OWNER’S MANUAL XT500E XT600E YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001·7–0.
4PT-E7 (English) 6/29/01 9:13 AM Page 1 EAU03338 INTRODUCTION Welcome to the Yamaha world of motorcycling! As the owner of an XT500E/XT600E, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XT500E/XT600E.
4PT-E7 (English) 6/29/01 9:13 AM Page 2 EAU00005 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Q w Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.
PT-E7 (English) 6/29/01 9:13 AM Page 3 IMPORTANT MANUAL INFORMATION w EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
4PT-E7 (English) 6/29/01 9:13 AM Page 4 EAU04229 XT500E/XT600E OWNER’S MANUAL ©2001 by 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.
4PT-E7 (English) 6/29/01 9:13 AM Page 5 EAU00009 TABLE OF CONTENTS 1 GIVE SAFETY THE RIGHT OF WAY 1 2 DESCRIPTION 2 3 INSTRUMENT AND CONTROL FUNCTIONS 3 4 PRE-OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX
4PT-E7 (English) 6/29/01 9:13 AM Page 6
4PT-E7 (English) 6/29/01 9:13 AM Page 7 Q GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY ..............................................
4PT-E7 (English) 6/29/01 9:13 AM Page 8 Q GIVE SAFETY THE RIGHT OF WAY 1 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 ignore the laws of physics. Regular care and maintenance are essential for preserving value and operating condition of your motorcycle.
4PT-E7 (English) 6/29/01 9:13 AM Page 9 DESCRIPTION Left view ........................................................................................... 2-1 Right view ......................................................................................... 2-2 Controls and instruments ..................................................................
4PT-E7 (English) 6/29/01 9:13 AM Page 10 EAU00026 DESCRIPTION Part locations Left view 1 2 3 4 5 2 9 8 1. 2. 3. 4. 5. Headlight Fuel cock Battery Owner’s tool kit Helmet holder (page 6-33) (page 3-8) (page 6-31) (page 6-1) (page 3-10) 7 6 6. Shock absorber spring preload adjusting nut 7. Fuse 8. Starter (choke) knob 9.
4PT-E7 (English) 6/29/01 9:13 AM Page 11 DESCRIPTION Right view 10 11 12 2 13 10. 11. 12. 13.
4PT-E7 (English) 6/29/01 9:13 AM Page 12 DESCRIPTION Controls and instruments 1 2 3 4 5 6 7 2 9 1. 2. 3. 4. 5. Clutch lever Left handlebar switches Speedometer unit Main switch/steering lock Tachometer (page 3-4, 6-20) (page 3-3) (page 3-2) (page 3-1) (page 3-3) 2-3 8 6. 7. 8. 9.
4PT-E7 (English) 6/29/01 9:13 AM Page 13 INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock .................................................................. 3-1 Indicator lights .................................................................................. 3-2 Speedometer unit ............................................................................ 3-2 Tachometer ...................................................................................... 3-3 Handlebar switches ..............
4PT-E7 (English) 6/29/01 9:13 AM Page 14 EAU00027 INSTRUMENT AND CONTROL FUNCTIONS ON 1 OFF w 2 Never turn the key to “OFF” or “LOCK” while the motorcycle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the motorcycle is stopped before turning the key to “OFF” or “LOCK”. LOCK .
4PT-E7 (English) 6/29/01 9:13 AM Page 15 INSTRUMENT AND CONTROL FUNCTIONS EAU00057 1 2 1 Turn signal indicator light “5” 2 Turn signal indicator light & This indicator light flashes when the turn signal switch is pushed to the left or right. N 5 4 3 3 3 1. High beam indicator light “&” 2. Neutral indicator light “N” 3. Turn signal indicator light “5” 1. 2. 3. 4.
4PT-E7 (English) 6/29/01 9:13 AM Page 16 INSTRUMENT AND CONTROL FUNCTIONS EAU03888 3 1 2 1 Dimmer switch “%/&” Dimmer switch & N Set this switch to “&” for the high beam and to “%” for the low beam. a EAU03889 5 Turn signal switch “4/6” Turn signal switch * 3 5 1. Tachometer a. Red zone EAU00102 Tachometer 1. 2. 3. 4. 5.
