Yamaha XT600E 2000 Owner'S Manual Download

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6-38

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01397

Troubleshooting chart

EW000125

Keep away open flames and do not smoke while checking or working on the fuel system.

1. Fuel

2. Compression

3. Ignition

4. Battery

Use electric starter.

There is compression.

Go to ignition check.

No compression.

Ask a Yamaha dealer to inspect.

Wet.

Dry.

Wipe clean with dry cloth and

Ask a Yamaha dealer to inspect.

Check if there is fuel

Enough fuel

No fuel

Go to compression check.

Supply fuel.

in the fuel tank.

Remove 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

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.

3WR-9-2A (E) 6 6/28/00 11:17 AM Page 39

ProCarManuals.com

Summary of Contents for XT600E 2000

Page 1: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000 6 0 1 1 E OWNER S MANUAL 3WR 28199 2A XT600E N YAMAHA MOTOR CO LTD ProCarManuals com ...

Page 2: ... machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 1 ProCarManuals ...

Page 3: ...id 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 information a...

Page 4: ...IMPORTANT MANUAL INFORMATION 1 2 4 5 6 7 8 9 EW000002 w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 3 ProCarManuals com ...

Page 5: ...maha Motor Co Ltd 1st Edition June 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EAU03337 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 4 ProCarManuals com ...

Page 6: ... 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 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 5 ProCarManuals com ...

Page 7: ...3WR 9 2A E 1 5 6 28 00 9 00 AM Page 6 ProCarManuals com ...

Page 8: ...Y INFORMATION 1 1 Safe riding 1 1 Protective apparel 1 3 Modification 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of the important labels 1 7 1 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 7 ProCarManuals com ...

Page 9: ...RY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the m...

Page 10: ... wide on a turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic condi tions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hand...

Page 11: ...operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also m...

Page 12: ...ore riding Check accessory mounts and cargo restraints frequently 3 Never attach any large or heavy items to the handlebar front fork or front fender These items including such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test...

Page 13: ...s Wind may attempt to lift the motorcycle or the motorcycle may become unstable in cross winds These accessories may also cause instability when passing or being passed by large vehicles c Certain accessories can displace the operator from his or her normal riding position This improper position limits the freedom of movement of the operator and may limit control ability therefore such accessories...

Page 14: ... areas b Do not park the motorcycle on a slope or soft ground otherwise it may fall over c Do not park the motorcycle near a flammable source e g a kerosene heater or near an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock s are turned to ON or RES for vacuum type OFF for manual type If the moto...

Page 15: ...n of important labels Please read the following important labels carefully before operating this motorcycle 2 1 WARNING Before you operate this vehicle read the owner s manual English 3HP 21568 00 1 4AA 22259 40 2 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 14 ProCarManuals com ...

Page 16: ...DESCRIPTION Left view 2 1 Right view 2 2 Controls and instruments 2 3 2 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 15 ProCarManuals com ...

Page 17: ...3 Battery page 6 28 4 Owner s tool kit page 6 1 5 Helmet holder page 3 9 6 Rear shock absorber spring preload adjusting nut page 3 9 7 Fuse page 6 29 8 Starter choke knob page 3 8 9 Shift pedal page 3 5 1 2 3 4 5 6 7 8 9 Left view 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 16 ProCarManuals com ...

Page 18: ...4 5 6 7 8 9 2 2 10 Air filter element page 6 12 11 Oil filter element page 6 11 12 Engine oil dipstick page 6 9 13 Brake pedal page 3 5 6 19 10 11 13 12 Right view 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 17 ProCarManuals com ...

Page 19: ...3 3 3 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 18 8 Throttle grip page 6 14 9 Fuel tank cap page 3 6 1 2 3 4 5 6 7 8 9 Controls and instruments 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 18 ProCarManuals com ...

