Yamaha XT500E manual

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 · 7 – 0.9 × 1(E) ! 4PT-28199-E7 OWNER ’ S MANUAL Y AMAHA MOTOR CO. , L TD. XT600E XT500E[...]

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 [...]

EAU00005 IMPORT ANT MANUAL INFORMA TION Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person insp[...]

IMPORT ANT MANUAL INFORMA TION EW000002 w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. 4PT-E7 (English) 6/29/01 9:13 AM Page 3[...]

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. EAU04229 4PT-E7 (English) 6/29/01 9:13 AM Page 4[...]

EAU00009 T ABLE OF CONTENTS 1 GIVE SAFETY THE RIGHT OF WAY 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE-OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX 9 8 7 6 5 4 3 2 1 4PT-E7 (English) 6/29/01 9:13 AM Page 5[...]

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Q GIVE SAFETY THE RIGHT OF W A Y GIVE SAFETY THE RIGHT OF WAY .............................................. 1-1 1 4PT-E7 (English) 6/29/01 9:13 AM Page 7[...]

1-1 EAU00021 Q GIVE SAFETY THE RIGHT OF W A Y 1 Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and free- dom. 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 ope[...]

DESCRIPTION Left view ........................................................................................... 2-1 Right view ......................................................................................... 2-2 Controls and instruments .................................................................. 2-3 2 4PT-E7 (English) 6/29/01 9:13[...]

2-1 EAU00026 DESCRIPTION Part locations 2 1. Headlight (page 6-33) 2. Fuel cock (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 45 6 7 8 9 Left view 4PT-E7 [...]

2-2 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[...]

2-3 DESCRIPTION 2 1. Clutch lever (page 3-4, 6-20) 2. Left handlebar switches (page 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, 6-21) 8. Throttle grip (page 6-16, 6-27) 9. Fuel tank cap (page 3-6) 1 23 4 5 67 8 9 Controls and in[...]

INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock .................................................................. 3-1 Indicator lights .................................................................................. 3-2 Speedometer unit ............................................................................ 3-2 Tachometer .......[...]

3-1 EAU00029 Main switch/steering lock Main switch/steering lock The main switch/steering lock con- trols the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU00036 ON All electrical systems are supplied with power, and the engine can be started. The key cannot be removed. EAU00038 OFF A[...]

3-2 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00056 Indicator lights Indicator lights EAU00063 High beam indicator light “ & ” High beam indicator light This indicator light comes on when the high beam of the headlight is switched on. EAU00061 Neutral indicator light “ N ” Neutral indicator light This indicator light comes on when the trans[...]

3-3 EAU00102 T achometer Tachometer The tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. EC000003 c C Do not operate the engine in the tachometer red zone. Red zone: 7,000 r/min and above EAU03888 Dimmer switch “ % / & ” Dimmer switch Set this switch to “ & ” for the high beam and to [...]

3-4 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU03890 Engine stop switch “ $ / # ” Engine stop switch Set this switch to “ # ” before starting the engine. Set this switch to “ $ ” to stop the engine in case of an emer- gency, such as when the motorcycle overturns or when the throttle cable is stuck. EAU00143 Start switch “ , ” Start switc[...]

3-5 EAU00157 Shift pedal Shift 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. INSTRUMENT AND CONTROL FUNCTIONS 3 1 1. Shift pedal EAU00158 Brake lever Brake lever The brake lever is located[...]

3-6 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00177 Fuel tank cap Fuel tank cap To remove the fuel tank cap 1. Insert the key into the lock and turn it 1/4 turn counterclockwise. 2. Turn the fuel tank cap 1/3 turn counterclockwise and pull it off. To install the fuel tank cap 1. Insert the fuel tank cap into the tank opening with the key insert- ed in [...]

3-7 EAU00185 c C Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted sur- faces or plastic parts. EAU04284 ECA00102 c C Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and pis- ton rings, as well as to the exhaust system. You[...]

3-8 INSTRUMENT AND CONTROL FUNCTIONS 3 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 With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running. RES ON FUEL OFF 1 1. Arrow mark [...]

