YAMAHA XT 500E / XT600E Manual

OWNER’S MANUAL
XT500E
YAMAHA MOTOR CO., LTD.
XT600E
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2001·1–1.0×1(E) !
4PT-28199-E6
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 1
INTRODUCTION
EAU00001
Welcome to the Yamaha world of motorcycling! 1
As the owner of a XT500E/XT600E, you are benefiting from Yamaha’s vast experience in and 2
newest technology for the design and the 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 your XT500E/XT600E’s
4
advantages. The owner’s manual does not only instruct you in how to operate, inspect and maintain
your motorcycle, but also in how to safeguard yourself and others from trouble and injury.
5
In addition, the many tips given in this manual will help to keep your motorcycle in the best possible
condition. If you have any further questions, do not hesitate to contact your Yamaha dealer. 6
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first! 7
9
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM 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
1 Q IS INVOLVED!
2 Failure to follow WARNING instructions could result in severe injury or death to the
w
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
3
cC A CAUTION indicates special precautions that must be taken to avoid damage to

4 the motorcycle.
5 NOTE: A NOTE provides key information to make procedures easier or clearer.
7
NOTE:
8 8 This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
9 8 Yamaha continually seeks advancements in product design and quality. Therefore, while this
manual contains the most current product information available at the time of printing, there
may be minor discrepancies between your motorcycle and this manual. If there is any ques-
tion concerning this manual, please consult your Yamaha dealer.
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 3
IMPORTANT MANUAL INFORMATION

EW000002
w
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE. 1
9
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 4
6 EAU03337
XT500E/XT600E
7 OWNER’S MANUAL
© 2000 by Yamaha Motor Co., Ltd.
8 1st Edition, December 2000
All rights reserved.
9 Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 5
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-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 6
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 7
GIVE SAFETY THE RIGHT OF WAY
GIVE SAFETY THE RIGHT OF WAY ................................................1-1

1
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 8
EAU00021
Q GIVE SAFETY THE RIGHT OF WAY

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.
1
Regular care and maintenance are essential for preserving your motorcycle’s value and operating
2 condition. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
3 course, out of the question. Motorcycle riders more than car drivers must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
4 dangerous risks.
5 Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passen-
gers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic
materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum pro-
6
tective wear, however, should not encourage carelessness. Though full-coverage helmets and suits,
in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable.
7 Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is
even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensively
8 avoiding all dangers, including those caused by others.
9 Enjoy your ride!
1-1
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 9
DESCRIPTION
Left view .............................................................................................2-1

Right view ...........................................................................................2-2
Controls/Instruments ..........................................................................2-3
2
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 10
EAU00026
DESCRIPTION
Left view
1 2 3 4 5
1
8
9 8 7 6
9
1. Headlight (page 6-29) 6. Rear shock absorber spring preload
2. Fuel cock (page 3-7) adjusting nut (page 3-10)
3. Battery (page 6-28) 7. Fuse (page 6-28)
4. Tool kit (page 6-1) 8. Starter (choke) (page 3-8)
5. Helmet holder (page 3-9) 9. Shift pedal (page 3-5)
2-1
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 11
DESCRIPTION
Right view
10 11 12
1
8
13
9
10. Air filter (page 6-12)
11. Oil filter (page 6-11)
12. Engine oil dipstick (page 6-10)
13. Rear brake pedal (page 3-5, 6-19)
2-2
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 12
EAU00026
DESCRIPTION
Controls/Instruments
14 15 16 17 18 19 20
1
8 22 21
9
14. Clutch lever (page 3-4, 6-18) 19. Right handlebar switches (page 3-4)
15. Left handlebar switches (page 3-3) 20. Front brake lever (page 3-5, 6-18)
16. Speedometer (page 3-2) 21. Throttle grip (page 6-24)
17. Main switch/steering lock (page 3-1) 22. Fuel tank cap (page 3-6)
18. Tachometer (page 3-3)
2-3
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 13
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock.......................................................................3-1

Indicator lights .......................................................................................3-2
Speedometer .........................................................................................3-2
Tachometer ...........................................................................................3-3
Handlebar switches ...............................................................................3-3
Clutch lever............................................................................................3-4 3
Shift pedal..............................................................................................3-5
Front brake lever ...................................................................................3-5
Rear brake pedal ...................................................................................3-5
Fuel tank cap .........................................................................................3-6
Fuel........................................................................................................3-6
Fuel cock ...............................................................................................3-7
Starter (choke) “1” ...............................................................................3-8
Seat .......................................................................................................3-9
Helmet holder ........................................................................................3-9
Rear shock absorber adjustment.........................................................3-10
Sidestand.............................................................................................3-11
Sidestand/clutch switch operation check.............................................3-12
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 14
EAU00027

EW000016
ON
w
1 2
OFF Never turn the key to “OFF” or
1 “LOCK” when the motorcycle is
moving. The electrical circuits will
2 be switched off which may result
LOCK
in loss of control or an accident.
3 P Be sure the motorcycle is stopped
before turning the key to “OFF” or
1. Push 2. Turn “LOCK”.
4
EAU00029 EAU00042
Main switch/steering lock LOCK

EAU01590
5 The main switch controls the ignition The steering is locked in this position . (Parking)
and lighting systems. Its operation is and all electrical circuits are switched The steering is locked in this position,
6 described below. off. and the taillight and auxiliary light
The key can be removed in this posi- come on but all other circuits are off.
7 EAU00036 tion. The key can be removed in this posi-
ON To lock the steering, turn the handle- tion.
Electrical circuits are switched on. bars all the way to the left. With the
8 To use the parking position, first lock
The engine can be started. The key key at “OFF”, push it into the main the steering, then turn the key to “.”.
cannot be removed in this position. switch and release it, turn it counter- Do not use this position for an
9 clockwise to “LOCK” and remove it.
EAU00038
extended length of time as the bat-
OFF To release the lock, turn the key to tery may discharge.
All electrical circuits are switched off. "OFF".
The key can be removed in this posi-
tion.
3-1
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 15

EAU00063
1 2 High beam indicator light “&” 1 2
This indicator comes on when the
& N headlight high beam is used. 4 1
5
2
3
3 3
1. High beam indicator light “&” 1. Speedometer

2. Neutral indicator light “N” 2. Odometer 4
3. Turn indicator light “5” 3. Trip odometer
EAU00056 4. Reset knob
Indicator lights EAU00095 5
Speedometer
EAU00057 The speedometer shows riding 6
Turn indicator light “5” speed. This speedometer is equipped
This indicator flashes when the turn with an odometer and trip odometer.
switch is moved to the left or right. 7
The trip odometer can be reset to “0”
with the reset knob. Use the trip
EAU00061
odometer to estimate how far you 8
Neutral indicator light “N”
This indicator comes on when the can ride on a tank of fuel. This infor-
mation will enable you to plan fuel 9
transmission is in neutral.
stops in the future.
3-2
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 16

EAU00121
1 2 3 Dimmer switch
1
Turn the switch to “&” for the high
1 & N
beam and to “%” for the low beam.
2
5 EAU00127
2 Turn signal switch
* To signal a right-hand turn, push the
3 5 4 switch to “)”. To signal a left-hand
turn, push the switch to “(”. Once
1. Tachometer 1. Lights switch
4 2. Red zone 2. Pass switch “&”
the switch is released it will return to
EAU00102 3. Dimmer switch the center position. To cancel the sig-
Tachometer 4. Turn signal switch nal, push the switch in after it has
5 5. Horn switch “*”
This model is equipped with a EAU00118 returned to the center position.
tachometer so the rider can monitor Handlebar switches
6 the engine speed and keep it within EAU00129
the ideal power range. EAU00134 Horn switch “*”

7 Lights switch Press the switch to sound the horn.
EC000003 Turning the light switch to “'”,
8
cC turns on the auxiliary light, meter
Do not operate in the red zone. lights and taillight. Turning the light
Red zone: 7,000 r/min and above switch to “:”, turns the headlight on
9 also.
EAU00119
Pass switch “&”

Press the switch to operate the pass-
ing light.
3-3
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 17

EAU00143
Start switch “,”

The starter motor cranks the engine
when pushing the start switch.
1
1
EC000005
cC 2
,
1 See starting instructions prior to

2 3
starting the engine.
1. Engine stop switch 1. Clutch lever
2. Start switch “,” 4
EAU00152
EAU00138
Clutch lever
Engine stop switch
The clutch lever is located on the left 5
The engine stop switch is a safety
handlebar, and the ignition circuit cut-
device for use in an emergency such
off system is incorporated in the 6
as when the motorcycle overturns or
clutch lever holder. Pull the clutch
if trouble occurs in the throttle sys-
lever to the handlebar to disengage 7
tem. Turn the switch to “#” to start
the clutch, and release the lever to
the engine.
engage the clutch. The lever should
In case of emergency, turn the switch 8
be pulled rapidly and released slowly
to “$” to stop the engine.
for smooth clutch operation. (Refer to
the engine starting procedures for a 9
description of the ignition circuit cut-
off system.)
3-4
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 18
5 1
4
3 1 1
1 2
N
2 1
1. Shift pedal 1. Front brake lever 1. Rear brake pedal

4 N. Neutral EAU00158 EAU00162
EAU00157 Front brake lever Rear brake pedal
5 Shift pedal The front brake lever is located on The rear brake pedal is on the right
This motorcycle is equipped with a the right handlebar. Pull it toward the side of the motorcycle. Press down
6 constant-mesh 5-speed transmission. handlebar to apply the front brake. on the brake pedal to apply the rear
The shift pedal is located on the left brake.
side of the engine and is used in
7
combination with the clutch when
shifting.
8
3-5
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 19
NOTE:
The tank cap cannot be reinstalled 1
unless it is unlocked. The key must
2
1 1
remain in the cap until the cap is
properly installed and locked onto the
2 2
fuel tank.
EW000023 3
w
1. Unlock 1. Filler tube
2. Open Be sure the cap is properly 2. Fuel level 4
EAU00177 installed and locked in place EAU01183
Fuel tank cap before riding the motorcycle.

