 Tachometer page 3 3 6 Right handlebar switches page 3 4 7 Brake lever page 3 5 6 21 8 Throttle grip page 6 16 6 27 9 Fuel tank cap page 3 6 1 2 3 4 5 6 7 8 9 Controls and instruments 4PT E7 English 6 29 01 9 13 AM Page 12 ...

Page 14: ... 3 Handlebar switches 3 3 Clutch lever 3 4 Shift pedal 3 5 Brake lever 3 5 Brake pedal 3 5 Fuel tank cap 3 6 Fuel 3 6 Fuel cock 3 8 Starter choke knob 3 9 Seat 3 9 Helmet holder 3 10 Adjusting the shock absorber assembly 3 10 Sidestand 3 11 Ignition circuit cut off system 3 12 3 4PT E7 English 6 29 01 9 13 AM Page 13 ...

Page 15: ...e turn ing the key to OFF or LOCK EAU01590 Parking The steering is locked and the tail light and auxiliary light are 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 ECA00043 cC Do not use the parking position for an extended length of time other wise the battery may discharge EAU00027 INSTRUMENT AND CONTROL FUNCTIONS 3 ...

Page 16: ... is pushed to the left or right 1 2 3 5 N 1 High beam indicator light 2 Neutral indicator light N 3 Turn signal indicator light 5 EAU00095 Speedometer unit Speedometerunit The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter shows the distance traveled since it was last set to...

Page 17: ...he center position To cancel the turn signal lights push the switch in after it has returned to the center position EAU00129 Horn switch Hornswitch Press this switch to sound the horn INSTRUMENT AND CONTROL FUNCTIONS 3 1 5 N a 1 Tachometer a Red zone EAU00118 Handlebar switches Handlebarswitches EAU03898 Light switch 9 Lightswitch Set this switch to to turn on the auxiliary light meter lighting an...

Page 18: ...g instruc tions prior to starting the engine 1 2 1 Engine stop switch 2 Start switch EAU00152 Clutch lever Clutchlever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the han dlebar 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 cl...

Page 19: ...motorcycle INSTRUMENT AND CONTROL FUNCTIONS 3 1 1 Shift pedal EAU00158 Brake lever Brakelever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the han dlebar grip 1 1 Brake lever EAU00162 Brake pedal Brakepedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 1 Brake pedal 4PT E7 Engl...

Page 20: ...d then remove it NOTE The fuel tank cap cannot be installed unless the key is in the lock In addi tion the key cannot be removed if the cap is not properly installed and locked EW000023 w Make sure that the fuel tank cap is properly closed and locked before riding b a a Unlock b Open EAU03753 Fuel Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the fill...

Page 21: ... as well as to the exhaust system Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane num ber of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded fuel Use of unleaded fuel will extend spark plug life and reduce mainte nance costs INSTRUMENT AND CONTROL FUNCTIONS 3 Recommended fuel REGULAR UNLEADED GASOLINE O...

Page 22: ...rrow mark pointing over OFF RES This indicates reserve If you run out of fuel while riding move the lever to this position Fill the tank at the first opportunity Be sure to set the lever back to ON after refueling OFF ON FUEL RES 1 RES 1 Arrow mark pointing over RES ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position ON FUEL RES OFF...

Page 23: ...ke INSTRUMENT AND CONTROL FUNCTIONS 3 1 b a 1 Starter choke knob 1 To install the seat 1 Insert the projections on the front of the seat into the seat holders as shown 2 Place the seat in the original position and then tighten the bolts NOTE Make sure that the seat is properly secured before riding 1 2 1 Projection 2 2 Seat holder 2 EAU00240 Seat Seat To remove the seat Remove the bolts and then p...

Page 24: ...k absorber assembly is equipped with a spring preload adjusting nut EC000015 cC Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Adjust the spring preload as follows 1 Loosen the locknut a b 1 2 1 Locknut 2 Adjusting nut 2 To increase the spring preload and thereby harden the suspen sion turn the adjusting nut in direction a To decrease the spring preload and the...

