Yamaha XT500E, XT600E User Manual

OWNER’S MANUAL

XT500E

XT600E

4PT-28199-E6

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
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EAU00005

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:

Q	The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
	IS INVOLVED!

wFailure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

cC	A CAUTION indicates special precautions that must be taken to avoid damage to
	the motorcycle.
NOTE:	A NOTE provides key information to make procedures easier or clearer.

NOTE:

88This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold.

98Yamaha 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 question concerning this manual, please consult your Yamaha dealer.

		IMPORTANT MANUAL INFORMATION
		EW000002
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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING					1
THIS MOTORCYCLE.
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EAU03337

XT500E/XT600E

OWNER’S MANUAL

© 2000 by Yamaha Motor Co., Ltd. 1st Edition, December 2000

All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

is expressly prohibited. Printed in Japan.

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

GIVE SAFETY THE RIGHT OF WAY

GIVE SAFETY THE RIGHT OF WAY

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EAU00021

QGIVE SAFETY THE RIGHT OF WAY

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics.

Regular care and maintenance are essential for preserving your motorcycle’s value and operating 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 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 dangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers. 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 protective 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. 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 avoiding all dangers, including those caused by others.

Enjoy your ride!

1-1

DESCRIPTION

Left view .............................................................................................	2-1
Right view ...........................................................................................	2-2
Controls/Instruments ..........................................................................	2-3

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EAU00026

DESCRIPTION

Left view

1		2							3		4		5
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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

DESCRIPTION

Right view

10.Air filter

11.Oil filter

12.Engine oil dipstick

13.Rear brake pedal

10	11	12
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	13	8
		9

(page 6-12) (page 6-11) (page 6-10)

(page 3-5, 6-19)

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EAU00026

DESCRIPTION

Controls/Instruments

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			22	21
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

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

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EAU00027

INSTRUMENT AND CONTROL FUNCTIONS

ON

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2

OFF

LOCK

P

1. Push	2. Turn
EAU00029	EAU00042

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Never turn the key to “OFF” or “LOCK” when the motorcycle is moving. The electrical circuits will be switched off which may result in loss of control or an accident. Be sure the motorcycle is stopped before turning the key to “OFF” or “LOCK”.

Main switch/steering lock

The main switch controls the ignition and lighting systems. Its operation is described below.

EAU00036

ON

Electrical circuits are switched on. The engine can be started. The key cannot be removed in this position.

EAU00038

OFF

All electrical circuits are switched off. The key can be removed in this position.

LOCK

The steering is locked in this position and all electrical circuits are switched off.

The key can be removed in this position.

To lock the steering, turn the handlebars all the way to the left. With the key at “OFF”, push it into the main switch and release it, turn it counterclockwise to “LOCK” and remove it.

To release the lock, turn the key to "OFF".

EAU01590

.(Parking)

The steering is locked in this position, and the taillight and auxiliary light come on but all other circuits are off. The key can be removed in this position.

To use the parking position, first lock the steering, then turn the key to “.”. Do not use this position for an extended length of time as the battery may discharge.

3-1

INSTRUMENT AND CONTROL FUNCTIONS

1	2
&	N
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3

1.High beam indicator light “&”

2.Neutral indicator light “N”

3.Turn indicator light “5”

EAU00056

Indicator lights

EAU00057

Turn indicator light “ 5”

This indicator flashes when the turn switch is moved to the left or right.

EAU00061

Neutral indicator light “N”

This indicator comes on when the transmission is in neutral.

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

1.	Speedometer	4
2.	Odometer

3.Trip odometer

4.Reset knob

	Speedometer			EAU00095	5
	The	speedometer	shows	riding	6
	speed. This speedometer is equipped
	with an odometer and trip odometer.				7
	The trip odometer can be reset to “0”
	with	the reset knob.	Use	the trip	8
	odometer to estimate how far you
	can ride on a tank of fuel. This infor-				9
	mation will enable you to plan fuel
	stops in the future.

3-2

INSTRUMENT AND CONTROL FUNCTIONS

			1
1	&	N	2
2	5
3

4	1.	Tachometer
	2.	Red zone

EAU00102

Tachometer

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This model is equipped with a tachometer so the rider can monitor 6 the engine speed and keep it within

the ideal power range.