3-9 EAU04038 Starter (choke) knob “ 1 ” Starter (choke) knob 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). INSTRUMENT AND CONTROL FUNCTIONS 3 1 b a 1. Starter (choke)[...]

3-10 INSTRUMENT AND CONTROL FUNCTIONS 3 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. EW000030 w Never ride with a helmet attached to the helmet holder, since the hel- met may hit obj[...]

3-11 3. Tighten the locknut to the speci- fied torque. EC000018 c C Always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque. EAU00315 w This shock absorber contains highly pressurized nitrogen gas. For proper handling, read and understand the following informa- tion before handling the shock absorb[...]

3-12 INSTRUMENT AND CONTROL FUNCTIONS 3 EW000044 w 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 con- tact the ground and distract the operator, resulting in a possible loss of control. Yamaha ’ s ignition circuit cut-off system has b[...]

3-13 INSTRUMENT AND CONTROL FUNCTIONS 3 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? The neutral switch may be defective. The motorcycle shoul[...]

PRE-OPERA TION CHECKS Pre-operation check list .................................................................... 4-1 4 4PT-E7 (English) 6/29/01 9:13 AM Page 27[...]

4-1 EAU01114 PRE-OPERA TION CHECKS 4 The condition of a vehicle is the owner ’ s responsibility. Vital components can start to deteriorate quickly and unexpect- edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak- age or loss of tire air pressure could have serious consequences. [...]

4-2 PRE-OPERA TION CHECKS 4 Clutch • Check operation. • Lubricate cable if necessary. • Check lever free play. • Adjust if necessary. 3-4, 6-20 Throttle grip • Make sure that operation is smooth. • Check free play. • If necessary, have Yamaha dealer make adjustment or lubricate. 6-16, 6-27 Control cables • Make sure that operation i[...]

4-3 PRE-OPERA TION CHECKS 4 Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. • Tighten if necessary. — Instruments, lights, signals and switches • Check operation. • Correct if necessary. 3-1 – 3-4, 6-33 – 6-36 Sidestand switch • Check operation of ignition circuit cut-off system. • If system i[...]

OPERA TION AND IMPORT ANT RIDING POINTS Starting the engine ........................................................................... 5-1 Starting a warm engine ..................................................................... 5-2 Shifting .............................................................................................. 5-3 Recom[...]

1. Turn the fuel cock lever to “ ON ” . 2. Turn the key to “ ON ” and make sure that the engine stop switch is set to “ # ” . 3. Shift the transmission into the neutral position. NOTE: When the transmission is in the neu- tral position, the neutral indicator light should be on, otherwise have a Yamaha dealer check the electrical circuit[...]

5-2 OPERA TION AND IMPORT ANT RIDING POINTS 5 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. EAU01258 Starting a warm engine Engine, starting a warm Follow the same procedure as for starting a cold engine with the excep- tion that the [...]

5-3 OPERA TION AND IMPORT ANT RIDING POINTS 5 EAU00423 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. NOTE: To shift the transmission into the neu- tral position, press the shift pedal down repeatedly until [...]

5-4 OPERA TION AND IMPORT ANT RIDING POINTS 5 EAU00424 Tips for reducing fuel consumption Fuel consumption, tips for reducing Fuel consumption depends largely on your riding style. Consider the follow- ing 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 av[...]

5-5 OPERA TION AND IMPORT ANT RIDING POINTS 5 EC000053 c C 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. EAU00457 Parking Parking When parking, stop the engine, remove the key from the main switch, and then turn t[...]

PERIODIC MAINTENANCE AND MINOR REP AIR 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 oi[...]

6-1 EAU00462 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01175 Owner ’ s tool kit Tool kit The owner ’ s tool kit is located behind panel A. (See page 6-7 for panel removal and installation procedures.) The service information included in this manual and the tools provided in the owner ’ s tool kit are intended to assist you in the performanc[...]

6-2 PERIODIC MAINTENANCE AND MINOR REP AIR 6 NOTE: If you do not have the tools or experi- 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 ([...]