Page 25: ... other wise it may explode due to excessive gas pressure 8 Do not deform or damage the gas cylinder in any way as this will result in poor damp ing performance 8 Always have a Yamaha dealer service the shock absorber EAU00330 Sidestand Sidestand The sidestand is located on the left side of the frame Raise the side stand or lower it with your foot while holding the motorcycle upright NOTE The built...

Page 26: ...properly EAU03720 Ignition circuit cut off system Ignitioncircuitcut offsystem The ignition circuit cut off system comprising the sidestand switch clutch switch and neutral switch has the following functions 8 It prevents starting when the transmission is in gear and the sidestand is up but the clutch lever is not pulled 8 It prevents starting when the transmission is in gear and the clutch lever ...

Page 27: ... the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall 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 sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle sh...

Page 28: ...PRE OPERATION CHECKS Pre operation check list 4 1 4 4PT E7 English 6 29 01 9 13 AM Page 27 ...

Page 29: ...fuel level in fuel tank Refuel if necessary Check fuel line for leakage 3 6 3 7 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 10 6 13 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check fluid level in reservoir If necessary add recommended b...

Page 30: ...k chain slack Adjust if necessary Check chain condition Lubricate if necessary 6 25 6 26 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 16 6 19 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 28 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivotin...

Page 31: ...ut off system If system is defective have Yamaha dealer check vehicle 3 11 3 13 ITEM CHECKS PAGE 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 EWA00033 w If any item in the Pre operation check list is not working properly have it inspected and...

Page 32: ...POINTS Starting the 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 4PT E7 English 6 29 01 9 13 AM Page 31 ...

Page 33: ...the engine or oper ate it in a closed area for any length of time Exhaust fumes are poisonous and inhaling them can cause loss of con sciousness and death within a short time Always make sure that there is adequate ventila tion 8 Before starting out make sure that the sidestand is up If the sidestand is not raised com pletely it could contact the ground and distract the opera tor resulting in a po...

Page 34: ...the starter choke is not required when the engine is warm NOTE If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the engine more than 10 seconds on any one attempt 6 After starting the engine move the starter choke knob back halfway ECA00055 cC For maximum engine lif...

Page 35: ...e for long distances The transmission is properly lubricated only when the engine is running Inadequate lubrication may damage the transmission 8 Always use the clutch while changing gears to avoid dam aging the engine transmis sion and drive train which are not designed to withstand the shock of forced shifting EAU02941 Recommended shift points for Switzerland only Shiftpoints forSwitzerlandonly ...

Page 36: ...ne break in Enginebreak in There is never a more important peri od in the life of your engine than the period between 0 and 1 600 km For this reason you should read the fol lowing material carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km The various parts in the engine wear and polish them selves to the correct operating clear ances During this peri...

Page 37: ... check the vehi cle EAU00457 Parking Parking When parking stop the engine remove the key from the main switch and then turn the fuel cock lever to OFF EW000058 w 8 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them 8 Do not park on a slope or on soft ground otherwise the motorcycle may overturn 4PT E7 English 6 29 01 ...

Page 38: ...ear brake pads 6 22 Checking the brake fluid level 6 23 Changing the brake fluid 6 24 Drive chain slack 6 25 Lubricating the drive chain 6 26 Checking and lubricating the cables 6 27 Checking and lubricating the throttle grip and cable 6 27 Checking and lubricating the brake and shift pedals 6 28 Checking and lubricating the brake and clutch levers 6 28 Checking and lubricating the sidestand 6 28 ...

Page 39: ...f you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you EAU00464 Safety is an obligation of the owner Periodic inspection adjustment and lubrication will keep your vehicle in the safest and most efficient condi tion possible The most important points of inspection adjustment and lubrication are explained on the fol lowing pages The intervals given in the periodi...

Page 40: ...ri ence required for a particular job have a Yamaha dealer perform it for you EW000063 w Modifications not approved by Yamaha may cause loss of perfor mance and render the vehicle unsafe for use Consult a Yamaha dealer before attempting any changes 4PT E7 English 6 29 01 9 13 AM Page 39 ...

Page 41: ... and technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1 000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Clean Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on ...