4PT-E7 (English) 6/29/01 9:13 AM Page 17 INSTRUMENT AND CONTROL FUNCTIONS EAU00143 Start switch “,” Start switch Push this switch to crank the engine with the starter. EC000005 cC , 1 See page 5-1 for starting instructions prior to starting the engine. 1 2 1. Engine stop switch “$/#” 2. Start switch “,” 3 1. Clutch lever EAU00152 EAU03890 Clutch lever Engine stop switch “$/#” Clutch lever The clutch lever is located at the left handlebar grip.
4PT-E7 (English) 6/29/01 9:13 AM Page 18 INSTRUMENT AND CONTROL FUNCTIONS 1 1 1 3 1. Shift pedal 1. Brake lever 1. Brake pedal EAU00157 EAU00158 EAU00162 Shift pedal Brake lever Brake pedal Shift pedal Brake lever Brake pedal The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 5-speed constant-mesh transmission equipped on this motorcycle. The brake lever is located at the right handlebar grip.
4PT-E7 (English) 6/29/01 9:13 AM Page 19 INSTRUMENT AND CONTROL FUNCTIONS b NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. a EAU00177 Fuel tank cap Fuel tank cap 2 3 EW000023 w a. Unlock. b. Open. 1 Make sure that the fuel tank cap is properly closed and locked before riding. 1. Filler tube 2. Fuel level EAU03753 Fuel Fuel Make sure that there is sufficient fuel in the tank.
4PT-E7 (English) 6/29/01 9:13 AM Page 20 INSTRUMENT AND CONTROL FUNCTIONS cC EAU00185 Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. 3 EAU04284 Recommended fuel: REGULAR UNLEADED GASOLINE ONLY Fuel tank capacity: Total amount: 15.0 L Reserve amount: 2.0 L ECA00102 cC Use only unleaded gasoline.
4PT-E7 (English) 6/29/01 9:13 AM Page 21 INSTRUMENT AND CONTROL FUNCTIONS OFF: closed position ON: normal position RES: reserve position RES RES RES RES OFF OFF ON FUEL ON 1 1 ON 1. Arrow mark pointing over “OFF” EAU03050 Fuel cock Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF FUEL ON FUEL 1 1. Arrow mark pointing over “ON” 1.
4PT-E7 (English) 6/29/01 9:13 AM Page 22 INSTRUMENT AND CONTROL FUNCTIONS 1 b a 2 1 1 3 1. Starter (choke) knob “1” 1. Bolt (×2) EAU04038 EAU00240 Starter (choke) knob “1” Seat Starter (choke) knob Seat Starting a cold engine requires a richer 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). To remove the seat Remove the bolts, and then pull the seat off. 1.
4PT-E7 (English) 6/29/01 9:13 AM Page 23 INSTRUMENT AND CONTROL FUNCTIONS a 2 b a 1 1 A 1. Helmet holder a. Open. 1. Locknut 2. Adjusting nut EAU00260 Helmet holder Helmet holder To open the helmet holder, insert the key into the lock, and then turn the key as shown. To lock the helmet holder, place it in the original position, and then remove the key.
4PT-E7 (English) 6/29/01 9:13 AM Page 24 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00330 Sidestand Sidestand 3. Tighten the locknut to the specified torque. Tightening torque: Locknut: 42 Nm (4.2 m0kgf) cC EAU00315 w Spring preload: Minimum (soft): Distance A = 1 mm Standard: Distance A = 5.5 mm Maximum (hard): Distance A = 12 mm EC000018 Always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque.
4PT-E7 (English) 6/29/01 9:13 AM Page 25 INSTRUMENT AND CONTROL FUNCTIONS w EW000044 The motorcycle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off.
4PT-E7 (English) 6/29/01 9:13 AM Page 26 INSTRUMENT AND CONTROL FUNCTIONS NOTE: This check is most reliable if performed with a warmed-up engine. With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “#”. 3. Turn the key to “ON”. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? 3 YES NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
4PT-E7 (English) 6/29/01 9:13 AM Page 27 PRE-OPERATION CHECKS Pre-operation check list ....................................................................