Page 20: ...bar 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 7 Starter choke knob 1 3 8 Seat 3 9 Helmet holder 3 9 Adjusting the shock absorber assembly 3 10 Sidestand 3 11 Ignition circuit cut off system 3 11 3 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 19 ProCarManuals com ...

Page 21: ...l systems are off The key can be removed To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF position and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EW000016 w Never turn the key to OFF or LOCK while the motorcycle is moving otherwise the electrical ...

Page 22: ...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 zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel This information will enable you to plan future fuel stops 1 High...

Page 23: ... to flash the head light EAU00121 Dimmer switch Set this switch to for the high beam and to for the low beam EAU00127 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When released the switch returns to the center position To cancel the turn signal lights push the switch in after it has returned to the center position EAU00129 Horn s...

Page 24: ...o 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 clutch switch which is part of the igni tion circuit cut off system See page 3 12 for an explanation of the ignition circuit cut off system 1 1 Clutch lever 1 5 4 3 2 N 1 1 Shif...

Page 25: ...k opening with the key insert ed in the lock and then turn the cap 1 3 turn clockwise 2 Turn the key 1 4 turn clockwise and then remove it a Unlock b Open 1 EAU00158 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the han dlebar grip EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake ...

Page 26: ... Filler tube 2 Fuel level EAU01183 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown in the illustration EW000130 w 8 Do not overfill the fuel tank otherwise it may overflow when the fuel warms up and expands 8 Avoid spilling fuel on the hot engine EAU00185 cC Immediately wipe off spilled fuel with a clean dry soft cloth since fue...

Page 27: ...is position when the engine is not running Recommended fuel Regular gasoline For Australia Unleaded fuel only Fuel tank capacity Total amount 15 0 L Reserve amount 2 0 L RES ON FUEL OFF 1 1 Arrow mark positioned over OFF ON FUEL RES OFF 1 ON ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position 1 Arrow mark positioned over ON OFF Clos...

Page 28: ...ONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 1 b a EAU03032 Starter choke knob 1 Starting a cold engine requires a rich er air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the starter choke Move the knob in direction b to turn off the starter choke 1 Starter choke knob 1 RES Reserve position EAU00240 Seat To remove the seat Remove the bolts and then pull the se...

Page 29: ...shown To lock the helmet holder place it in the original position and then remove the key EW000030 w Never ride with a helmet attached to the helmet holder since the hel met may hit objects causing loss of control and possibly an acci dent 1 Helmet holder a Open a b 1 2 EAU03591 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting nut EC000...

Page 30: ...ance A Spring preload Minimum soft Distance A 1 mm Standard Distance A 5 5 mm Maximum hard Distance A 12 mm Tightening torque Locknut 42 Nm 4 2 m0kg EAU00315 w This shock absorber contains highly pressurized nitrogen gas For proper handling read and understand the following informa tion before handling the shock absorber The manufacturer can not be held responsible for proper ty damage or personal...

Page 31: ...st the operator in fulfilling the responsibility of rais ing the sidestand before starting off Therefore check this system regularly as described below and have a Yamaha dealer repair it if it does not function properly EAU00331 Ignition circuit cut off system The ignition circuit cut off system comprising the sidestand switch clutch switch and neutral switch has the following functions 8 It preve...

Page 32: ...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 sho...

Page 33: ...1 2 3 4 5 6 7 8 9 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 32 ProCarManuals com ...

Page 34: ...PRE OPERATION CHECKS Pre operation check list 4 1 4 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 33 ProCarManuals com ...

Page 35: ...Check operation brake pedal position fluid level and vehicle for fluid leakage 3 5 6 18 6 22 9 Fill with DOT 4 brake fluid if necessary Clutch 9 Check operation condition and free play 3 4 6 17 6 18 9 Adjust if necessary Throttle grip and housing 9 Check smooth operation 6 14 9 Lubricate if necessary Engine oil 9 Check oil level 6 9 6 12 9 Add oil if necessary Drive chain 9 Check chain slack and c...