Page 42: ...that the rear wheel is properly aligned Clean and lubricate Every 500 km and after washing the motorcycle or riding in the rain 14 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20 000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Chec...

Page 43: ...ars and if cracked or damaged 20 Rear suspension relay arm and connecting arm pivoting points Check operation Lubricate with molybdenum disulfide grease 21 Carburetor Check starter choke operation Adjust engine idling speed 22 Engine oil Change Check oil level and vehicle for oil leakage 23 Engine oil filter element Replace 24 Front and rear brake switches Check operation 25 Moving parts and cable...

Page 44: ...anels removingandinstalling The cowling and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter 1 1 Cowling A 1 1 Panel B Refer to this section each time the cowling or a panel needs to be removed and installed 1 1 Panel A 4PT E7 English 6 29 01 9 13 AM Page 43 ...

Page 45: ... EAU04003 Panels A and B To remove one of the panels Remove the screw and then pull the panel off as shown To install the panel Place the panel in the original posi tion and then install the screw 1 2 1 Panel A 2 Screw To install the cowling Place the cowling in the original posi tion and then install the screw 4PT E7 English 6 29 01 9 13 AM Page 44 ...

Page 46: ... spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 1 1 Spark plug cap ...

Page 47: ...th the spark plug wrench and then tighten it to the specified torque NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as pos sible 4 Install the spark plug cap To install the spark plug 1 Measure the spark plug gap with a wire thick...

Page 48: ...cle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 4 Wait a few minutes until the oil settles remove the oil filler cap wipe the dipstick clean insert it back into the oil filler hole with out screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 1 2 3 1...

Page 49: ...nd replace them if necessary NOTE Skip steps 5 8 if the oil filter element is not being replaced 5 Remove the oil filter element cover by removing the bolts NOTE The oil filter element cover is secured by two bolts and a drain bolt First remove the drain bolt to drain the oil filter element cavity 1 3 2 1 Oil filter cover bolt 2 2 Oil filter cover 3 Oil filter drain bolt To change the engine oil w...

Page 50: ...over ECA00105 cC 8 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives with the oil or use oils of grade CD or higher In addition do not use oils labeled ENERGY CONSERVING II or higher 8 Make sure that no foreign material enters the crankcase 1 2 1 Oil filter element 2 O ring 2 Tightening torque Oil filter element cover bolt 10 Nm ...

Page 51: ...il leakage If oil is leaking immediately turn the engine off and check for the cause 13 Turn the engine off and then check the oil level and correct it if necessary 1 1 Air bleed screw EAU03514 Cleaning the air filter element Airfilterelement cleaning The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrica tion chart Clean the air filter element ...

Page 52: ...the necessary professional knowledge and experience The adjustment described in the following section however may be serviced by the owner as part of routine mainte nance EC000094 cC The carburetor has been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine 1 1 Mesh side EC00008...

Page 53: ... 000 r min NOTE The engine is warm when it quickly responds to the throttle NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment 2 Check the engine idling speed and if necessary adjust it to specification by turning the throt tle stop screw To increase the engine idling speed turn the screw in direction a To decrease the engine idling sp...

Page 54: ...ecked and if necessary adjusted before each ride EW000082 w 8 The tire air pressure must be checked and adjusted on cold tires i e when the tempera ture of the tires equals the ambient temperature 8 The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passen ger cargo and accessories approved for this model EAU00637 Adjusting the valve clear...

Page 55: ...accessories does not exceed the specified maximum load for the vehicle 8 Do not carry along loosely packed items which can shift during a ride 8 Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides Tire air pressure measured on cold tires Load Front Rear Up to 90 kg 150 kPa 1 50 kgf cm2 1 50 bar 150 kPa 1 50 kgf cm2 1 50 bar 90 kg ma...

Page 56: ...torcy cle cannot be guaranteed 8 After extensive tests only the tires listed below have been approved for this model by Yamaha Motor Co Ltd NOTE The tire tread depth limits may differ from country to country Always com ply with the local regulations Tire information This motorcycle is equipped with tube tires Minimum tire tread depth front and rear 1 6 mm FRONT Manufacturer Size Type BRIDGESTONE 9...