Fuel 5
To open Make sure there is sufficient fuel in
Insert the key and turn it 1/4 turn the tank. Fill the fuel tank to the bot-
tom of the filler tube as shown in the 6
counterclockwise. Turn the cap 1/3
turn counterclockwise and remove it illustration.
from the tank. EW000130 7
w
To close Do not overfill the fuel tank. Avoid 8
Put the cap in the filler neck and turn spilling fuel on the hot engine. Do
it 1/3 turn clockwise. Lock the cap by not fill the fuel tank above the bot- 9
turning the key 1/4 turn clockwise, tom of the filler tube or it may
and remove the key. overflow when the fuel heats up
later and expands.
3-6
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 20

EAU00185 EAU00191
cC OFF: closed position

Recommended fuel:
Always wipe off spilled fuel imme-
1 Regular unleaded gasoline RES
diately with a dry and clean soft
with a research octane
cloth. Fuel may deteriorate painted
number of 91 or higher. OFF
2 surfaces or plastic parts.
Fuel tank capacity: FUEL
ON
Total:
3 15.0 L 1
Reserve: 1. Arrow mark pointing to “OFF”
4 2.0 L EAU03050
Fuel cock
5 NOTE: The fuel cock supplies fuel from the
If knocking or pinging occurs, use a tank to the carburetor while filtering it
6 different brand of gasoline or higher also.
octane grade. The fuel cock has three positions:
7
OFF
8 With the lever in this position, fuel will
not flow. Always return the lever to
this position when the engine is not
9
running.
3-7
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 21

ON: normal position RES: reserve position
RES
RES b a
RES
1
OFF
OFF 2
ON
FUEL 1
FUEL 1
ON
ON 1 3
1. Arrow mark pointing to “ON” 1. Arrow mark pointing to “RES” 1. Starter (choke) “1”
4
EAU00210
ON RES
With the lever in this position, fuel This indicates reserve. If you run out Starter (choke) “1”
Starting a cold engine requires a rich- 5
flows to the carburetor. Normal riding of fuel while riding, move the lever to
is done with the lever in this position. this position. Fill the tank at the first er air-fuel mixture. A separate starter
circuit supplies this mixture. 6
opportunity. Be sure to set the lever
back to “ON” after refueling! Move in direction a to turn on the
starter (choke). 7
Move in direction b to turn off the
starter (choke). 8
3-8
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 22
1
2
2
1
3
1. Helmet holder
4 2. Open
EAU00240
When reinstalling the seat, insert the
Seat EAU00260
5 To remove the seat, remove the

projections on the front of the seat Helmet holder
into the holders, then tighten the To open the helmet holder, insert the
bolts.
bolts. key in the lock and turn it as shown.
6
To lock the helmet holder, replace
NOTE: the holder in its original position.
7 Make sure that the seat is securely EW000030
fitted. w
8 Never ride with a helmet in the hel-
met holder. The helmet may hit
9 objects, causing loss of control
and possibly an accident.
3-9
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 23

EC000015
cC
a Never attempt to turn an adjuster
2 beyond the maximum or minimum 1
b setting.
1 2
1
3. Tighten the locknut to the speci-
fied torque. 3
1. Locknut 1. Measuring distance “A” Tightening torque:

2. Adjusting nut 4
Shortening spring set length Locknut:
EAU01650
increases spring preload, length- 42 Nm (4.2 m0kg)

Rear shock absorber 5
adjustment ening spring set length decreas- EC000018
This shock absorber is equipped with es spring preload. cC 6

a spring preload adjuster. Adjust Always tighten the locknut against
spring preload as follows. Spring preload:
the spring adjusting nut and tight- 7
1. Loosen the locknut. Minimum (soft):
en the locknut to the specified
2. Turn the adjusting nut in direc- Distance “A” = 248.5 mm
torque.
tion a to increase spring preload Standard: 8
and in direction b to decrease Distance “A” = 243 mm
spring preload. The spring pre- Maximum (hard): 9
load is determined by the spring Distance “A” = 237.5 mm
set length.
3-10
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 24

EAU00315 EAU00330 EW000044
w Sidestand w
This model is equipped with an igni-
This shock absorber contains This motorcycle must not be oper-
1 tion circuit cut-off system. The motor-
highly pressurized nitrogen gas. ated with the sidestand in the
cycle must not be ridden when the
Read and understand the following down position. If the stand is not
2 sidestand is down. The sidestand is
information before handling the properly retracted, it could contact
located on the left side of the frame.
shock absorber. The manufacturer the ground and distract the opera-
(Refer to page 5-1 for an explanation
3 cannot be held responsible for tor, resulting in a possible loss of
of this system.)
property damage or personal control. Yamaha has designed into
4 injury that may result from improp- this motorcycle a lockout system
er handling. to assist the operator in fulfilling
8 Do not tamper with or attempt the responsibility of retracting the
5
to open the cylinder assembly. sidestand. Please check carefully
8 Do not subject the shock the operating instructions listed
6 absorber to an open flame or below and if there is any indication
other high heat source. This of a malfunction, return the motor-
7 may cause the unit to explode cycle to a Yamaha dealer immedi-
due to excessive gas pres- ately for repair.
8 sure.
8 Do not deform or damage the
9 cylinder in any way. Cylinder
damage will result in poor
damping performance.
8 Take your shock absorber to a
Yamaha dealer for any service.
3-11
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 25

EAU00331
SIDESTAND IS DOWN.
Sidestand/clutch switch
operation check
Check the operation of the sidestand ENGINE WILL STALL. 1
switch and clutch switch against the
information below. SIDESTAND SWITCH IS OK. 2
EW000045
TURN THE MAIN SWITCH TO “ON” AND w 3
THE ENGINE STOP SWITCH TO “#”.
If improper operation is noted,
consult a Yamaha dealer immedi- 4
TRANSMISSION IS IN GEAR AND
ately.
SIDESTAND IS UP.
5
PULL IN CLUTCH LEVER AND

6
PUSH THE START SWITCH.
7
ENGINE WILL START.
8
CLUTCH SWITCH IS OK.
3-12
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 26
9
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 27
PRE-OPERATION CHECKS
Pre-operation check list ......................................................................4-1
4
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 28
EAU01114
Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid
leak or loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thor-
1
ough visual inspection, you check the following points before each ride.
EAU00340
2 PRE-OPERATION CHECK LIST
ITEM CHECKS PAGE
3
9 Check operation, free play, fluid level and vehicle for fluid leakage.
Front brake
9 Fill with DOT 4 (or DOT 3) brake fluid if necessary.
3-5, 6-18 ~ 6-22
4 9 Check operation, free play, fluid level and vehicle for fluid leakage.
Rear brake
9 Fill with DOT 4 brake fluid if necessary.
9 Check operation, condition and free play.
Clutch 3-4, 6-18
5 9 Adjust if necessary.
9 Check for smooth operation.
Throttle grip and housing 6-24
9 Lubricate.
6 Engine oil
9 Check oil level.
6-10 ~ 6-12
9 Fill with oil if necessary.
9 Check chain slack and condition.
7 Drive chain 6-22 ~ 6-24
9 Adjust if necessary.
9 Check tire pressure, wear, damage and spoke tightness.
Wheels and tires 6-15 ~ 6-17
9 Tighten spokes if necessary.
8 9 Check for smooth operation.
Control and meter cable 6-24
9 Lubricate if necessary.
9 9 Check for smooth operation.
Brake and shift pedal shafts 6-25
Brake and clutch lever pivots 6-25
4-1
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 29
ITEM CHECKS PAGE
Sidestand pivot 6-25
9 Make sure that all nuts, bolts, and screws are properly tightened. 1
Chassis fasteners —
9 Tighten if necessary.
9 Check fuel level.
Fuel tank 3-6 ~ 3-7
9 Fill with fuel if necessary. 2
Lights, signals and
9 Check for proper operation. 6-29 ~ 6-32
switches
3
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a 4
very short time; and the added safety it assures is more than worth the time involved.
5
w
If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating 6
the motorcycle.
7
4-2
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 30
9
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 31
OPERATION AND IMPORTANT RIDING POINTS
Starting the engine .............................................................................5-1

Starting a warm engine.......................................................................5-3
Shifting................................................................................................5-4
Recommended shift point (for Switzerland only) ................................5-4
Tips for reducing fuel consumption.....................................................5-5
Engine break-in ..................................................................................5-5
Parking ...............................................................................................5-6
5
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 32
EAU00372

EAU00373 EAU03011
w Starting the engine

8 Before riding this motorcycle,
1 become thoroughly familiar NOTE:
with all operating controls and This motorcycle is equipped with an
2 their functions. Consult a ignition circuit cut-off system. The
Yamaha dealer regarding any engine can be started only under one
control or function that you do of the following conditions:
3
not thoroughly understand. 8 The transmission is in neutral.
8 Never start your engine or let 8 The sidestand is up, the trans-
4 mission is in gear and the clutch
it run for any length of time in
a closed area. The exhaust is disengaged.
5 The motorcycle must not be ridden
fumes are poisonous and can
cause loss of consciousness when the sidestand is down.
6 and death within a short time.
EW000054
Always operate your motorcy-
7
w
cle in an area with adequate
ventilation. Before going through the following
8 8 Before starting out, always be steps, check the function of the
sure the sidestand is up. sidestand switch and clutch
Failure to retract the sidestand switch. (Refer to page 3-12.)
9
completely can result in a seri-
ous accident when you try to
turn a corner.
5-1
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 33
TURN THE MAIN SWITCH TO “ON” AND

THE ENGINE STOP SWITCH TO “#”.
1
IF THE TRANSMISSION IS IN NEUTRAL IF THE TRANSMISSION IS IN GEAR
AND THE SIDESTAND IS DOWN, AND THE SIDESTAND IS UP, 2
PUSH START SWITCH.
PULL IN THE CLUTCH LEVER AND 3

PUSH THE START SWITCH.
4
THE ENGINE WILL START. THE ENGINE WILL START.
5
RETRACT THE SIDESTAND AND PUT
THE TRANSMISSION IN GEAR. 6
THE MOTORCYCLE CAN BE RIDDEN. THE MOTORCYCLE CAN BE RIDDEN. 7
5-2
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 34

EAU01258
1. Turn the fuel cock to “ON”. NOTE:
Starting a warm engine
2. Turn the main switch to “ON” and If the engine fails to start, release the
The starter (choke) is not required
the engine stop switch to “#”. start switch, wait a few seconds, then
1 when the engine is warm.
3. Shift the transmission into neu- try again. Each attempt should be as EC000046
tral. short as possible to preserve the bat- cC

2 tery. Do not crank the engine more See the “Engine break-in” section
NOTE: than 10 seconds on any one attempt. prior to operating the motorcycle
3 When the transmission is in neutral,
for the first time.
the neutral indicator light should be 6. After starting the engine, move
4 on. If the light does not come on, ask the starter (choke) to the halfway
a Yamaha dealer to inspect it. position.
5
4. Turn on the starter (choke) and NOTE:
completely close the throttle grip. For maximum engine life, never
6
5. Start the engine by pushing the accelerate hard with a cold engine!
start switch.
7
7. After warming up the engine,
turn off the starter (choke) com-
8 pletely.
9 NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
5-3
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 35