Page 36: ... Add fuel if necessary Lights signals and 9 Check proper operation switches 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 repaired before oper...

Page 37: ...1 2 3 4 5 6 7 8 9 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 36 ProCarManuals com ...

Page 38: ...RIDING POINTS Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 4 Tips for reducing fuel consumption 5 4 Engine break in 5 5 Parking 5 6 5 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 37 ProCarManuals com ...

Page 39: ...starting one of the following conditions must be met 8 The transmission is in the neutral position 8 The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 w 8 Before starting the engine check the function of the igni tion circuit cut off system according to the procedure described on page 3 12 8 Never ride with the sidestand down 1 Turn the fuel cock lever to ON 2 ...

Page 40: ...OTE The engine is warm when it responds normally to the throttle with the starter choke turned off EAU01258 Starting a warm engine Follow the same procedure as for starting a cold engine with the excep tion that the starter choke is not required when the engine is warm EAU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hill...

Page 41: ...tly and avoid high engine speeds during accelera tion 8 Do not rev the engine while shift ing down and avoid high engine speeds with no load on the engine 8 Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad cross ings EAU00436 Engine break in There is never a more important peri od in the life of your engine than the...

Page 42: ...hanged and the oil filter cartridge element replaced 1 000 km and beyond The vehicle can now be operated normally EC000053 cC 8 Keep the engine speed out of the tachometer red zone 8 If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehi cle OPERATION AND IMPORTANT RIDING POINTS 1 2 3 4 5 6 7 8 9 EAU00457 Parking When parking stop the e...

Page 43: ...1 2 3 4 5 6 7 8 9 3WR 9 2A E 1 5 6 28 00 9 00 AM Page 42 ProCarManuals com ...

Page 44: ...king the front and rear brake pads 6 20 Checking the brake fluid level 6 21 Changing the brake fluid 6 22 Drive chain slack 6 22 Lubricating the drive chain 6 24 Checking and lubricating the cables 6 24 Checking and lubricating the brake and shift pedals 6 25 Checking and lubricating the brake and clutch levers 6 25 Checking and lubricating the sidestand 6 26 Lubricating the rear suspension 6 26 C...

Page 45: ...red as a general guide under normal riding conditions However DEPENDING ON THE WEATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTE NANCE INTERVALS MAY NEED TO BE SHORTENED EW000060 w If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you EAU00462 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 9 1 EAU01175 Owner s tool kit The owner s too...

Page 46: ... 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever worn to the limit 8 Rear brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever worn to the limit NOTE 8 The annual checks must be performed every year except if kilometer based maintenance is performed instead 8 From 50...

Page 47: ...rcycle and riding in the rain 15 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20 000km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Rear shock absorber assembly Check...

Page 48: ...ears replace the internal components of the brake master cylinder and caliper and change the brake fluid 23 Engine oil Change 24 Engine oil filter element Replace 25 Front and rear brake switches Check operation 26 Moving parts and cables Lubricate 27 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1 000 km ANNUAL CHECK 1 10 20 30...

Page 49: ... panels The cowling and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time the cowling or a panel needs to be removed and installed 1 1 Cowling A 1 1 Panel A 1 1 Panel B 3WR 9 2A E 6 6 28 00 11 17 AM Page 6 ProCarManuals com ...

Page 50: ...as shown To install the cowling Place the cowling in the original posi tion and then install the screw 1 2 EAU00488 Panel A To remove the panel 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 Panel A 2 Screw 3WR 9 2A E 6 6 28 00 11 17 AM Page 7 ProCarManuals com ...

Page 51: ...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 2 1 Spark plug wrench 2 Remove the...

Page 52: ...rk plug 1 Measure the spark plug gap with a wire thickness gauge and if necessary adjust the gap to specification 2 Clean the surface of the spark plug gasket and its mating sur face and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tighten it to the specified torque NOTE If a torque wrench is not available when installing a spark ...