Page 57: ...eds after changing a tire since the tire sur face must first be broken in for it to develop its optimal charac teristics EAU00685 Spoke wheels Wheels To maximize the performance dura bility and safe operation of your motorcycle note the following points regarding the specified wheels 8 The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or damage before each r...

Page 58: ...on b a b 1 2 c 1 Locknut clutch lever 2 Adjusting bolt c Free play 7 Tighten the locknut at the clutch lever and the crankcase 3 If the specified clutch lever free play could be obtained as described above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 4 Fully turn the adjusting bolt at the clutch lever in direction a to loosen the clutch cable 5 Loosen the loc...

Page 59: ...lposition adjusting The top of the brake pedal should be positioned approximately 12 mm below the top of the footrest as shown Periodically check the brake pedal position and if necessary have a Yamaha dealer adjust it a a Brake pedal position 3 Tighten the locknut EW000099 w 8 After adjusting the brake lever free play check the free play and make sure that the brake is working properly 8 A soft o...

Page 60: ...t be checked for wear at the intervals specified in the periodic maintenance and lubrication chart EAU00713 Adjusting the rear brake light switch Rearbrakelightswitch adjusting The rear brake light switch which is activated by the brake pedal is prop erly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting...

Page 61: ...ome ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake system for leak age 1 1 Minimum level mark EAU04288 Rear brake pads The rear brake is provided with a check plug which if ...

Page 62: ...rake fluid may deteriorate paint ed surfaces or plastic parts Always clean up spilled fluid immediately 8 As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause EAU03976 Changing the brake fluid Brakefluid changing Have a Yamaha dealer change the brake fluid at the intervals specif...

Page 63: ... adjust the drive chain slack adjusting 1 Loosen the axle nut and the brake caliper bracket bolt 2 To tighten the drive chain turn the adjusting plate on each side of the swingarm in direction a To loosen the drive chain turn the adjusting plate on each side of the swingarm in direction b and then push the rear wheel for ward a b 2 1 3 1 Adjusting plate 2 Axle nut 3 Brake caliper bracket bolt 3 Mo...

Page 64: ...bricants for the drive chain as they may contain substances that could damage the O rings EAU03006 Lubricating the drive chain Drivechain lubricating The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows EC000097 c...

Page 65: ...eplace it EAU04034 Checking and lubricating the throttle grip and cable Throttlegripandcable checkingandlubricating The operation of the throttle grip should be checked before each ride In addition the cable should be lubri cated or replaced at the intervals specified in the periodic maintenance chart EW000112 w Damage to the outer sheath may interfere with proper cable opera tion and will cause t...

Page 66: ...efore each ride and the lever pivots should be lubricated if necessary EAU03165 Checking and lubricating the sidestand Sidestand checkingandlubricating The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary EW000113 w If the sidestand does not move up and down smoothly have a Yamaha dealer chec...

Page 67: ...es to check if the front fork compresses and rebounds smoothly EC000098 cC If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or repair it EAU02939 Checking the front fork Frontfork checking The condition and operation of the front fork must be checked as follows at the intervals specified in the peri odic maintenance and lubrication chart To check the co...

Page 68: ...y support the motorcycle so that there is no danger of it falling over EAU01144 Checking the wheel bearings Wheelbearings checking The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings 2 Hold the lower ends o...

Page 69: ...dangerous since it contains sulfuric acid which causes severe burns Avoid any con tact with skin eyes or clothing and always shield your eyes when working near batteries In case of contact administer the following FIRST AID 9 9 EXTERNAL Flush with plen ty of water 9 9 INTERNAL Drink large quan tities of water or milk and immediately call a physician 9 9 EYES Flush with water for 15 minutes and see...

Page 70: ...t the battery leads are properly connected to the battery termi nals EAU01307 Replacing the fuse Fuse replacing The fuse holder is located behind panel A See page 6 7 for panel removal and installation procedures If the fuse is blown replace it as fol lows 1 Turn the key to OFF and turn off all electrical circuits 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 2 1 ...