EC000048 EAU02941
cC Recommended shift points

5
4 8 Do not coast for long periods (for Switzerland only)
3 1 with the engine off, and do not The recommended shift points are 1
2
N tow the motorcycle a long dis- shown in the table below.
1 tance. Even with gears in neu- Acceleration shift point 2
(km/h)
tral, the transmission is only
properly lubricated when the 1st → 2nd 23
2nd → 3rd 36
3
engine is running. Inadequate 3rd → 4th 50
1. Shift pedal lubrication may damage the 4th → 5th 60
N. Neutral 4
EAU00423
transmission.
Shifting 8 Always use the clutch when NOTE: 5
The transmission lets you control the changing gears. The engine, When shifting two gears down from
amount of power you have available transmission, and driveline are 4th to 2nd, bring your motorcycle to a
not designed to withstand the 6
at a given speed for starting, acceler- speed of 35 km/h.
ating, climbing hills, etc. The use of shock of forced shifting and
the shift pedal is shown in the illustra- can be damaged by shifting 7
tion. without using the clutch.
8
To shift into neutral, depress the shift
pedal repeatedly until it reaches the 9
end of its travel, then raise the pedal
slightly.
5-4
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 36

EAU00424 EAU00436 EAU00440
Tips for reducing fuel Engine break-in 0 ~ 150 km

consumption There is never a more important peri- Avoid operation above 4,000 r/min.
1 Your motorcycle’s fuel consumption od in the life of your motorcycle than Stop the engine and let it cool for 5 to
depends to a large extent on your rid- the period between zero and 1,000 10 minutes after every hour of opera-
2 ing style. The following tips can help km. For this reason we ask that you tion. Vary the speed of the motorcy-
reduce fuel consumption: carefully read the following material. cle from time to time. Do not operate
8 Warm up the engine before rid- Because the engine is brand new, it at one set throttle position.
3
ing. you must not put an excessive load 150 ~ 500 km
8 Turn off the starter (choke) as on it for the first 1,000 km. The vari- Avoid prolonged operation above
4 soon as possible. ous parts in the engine wear and pol- 5,000 r/min. Rev the motorcycle
8 Shift up swiftly and avoid high ish themselves to the correct operat- freely through the gears, but do not
5 engine speeds during accelera- ing clearances. During this period, use full throttle at any time.
tion. prolonged full throttle operation, or 500 ~ 1,000 km
6 8 Do not double-clutch or rev the any condition which might result in Avoid prolonged full throttle opera-
engine while shifting down and excessive heating of the engine, tion. Avoid cruising speeds in excess
7 avoid high engine speeds with must be avoided. of 6,000 r/min.
no load on the engine.
8 Turn off the engine instead of let-
8
ting it idle for an extended length
of time, i.e. in traffic jams, at traf-
9 fic lights or railroad crossings.
5-5
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 37

EC000052 EAU00457
cC Parking
When parking the motorcycle, stop
After 1,000 km of operation, be
the engine and remove the ignition 1
sure to replace the engine oil and
key. Turn the fuel cock to “OFF”
oil filter.
whenever stopping the engine. 2
EW000058
1,000 km and beyond w
Full throttle can be used. 3
EC000053 The exhaust system is hot. Park
cC the motorcycle in a place where
pedestrians or children are not 4
8 Never let engine speeds enter
the red zone. likely to touch the motorcycle. Do
8 If any engine trouble should not park the motorcycle on a slope 5
occur during the break-in peri- or soft ground; the motorcycle
od, consult a Yamaha dealer may overturn. 6
immediately.
7
5-6
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 38
9
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 1
PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit ...................................................................6-1 Drive chain lubrication............................................6-23

Periodic maintenance and lubrication chart ...........6-3 Cable inspection and lubrication ............................6-24
Cowling and panel removal and installation...........6-6 Throttle cable and grip lubrication..........................6-24
Cowling A...............................................................6-7 Brake and shift pedal lubrication............................6-25
Panel A, B ..............................................................6-7 Brake and clutch lever lubrication ..........................6-25
Spark plug..............................................................6-8 Sidestand lubrication..............................................6-25
Engine oil .............................................................6-10 Rear suspension lubrication...................................6-26
Air filter.................................................................6-12 Front fork inspection ..............................................6-26
Carburetor adjustment .........................................6-13 Steering inspection ................................................6-27
Idle speed adjustment..........................................6-14 Wheel bearings ......................................................6-27
Throttle cable free play adjustment......................6-14 Battery....................................................................6-28
Valve clearance adjustment.................................6-15 Fuse replacement ..................................................6-29
Tires .....................................................................6-15 Headlight bulb replacement ...................................6-29 6
Wheels .................................................................6-17 Turn signal light bulb replacement .........................6-31
Clutch lever free play adjustment.........................6-18 Taillight bulb replacement ......................................6-32
Front brake lever free play adjustment ................6-18 Supporting the motorcycle .....................................6-32
Rear brake pedal height adjustment ....................6-19 Front wheel removal ..............................................6-33
Brake light switch adjustment ..............................6-20 Front wheel installation ..........................................6-34
Checking the front and rear brake pads...............6-20 Rear wheel removal ...............................................6-35
Inspecting the brake fluid level.............................6-21 Rear wheel installation...........................................6-36
Brake fluid replacement .......................................6-22 Troubleshooting .....................................................6-36
Drive chain slack check .......................................6-22 Troubleshooting chart ............................................6-37
Drive chain slack adjustment ...............................6-23
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 2
EAU00462

EAU00464 EW000060
Periodic inspection, adjustment and w 1

lubrication will keep your motorcycle If you are not familiar with motor-
1 in the safest and most efficient condi- cycle service, this work should be
tion possible. Safety is an obligation done by a Yamaha dealer.
2 of the motorcycle owner. The mainte-
nance and lubrication schedule chart
3 should be considered strictly as a
guide to general maintenance and
lubrication intervals. 1. Tool kit
4
YOU MUST TAKE INTO CONSIDER- EAU01175
ATION THAT WEATHER, TERRAIN, Tool kit

5 GEOGRAPHICAL LOCATIONS, AND The tool kit is located behind panel A.
A VARIETY OF INDIVIDUAL USES (See page 6-7 for panel removal and
6 ALL TEND TO DEMAND THAT installation procedures.) The tools
EACH OWNER ALTER THIS TIME provided in the owner's tool kit are to
7 SCHEDULE TO SHORTER INTER- assist you in the performance of peri-
VALS TO MATCH THE ENVIRON- odic maintenance. However, some
MENT. The most important points of other tools such as a torque wrench
8
motorcycle inspection, adjustment, are also necessary to perform the
and lubrication are explained in the maintenance correctly.
9 The service information included in
following pages.
this manual is intended to provide
you, the owner, with the necessary
information for completing some of
your own preventive maintenance
and minor repairs.
6-1
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 3
NOTE:
If you do not have necessary tools
required during a service operation,
1
take your motorcycle to a Yamaha
dealer for service.
2
EW000063
w 3
Modifications to this motorcycle
not approved by Yamaha may 4
cause loss of performance, and
render it unsafe for use. Consult a 5
Yamaha dealer before attempting
any changes. 6
6-2
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 4

EAU03685
Periodic maintenance and lubrication chart

NOTE:
1 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.
2 8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
3
ODOMETER READING (× 1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1 10 20 30 40 CHECK
4 1 Fuel line • Check fuel hoses for cracks or damage. √ √ √ √ √
*
• Check condition.
√ √
5 2 Spark plug • Clean and regap.
• Replace. √ √
• Check valve clearance.
6 3 * Valves √ √ √ √
• Adjust.
• Clean. √ √
4 Air filter element
7 • Replace. √ √
• Check operation.
5 Clutch √ √ √ √ √
• Adjust.
8 • Check operation, fluid level and vehicle for fluid leakage.
√ √ √ √ √ √
6 * Front brake (See NOTE on page 6-5.)
9 • Replace brake pads. Whenever worn to the limit
• Check operation, fluid level and vehicle for fluid leakage.
√ √ √ √ √ √
7 * Rear brake (See NOTE on page 6-5.)
• Replace brake pads. Whenever worn to the limit
• Check for cracks or damage. √ √ √ √ √
8 * Brake hoses
• Replace. (See NOTE on page 6-5.) Every 4 years
6-3
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 5

1 10 20 30 40 CHECK
• Check runout, spoke tightness and for damage.
9 * Wheels √ √ √ √
• Tighten spokes if necessary.
• Check tread depth and for damage.
• Replace if necessary.
10 * Tires √ √ √ √
• Check air pressure.
• Correct if necessary.
11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √
12 * Swingarm • Check operation and for excessive play. √ √ √ √
• Check chain slack.
Every 500 km and after washing
13 Drive chain • Make sure that the rear wheel is properly aligned.
the motorcycle or riding in the rain.
• Clean and lubricate.
• Check bearing play and steering for roughness. √ √ √ √ √
14 * Steering bearings
• Lubricate with lithium-soap-based grease. Every 20,000 km
15 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √
• Check operation.
6
16 Sidestand √ √ √ √ √
• Lubricate.
17 * Sidestand switch • Check operation. √ √ √ √ √ √
18 * Front fork • Check operation and for oil leakage. √ √ √ √
Shock absorber
19 * • Check operation and shock absorber for oil leakage. √ √ √ √
assembly
6-4
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 6

1 10 20 30 40 CHECK
Rear suspension relay • Check operation. √ √ √ √
1 20 * arm and connecting arm
pivoting points • Lubricate with molybdenum disulfide grease. √ √
• Check starter (choke) operation.
2 21 * Carburetor √ √ √ √ √ √
• Adjust engine idling speed.
22 Engine oil • Change. √ √ √ √ √ √
3 23 Engine oil filter element • Replace. √ √ √
Front and rear brake
24 * • Check operation. √ √ √ √ √ √
switches
4
25 Moving parts and cables • Lubricate. √ √ √ √ √
Lights, signals and • Check operation.
26 * √ √ √ √ √ √
5 switches • Adjust headlight beam.
EAU03884
6 NOTE:
8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
7 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 change the
8
brake fluid.
9 Replace the brake hoses every four years and if cracked or damaged.
9
6-5
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 7
1 1
1
1
1. Cowling A 1. Panel A 1. Panel B

4
EAU01139
Cowling and panel removal

and installation 5
The cowlings and panels illustrated
need to be removed to perform some 6
of the maintenance described in this
chapter. 7
Refer to this section each time a
cowling or panel has to be removed 8
or reinstalled.
9
6-6
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 8
1
1
2
2
3 1
1. Screw 1. Panel A
4 2. Screw
EAU01145
To install
Cowling A Panel A
EAU00488
Place in the original position and

5 To remove
install the screw. To remove
Remove the cowling screw and pull
Remove the screw and pull outward
6 outward on the areas shown.
on the areas shown.
7 To install
Place the panel in the original posi-
8 tion and install the screw.
6-7
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 9
1
1
2 2
2
3
1. Panel B 1. Spark plug cap 1. Spark plug wrench