Page 53: ...d straight up when checking the oil level A slight tilt to the side can result in a false reading 2 1 1 Screw 2 Oil filler cap cover 1 2 3 2 Remove the oil filler cap cover by removing the screw 3 Start the engine warm it up for at least 10 seconds and then turn it off 1 Oil filler cap 2 Maximum level mark 3 Minimum level mark 4 Wait a few minutes until the oil settles remove the oil filler cap wi...

Page 54: ...ine warm it up for several minutes and then turn it off 2 Place an oil pan under the engine to collect the used oil 3 Remove the oil filler cap cover the oil filler cap and the drain bolts to drain the oil from the crankcase and oil tank 2 EC000000 cC Do not operate the motorcycle until you know that the engine oil level is sufficient EW000065 w Never remove the engine oil tank cap after high spee...

Page 55: ...l See page 8 1 Oil quantity Without oil filter element replacement 2 7 L With oil filter element replacement 2 8 L Total amount dry engine 3 3 L EC000076 cC After changing the engine oil be sure to check the oil pressure as described below 11 Remove the air bleed screw then start the engine If oil does not seep out of the hole after a few minutes immediately stop the engine and have a Yamaha deale...

Page 56: ...l the air filter element out 1 Screw 7 1 3 Lightly tap the air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it 4 Insert the air filter element into the air filter case with the arrow mark on the top pointing inward 1 Mesh side 12 Start the engine and then let it idle for several min...

Page 57: ...ti cated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has 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 t...

Page 58: ...sting the valve clearance The valve clearance changes with use resulting in improper air fuel mix ture and or engine noise To prevent this from occurring the valve clear ance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 3 5 mm at the thrott...

Page 59: ...r pressure measured on cold tires Load Front Rear Up to 90 kg 150 kPa 1 50 kg cm2 1 50 bar 150 kPa 1 50 kg cm2 1 50 bar 90 kg maximum 150 kPa 1 50 kg cm2 1 50 bar 225 kPa 2 25 kg cm2 2 25 bar Off roadriding 125 kPa 1 25 kg cm2 1 25 bar 125 kPa 1 25 kg cm2 1 25 bar High speed riding 150 kPa 1 50 kg cm2 1 50 bar 150 kPa 1 50 kg cm2 1 50 bar Maximum load 202 kg Total weight of rider passenger cargo a...

Page 60: ...tability and can lead to loss of control 8 The replacement of all wheel and brake related parts including the tires should be left to a Yamaha dealer who has the necessary profession al knowledge and experience 2 Tire information This motorcycle is equipped with tube tires EW000078 w 8 The front and rear tires should be of the same make and design otherwise the handling characteristics of the moto...

Page 61: ... its optimal charac teristics 1 2 a b c EAU00694 Adjusting the clutch lever free play The clutch lever free play should measure 2 3 mm as shown Periodically check the clutch lever free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch lever 2 To increase the clutch lever free play turn the adjusting bolt in direction a To decrease the clutch lever free play turn the adj...

Page 62: ... decrease the clutch lever free play turn the adjusting nut in direction b 1 Adjusting nut 2 Locknut EAU00696 Adjusting the brake lever free play 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 directi...

Page 63: ...imately 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 th...

Page 64: ... adjusting nut in direc tion b 2 1 a b 1 Brake light switch 2 Adjusting nut EAU00721 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart EAU01119 Front brake pads Each front brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without havin...

Page 65: ...bly causing it to become 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 Minimum level mark a 1 EAU00730 Rear brake pads The rear brake is provided with...

Page 66: ...hanging the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrica tion chart In addition have the oil seals of the master cylinder and caliper as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking 8 Oil seals Replace every two years 8 Brake hoses Replace every four years EAU0074...

Page 67: ...bracket bolt 48 Nm 4 8 m0kg EAU01134 To adjust the drive chain slack 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 Br...