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EC000003

8 cC

Do not operate in the red zone.

9	Red zone: 7,000 r/min and above

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		*
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1.Lights switch

2.Pass switch “&”

3.Dimmer switch

4.Turn signal switch

5.Horn switch “*”

EAU00118

Handlebar switches

EAU00134

Lights switch

Turning the light switch to “'”, turns on the auxiliary light, meter lights and taillight. Turning the light switch to “:”, turns the headlight on also.

EAU00119

Pass switch “ &”

Press the switch to operate the passing light.

EAU00121

Dimmer switch

Turn the switch to “&” for the high beam and to “%” for the low beam.

EAU00127

Turn signal switch

To signal a right-hand turn, push the switch to “)”. To signal a left-hand turn, push the switch to “(”. Once the switch is released it will return to the center position. To cancel the signal, push the switch in after it has returned to the center position.

EAU00129

Horn switch “ *”

Press the switch to sound the horn.

3-3

INSTRUMENT AND CONTROL FUNCTIONS

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EAU00143

Start switch “ ,”

The starter motor cranks the engine when pushing the start switch.

EC000005

cC

See starting instructions prior to starting the engine.

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1.Engine stop switch

2.Start switch “,”

EAU00138

Engine stop switch

The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system. Turn the switch to “#” to start the engine.

In case of emergency, turn the switch to “$” to stop the engine.

1. Clutch lever

EAU00152

Clutch lever

The clutch lever is located on the left handlebar, and the ignition circuit cutoff system is incorporated in the clutch lever holder. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. (Refer to the engine starting procedures for a description of the ignition circuit cutoff system.)

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3-4

INSTRUMENT AND CONTROL FUNCTIONS

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		N
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4	1.	Shift pedal
	N.	Neutral
			EAU00157
5	Shift pedal

This motorcycle is equipped with a

6constant-mesh 5-speed transmission. The shift pedal is located on the left

	7	side of the engine and is used in
		combination with the clutch when
	8	shifting.

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1. Front brake lever

EAU00158

Front brake lever

The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake.

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1. Rear brake pedal

EAU00162

Rear brake pedal

The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake.

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3-5

INSTRUMENT AND CONTROL FUNCTIONS

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2

1. Unlock

2. Open

EAU00177

Fuel tank cap

To open

Insert the key and turn it 1/4 turn counterclockwise. Turn the cap 1/3 turn counterclockwise and remove it from the tank.

To close

Put the cap in the filler neck and turn it 1/3 turn clockwise. Lock the cap by turning the key 1/4 turn clockwise, and remove the key.

NOTE:

The tank cap cannot be reinstalled unless it is unlocked. The key must remain in the cap until the cap is properly installed and locked onto the fuel tank.

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Be sure the cap is properly installed and locked in place before riding the motorcycle.

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1.Filler tube

2.Fuel level

EAU01183

Fuel

Make sure there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown in the illustration.

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Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube or it may overflow when the fuel heats up later and expands.

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INSTRUMENT AND CONTROL FUNCTIONS

EAU00185

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Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts.

	EAU00191	OFF: closed position
Recommended fuel:
Regular unleaded gasoline		RES
with a research octane
number of 91 or higher.		OFF
Fuel tank capacity:		ON
Total:
		1
15.0 L
Reserve:		1. Arrow mark pointing to “OFF”
2.0 L
		EAU03050

NOTE:

If knocking or pinging occurs, use a different brand of gasoline or higher octane grade.

Fuel cock

The fuel cock supplies fuel from the tank to the carburetor while filtering it also.

The fuel cock has three positions:

OFF

With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.

3-7

INSTRUMENT AND CONTROL FUNCTIONS

ON: normal position
RES
OFF
ON	1

1. Arrow mark pointing to “ON”

ON

With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.

RES: reserve position
RES
OFF
UEL	1
ON

1. Arrow mark pointing to “RES”

RES

This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to “ON” after refueling!

	b	a	1
		1	2
			3
1.	Starter (choke) “1”		4
			EAU00210
Starter (choke) “ 1”

Starting a cold engine requires a rich-	5
er air-fuel mixture. A separate starter
circuit supplies this mixture.	6
Move in direction a to turn on the
starter (choke).	7
Move in direction b to turn off the

starter (choke).	8

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INSTRUMENT AND CONTROL FUNCTIONS

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EAU00240

Seat

5To remove the seat, remove the bolts.