2. Screw 4
EAU01833
EAU00488 2. Use the spark plug wrench in the
Panel B Spark plug tool kit to remove the spark plug
Removal 5
To remove as shown.
Remove the screw and pull outward 1. Remove the spark plug cap.
on the areas shown. 6
To install 7
Place the panel in the original posi-
tion and install the screw. 8
6-8
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 10

Inspection NOTE:
The spark plug is an important If a torque wrench is not available
engine component and is easy to when you are installing a spark plug,
1
inspect. The condition of the spark a good estimate of the correct torque
plug can indicate the condition of the is 1/4 to 1/2 turn past finger tight.
2 engine. 1 Have the spark plug tightened to the
The ideal color on the white insulator specified torque as soon as possible.
3 around the center electrode is a
medium-to-light tan color for a motor- 4. Install the spark plug cap.
1. Spark plug gap
4 cycle that is being ridden normally.
Do not attempt to diagnose such Installation
problems yourself. Instead, take the 1. Measure the electrode gap with
5
motorcycle to a Yamaha dealer. You a wire thickness gauge and, if
should periodically remove and necessary, adjust the gap to
6
inspect the spark plug because heat specification.
and deposits will cause any spark Spark plug gap:
7 plug to slowly break down and erode. 0.8 ~ 0.9 mm
If electrode erosion becomes exces-
8 sive, or if carbon and other deposits 2. Clean the gasket surface. Wipe
are excessive, you should replace off any grime from the threads.
9 the spark plug with the specified plug. 3. Install the spark plug and tighten
it to the specified torque.
Specified spark plug:
Tightening torque:
DPR8EA-9 or
Spark plug:
DPR9EA-9 (NGK)
17.5 Nm (1.75 m0kg)
6-9
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 11

EC000000
cC
Do not run the motorcycle until
you know it has sufficient engine 1
oil.
1 2
1 2 EW000065
2 3 w 3
Never remove the dipstick just
1. Screw 1. Oil tank cap/dipstick
2. Cover 2. Maximum level mark
after high-speed operation. Hot oil 4
EAU00526* 3. Minimum level mark could spout out, causing danger.
Engine oil 4. Idle the engine for at least 10 Always wait until the oil cools
5
Oil level measurement seconds and stop it. While keep- down before removing the dip-
1. Place the motorcycle on a level ing the motorcycle upright, stick.
place and hold it in an upright 6
remove the dipstick (oil tank cap)
position. and check the oil level.
2. Remove the screw and pull out- 7
5. The oil level should be between
ward on the oil tank cap cover to the minimum and maximum
remove it. marks. If the level is low, fill with 8
3. Start the engine and warm it up. oil to the maximum level line.
9
6-10
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 12
1
1
1 1
2 2
4
3 2
3 2
1. Drain bolt (oil tank) 1. Air bleed screw 1. Oil filter element
4 2. Drain bolt (crankcase) 2. Oil filter cover bolt (×2) 2. O-ring (×2)
3. Oil filter drain bolt
Engine oil and oil filter 4. Oil filter cover 6. Check the O-rings for damage.
5 element replacement Replace if damaged.
4. Check each gasket. If damaged,
1. Warm up the engine for a few 7. Install the drain plugs, filter cover
replace.
6 minutes. and bolts. Tighten to the speci-
5. Remove the filter cover bolts and
2. Place an oil pan under the fied torque.
the oil filter cover. Replace the oil
7 engine. filter element.
3. Remove the oil tank cap, drain
bolts. NOTE:
8
The oil filter cover is secured by three
bolts. The lower one should be
9
removed first so that the filter cavity
will drain.
6-11
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 13

9. Start the engine and warm it up 1
Tightening torque:
for a few minutes. While warming
Drain plug (crankcase):
up, check for oil leakage. If oil
30 Nm (3.0 m0kg) 1
leakage is found, stop the engine
Drain plug (oil tank):
immediately and check for the
17.5 Nm (1.75 m0kg) 2
cause.
Filter cover bolt: 1
10. Stop the engine and check the
10 Nm (1.0 m0kg)
oil level. 3
Air bleed screw: EC000076
5 Nm (0.5 m0kg) cC 1. Screw (×7)
4
EAU01083
After replacing the engine oil, be Air filter
8. Fill the engine with oil. Install the
sure to check the oil pressure as The air filter should be cleaned at the 5
oil tank cap.
described below. specified intervals. It should be
8 Remove the air bleed screw cleaned more frequently if you are 6
Recommended oil: from the oil filter cover. riding in unusually wet or dusty
See page 8-1 8 Start the engine and keep it areas.
Oil quantity: idling until oil flows out of the 7
1. Remove panel B. (See page 6-7
Total amount: bleed hole. If no oil comes out for panel removal and installation
3.3 L after one minute, turn off the 8
procedures.)
Periodic oil change: engine immediately so it will 2. Remove the air filter case fitting
2.7 L not seize. In such a case go to screws and the filter case cover. 9
With oil filter replacement: the nearest Yamaha dealer for
2.8 L repairs.
8 After checking, tighten the air
bleed screw securely.
6-12
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 14

EAU00629
Carburetor adjustment
The carburetor is a vital part of the
1 engine and requires very sophisticat-
ed adjustment. Most adjustments
2 should be left to a Yamaha dealer
1 who has the professional knowledge
and experience to do so. However,
3
the following may be serviced by the
1. Mesh side owner as part of routine mainte-
4 nance.
3. Remove the air filter. 5. Install the air filter with the arrow EC000094
5
4. Tap the air filter lightly to remove mark on the top pointing inward. cC
most of the dust and dirt and 6. Install the air filter case cover
The carburetor was set at the
blow out the remaining dirt with and the panel.
6 Yamaha factory after many tests. If
compressed air from the mesh EC000082
side of the air filter. If it is dam- cC the settings are changed, poor
7 engine performance and damage
aged, replace it. 8 Make sure the air filter is prop-
may result.
erly seated in the air filter
8 case.
8 The engine should never be
9 run without the air filter
installed. Excessive piston
and/or cylinder wear may
result.
6-13
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 15
Standard idle speed:

1,200 ~ 1,400 r/min
(Except for CH) 1
b 1,300 ~ 1,400 r/min
a (For CH) 2
a
1 NOTE:
3
If the specified idle speed cannot be
1. Throttle stop screw obtained by performing the above a. Free play
adjustment, consult a Yamaha deal- 4
EAU00632 EAU00635
Idle speed adjustment er. Throttle cable free play

1. Start the engine and warm it up inspection 5
for a few minutes at approxi- There should be a free play of 3 ~
mately 1,000 to 2,000 r/min. 5 mm at the throttle grip. If the free 6
Occasionally rev the engine to play is incorrect, ask a Yamaha deal-
4,000 to 5,000 r/min. The engine er to make this adjustment. 7
is warm when it quickly responds
to the throttle.
8
2. Set the idle to the specified
engine speed by adjusting the
throttle stop screw. Turn the 9
screw in direction a to increase
engine speed and in direction b
to decrease engine speed.
6-14
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 16

EAU00637 EAU00652
176 kg (XT500E)
Valve clearance adjustment Tires Maximum load*
180 kg (XT600E)
The correct valve clearance changes To ensure maximum performance, Cold tire pressure: Front Rear
1 with use, resulting in improper fuel/air long service and safe operation, note 150 kPa 150 kPa
Up to 90 kg (1.5 kg/cm2, (1.5 kg/cm2,
supply or engine noise. To prevent the following: 1.5 bar) 1.5 bar)
2 this, the valve clearance must be Tire air pressure 150 kPa 225 kPa
90 kg load ~
adjusted regularly. This adjustment Always check and adjust the tire Maximum load*
(1.5 kg/cm2, (2.25 kg/cm2,
1.5 bar) 2.25 bar)
however, should be left to a profes- pressure before operating the motor-
3 125 kPa 125 kPa
sional Yamaha service technician. cycle. Off-road riding (1.25 kg/cm2, (1.25 kg/cm2,
EW000082 1.25 bar) 1.25 bar)
4 w 150 kPa 150 kPa
High speed riding (1.5 kg/cm2, (1.5 kg/cm2,
Tire inflation pressure should be 1.5 bar) 1.5 bar)
5 checked and adjusted when the * Load is the total weight of cargo, rider, passenger
temperature of the tire equals the and accessories.
6 ambient air temperature. Tire infla-

tion pressure must be adjusted
7 according to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if
8
approved for this model), and vehi-
cle speed.
9
6-15
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 17

EW000083 EW000078
w w
1
Proper loading of your motorcycle After extensive tests, the tires
is important for several character- mentioned below have been 1
istics of your motorcycle, such as approved by Yamaha Motor Co.,
handling, braking, performance 2 Ltd. for this model. No guarantee 2
and safety. Do not carry loosely for handling characteristics can be
packed items that can shift. given if tire combinations other 3
Securely pack your heaviest items than what is approved are used on
close to the center of the motorcy- 1. Tread depth this motorcycle. The front and rear
2. Side wall 4
cle, and distribute the weight even- tires should be of the same manu-
ly from side to side. Properly Tire inspection facture and design.
Always check the tires before operat- 5
adjust the suspension for your
load, and check the condition and ing the motorcycle. If center tread
FRONT
pressure of your tires. NEVER depth reaches the limit as shown, if 6
Manufacturer Size Type
OVERLOAD YOUR MOTORCYCLE. the tire has a nail or glass fragments BRIDGESTONE 90/90-21 54S TW47
Make sure the total weight of the in it, or if the side wall is cracked, DUNLOP 90/90-21 54S TRAIL MAX L 7
cargo, rider, passenger, and contact a Yamaha dealer immediate-
ly and have the tire replaced. REAR
accessories (fairing, saddlebags, 8
Manufacturer Size Type
etc. if approved for this model) BRIDGESTONE 120/90-17 64S TW48
does not exceed the maximum DUNLOP 120/90-17 64S TRAIL MAX 9
load of the motorcycle. Operation
of an overloaded motorcycle could Minimum tire tread
cause tire damage, an accident, or depth 0.8 mm
(front and rear)
even injury.
6-16
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 18

EAU00681 EAU00685
NOTE: w Wheels
These limits may be different by regu- To ensure maximum performance,
8 Operating the motorcycle with
lation from country to country. If so, long service, and safe operation, note
1 excessively worn tires
conform to the limits specified by the the following:
decrease riding stability and
regulations of your own country. 8 Always inspect the wheels
2 can lead to loss of control.
before a ride. Check for cracks,
Have excessively worn tires
bends or warpage of the wheel.
3 replaced by a Yamaha dealer
Be sure the spokes are tight and
immediately. Brakes, tires, and
undamaged. If any abnormal
4 related wheel parts replace-
condition exists in a wheel, con-
ment should be left to a
sult a Yamaha dealer. Do not
Yamaha Service Technician.
5 attempt even small repairs to the
8 Patching a punctured tube is
wheel. If a wheel is deformed or
not recommended. If it is
6 cracked, it must be replaced.
absolutely necessary to do so,
8 Tires and wheels should be bal-
use great care and replace the
7 anced whenever either one is
tube as soon as possible with
changed or replaced. Failure to
a good quality replacement.
have a wheel balanced can
8
result in poor performance,
adverse handling characteristics,
9 and shortened tire life.
8 Ride at moderate speeds after
changing a tire since the tire sur-
face must first be broken in for it
to develop its optimal character-
istics.
6-17
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 19
1 2 a b
b 3 1
a
b
3 2 1 2
a
1 2
3
1. Locknut 1. Adjusting nut 1. Locknut