Page 68: ... rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECA00052 cC Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings EAU02962 Checking and lubricating the cables The oper...

Page 69: ...s The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lubricated if necessary Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease all purpose grease EW000112 w Damage to the outer sheath may interfere with proper cable opera tion and will cause the inner cable to rust Replace a ...

Page 70: ... 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 check or repair it EAU02939 Checking the front fork 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 condition EW000115 w Securely sup...

Page 71: ...dic maintenance and lubrica tion chart 1 Place a stand under the engine to raise the front wheel off the ground EW000115 w Securely support the motorcycle so that there is no danger of it falling over To check the operation 1 Place the motorcycle on a level surface and hold it in an upright position 2 While applying the front brake push down hard on the handle bars several times to check if the fr...

Page 72: ...would per manently damage the battery EW000116 w 8 Electrolyte is poisonous and 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 8 EXTERNAL Flush with plenty of water 8 INTERNAL Drink large quantities of water or milk and imm...

Page 73: ...ories To store the battery 1 If the motorcycle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 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 installation 4 After installation make sure that the battery leads are properly conn...

Page 74: ... headlight bulb This motorcycle is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove cowling A See page 6 6 for cowling removal and installation procedures 2 Remove the headlight unit by removing the bolts PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 9 1 1 Bolt 3 3 1 2 3 Disconnect the headlight coupler and the auxiliary light leads and t...

Page 75: ...a cloth moistened with alcohol or thinner 4 Remove the headlight bulb hold er by turning it counterclockwise and then remove the defective bulb EW000119 w Headlight bulbs get very hot Therefore keep flammable prod ucts away from a lit headlight bulb and do not touch the bulb until it has cooled down 1 1 Headlight bulb holder a a Do not touch this area 6 Install the bulb cover and then connect the ...

Page 76: ...un 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 2 1 Screw 2 Lens 1 1 Bulb EAU01623 Replacing the tail brake light bulb 1 Remove the tail brake light lens by removing the screws 2 1 1 Screw 2 2 Lens 3WR 9 2A E 6 6 28 00 11 17 A...

Page 77: ...ional motorcycle stand is not available by placing a jack under the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand 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 screws EC000108 cC Do not o...

Page 78: ...dure on page 6 33 4 Pull the wheel axle out and then remove the wheel ECA00048 cC Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut 1 2 1 Axle holder nut 4 2 Wheel axle EAU00897 Front wheel To remove the front wheel EW000122 w 8 It is advisable to have a Yamaha dealer service the wheel 8 Securely support the motorcy cl...

Page 79: ...rt ing the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg 3 Install the wheel axle 4 Lower the front wheel so that it is on the ground 5 Tighten the wheel axle to the specified torque 1 Retainer Tightening torque Wheel axle 59 Nm 5 9 m0kg 7 After tightening the holder nuts while applying the front brake push down on the handlebars several times to ...

Page 80: ...er with the brake disc otherwise the brake pads will be forced shut 3 Remove the bolt on each end of the swingarm 4 Lift the rear wheel off the ground according to the procedure on page 6 33 1 1 1 Bolt 2 EAU00963 Rear wheel To remove the rear wheel EW000122 w 8 It is advisable to have a Yamaha dealer service the wheel 8 Securely support the motorcy cle so that there is no danger of it falling over...

Page 81: ...may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills EAU01136 To install the rear wheel 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 ...

Page 82: ...oth and Ask a Yamaha dealer to inspect Check if there is fuel Enough fuel No fuel Go to compression check Supply fuel in the fuel tank Remove 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 ...

Page 83: ...3WR 9 2A E 6 6 28 00 11 17 AM Page 40 ProCarManuals com ...

Page 84: ...MOTORCYCLE CARE AND STORAGE Care 7 1 Storage 7 4 7 3WR 9 2A E 7 9 6 28 00 9 02 AM Page 1 ProCarManuals com ...

Page 85: ...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 Avoid using strong acidic wheel cleaners especially on spoked wheels If such prod ucts are used...