4PT-E7 (English) 6/29/01 9:13 AM Page 28 EAU01114 PRE-OPERATION CHECKS The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
4PT-E7 (English) 6/29/01 9:13 AM Page 29 PRE-OPERATION CHECKS ITEM Clutch Throttle grip Control cables Drive chain Wheels and tires Brake and shift pedals Brake and clutch levers Sidestand • • • • • • • • • • • • • • • • • • • • • • • CHECKS Check operation. Lubricate cable if necessary. Check lever free play. Adjust if necessary. Make sure that operation is smooth. Check free play. If necessary, have Yamaha dealer make adjustment or lubricate. Make sure that operation is smooth.
4PT-E7 (English) 6/29/01 9:13 AM Page 30 PRE-OPERATION CHECKS ITEM Chassis fasteners Instruments, lights, signals and switches Sidestand switch 4 • • • • • • CHECKS Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary. Check operation. Correct if necessary. Check operation of ignition circuit cut-off system. If system is defective, have Yamaha dealer check vehicle.
4PT-E7 (English) 6/29/01 9:13 AM Page 31 OPERATION AND IMPORTANT RIDING 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 ........
4PT-E7 (English) 6/29/01 9:13 AM Page 32 EAU00372 OPERATION AND IMPORTANT RIDING POINTS w EAU00373 EAU03515 Starting the engine Starting the engine 5 8 Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. 8 Never start the engine or operate it in a closed area for any length of time.
4PT-E7 (English) 6/29/01 9:13 AM Page 33 OPERATION AND IMPORTANT RIDING POINTS 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 preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. 7. When the engine is warm, turn the starter (choke) off. NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. 6.
4PT-E7 (English) 6/29/01 9:13 AM Page 34 OPERATION AND IMPORTANT RIDING POINTS 5 4 3 2 N 1 1 1. Shift pedal N. Neutral position EAU00423 5 EC000048 cC Shifting Shifting Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration.
4PT-E7 (English) 6/29/01 9:13 AM Page 35 OPERATION AND IMPORTANT RIDING POINTS EAU00424 Tips for reducing fuel consumption Fuel consumption, tips for reducing Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: 8 Thoroughly warm up the engine. 8 Turn the starter (choke) off as soon as possible. 8 Shift up swiftly, and avoid high engine speeds during acceleration.
4PT-E7 (English) 6/29/01 9:13 AM Page 36 OPERATION AND IMPORTANT RIDING POINTS cC EC000053 EAU00457 Parking Parking 8 Keep the engine speed out of the tachometer red zone. 8 If any engine trouble should occur during the engine breakin period, immediately have a Yamaha dealer check the vehicle. 5 When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”.
4PT-E7 (English) 6/29/01 9:13 AM Page 37 PERIODIC MAINTENANCE AND MINOR REPAIR Owner’s tool kit ................................................ 6-1 Periodic maintenance and lubrication chart ..... 6-3 Removing and installing the cowling and panels .................................................... 6-6 Checking the spark plug .................................. 6-8 Engine oil and oil filter element ...................... 6-10 Cleaning the air filter element ........................
4PT-E7 (English) 6/29/01 9:13 AM Page 38 EAU00462 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00464 6 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages.
4PT-E7 (English) 6/29/01 9:13 AM Page 39 PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. w EW000063 Modifications not approved by Yamaha may cause loss of performance 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 40 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03685 Periodic maintenance and lubrication chart Periodic maintenance and lubrication chart NOTE: 8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. 8 From 50,000 km, repeat the maintenance intervals starting from 10,000 km. 8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. NO.
4PT-E7 (English) 6/29/01 9:13 AM Page 41 PERIODIC MAINTENANCE AND MINOR REPAIR NO. ITEM 8 * Brake hoses 9 * Wheels 10 * Tires 11 * * Wheel bearings 12 13 CHECK OR MAINTENANCE JOB • Check for cracks or damage. • Replace. (See NOTE on page 6-5.) • Check runout, spoke tightness and for damage. • Tighten spokes if necessary. • Check tread depth and for damage. • Replace if necessary. • Check air pressure. • Correct if necessary.
4PT-E7 (English) 6/29/01 9:13 AM Page 42 PERIODIC MAINTENANCE AND MINOR REPAIR NO. 20 * 21 * 22 23 24 6 * ITEM CHECK OR MAINTENANCE JOB Rear suspension relay • Check operation. arm and connecting arm • Lubricate with molybdenum disulfide grease. pivoting points • Check starter (choke) operation. Carburetor • Adjust engine idling speed. • Change. Engine oil • Check oil level and vehicle for oil leakage.