Page 71: ... the electrical system 3 Disconnect the headlight coupler and the auxiliary light leads and then remove the headlight bulb cover 3 1 2 1 Headlight coupler 2 Auxiliary light lead 2 3 Headlight bulb cover EAU01146 Replacing the headlight bulb Headlightbulb replacing This motorcycle is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove cowling A See p...

Page 72: ...s 7 Install the headlight unit by installing the bolts 8 Install the cowling 9 Have a Yamaha dealer adjust the headlight beam if necessary 5 Place a new bulb into position and then secure it with the bulb holder EC000105 cC Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversel...

Page 73: ...b Tail brakelightbulb replacing 1 Remove the tail brake light lens by removing the screws 2 1 1 Screw 2 2 Lens 2 Remove the defective bulb by pushing it in and turning it coun terclockwise 3 Insert 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 ECA00065 cC Do not overtighten the screw oth erwise the lens may break 1 1 Bul...

Page 74: ...r each side of the swingarm EAU01579 Supporting the motorcycle Supportingthemotorcycle Since this model is not equipped with a centerstand follow these precau tions when removing the front and rear wheel or performing other main tenance requiring the motorcycle to stand upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be p...

Page 75: ...g 1 Install the speedometer gear unit into the wheel hub so that the projections mesh with the slots 2 Lift the wheel up between the fork legs 1 1 Speedometer gear unit 2 Loosen the wheel axle holder nuts then the wheel axle 3 Lift the front wheel off the ground according to the procedure on page 6 36 4 Pull the wheel axle out and then remove the wheel ECA00048 cC Do not apply the brake after the ...

Page 76: ...the holder nuts while applying the front brake push down on the handlebars several times to check if the front fork compresses and rebounds smoothly 8 Connect the speedometer cable 1 1 Retainer 6 Tighten the axle holder nuts to the specified tightening torque Tighten the upper nuts first and then lower ones When tightened in this sequence there should be a gap formed at the bottom of the axle hold...

Page 77: ...anger of it falling over 1 Remove the axle nut 2 Loosen the brake caliper bracket bolt 2 1 1 Axle nut 2 Brake caliper bracket bolt 5 Turn the drive chain adjusting plate on each side of the swingarm fully in direction a 1 a 1 Chain adjusting plate 3 Lift the rear wheel off the ground according to the procedure on page 6 36 4 Remove the swingarm end bolts 1 1 1 Swingarm end bolt 2 4PT E7 English 6 ...

Page 78: ... install the rear wheel Install 1 Install the drive chain onto the rear sprocket and then insert the wheel axle from the left hand side NOTE 8 Make sure that there is enough space between the brake pads before inserting the brake disc between the brake pads 8 Make sure that the drive chain adjusting plates are installed with the punched sides facing to the outside 2 Install the swingarm end bolts ...

Page 79: ...y proce dure for checking these vital systems yourself However should your motorcycle require 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 inferior have a shorter service life and can lead to ...

Page 80: ...emove spark electrodes plug and check Open throttle half way and start the Engine doesn t start go to battery check engine correct spark gap or replace spark plug Engine turns over Engine turns over Battery good Check connections quickly slowly or recharge Engine doesn t start ask a Yamaha dealer to inspect Engine doesn t start go to compression check Use the electric starter EAU01397 Troubleshoot...

Page 81: ...4PT E7 English 6 29 01 9 13 AM Page 80 ...

Page 82: ...MOTORCYCLE CARE AND STORAGE Care 7 1 Storage 7 4 7 4PT E7 English 6 29 01 9 13 AM Page 81 ...

Page 83: ...s all electrical cou plers and connectors including the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such products onto seals gaskets sprockets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 cC 8 8 Avoid using strong acidic wheel clean...

Page 84: ...ot leave any marks If the windshield is scratched use a quality plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottle brush 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...

Page 85: ...nor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry complete ly before storing or covering it EWA00001 w 8 Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or acetone and wash the tires with warm water and a mild detergent 8 Before operating the motorcy cle test ...

Page 86: ...bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to protect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the s...

Page 87: ...little every month in order to pre vent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 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 excessively cold or warm place less than 0 C or more than 30 C For more informa tion on storing the batt...