Page 86: ... 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 before cleaning After riding in the rain near th...

Page 87: ...sing abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermal...

Page 88: ...h a tarp while it is still wet will allow water and humidity to seep in and cause rust 8 To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for several months 1 Follow all the instructions in the Care section of this chapter 2 For motorcycles equipped with a fuel cock that has an O...

Page 89: ...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 information on storing the batte...

Page 90: ...SPECIFICATIONS Specifications 8 1 Conversion table 8 5 8 3WR 9 2A E 7 9 6 28 00 9 02 AM Page 7 ProCarManuals com ...

Page 91: ...arter 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 contain anti friction additives which will cause clutch and or starter clutch slippage resulting in reduced component life and poor engine perform...

Page 92: ... reduction ratio 71 34 2 088 Secondary reduction system Chain drive Secondary reduction ratio 3 000 Number of drive chain sprocket teeth rear front 45 15 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 2 583 2nd 1 588 3rd 1 200 4th 0 955 5th 0 792 Chassis Frame type Diamond Caster angle 27 75 Trail 120 mm Tires Type With tube Front Size 90 90 21 54S Manufacture...

Page 93: ...50 kgf cm2 1 50 bar Rear 150 kPa 1 50 kgf cm2 1 50 bar Load is total weight of cargo rider passenger and accessories Wheels Front Type Spoke wheel Size 21 1 85 Rear Type Spoke wheel Size 17 MT2 50 Brakes Front Type Single disc brake Operation Right hand operation Fluid DOT 4 Rear Type Single disc brake Operation Right foot operation Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm new mo...

Page 94: ...ght bulb 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 Front turn signal light 12 V 21W 2 Rear turn signal 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 3WR 9 2A E 7 9 6 28 00 9 02 AM Page 11 ProCarManual...

Page 95: ...tiplier Imperial unit m kg 7 233 ft lb Torque m kg 86 794 in lb cm kg 0 0723 ft lb cm kg 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 kg mm 55 997 lb in Misc kg cm2 14 2234 psi lb in2 Centig...

Page 96: ...ON Identification numbers record 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 Motorcycle noise regulation For Australia 9 2 9 3WR 9 2A E 7 9 6 28 00 9 02 AM Page 13 ProCarManuals com ...

Page 97: ...ey identification number is stamped into the key tag Record this number in the space pro vided and use it for reference when ordering a new key EAU01043 Vehicle identification number 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...

Page 98: ...ustralia TAMPERING WITH NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inoper ative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehi cle for the purpose of noise con trol prior to its sale or delivery to the ultimate purchaser or while it is in use an...

Page 99: ...6 26 Rear wheel 6 36 Removing 6 36 Installing 6 36 S Safety information 1 1 Seat 3 8 Shift pedal 3 4 Shifting 5 2 Shock absorber assembly adjusting 3 9 Sidestand 3 11 Sidestand checking and lubricating 6 26 Spark plug checking 6 7 Specifications 8 1 Speedometer unit 3 2 Starter choke knob 3 8 Starting and warming up a cold engine 5 1 Steering checking 6 27 A Air filter element cleaning 6 12 B Batt...

Page 100: ... Throttle cable free play adjusting 6 14 Tires 6 15 Troubleshooting 6 37 Troubleshooting chart 6 38 Turn signal light bulb replacing 6 32 V Valve clearance adjusting 6 14 Vehicle identification number 9 1 W Wheel bearings checking 6 28 Wheels 6 17 3WR 9 2A E 7 9 6 28 00 9 02 AM Page 17 ProCarManuals com ...

Page 101: ...3WR 9 2A E 7 9 6 28 00 9 02 AM Page 18 ProCarManuals com ...

Page 102: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000 6 0 1 1 E OWNER S MANUAL 3WR 28199 2A XT600E N YAMAHA MOTOR CO LTD ProCarManuals com ...

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