4PT-E7 (English) 6/29/01 9:13 AM Page 43 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1. Cowling A 1. Panel A EAU03516 Removing and installing the cowling and panels Cowling and panels, removing and instal ing 1 1. Panel B Refer to this section each time the cowling or a panel needs to be removed and installed. The cowling and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter.
4PT-E7 (English) 6/29/01 9:13 AM Page 44 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 1 1. Screw EAU01145 6 Cowling A To remove the cowling Remove the screw, and then pull the cowling off as shown. 1. Panel A 2. Screw To install the cowling Place the cowling in the original position, and then install the screw. EAU04003 Panels A and B To remove one of the panels Remove the screw, and then pull the panel off as shown.
4PT-E7 (English) 6/29/01 9:13 AM Page 45 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1 2 1. Panel B 2. Screw 1. Spark plug cap 1. Spark plug wrench EAU01833 Checking the spark plug Spark plug, checking The 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.
4PT-E7 (English) 6/29/01 9:13 AM Page 46 PERIODIC MAINTENANCE AND MINOR REPAIR To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-tolight tan (the ideal color when the motorcycle is ridden normally). 6 NOTE: If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the motorcycle. 2.
4PT-E7 (English) 6/29/01 9:13 AM Page 47 PERIODIC MAINTENANCE AND MINOR REPAIR EAU04354 Engine oil and oil filter element Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the motorcycle on a level surface and hold it in an upright position.
4PT-E7 (English) 6/29/01 9:13 AM Page 48 PERIODIC MAINTENANCE AND MINOR REPAIR cC EC000000 Do not operate the motorcycle until you know that the engine oil level is sufficient. w 6 1 1 2 EW000065 Never remove the engine oil tank cap after high-speed operation, otherwise hot engine oil could spout out and cause damage or injury. Always let the engine oil cool down sufficiently before removing the oil tank cap. 5.
4PT-E7 (English) 6/29/01 9:13 AM Page 49 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 1. Oil filter element 2. O-ring (×2) 6. Remove and replace the oil filter element. 7. Check the O-rings for damage and replace them if necessary. 8. Install the oil filter element cover by installing the bolts, then tightening them to the specified torque. NOTE: Make sure that the O-ring is properly seated. 9. Install the engine oil drain bolts, and then tighten them to the specified torques.
4PT-E7 (English) 6/29/01 9:13 AM Page 50 PERIODIC MAINTENANCE AND MINOR REPAIR 12. Start the engine, and then let it idle for several minutes while checking it for oil 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 cC 6 1 1 1.
4PT-E7 (English) 6/29/01 9:13 AM Page 51 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00629 1 Adjusting the carburetor Carburetor, adjusting 1 1. Mesh side 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.
4PT-E7 (English) 6/29/01 9:13 AM Page 52 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00632 NOTE: If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. Adjusting the engine idling speed Engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart. 1.
4PT-E7 (English) 6/29/01 9:13 AM Page 53 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 Adjusting the valve clearance Valve clearance, adjusting a a. Throttle cable free play EAU00635 The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
4PT-E7 (English) 6/29/01 9:13 AM Page 54 PERIODIC MAINTENANCE AND MINOR REPAIR Tire air pressure (measured on cold tires) Load* Rear Up to 90 kg 150 kPa 150 kPa (1.50 kgf/cm2, (1.50 kgf/cm2, 1.50 bar) 1.50 bar) 90 kg– maximum 150 kPa 225 kPa (1.50 kgf/cm2, (2.25 kgf/cm2, 1.50 bar) 2.25 bar) Off-road riding 125 kPa 125 kPa (1.25 kgf/cm2, (1.25 kgf/cm2, 1.25 bar) 1.25 bar) High speed riding 150 kPa 225 kPa (1.50 kgf/cm2, (2.25 kgf/cm2, 1.50 bar) 2.
4PT-E7 (English) 6/29/01 9:13 AM Page 55 PERIODIC MAINTENANCE AND MINOR REPAIR a NOTE: The tire tread depth limits may differ from country to country. Always comply with the local regulations. 1 Tire information This motorcycle is equipped with tube tires. 1. Side wall a. Tire tread depth Tire inspection The tires must be checked before each ride.