2. Adjusting bolt 2. Locknut 2. Adjusting bolt 4
3. Free play 3. Free play
4. Loosen the locknut at the clutch EAU00696
EAU00694
lever. 5
Clutch lever free play Front brake lever free play
5. Turn the adjusting bolt at the adjustment
adjustment
clutch lever in direction a to The free play at the front brake lever 6
The clutch lever free play should be
loosen the cable. should be 2 ~ 5 mm.
adjusted to 10 ~ 15 mm.
6. Loosen the locknut at the 1. Loosen the locknut. 7
1. Loosen the locknut at the clutch
crankcase side. 2. Turn the adjusting bolt in direc-
lever.
7. Turn the adjusting nut at the tion a to increase free play or in
2. Turn the adjusting bolt at the 8
crankcase in direction a to direction b to decrease free
clutch lever in direction a to
increase free play or in direction play.
increase free play or in direction 9
b to decrease free play.
b to decrease free play. 3. After adjusting, tighten the lock-
8. Tighten the locknut at the nut.
3. Tighten the locknut at the clutch
crankcase and the clutch lever.
lever.
If the specified free play cannot be
obtained, proceed with the following
steps.
6-18
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 20

EW000099 EW000109
w w
8 Check the brake lever free A soft or spongy feeling in the
1 play. Be sure the brake is brake pedal can indicate the pres-
working properly. a ence of air in the brake system.
2 8 A soft or spongy feeling in the This air must be removed by
brake lever can indicate the bleeding the brake system before
3 presence of air in the brake the motorcycle is operated. Air in
system. This air must be the system will cause greatly
removed by bleeding the brake a. Pedal height diminished braking capability and
4 EAU00712
system before the motorcycle can result in loss of control and an
is operated. Air in the system Rear brake pedal height accident. Have a Yamaha dealer
5 adjustment
will cause greatly diminished inspect and bleed the system if
braking capability and can The top of the brake pedal should be necessary.
6 result in loss of control and an positioned 12 mm below the top of
accident. Have a Yamaha deal- the footrest. If not, ask a Yamaha
7 er inspect and bleed the sys- dealer to adjust it.
tem if necessary.
8
6-19
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 21

EAU00716
Checking the front and rear

1
brake pads
A wear indicator is provided on each 1
2 brake. This indicator allows checking 1 1
a
b of brake pad wear without disassem- 2
bling the brake. Apply the brake and
inspect the wear indicator. If the 3
brake pads are worn to wear limit,
1. Brake light switch have a Yamaha dealer to replace the 1. Wear indicator groove (×3)
2. Adjusting nut 4
pads. EAU01119
EAU00713
Front brake
Brake light switch Wear indicator grooves are provided 5
adjustment on each brake pad. These indicators
The rear brake light switch is activat- allow checking of brake pad wear 6
ed by the brake pedal and is properly without disassembling the brake.
adjusted when the brake light comes Inspect the grooves. If they have
on just before braking takes effect. 7
almost disappeared, ask a Yamaha
To adjust the rear brake light switch, dealer to replace the pads.
hold the switch body so it does not 8
rotate while turning the adjusting nut.
Turn the adjusting nut in direction a 9
to make the brake light come on earli-
er.
Turn the adjusting nut in direction b
to make the brake light come on
later.
6-20
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 22
1
1
1 1
2
1. Wear limit: 0.8 mm 1. Minimum level mark 1. Minimum level mark

4
EAU00733
8 Use only the designated quality
EAU00729
Inspecting the brake fluid
Rear brake brake fluid. Otherwise, the rub-
5 level
Remove the cap and inspect the ber seals may deteriorate, caus-
Insufficient brake fluid may let air
pads. If the thickness is less than the ing leakage and poor brake per-
6 enter the brake system, possibly
specified value, have a Yamaha deal- formance.
causing the brakes to become inef-
er replace the pads.
7 fective.
Recommended brake fluid:
Before riding, check that the brake
DOT 4
fluid is above the minimum level and
8
replenish when necessary.
NOTE:
Observe these precautions:
9 If DOT 4 is not available, DOT 3 can
8 When checking the fluid level,
be used for the front brake only.
make sure the top of the master
cylinder is level by turning the
handlebars.
6-21
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 23

8 Refill with the same type of brake EAU00742
Brake fluid replacement

fluid. Mixing fluids may result in a
The brake fluid should be replaced
harmful chemical reaction and
only by trained Yamaha service per- 1
lead to poor brake performance.
sonnel. Have the Yamaha dealer
8 Be careful that water does not
replace the following components 2
enter the master cylinder when
during periodic maintenance or when
refilling. Water will significantly
they are damaged or leaking: a
lower the boiling point of the fluid 3
8 oil seals (every two years)
and may result in vapor lock.
8 brake hoses (every four years) a. Chain slack
8 Brake fluid may deteriorate paint- 4
EAU00744
ed surfaces or plastic parts. Drive chain slack check
Always clean up spilled fluid 5
immediately. NOTE:
8 Have a Yamaha dealer check Spin the wheel several times and find
the tightest position of the chain. 6
the cause if the brake fluid level
goes down. Check and/or adjust the chain slack
while it’s in this tightest position. 7
To check the chain slack the motor- 8

cycle must be held straight up with
both wheels on the ground and with- 9
out rider. Check the slack at the posi-
tion shown in the illustration. Normal
slack is approximately 30 ~ 40 mm. If
the slack exceeds 40 mm, adjust.
6-22
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 24

EC000096 EAU03006
cC Drive chain lubrication

1 The chain consists of many parts
Too little chain slack will overload
1 the engine and other vital parts. which work with each other. If the
a Keep the slack within the specified chain is not maintained properly, it
2 2 3 limits. will wear out quickly. Therefore, the
b chain must be serviced regularly.
3 3. After adjusting, be sure to tighten This service is especially necessary
the axle nut and caliper bracket when riding in dusty areas. This
1. Chain adjusting plate
bolt to the specified tightening motorcycle is equipped with a sealed
4 2. Axle nut
3. Caliper bracket bolt torque. type chain. Steam cleaning, high-
EAU01134 pressure washers, and solvents can
5 damage the drive chain, so do not
Drive chain slack adjustment Tightening torque:
1. Loosen the axle nut and caliper use these for cleaning it. Use only
Axle nut:
6 bracket bolt. kerosene to clean the drive chain.
105 Nm (10.5 m0kg)
2. Turn both left and right chain Wipe it dry, and thoroughly lubricate it
Caliper bracket bolt:
7 adjusting plates the same with SAE 30 ~ 50W motor oil. Do not
48 Nm (4.8 m0kg)
amount. Make sure that they are use any other lubricants on the drive
8 in the same position for proper chain. They may contain solvents
wheel alignment. To tighten the that could damage the sealed chain.
9 chain, turn in direction a. To
loosen the chain, turn in direction
b.
6-23
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 25

EC000097 EAU02962 EAU00773
cC Cable inspection and Throttle cable and grip

Be sure to oil the chain after wash- lubrication lubrication
ing the motorcycle or riding in the
EW000112
The throttle twist grip assembly 1
w should be greased at the time that
rain.
Damage to the outer housing of the cable is lubricated, since the grip 2
cables may lead to internal rusting must be removed to get at the end of
and interfere with the cable move- the throttle cable. After removing the 3
ment. Replace damaged cables as screws, hold the end of the cable up
soon as possible to prevent unsafe in the air and put in several drops of
4
conditions. lubricant. With the throttle grip disas-
sembled, coat the metal surface of
the grip assembly with a suitable all- 5
Lubricate the cables and cable ends.
If a cable does not operate smoothly, purpose grease.
ask a Yamaha dealer to replace it. 6
Recommended lubricant: 7
Engine oil
8
6-24
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 26
4
EAU02984 EAU02985 EAU02986
Brake and shift pedal Brake and clutch lever Sidestand lubrication
5 lubrication lubrication Lubricate the sidestand pivoting point
Lubricate the pivoting parts. Lubricate the pivoting parts. and metal-to-metal contact surfaces.
6 Check that the sidestand moves up
Recommended lubricant: Recommended lubricant: and down smoothly.
Engine oil Engine oil
7
Recommended lubricant:
Engine oil
8
EW000113
9 w
If the sidestand does not move
smoothly, consult a Yamaha deal-
er.
6-25
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 27

EAU02939
Front fork inspection

Visual check
EW000115
1
w
Securely support the motorcycle 2
1
so there is no danger of it falling
over. 3
1
1. Grease nipple (×2) Check for scratches or damage on
EAU00790
4
the inner tube and excessive oil leak- Operation check
Rear suspension lubrication age from the front fork. 1. Place the motorcycle on a level
Lubricate the pivoting parts. 5
place.
Recommended lubricant: 2. Hold the motorcycle in an upright
6
Molybdenum disulfide grease position and apply the front
brake.
3. Push down hard on the handle- 7
bars several times and check if
the fork rebounds smoothly. 8
EC000098
cC
9
If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
6-26
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 28

EW000115 EAU01144
w Wheel bearings
If there is play in the front or rear
Securely support the motorcycle
1 wheel hub or if the wheel does not
so there is no danger of it falling
turn smoothly, have a Yamaha dealer
over.
2 inspect the wheel bearings.
4
EAU00794
Steering inspection
5 Periodically inspect the condition of
the steering. Worn out or loose steer-
6 ing bearings may be dangerous.
Place a stand under the engine to
7 raise the front wheel off the ground.
Hold the lower end of the front forks
and try to move them forward and
8
backward. If any free play can be felt,
ask a Yamaha dealer to inspect and
9 adjust the steering. Inspection is eas-
ier if the front wheel is removed.
6-27
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 29