6-3 PERIODIC MAINTENANCE AND MINOR REP AIR 6 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 w[...]

6-4 PERIODIC MAINTENANCE AND MINOR REP AIR 6 8 * Brake hoses • Check for cracks or damage. √√√√ √ • Replace. (See NOTE on page 6-5.) Every 4 years 9 * Wheels • Check runout, spoke tightness and for damage. • Tighten spokes if necessary. √√√√ 10 * Tires • Check tread depth and for damage. • Replace if necessary. • Che[...]

6-5 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03884 NOTE: 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 8 Hydraulic brake service 9 Regularly check and, if necessary, correct the brake fluid level. 9 Every two years replace the internal components of the brake master cylinders and calipers, and ch[...]

6-6 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03516 Removing and installing the cowling and panels Cowling and panels, removing and installing 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 n[...]

6-7 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01145 Cowling A To remove the cowling Remove the screw, and then pull the cowling off as shown. 1 1. Screw 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 s[...]

6-8 PERIODIC MAINTENANCE AND MINOR REP AIR 6 1 2 1. Panel B 2. Screw 2. Remove the spark plug as shown, with the spark plug wrench included in the owner ’ s tool kit. 1 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 ca[...]

6-9 PERIODIC MAINTENANCE AND MINOR REP AIR 6 To check the spark plug 1. Check that the porcelain insula- tor around the center electrode of the spark plug is a medium-to- light tan (the ideal color when the motorcycle is ridden normally). NOTE: If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to di[...]

6-10 PERIODIC MAINTENANCE AND MINOR REP AIR 6 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[...]

6-11 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EC000000 c C 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-speed operation, otherwise hot engine oil could spout out and cause damage or injury. Always let the engine oil cool down sufficiently before remo[...]

6-12 PERIODIC MAINTENANCE AND MINOR REP AIR 6 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 tight- ening them to the specified torque. NOTE: Make sure that the O-ring is properly seated. 9. Install the engine oil drai[...]

6-13 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EC000076 c C After changing the engine oil, be sure to check the oil pressure as described below. 11. Remove the air bleed screw, and 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 dealer check for the cause. If oil seeps ou[...]

6-14 PERIODIC MAINTENANCE AND MINOR REP AIR 6 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. EAU006[...]

6-15 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00632 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 lubrica- tion chart. 1. Start the engine and warm it up for several minutes at 1,000 – 2,000 r/min wh[...]

6-16 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00635 Adjusting the throttle cable free play Throttle cable free play, adjusting The throttle cable free play should measure 3 – 5 mm at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer adjust it. a a. Throttle cable free play EAU04259 Tires[...]

6-17 PERIODIC MAINTENANCE AND MINOR REP AIR 6 8 8 Adjust the suspension and tire air pressure with regard to the load. 8 Check the tire condition and air pressure before each ride. EWA00012 w Because loading has an enormous impact on the handling, braking, performance and safety character- istics of your motorcycle, you should keep the following pr[...]

6-18 PERIODIC MAINTENANCE AND MINOR REP AIR 6 Tire inspection The tires must be checked before each ride. If the center tread depth reaches the specified limit, if the tire has a nail or glass fragments in it, or if the sidewall is cracked, have a Yamaha dealer replace the tire imme- diately. a 1 1. Side wall a. Tire tread depth EW000078 w 8 The fr[...]

6-19 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00681 w 8 Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operat- ing the motorcycle with exces- sively worn tires decreases riding stability 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 [...]

6-20 PERIODIC MAINTENANCE AND MINOR REP AIR 6 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. Loosen the locknut at the clutch lever. 2. To increase the clutch lev[...]

6-21 PERIODIC MAINTENANCE AND MINOR REP AIR 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 [...]

6-22 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EW000109 w A soft or spongy feeling in the brake pedal can indicate the pres- ence of air in the hydraulic system. If there is air in the hydraulic sys- tem, have a Yamaha dealer bleed the system before operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which ma[...]

6-23 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03938 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. If a brake pad has worn to the point that the wear indicator grooves[...]