4PT-E7 (English) 6/29/01 9:13 AM Page 56 PERIODIC MAINTENANCE AND MINOR REPAIR w EAU00681 EAU00685 Spoke wheels Wheels 6 8 Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operating the motorcycle with excessively worn tires decreases riding stability and can lead to loss of control. 8 The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.
4PT-E7 (English) 6/29/01 9:13 AM Page 57 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 a c 7. Tighten the locknut at the clutch lever and the crankcase. b a b 1 1. Locknut (clutch lever) 2. Adjusting bolt c. Free play 2 1. Locknut (crankcase) 2. Adjusting nut EAU00694 Adjusting the clutch lever free play Clutch lever free play, adjusting The clutch lever free play should measure 10–15 mm as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows. 1.
4PT-E7 (English) 6/29/01 9:13 AM Page 58 PERIODIC MAINTENANCE AND MINOR REPAIR 3. Tighten the locknut. b 1 2 c a 1. Locknut 2. Adjusting bolt c. Free play EAU00696 Adjusting the brake lever free play 6 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.
4PT-E7 (English) 6/29/01 9:13 AM Page 59 PERIODIC MAINTENANCE AND MINOR REPAIR w EW000109 A soft or spongy feeling in the brake pedal 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 60 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1 1. Wear indicator groove (×3) EAU03938 6 FRONT 2 1 Front brake pads Each front brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves.
4PT-E7 (English) 6/29/01 9:13 AM Page 61 PERIODIC MAINTENANCE AND MINOR REPAIR REAR 1 1. Minimum level mark Observe these precautions: 8 When checking the fluid level, make sure that the top of the brake fluid reservoir is level. 8 Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4 8 Refill with the same type of brake fluid.
4PT-E7 (English) 6/29/01 9:13 AM Page 62 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00744 Drive chain slack 1 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. a 2 To check the drive chain slack Checking 1. Place the motorcycle on a level surface and hold it in an upright position. 6 NOTE: When checking and adjusting the drive chain slack, the motorcycle should be positioned straight up and there should be no weight on it. 2.
4PT-E7 (English) 6/29/01 9:13 AM Page 63 PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Make sure that both adjusting plates are in the same position for proper wheel alignment. cC EC000096 Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits. 3. Tighten the axle nut and the brake caliper bracket bolt to the specified torques.
4PT-E7 (English) 6/29/01 9:13 AM Page 64 PERIODIC MAINTENANCE AND MINOR REPAIR EW000112 w Damage to the outer sheath may interfere with proper cable operation and will cause the inner cable to rust. Replace a damaged cable as soon as possible to prevent unsafe conditions.
4PT-E7 (English) 6/29/01 9:13 AM Page 65 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03370 EAU03164 EAU03165 Checking and lubricating the brake and shift pedals Checking and lubricating the brake and clutch levers Checking and lubricating the sidestand Brake and shift pedals, checking and lubricating Brake and clutch levers, checking and lubricating Sidestand, checking and lubricating The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lub
4PT-E7 (English) 6/29/01 9:13 AM Page 66 PERIODIC MAINTENANCE AND MINOR REPAIR EAU02939 Checking the front fork Front fork, checking The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1 1 To check the condition 1.
4PT-E7 (English) 6/29/01 9:13 AM Page 67 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00794 EAU01144 Checking the steering Checking the wheel bearings Steering, checking Wheel bearings, checking Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground.
4PT-E7 (English) 6/29/01 9:13 AM Page 68 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00800 Battery EW000116 w Battery This motorcycle is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. cC EC000101 Never attempt to remove the battery cell seals, as this would permanently damage the battery. 6 8 Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns.
4PT-E7 (English) 6/29/01 9:13 AM Page 69 PERIODIC MAINTENANCE AND MINOR REPAIR To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the motorcycle is equipped with optional electrical accessories. 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.
4PT-E7 (English) 6/29/01 9:13 AM Page 70 PERIODIC MAINTENANCE AND MINOR REPAIR cC EC000103 3 Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. 6 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 1 2 1 1.