EAU00800 EW000116
Battery storage
Battery w
When the motorcycle is not used for
This motorcycle is equipped with a
Battery electrolyte is poisonous a month or longer, remove the bat-
sealed-type battery. Therefore it is 1
and dangerous, causing severe tery, fully charge it and store it in a
not necessary to check the elec-
burns, etc. It contains sulfuric cool, dry place.
trolyte or fill the battery with distilled 2
acid. Avoid contact with skin, eyes EC000102
water.
or clothing. cC
8 If the battery seems to have dis-
ANTIDOTE: 8 Completely recharge the bat- 3
charged, consult a Yamaha deal-
8 EXTERNAL: Flush with water. tery before storing. Storing a
er.
8 INTERNAL: Drink large quanti- discharged battery can cause 4
8 If the motorcycle is equipped
ties of water or milk. Follow permanent battery damage.
with optional electrical acces-
with milk of magnesia, beaten 8 Use a battery charger
sories, the battery tends to dis- 5
egg, or vegetable oil. Call a designed for a sealed-type
charge more quickly, so be sure
physician immediately. (MF) battery. Using a conven-
to recharge it periodically. 6
EC000101
8 EYES: Flush with water for 15 tional battery charger will
cC minutes and get prompt med- cause battery damage. If you
ical attention. do not have a sealed-type bat- 7
Never try to remove the sealing
Batteries produce explosive tery charger, contact your
caps of the battery cells. The bat-
gases. Keep sparks, flame, ciga- Yamaha dealer. 8
tery will be damaged.
rettes etc., away. Ventilate when 8 Always make sure the connec-
charging or using in an enclosed tions are correct when rein- 9
space. Always shield your eyes stalling the battery.
when working near batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
6-28
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 30

EC000103
cC
1 Do not use fuses of higher amper-
1 age rating than those recommend- 1
ed. Substitution of a fuse of
2
2 improper rating can cause exten-
sive electrical system damage and
3 possibly a fire.
1. Main fuse 1. Bolt (×3)

4 2. Spare fuse Specified fuse: EAU01146
EAU01307
20 A Headlight bulb replacement
5
Fuse replacement
The fuse is located behind panel A. This motorcycle is equipped with a
(See page 6-7 for panel removal and quartz bulb headlight. If the headlight
6 installation procedures.) bulb burns out, replace it as follows:
If the fuse is blown, turn off the main 1. Remove cowling A. (See page
7 switch and the switch of the circuit in 6-7 for cowling removal and
question. Install a new fuse of proper installation procedures.)
8 amperage. Turn on the switches and 2. Remove the headlight unit.
see if the electrical device operates.
9 If the fuse immediately blows again,
consult a Yamaha dealer.
6-29
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 31
1
2
1
1
1
1. Connector (×3) 1. Bulb holder 1. Don’t touch

2. Bulb holder cover 4
4. Turn the bulb holder counter- 5. Put a new bulb into position and
3. Remove the connectors and the clockwise to remove it and secure it in place with the bulb
bulb holder cover. 5
remove the defective bulb. holder.
EW000119 EC000105
w cC 6
Keep flammable products and your Avoid touching the glass part of a
hands away from a bulb while it is bulb. Keep it free from oil; other- 7
on, as it is hot. Do not touch a bulb wise, the transparency of the
until it cools down. glass, life of the bulb, and lumi- 8
nous flux will be adversely affect-
ed. If oil gets on a bulb, thoroughly 9
clean it with a cloth moistened
with alcohol or lacquer thinner.
6-30
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 32

6. Install the bulb holder cover, con-
nectors and headlight unit.
7. Install the cowling.
1
1
8. If the headlight beam adjustment
is necessary, ask a Yamaha
2 dealer to make that adjustment.
2 1
1. Screw 1. Bulb
4 2. Lens
EAU01095
2. Remove the defective bulb by
Turn signal light bulb pushing it inward and turning it
5
replacement counterclockwise.
1. Remove the screw and the lens. 3. Install a new bulb by pushing it
6
inward and turning it clockwise.
4. Install the lens and tighten the
7 screw.
6-31
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 33

EAU01579
1 Supporting the motorcycle

1 Since the Yamaha XT500E/XT600E
has no centerstand, follow these pre- 1
cautions when removing the front and
rear wheel or performing other main- 2
tenance requiring the motorcycle to
stand upright. Check that the motor- 3
2 cycle is in a stable and level position
1. Screw (×2) 1. Bulb before starting any maintenance. A
2. Lens 4
EAU01623 2. Remove the defective bulb by strong wooden box can be placed
Taillight bulb replacement pushing it inward and turning it under the engine for added stability.
5
1. Remove the screws and the counterclockwise.
lens. 3. Install a new bulb by pushing it Front wheel service
To stabilize the rear of the motorcy- 6
inward and turning it clockwise.
4. Install the lens and tighten the cle, either use a motorcycle stand or
screws. place a motorcycle jack under the 7
frame in front of the rear wheel to
EC000108 prevent it from moving from side to 8
cC side. Then use a motorcycle stand to
Do not over-tighten the screws as elevate the front wheel off of the
9
the lens may break. ground.
6-32
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 34

Rear wheel service
Use a motorcycle stand or motorcycle
jack to elevate the motorcycle so the
1
1 1
rear wheel is off the ground. 2
Alternatively, two jacks can be placed
2 under the frame or swingarm.
1. Speedometer cable 1. Axle holder nut (×4)

4 2. Wheel axle
EAU00897
Front wheel removal 2. Loosen the wheel axle holder

5 EW000122
nuts and wheel axle.
w 3. Elevate the front wheel by plac-
6 8 It is advisable to have a ing a suitable stand under the
Yamaha dealer service the engine.
wheel. 4. Remove the wheel axle and the
7
8 Securely support the motorcy- front wheel. Make sure the
cle so there is no danger of it motorcycle is properly supported.
8
falling over.
NOTE:
9 1. Remove the speedometer cable Do not depress the brake lever when
from the front wheel side. the disc and caliper are separated.
6-33
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 35
1
1
2
2
3
1. Upper nut (×2)

2. Lower nut (×2) 4
EAU01135
3. Make sure the slot in the 3. Gap
Front wheel installation speedometer gear unit fits over 5. Before tightening the holder nuts, 5
1. Install the speedometer gear unit the stopper on the front fork push down on the handlebars
housing into the wheel hub. outer tube. several times and check if the
Make sure the speedometer gear 6
4. Install the wheel axle and tighten fork rebounds smoothly.
unit housing is installed with the it to the specified torque. 6. Tighten the axle holder nuts to
projections meshed into the 7
the specified tightening torque.
slots. Tightening torque:
Tighten the upper nuts first and
2. Lift up the wheel between the Wheel axle: 8
then lower ones. When tightened
front fork legs and guide the 59 Nm (5.9 m0kg)
in this sequence, there should be
brake disc between the brake
a gap formed at the bottom of 9
pads. Make sure there is enough
the axle holder.
gap between the brake pads
before inserting the brake disc.
6-34
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 36
Tightening torque:
1
Axle holder nut:
9 Nm (0.9 m0kg)
1
1
2 2
1
3
1. Axle nut 1. Swingarm end bolt (×2)

4 2. Caliper bracket bolt
EAU00963* 3. Remove the swingarm end bolts.
Rear wheel removal 4. Elevate the rear wheel by placing
5 EW000122
a suitable stand under the
w
engine.
6 8 It is advisable to have a
Yamaha dealer service the
7 wheel.
8 Securely support the motorcy-
8 cle so there is no danger of it
falling over.
9
1. Remove the axle nut.
2. Loosen the caliper bracket bolt.
6-35
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 37

EAU01136* EAU01008
Rear wheel installation Troubleshooting

1. Install the rear wheel and chain. Although Yamaha motorcycles
Guide the brake disc between receive a rigid inspection before ship- 1
the brake pads. Make sure there ment from the factory, trouble may
is enough gap between the occur during operation. 2
brake pads before inserting the Any problem in the fuel, compres-
brake disc. sion, or ignition systems can cause
2. Make sure the wheel axle is poor starting and loss of power. The
inserted from the left-hand side troubleshooting chart describes a
quick, easy procedure for making 4
5. Push the wheel forward and and that the chain adjusting
plates are installed with the checks.
remove the drive chain.
punched side outward. If your motorcycle requires any 5
6. Pull out the wheel axle, then
3. Install the swingarm end bolts. repair, bring it to a Yamaha dealer.
remove the wheel assembly by
4. Adjust the drive chain. The skilled technicians at a Yamaha 6
pulling backwards.
5. Tighten the following parts to the dealership have the tools, experi-
NOTE: specified torque. ence, and know-how to properly ser- 7
8 Do not depress the brake pedal vice your motorcycle. Use only gen-
when the disc and caliper are Tightening torque: uine Yamaha parts on your
8
separated. Axle nut: motorcycle. Imitation parts may look
8 You do not have to disassemble 105 Nm (10.5 m0kg) like Yamaha parts, but they are often
inferior. Conse-quently, they have a 9
the chain in order to remove or Caliper bracket bolt:
install the rear wheel. 48 Nm (4.8 m0kg) shorter service life and can lead to
Swingarm end bolt: expensive repair bills.
2.5 Nm (0.25 m0kg)
6-36
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 38

EAU01397
Troubleshooting chart
EW000125
w
1
Never check the fuel system while smoking or in the vicinity of an open flame.
2
1. Fuel Enough fuel. Go to compression check.
3
Check if there is fuel
in the fuel tank.
4 Engine doesn’t start, go to
No fuel. Supply fuel.
compression check.
5 2. Compression There is compression. Go to ignition check.

Use the electric starter.
6 No compression. Ask a Yamaha dealer to inspect.
3. Ignition
Wipe clean with dry cloth and Open throttle half-way and start the
7 Remove spark
Wet.
correct spark gap or replace spark plug. engine.
plug and check
8 electrodes.
Dry. Ask a Yamaha dealer to inspect. Engine doesn’t start, go to battery
check.
9 4. Battery
Engine turns over
Battery good.
quickly.
Use the electric Engine doesn’t start, ask a Yamaha
starter. dealer to inspect.
Engine turns over Check connections
slowly. or recharge.
6-37
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 1
MOTORCYCLE CARE AND STORAGE
Care....................................................................................................7-1
Storage ...............................................................................................7-4
7
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 2
EAU01518

Care Before cleaning Cleaning
The exposure of its technology 1. Cover up the muffler outlet with a After normal use
makes a motorcycle charming but plastic bag. Remove dirt with warm water, a neu-
1 also vulnerable. Although high-quality 2. Make sure that all caps and cov- tral detergent and a soft clean
components are used, they are not ers as well as all electrical cou- sponge, then rinse with plenty of
2 all rust-resistant. While a rusty plers and connectors, including clean water. Use a brush for hard-to-
exhaust pipe may remain unnoticed the spark plug cap, are tightly reach parts. Tougher dirt and insects
3 on a car, it does look unattractive on
installed. will come off more easily if the area is
a motorcycle. Frequent and proper
3. Remove extremely stubborn dirt, covered with a wet cloth for a few
care, however, will keep your motor-
4 cycle looking good, extend its life and like oil burnt onto the crankcase, minutes before cleaning.
maintain its performance. Moreover, with a degreasing agent and a ECA00010
tooth or bottle brush, but never cC