6-24 PERIODIC MAINTENANCE AND MINOR REP AIR 6 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 qual- ity brake fluid, otherwise the rub- ber seals may deteriorate, caus- ing leakage and poor braking performance. 8 Refill with the same type of brake f[...]

6-25 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00744 Drive chain slack Drive chain slack The drive chain slack should be checked before each ride and adjust- ed if necessary. To check the drive chain slack Checking 1. Place the motorcycle on a level surface and hold it in an upright position. NOTE: When checking and adjusting the drive chain slac[...]

6-26 PERIODIC MAINTENANCE AND MINOR REP AIR 6 NOTE: Make sure that both adjusting plates are in the same position for proper wheel alignment. EC000096 c C 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[...]

6-27 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU02962 Checking and lubricating the cables Cables, checking and lubricating The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Y[...]

6-28 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03370 Checking and lubricating the brake and shift pedals Brake and shift pedals, checking and lubricating The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. EAU03164 Checking and lubricating the brake and clutch lev[...]

6-29 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00790 Lubricating the rear suspension Rear suspension, lubricating The pivoting points of the rear sus- pension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. 1 1 1. Grease nipple ( × 2) To check the operation 1. Place the motorcycle on a level surfa[...]

6-30 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00794 Checking the steering Steering, checking Worn or loose steering bearings may cause danger. Therefore, the opera- tion of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrica- tion chart. 1. Place a stand under the engine to raise the front w[...]

6-31 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00800 Battery 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. EC000101 c C Never attempt to remove the bat- tery cell seals, as this would per- manently damage the battery[...]

6-32 PERIODIC MAINTENANCE AND MINOR REP AIR 6 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 dis- charge more quickly if the motorcycle is equipped with optional electrical accessories. To store the battery 1. If the motorcycle will not be used[...]

6-33 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EC000103 c C Do not use a fuse of a higher amperage rating than recommend- ed to avoid causing extensive damage to the electrical system and possibly a fire. 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 [...]

6-34 PERIODIC MAINTENANCE AND MINOR REP AIR 6 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 6. Instal[...]

6-35 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03497 Replacing a turn signal light bulb Turn signal light bulb, replacing 1. Remove the turn signal light lens by removing the screw. 1 2 1. Screw 2. Lens EAU01623 Replacing the tail/brake light bulb Tail/brake light bulb, replacing 1. Remove the tail/brake light lens by removing the screws. 2 1 1. [...]

6-36 PERIODIC MAINTENANCE AND MINOR REP AIR 6 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 c C Do not overtighten the screws, otherwise the lens may break. 1 1. Bul[...]

6-37 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00897 Front wheel Removing To remove the front 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. 1. Disconnect the speedometer cable from the front wheel. 1 1. Speedometer cable EAU03555 To [...]

6-38 PERIODIC MAINTENANCE AND MINOR REP AIR 6 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. Install the wheel axle. 4. Lower the front wheel so that it is on the ground. 5. Tighten the wheel axle to the speci[...]

6-39 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU04314 Rear wheel To remove the rear wheel EW000122 w 8 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. 1. Remove the axle nut. 2. Loosen the brake caliper bracket bolt. 2 1 1. Axle nut 2. Brake caliper bra[...]

6-40 PERIODIC MAINTENANCE AND MINOR REP AIR 6 6. Push the wheel forward, and then remove the drive chain from the rear sprocket. NOTE: The drive chain does not need to be disassembled in order to remove and install the wheel. 7. Pull the wheel axle out, and then remove the wheel. ECA00048 c C Do not apply the brake after the wheel has been removed [...]

6-41 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01008 T roubleshooting 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. The following troub[...]

6-42 PERIODIC MAINTENANCE AND MINOR REP AIR 6 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. Supp[...]

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MOT ORCYCLE CARE AND ST ORAGE Care .................................................................................................. 7-1 Storage ............................................................................................. 7-4 7 4PT-E7 (English) 6/29/01 9:13 AM Page 81[...]