4PT-E7 (English) 6/29/01 9:13 AM Page 71 PERIODIC MAINTENANCE AND MINOR REPAIR 1 a 1. Headlight bulb holder a. Do not touch this area. 4. Remove the headlight bulb holder by turning it counterclockwise, and then remove the defective bulb. w 6. Install the bulb cover, and then connect the coupler and leads. 7. Install the headlight unit by installing the bolts. 8. Install the cowling. 9. Have a Yamaha dealer adjust the headlight beam if necessary. EW000119 Headlight bulbs get very hot.
4PT-E7 (English) 6/29/01 9:13 AM Page 72 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1 2 2 1. Screw 2. Lens 1. Bulb EAU03497 Replacing a turn signal light bulb Turn signal light bulb, replacing 6 1. Remove the turn signal light lens by removing the screw. 1. Screw (×2) 2. Lens 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screw.
4PT-E7 (English) 6/29/01 9:13 AM Page 73 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 Supporting the motorcycle 1 Supporting the motorcycle 1. Bulb 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. cC EC000108 Do not overtighten the screws, otherwise the lens may break.
4PT-E7 (English) 6/29/01 9:13 AM Page 74 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 2 1 1. Speedometer cable EAU00897 Front wheel Removing To remove the front wheel 6 w EW000122 8 It is advisable to have a Yamaha dealer service the wheel. 8 Securely support the motorcycle so that there is no danger of it falling over. 1. Disconnect the speedometer cable from the front wheel. 1. Wheel axle holder nut (×4) 2. Wheel axle 1. Speedometer gear unit EAU03555 2.
4PT-E7 (English) 6/29/01 9:13 AM Page 75 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 a 7. After tightening 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 NOTE: Make sure that there is enough space between the brake pads before inserting the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg. 3.
4PT-E7 (English) 6/29/01 9:13 AM Page 76 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1 1 2 1. Axle nut 2. Brake caliper bracket bolt 1. Swingarm end bolt (×2) EAU04314 Rear wheel 6 To remove the rear wheel w a 3. Lift the rear wheel off the ground according to the procedure on page 6-36. 4. Remove the swingarm end bolts. EW000122 8 It is advisable to have a Yamaha dealer service the wheel. 8 Securely support the motorcycle so that there is no danger of it falling over. 1. Remove the axle nut.
4PT-E7 (English) 6/29/01 9:13 AM Page 77 PERIODIC MAINTENANCE AND MINOR REPAIR ECA00048 cC EAU01136 To install the rear wheel Instal 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. 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.
4PT-E7 (English) 6/29/01 9:13 AM Page 78 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01008 Tightening torque: Axle nut: 105 Nm (10.5 m0kgf) Brake caliper bracket bolt: 48 Nm (4.8 m0kgf) Swingarm end bolt: 2.5 Nm (0.25 m0kgf) 6 Troubleshooting Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.
4PT-E7 (English) 6/29/01 9:13 AM Page 79 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01397 Troubleshooting chart Troubleshooting chart EW000125 w Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel Enough fuel Go to compression check. No fuel Supply fuel. Check if there is fuel in the fuel tank. 2. Compression Engine doesn’t start, go to compression check. There is compression. Go to ignition check. No compression. Ask a Yamaha dealer to inspect.
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4PT-E7 (English) 6/29/01 9:13 AM Page 81 MOTORCYCLE CARE AND STORAGE Care .................................................................................................. 7-1 Storage .............................................................................................
4PT-E7 (English) 6/29/01 9:13 AM Page 82 EAU03521 MOTORCYCLE CARE AND STORAGE Care Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle.
4PT-E7 (English) 6/29/01 9:13 AM Page 83 MOTORCYCLE CARE AND STORAGE 8 Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
4PT-E7 (English) 6/29/01 9:13 AM Page 84 MOTORCYCLE CARE AND STORAGE 7 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 stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.) 4.
4PT-E7 (English) 6/29/01 9:13 AM Page 85 MOTORCYCLE CARE AND STORAGE Storage Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. cC ECA00014 8 Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.
4PT-E7 (English) 6/29/01 9:13 AM Page 86 MOTORCYCLE CARE AND STORAGE 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8.
4PT-E7 (English) 6/29/01 9:13 AM Page 87 SPECIFICATIONS Specifications ................................................................................... 8-1 Conversion table ...............................................................................