5 the warranty states that the vehicle
must be properly taken care of. For apply such products onto seals, 8 Avoid using strong acidic
all these reasons, it is recommended gaskets, sprockets, the drive wheel cleaners, especially on
6
that you observe the following clean- chain and wheel axles. Always spoked wheels. If you do use
ing and storing precautions. rinse the dirt and degreaser off such products for hard-to-
7 with water. remove dirt, do not leave it on
any longer than instructed,
8 then thoroughly rinse it off
with water, immediately dry
9 the area and apply a corrosion
protection spray.
7-1
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 3

8 Improper cleaning can damage 8 Do not use high-pressure After riding in the rain, near the sea
windshields, cowlings, panels washers or steam-jet cleaners or on salt-sprayed roads.
and other plastic parts. Use since they cause water seep- Since sea salt or salt sprayed on the
1
only a soft, clean cloth or age and deterioration in the roads in the winter are extremely cor-
sponge with mild detergent following areas: seals (of rosive in combination with water,
and water to clean plastic. wheel bearings, swingarm carry out the following steps after 2
8 Do not use any harsh chemical bearings, forks and brakes), each ride in the rain, near the sea or
products on plastic parts. Be electric components (cou- on salt-sprayed roads. (Salt sprayed 3
sure to avoid using cloths or plers, connectors, instru- in the winter may remain on the roads
sponges which have been in ments, switches and lights), well into spring.) 4
contact with strong or abra- breather hoses and vents. 1. Clean your motorcycle with cold
sive cleaning products, sol- 8 For motorcycles equipped water and soap after the engine 5
vent or thinner, fuel (gasoline), with a windshield: Do not use has cooled down.
rust removers or inhibitors, strong cleaners or hard ECA00012
brake fluid, antifreeze or elec- sponges as they will cause cC 6

trolyte. dulling or scratching. Some Do not use warm water since it
cleaning compounds for plas- increases the corrosive action of 7
tic may leave scratches on the the salt.
windshield. Test the product 8
on a small hidden part of the 2. Be sure to apply a corrosion pro-
windshield to make sure they tection spray on all (even 9
do not leave any marks. If the chrome- and nickel-plated) metal
windshield is scratched, use a surfaces to prevent corrosion.
quality plastic polishing com-
pound after washing.
7-2
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 4

EWA00001
After cleaning NOTE:
1. Dry the motorcycle with a
w
Consult a Yamaha dealer for advice
chamois or an absorbing cloth. Make sure that there is no oil or
on what products to use.
1 2. Immediately dry the drive chain wax on the brakes and tires. If nec-
and lubricate it to prevent it from essary, clean the brake discs and
2 rusting. linings with a regular brake disc
3. Use a chrome polish to shine cleaner or acetone, and wash the
3 chrome, aluminum and stainless- tires with warm water and mild
steel parts, including the exhaust soap. Then, carefully test the
system. (Even the thermally motorcycle for its braking perfor-
4
induced discoloring of stainless- mance and cornering behavior.
steel exhaust systems can be
5 removed through polishing.) ECA00013
4. To prevent corrosion, it is recom- cC
6 mended to apply a corrosion pro-
8 Apply spray oil and wax spar-
tection spray on all (even
ingly and wipe off any excess.
7 chrome- and nickel-plated) metal
8 Never apply oil or wax on rub-
surfaces.
5. Use spray oil as a universal ber and plastic parts, but treat
8 them with a suitable care prod-
cleaner to remove any remaining
dirt. uct.
9 6. Touch up minor paint damage 8 Avoid using abrasive polish-
caused by stones, etc. ing compounds as they wear
7. Wax all painted surfaces. away the paint.
8. Let the motorcycle dry complete-
ly before storing it or covering it.
7-3
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 5

Storage Long-term a. Remove the spark plug cap and
Short-term Before storing your motorcycle for spark plug.
Always store your motorcycle in a several months: b. Pour a teaspoonful of engine oil
1
cool, dry place and, if necessary, pro- 1. Follow all the instructions in the into the spark plug bore.
tect it against dust with a porous “Care” section of this chapter. c. Install the spark plug cap onto
cover. 2. Drain the carburetor float cham- the spark plug and place the 2
ECA00014 ber by loosening the drain bolt; spark plug on the cylinder head
cC this will prevent fuel deposits so that the electrodes are 3
8 Storing the motorcycle in a from building up. Pour the grounded. (This will limit spark-
poorly ventilated room or cov- drained fuel into the fuel tank. ing during the next step.) 4
ering it with a tarp while it is 3. Only for motorcycles equipped d. Turn the engine over several
still wet will allow water and with a fuel cock which has an times with the starter. (This will 5
humidity to seep in and cause “OFF” position: Turn the fuel coat the cylinder wall with oil.)
rust. cock to “OFF”. e. Remove the spark plug cap from
6
8 To prevent corrosion, avoid 4. Fill up the fuel tank and add fuel the spark plug, install the spark
damp cellars, stables (because stabilizer (if available) to prevent plug and then the spark plug
the fuel tank from rusting and the cap. 7
of the presence of ammonia)
EWA00003
and areas where strong chemi- fuel from deteriorating.
w 8
cals are stored. 5. Perform the following steps to
protect the cylinder, piston rings, When turning the engine over, be
etc. from corrosion. sure to ground the spark plug elec- 9
trodes to prevent damage or injury
from sparking.
7-4
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 6

6. Lubricate all control cables and 9. Remove the battery and fully
the pivoting points of all levers charge it. Store it in a cool, dry
and pedals as well as of the place and recharge it once a
1 sidestand/centerstand. month. Do not store the battery
7. Check and, if necessary, correct in an excessively cold or warm
2 the tire air pressure, then raise place (less than 0°C or more
the motorcycle so that both of its than 30°C). For more informa-
3 wheels are off the ground. tion, see “Battery storage” in the
Alternatively, turn the wheels a chapter “PERIODIC MAINTE-
little every month in order to pre- NANCE AND MINOR
4
vent the tires from becoming REPAIRS”.
degraded in one spot.
5 8. Cover up the muffler outlet with a NOTE:
plastic bag to prevent moisture Make any necessary repairs before
6 from entering. storing the motorcycle.
7-5
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 7
SPECIFICATIONS
Specifications .....................................................................................8-1
HOW TO USE THE CONVERSION TABLE.......................................8-5
8
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 8
EAU01038
SPECIFICATIONS
Specifications
Engine oil
Model XT500E/XT600E
1 Type
Dimensions –20° –10° 0° 10° 20° 30° 40° 50°C
Overall length 2,220 mm
2 2.295 mm (N, S, CH only) SAE 10W/30
Overall width 865 mm SAE 10W/40

3 825 mm (CH only) SAE 15W/40
Overall height 1,205 mm
SAE 20W/40
4 Seat height 855 mm
SAE 20W/50
Wheel base 1,440 mm
5 Minimum ground clearance 230 mm Recommended engine oil

classification API Service SE, SF, SG type
Minimum turning radius 2,300 mm or higher
Basic weight (with oil and full
6 fuel tank) 176 kg
172 kg (CH only)
cC
Engine Be sure to use motor oils that do not contain anti-friction
7
Engine type Air-cooled 4-stroke, SOHC, modifiers. Passenger car motor oils (often labeled
gasoline “Energy Conserving”) contain anti-friction additives which
8 Cylinder arrangement Forward inclined single
will cause clutch and/or starter clutch slippage, resulting in
cylinder reduced component life and poor engine performance.
9 Displacement 499 cm3

595 cm3 Capacity
Bore × Stroke 87.0 × 84.0 mm (XT500E) Periodic oil change 2.7 L
95.0 × 84.0 mm (XT600E)
With oil filter replacement 2.8 L
Compression ratio 8.5:1
Total amount 3.3 L
Starting system Electric starter
Lubrication system Dry sump
8-1
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 9
SPECIFICATIONS
Air filter Dry type element Gear ratio 1st 2.583

1
Fuel 2nd 1.588
Type Regular unleaded gasoline 3rd 1.200
2
Fuel tank capacity 15 L 4th 0.954 (XT500E)
0.955 (XT600E)
Reserve amount 2L
5th 0.792 3
Carburetor
Chassis
Type/quantity Y26PV/1
Frame type Diamond 4
Manufacturer TEIKEI
Caster angle 27.75° (XT500E)
Spark plug 27°45’ (XT600E) 5
Type/Manufacturer DPR8EA-9 or DPR9EA-9/NGK Trail 120 mm
Spark plug gap 0.8 ~ 0.9 mm Tire 6
Clutch type Wet, multiple-disc Type With tube
Transmission Front 7
Primary reduction system Spur gear Size 90/90-21 54S
Primary reduction ratio 74/31 (2.387) (XT500E) Manufacturer/ BRIDGESTONE/TW47 8
71/34 (2.088) (XT600E) model DUNLOP/TRAIL MAX L
Secondary reduction system Chain drive Rear
Secondary reduction ratio 38/15 (2.533) (XT500E) 9
Size 120/90/17 64S
45/15 (3.000) (XT600E)
Manufacturer/ BRIDGESTONE/TW48
Transmission type Constant mesh 5-speed model DUNLOP/TRAIL MAX
Operation Left foot operation Maximum load* 176 kg (XT500E)
180 kg (XT600E)
8-2
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 10
SPECIFICATIONS
Air pressure (cold tire) Brakes