7-1 EAU03521 MOT ORCYCLE CARE AND ST ORAGE 7 Care Care While the open design of a motorcy- cle reveals the attractiveness of the technology, it also makes it more vul- nerable. Rust and corrosion can develop even if high-quality compo- nents are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appear- ance[...]

7-2 MOT ORCYCLE CARE AND ST ORAGE 7 8 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 abra- sive cleaning products, sol- vent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or elec- trolyte. 8 8 Do not use high-pressure w[...]

7-3 MOT ORCYCLE CARE AND ST ORAGE 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 stainless- steel parts, including the exhaust system. (Even the thermally induced discoloring of stainless[...]

7-4 MOT ORCYCLE CARE AND ST ORAGE 7 Storage Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, pro- tect it against dust with a porous cover. ECA00014 c C 8 Storing the motorcycle in a poorly ventilated room or cov- ering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause r[...]

7-5 MOT ORCYCLE CARE AND ST ORAGE 7 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 or[...]

SPECIFICA TIONS Specifications ................................................................................... 8-1 Conversion table ............................................................................... 8-5 8 4PT-E7 (English) 6/29/01 9:13 AM Page 87[...]

8-1 EAU01038 SPECIFICA TIONS 8 Specifications Specifications Model XT500E/XT600E Dimensions Overall length 2,220 mm 2.295 mm (N, S, CH only) Overall width 865 mm 825 mm (CH only) Overall height 1,205 mm Seat height 855 mm Wheel base 1,440 mm Ground clearance 230 mm Minimum turning radius 2,300 mm Basic weight (with oil and full fuel tank) 176 kg 17[...]

8-2 SPECIFICA TIONS 8 Air filter Dry type element Fuel Type REGULAR UNLEADED GASOLINE ONLY Fuel tank capacity 15 L Reserve amount 2 L Carburetor Type × quantity Y26PV × 1 Manufacturer TEIKEI Spark plug Type/Manufacturer DPR8EA-9 or DPR9EA-9/NGK Spark plug gap 0.8 – 0.9 mm Clutch type Wet, multiple-disc Transmission Primary reduction system Spur[...]

8-3 SPECIFICA TIONS 8 Air pressure (cold tire) up to 90 kg load* Front 150 kPa (1.50 kgf/cm 2 , 1.50 bar) Rear 150 kPa (1.50 kgf/cm 2 , 1.50 bar) 90 kg load – Maximum load* Front 150 kPa (1.50 kgf/cm 2 , 1.50 bar) Rear 225 kPa (2.25 kgf/cm 2 , 2.25 bar) Off-road riding Front 125 kPa (1.25 kgf/cm 2 , 1.25 bar) Rear 125 kPa (1.25 kgf/cm 2 , 1.25 ba[...]

8-4 SPECIFICA TIONS 8 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 1[...]

8-5 SPECIFICA TIONS 8 EAU03941 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. Ex. METRIC MULTIPLIER IMPERIAL ** mm × 0.03937 = ** in 2 mm × 0.03937 = 0.08 in METRIC TO IMPERIAL Metric unit Multiplier Imper[...]

CONSUMER INFORMA TION Identification numbers ...................................................................... 9-1 Key identification number ................................................................. 9-1 Vehicle identification number ............................................................ 9-1 Model label ...........................[...]

9-1 EAU01039 CONSUMER INFORMA TION 9 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. KEY IDENTIFICATION N[...]

9-2 CONSUMER INFORMA TION 9 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 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 (Engli[...]

INDEX E Engine break-in ..................................... 5-4 Engine idling speed ............................. 6-15 Engine oil and oil filter element ........... 6-10 Engine, starting a warm ......................... 5-2 F Front and rear brake pads, checking ... 6-22 Front fork, checking ............................. 6-29 Front wheel .........[...]

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 .[...]

4PT-E7 (English) 6/29/01 9:13 AM Page 98[...]

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 · 7 – 0.9 × 1(E) ! 4PT-28199-E7 OWNER ’ S MANUAL Y AMAHA MOTOR CO. , L TD. XT600E XT500E[...]