4PT-E7 (English) 6/29/01 9:13 AM Page 88 EAU01038 SPECIFICATIONS Specifications Specifications Engine oil Model XT500E/XT600E Type Dimensions Overall length Overall width Overall height SAE 15W/40 SAE 20W/40 1,205 mm Wheel base 1,440 mm 40° 50°C SAE 10W/40 SAE 20W/50 Recommended engine oil classification 230 mm 2,300 mm API Service SE, SF, SG type or higher cC 176 kg 172 kg (CH only) Be sure to use motor oils that do not contain anti-friction modifiers.
4PT-E7 (English) 6/29/01 9:13 AM Page 89 SPECIFICATIONS Air filter Dry type element Gear ratio Fuel Type REGULAR UNLEADED GASOLINE ONLY Fuel tank capacity 15 L Reserve amount 2L Carburetor 1st 2.583 2nd 1.588 3rd 1.200 4th 0.954 (XT500E) 0.955 (XT600E) 5th 0.792 Chassis Type×quantity Y26PV×1 Frame type Diamond Manufacturer TEIKEI Caster angle 27.75° (XT500E) 27°45’ (XT600E) Trail 120 mm Spark plug Type/Manufacturer DPR8EA-9 or DPR9EA-9/NGK Spark plug gap 0.8–0.
4PT-E7 (English) 6/29/01 9:13 AM Page 90 SPECIFICATIONS Air pressure (cold tire) up to 90 kg load* Brakes Front Front 150 kPa (1.50 kgf/cm2, 1.50 bar) Type Single disc brake Rear 150 kPa (1.50 kgf/cm2, 1.50 bar) Operation Right hand Fluid DOT 4 Type Single disc brake Operation Right foot Fluid DOT 4 90 kg load–Maximum load* Front 150 kPa (1.50 kgf/cm2, 1.50 bar) Rear 225 kPa (2.25 kgf/cm2, 2.25 bar) Rear Off-road riding Front Rear 125 kPa (1.25 kgf/cm2, 1.
4PT-E7 (English) 6/29/01 9:13 AM Page 91 SPECIFICATIONS Electrical Ignition system T.C.I. (Digital) Charging system Type A.C. magneto Standard output 14 V, 13.5A @ 5,000 rpm Battery Type YTX9-BS Voltage, capacity 12 V, 8 AH Headlight 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 12 V, 3.
4PT-E7 (English) 6/29/01 9:13 AM Page 92 SPECIFICATIONS EAU03941 Conversion table CONVERSION TABLE Conversion table Conversion table All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC TO IMPERIAL Metric unit Ex. METRIC ** mm 2 mm MULTIPLIER × × 0.03937 0.03937 Torque ft • lb in • lb ft • lb in • lb Weight kg g 2.205 0.03527 lb oz Speed km/hr 0.6214 mph Distance km m m cm mm 0.6214 3.281 1.
4PT-E7 (English) 6/29/01 9:13 AM Page 93 CONSUMER INFORMATION Identification numbers ...................................................................... 9-1 Key identification number ................................................................. 9-1 Vehicle identification number ............................................................ 9-1 Model label .......................................................................................
4PT-E7 (English) 6/29/01 9:13 AM Page 94 EAU01039 CONSUMER INFORMATION EAU02944 Identification numbers Identification numbers Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1 1 1. Key identification number 9 1. Vehicle identification number 1.
4PT-E7 (English) 6/29/01 9:13 AM Page 95 CONSUMER INFORMATION 1 1. Model label EAU01050 Model label Model label The model label is affixed to the frame under the seat. (See page 3-9 for seat removal and installation procedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
4PT-E7 (English) 6/29/01 9:13 AM Page 96 INDEX A Air filter element, cleaning ................... 6-13 B Battery ................................................. 6-31 Brake and clutch levers, checking and lubricating ......................................... 6-28 Brake and shift pedals, checking and lubricating ......................................... 6-28 Brake fluid level, checking ................... 6-23 Brake fluid, changing ........................... 6-24 Brake lever ............................
4PT-E7 (English) 6/29/01 9:13 AM Page 97 INDEX Sidestand, checking and lubricating .... 6-28 Spark plug, checking ............................. 6-8 Specifications ........................................ 8-1 Speedometer unit .................................. 3-2 Starter (choke) knob .............................. 3-9 Starting the engine ................................ 5-1 Steering, checking ............................... 6-30 Storage ..................................................
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OWNER’S MANUAL XT500E XT600E YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001·7–0.