1
up to 90 kg load* Front
Front 150 kPa (1.50 kg/cm , 1.50 bar)
2
Type Single disc brake
2
Rear 150 kPa (1.50 kg/cm2, 1.50 bar) Operation Right hand operation
90 kg load ~ Maximum Fluid DOT 3 or DOT 4
3 load*
Rear
Front 150 kPa (1.50 kg/cm2, 1.50 bar)
Type Single disc brake
4 Rear 225 kPa (2.25 kg/cm2, 2.25 bar)
Operation Right foot operation
Off-road riding
Fluid DOT 4
5 Front 125 kPa (1.25 kg/cm2, 1.25 bar)
Suspension
Rear 125 kPa (1.25 kg/cm2, 1.25 bar)
Front
6 High speed riding
Type Telescopic fork
Front 150 kPa (1.50 kg/cm2, 1.50 bar)
Rear
7 Rear 150 kPa (1.50 kg/cm2, 1.50 bar)
Type Swingarm (new monocross)
* Load is total weight of cargo, rider, passenger and accessories.
Shock absorber
8 Wheels
Front Coil spring/oil damper
Front
Rear Coil spring/gas-oil damper
9 Type Spoke wheel
Wheel travel
Size 21 × 1.85
Front 225 mm
Rear
Rear 200 mm
Type Spoke wheel
Size 17 × MT2.50
8-3
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 11
SPECIFICATIONS
Electrical
1
Ignition system T.C.I. (Digital)
Charging system
2
Type A.C. magneto
Standard output 14 V, 13.5A@5,000 rpm
3
Battery
Type YTX9-BS
4
Voltage, capacity 12 V, 8 AH
Headlight bulb type Halogen bulb
5
Bulb voltage, wattage × quantity
Headlight 12 V, 60/55W × 1
6
Tail / brake light 12 V, 5/21W × 1
Auxiliary light 12 V, 4W × 1
12 V, 3.4W × 1 (GB only) 7
Front flasher light 12 V, 21W × 2
Rear flasher light 12 V, 21W × 2 8
Meter light 12 V, 3.4W × 1
Neutral indicator light 12 V, 3.4W × 1 9
High beam indicator light 12 V, 3.4W × 1
Turn indicator light 12 V, 3.4W × 1
Fuse
Main 20A
8-4
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 12
SPECIFICATIONS
CONVERSION TABLE
EAU01064
METRIC TO IMPERIAL
1 HOW TO USE THE CONVERSION TABLE Metric unit Multiplier Imperial unit
All specification data in this manual are listed in SI and m • kg 7.233 ft• lb
m • kg 86.794 in• lb
2 METRIC UNITS. Torque
cm • kg 0.0723 ft • lb
Use this table to convert METRIC unit data to cm • kg 0.8679 in • lb
kg 2.205 lb
3 IMPERIAL unit data. Weight
g 0.03527 oz
Speed km/hr 0.6214 mph
Ex. km 0.6214 mi
4 m 3.281 ft
Distance m 1.094 yd
METRIC MULTIPLIER IMPERIAL cm 0.3937 in
5 mm 0.03937 in
cc (cm3) 0.03527 oz (IMP liq.)
** mm × 0.03937 = ** in Volume/ cc (cm3) 0.06102 cu • in
6 2 mm × 0.03937 = 0.08 in Capacity lt (liter)
lt (liter)
0.8799
0.2199
qt (IMP liq.)
gal (IMP liq.)
kg/mm 55.997 lb/in
7 Misc. kg/cm2 14.2234 psi (lb/in2)
Centigrade(°C) 9/5 + 32 Fahrenheit(°F)
8-5
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 13
CONSUMER INFORMATION
Identification number records .............................................................9-1

Key identification number ...................................................................9-1
Vehicle identification number..............................................................9-1
Model label .........................................................................................9-2
9 9
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 14
EAU01039
EAU02944
Identification number
records
1 Record the key identification number,
vehicle identification number and 1
2 model label information in the spaces
1
provided for assistance when order-
3 ing spare parts from a Yamaha deal-
er or for reference in case the vehicle
is stolen. 1. Key identification number 1. Vehicle identification number
4
EAU01041 EAU01043
1. KEY IDENTIFICATION Key identification number Vehicle identification

5 NUMBER: The key identification number is number
stamped on the key tag. The vehicle identification number is
6 Record this number in the space pro- stamped into the steering head pipe.
vided and use it for reference when Record this number in the space pro-
7 2. VEHICLE IDENTIFICATION obtaining a new key. vided.
NUMBER:
NOTE:
8
The vehicle identification number is
used to identify your motorcycle and
9 may be used to register your motor-
3. MODEL LABEL INFORMATION: cycle with the licensing authority in
1 your state.
6
9-1
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 15
1
1. Model label
4
EAU01050
Model label
The model label is affixed to the 5
frame under the seat. (See page
3-9 for seat removal procedures.) 6
Record the information on this label
in the space provided. This informa- 7
tion will be needed to order spare
parts from your Yamaha dealer.
8
9 9
9-2
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 16
INDEX
A Front brake lever free play K

Air filter ..................................................6-12 adjustment ..........................................6-18 Key identification number ........................9-1
B Front fork inspection..............................6-26 L
Battery ...................................................6-28 Front wheel installation..........................6-34 Lights switch............................................3-3
Brake and clutch lever lubrication .........6-25 Front wheel removal..............................6-33 M
Brake and shift pedal lubrication ...........6-25 Fuel .........................................................3-6 Main switch/Steering lock........................3-1
Brake fluid replacement.........................6-22 Fuel cock .................................................3-7 Model label ..............................................9-2
Brake light switch adjustment................6-20 Fuel tank cap...........................................3-6 N
C Fuse replacement..................................6-29 Neutral indicator light...............................3-2
Cable inspection and lubrication ...........6-24 H P
Carburetor adjustment...........................6-13 Handlebar switches .................................3-3 Panel A, B ...............................................6-7
Care.........................................................7-1 Dimmer switch ......................................3-3 Parking ....................................................5-6
Carrier (optional) ...................................3-11 Engine stop switch ................................3-4 Pass switch .............................................3-3
Checking the front and rear brake Horn switch ...........................................3-3 Periodic maintenance and
pads ....................................................6-20 Lights switch .........................................3-3 lubrication chart ....................................6-3
Clutch lever .............................................3-4 Pass switch ...........................................3-3 Pre-operation check list...........................4-1
Clutch lever free play adjustment ..........6-18 Start switch ...........................................3-4 R
Cowling A ................................................6-7 Turn signal switch .................................3-3 Rear brake pedal.....................................3-5
Cowling and panel removal and Headlight bulb replacement...................6-29 Rear brake pedal height adjustment .....6-19
installation .............................................6-6 Helmet holder ..........................................3-9 Rear shock absorber adjustment ..........3-10
D High beam indicator light.........................3-2 Rear suspension lubrication ..................6-26
Description ..............................................2-1 Horn switch..............................................3-3 Rear wheel installation ..........................6-36
Dimmer switch.........................................3-3 How to use the conversion table .............9-3 Rear wheel removal ..............................6-35
Drive chain lubrication ...........................6-23 I Recommended shift point
Drive chain slack adjustment.................6-23 Identification number records ..................9-1 (for Switzerland only) ............................5-4
Drive chain slack check.........................6-22 Idle speed adjustment ...........................6-14 S
E Indicator lights .........................................3-2 Seat .........................................................3-9
Engine break-in .......................................5-5 High beam indicator light ......................3-2 Shift pedal ..............................................3-5
Engine oil...............................................6-10 Neutral indicator light ............................3-2 Shifting ....................................................5-4
Engine stop switch ..................................3-4 Turn indicator light ................................3-2 Sidestand ..............................................3-11
F Inspecting the brake fluid level ..............6-21 Sidestand lubrication .............................6-25
Front brake lever .....................................3-5
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 17
INDEX
Sidestand/clutch switch operation

check ..................................................3-12
Spark plug ...............................................6-8
Specifications ..........................................8-1
Speedometer...........................................3-2
Start switch..............................................3-4
Starter (choke).........................................3-8
Starting a warm engine ...........................5-3
Starting the engine ..................................5-1
Steering inspection................................6-27
Storage....................................................7-4
Supporting the motorcycle.....................6-32
T
Tachometer .............................................3-3
Taillight bulb replacement .....................6-32
Throttle cable and grip lubrication .........6-24
Throttle cable free play adjustment .......6-14
Tips for reducing fuel consumption .........5-5
Tires ......................................................6-15
Tool kit.....................................................6-1
Troubleshooting.....................................6-36
Troubleshooting chart............................6-37
Turn indicator light...................................3-2
Turn signal light bulb replacement ........6-31
Turn signal switch....................................3-3
V
Valve clearance adjustment ..................6-15
Vehicle identification number ..................9-1
W
Wheel bearings .....................................6-27
Wheels ..................................................6-17
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 18
OWNER’S MANUAL
XT500E
YAMAHA MOTOR CO., LTD.
XT600E
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2001·1–1.0×1(E) !
4PT-28199-E6

YAMAHA XT 500E / XT600E Manual

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YAMAHA XT 500E / XT600E Manual

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OWNER’S MANUAL

Welcome to the Yamaha world of motorcycling! 1

IMPORTANT MANUAL INFORMATION

cC A CAUTION indicates special precautions that must be taken to avoid damage to

5 NOTE: A NOTE provides key information to make procedures easier or clearer.

IMPORTANT MANUAL INFORMATION

1 GIVE SAFETY THE RIGHT OF WAY 1

3 INSTRUMENT AND CONTROL FUNCTIONS 3

5 OPERATION AND IMPORTANT RIDING POINTS 5

6 PERIODIC MAINTENANCE AND MINOR REPAIR 6

7 MOTORCYCLE CARE AND STORAGE 7

GIVE SAFETY THE RIGHT OF WAY

GIVE SAFETY THE RIGHT OF WAY ................................................1-1

Q GIVE SAFETY THE RIGHT OF WAY

9 Enjoy your ride!

Left view .............................................................................................2-1

INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock.......................................................................3-1

INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock LOCK

INSTRUMENT AND CONTROL FUNCTIONS

1. High beam indicator light “&” 1. Speedometer

INSTRUMENT AND CONTROL FUNCTIONS

the ideal power range. EAU00134 Horn switch “*”

Pass switch “&”

INSTRUMENT AND CONTROL FUNCTIONS

Start switch “,”

1 See starting instructions prior to

INSTRUMENT AND CONTROL FUNCTIONS

1. Shift pedal 1. Front brake lever 1. Rear brake pedal

INSTRUMENT AND CONTROL FUNCTIONS

Fuel tank cap before riding the motorcycle.

INSTRUMENT AND CONTROL FUNCTIONS

cC OFF: closed position

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

5 To remove the seat, remove the

INSTRUMENT AND CONTROL FUNCTIONS

1. Locknut 1. Measuring distance “A” Tightening torque:

increases spring preload, length- 42 Nm (4.2 m0kg)

This shock absorber is equipped with es spring preload. cC 6

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

PULL IN CLUTCH LEVER AND

Pre-operation check list ......................................................................4-1

OPERATION AND IMPORTANT RIDING POINTS

Starting the engine .............................................................................5-1

OPERATION AND IMPORTANT RIDING POINTS

w Starting the engine

OPERATION AND IMPORTANT RIDING POINTS

TURN THE MAIN SWITCH TO “ON” AND

PULL IN THE CLUTCH LEVER AND 3

THE MOTORCYCLE CAN BE RIDDEN. THE MOTORCYCLE CAN BE RIDDEN. 7

OPERATION AND IMPORTANT RIDING POINTS

tral. short as possible to preserve the bat- cC

OPERATION AND IMPORTANT RIDING POINTS

cC Recommended shift points

OPERATION AND IMPORTANT RIDING POINTS

Tips for reducing fuel Engine break-in 0 ~ 150 km

OPERATION AND IMPORTANT RIDING POINTS

PERIODIC MAINTENANCE AND MINOR REPAIR

Tool kit ...................................................................6-1 Drive chain lubrication............................................6-23

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic inspection, adjustment and w 1

ATION THAT WEATHER, TERRAIN, Tool kit

PERIODIC MAINTENANCE AND MINOR REPAIR