Page 88: ...SPECIFICATIONS Specifications 8 1 Conversion table 8 5 8 4PT E7 English 6 29 01 9 13 AM Page 87 ...

Page 89: ... 95 0 84 0 mm XT600E Compression ratio 8 5 1 Starting system Electric starter Lubrication system Dry sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher cC Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled ENERGY CONSERVING II contain anti friction additives which will cause clutch and or starter ...

Page 90: ...reduction ratio 2 533 XT500E 3 000 XT600E Number of drive chain 38 15 XT500E sprocket teeth rear front 45 15 XT600E Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 2 583 2nd 1 588 3rd 1 200 4th 0 954 XT500E 0 955 XT600E 5th 0 792 Chassis Frame type Diamond Caster angle 27 75 XT500E 27 45 XT600E Trail 120 mm Tire Front Type With tube Size 90 90 21 54S or 90 90 2...

Page 91: ...f cm2 1 50 bar Rear 225 kPa 2 25 kgf cm2 2 25 bar Total weight of rider passenger cargo and accessories Wheels Front Type Spoke wheel Size 21 1 85 Rear Type Spoke wheel Size 17 MT2 50 or 17 M C MT2 50 Brakes Front Type Single disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Type Telescopic fork Rear Type Swingarm new monocros...

Page 92: ...lb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 60 55W 1 Tail brake light 12 V 5 21W 1 Auxiliary light 12 V 4W 1 12 V 3 4W 1 GB only Front flasher light 12 V 21W 2 Rear flasher light 12 V 21W 2 Meter lighting 12 V 3 4W 1 Neutral indicator light 12 V 3 4W 1 High beam indicator light 12 V 3 4W 1 Turn indicator light 12 V 3 4W 1 Fuse 20A 4PT E7 English 6 29 01 9 13 AM Page 91 ...

Page 93: ...etric unit Multiplier Imperial unit m kgf 7 233 ft lb Torque m kgf 86 794 in lb cm kgf 0 0723 ft lb cm kgf 0 8679 in lb Weight kg 2 205 lb g 0 03527 oz Speed km hr 0 6214 mph km 0 6214 mi m 3 281 ft Distance m 1 094 yd cm 0 3937 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 Misc kgf cm2 14 22...

Page 94: ...CONSUMER INFORMATION Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 9 4PT E7 English 6 29 01 9 13 AM Page 93 ...

Page 95: ...ication number Vehicleidentificationnumber The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motor cycle with the licensing authority in your area 1 1 Vehicle identification number EAU01041 Key identification number Keyidentifi...

Page 96: ...xed to the frame under the seat See page 3 9 for seat removal and installation pro cedures Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 1 Model label 4PT E7 English 6 29 01 9 13 AM Page 95 ...

Page 97: ...P Parking 5 5 Part locations 2 1 Periodic maintenance and lubrication chart 6 3 Pre operation check list 4 1 R Rear brake light switch adjusting 6 22 Rear suspension lubricating 6 29 Rear wheel 6 39 Removing 6 39 Install 6 40 S Seat 3 9 Shift pedal 3 5 Shift points for Switzerland only 5 3 Shifting 5 3 Shock absorber assembly adjusting 3 10 Sidestand 3 11 A Air filter element cleaning 6 13 B Batte...

Page 98: ...36 T Tachometer 3 3 Tail brake light bulb replacing 6 35 Throttle cable free play adjusting 6 16 Throttle grip and cable checking and lubricating 6 27 Tires 6 16 Tool kit 6 1 Troubleshooting 6 41 Troubleshooting chart 6 42 Turn signal light bulb replacing 6 35 V Valve clearance adjusting 6 16 Vehicle identification number 9 1 W Wheel bearings checking 6 30 Wheels 6 19 INDEX 4PT E7 English 6 29 01 ...

Page 99: ...4PT E7 English 6 29 01 9 13 AM Page 98 ...

Page 100: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 7 0 9 1 E 4PT 28199 E7 OWNER S MANUAL YAMAHA MOTOR CO LTD XT600E XT500E ...

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