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When reinstalling the seat, insert the projections on the front of the seat into the holders, then tighten the bolts.

NOTE:

Make sure that the seat is securely fitted.

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1.Helmet holder

2.Open

EAU00260

Helmet holder

To open the helmet holder, insert the key in the lock and turn it as shown. To lock the helmet holder, replace the holder in its original position.

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Never ride with a helmet in the helmet holder. The helmet may hit objects, causing loss of control and possibly an accident.

3-9

INSTRUMENT AND CONTROL FUNCTIONS

	a
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	1

1.Locknut

2.Adjusting nut

EAU01650

Rear shock absorber adjustment

This shock absorber is equipped with a spring preload adjuster. Adjust spring preload as follows.

1.Loosen the locknut.

2.Turn the adjusting nut in direction a to increase spring preload and in direction b to decrease spring preload. The spring preload is determined by the spring set length.

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1. Measuring distance “A”

Shortening spring set length increases spring preload, lengthening spring set length decreases spring preload.

Spring preload: Minimum (soft):

Distance “A” = 248.5 mm Standard:

Distance “A” = 243 mm Maximum (hard):

Distance “A” = 237.5 mm

EC000015

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Never attempt to turn an adjuster beyond the maximum or minimum setting.

3.Tighten the locknut to the specified torque.

Tightening torque: Locknut:

42 Nm (4.2 m0kg)

EC000018

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Always tighten the locknut against the spring adjusting nut and tighten the locknut to the specified torque.

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INSTRUMENT AND CONTROL FUNCTIONS

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This shock absorber contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling.

8Do not tamper with or attempt to open the cylinder assembly.

8Do not subject the shock absorber to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure.

8Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance.

8Take your shock absorber to a Yamaha dealer for any service.

EAU00330

Sidestand

This model is equipped with an ignition circuit cut-off system. The motorcycle must not be ridden when the sidestand is down. The sidestand is located on the left side of the frame. (Refer to page 5-1 for an explanation of this system.)

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This motorcycle must not be operated with the sidestand in the down position. If the stand is not properly retracted, it could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha has designed into this motorcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand. Please check carefully the operating instructions listed below and if there is any indication of a malfunction, return the motorcycle to a Yamaha dealer immediately for repair.

3-11

INSTRUMENT AND CONTROL FUNCTIONS

EAU00331

Sidestand/clutch switch operation check

Check the operation of the sidestand switch and clutch switch against the information below.

TURN THE MAIN SWITCH TO “ON” AND THE ENGINE STOP SWITCH TO “#”.

TRANSMISSION IS IN GEAR AND SIDESTAND IS UP.

PULL IN CLUTCH LEVER AND

PUSH THE START SWITCH.

SIDESTAND IS DOWN.

ENGINE WILL STALL.

SIDESTAND SWITCH IS OK.

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If improper operation is noted, consult a Yamaha dealer immediately.

ENGINE WILL START.

CLUTCH SWITCH IS OK.

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PRE-OPERATION CHECKS

Pre-operation check list

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EAU01114

PRE-OPERATION CHECKS

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 thorough visual inspection, you check the following points before each ride.

EAU00340

PRE-OPERATION CHECK LIST

	ITEM		CHECKS	PAGE
	Front brake	9	Check operation, free play, fluid level and vehicle for fluid leakage.
		9	Fill with DOT 4 (or DOT 3) brake fluid if necessary.
				3-5, 6-18 ~ 6-22
	Rear brake	9	Check operation, free play, fluid level and vehicle for fluid leakage.
		9	Fill with DOT 4 brake fluid if necessary.
	Clutch	9	Check operation, condition and free play.	3-4, 6-18
		9	Adjust if necessary.
	Throttle grip and housing	9Check for smooth operation.		6-24
		9	Lubricate.
	Engine oil	9	Check oil level.	6-10 ~ 6-12
		9	Fill with oil if necessary.
	Drive chain	9	Check chain slack and condition.	6-22 ~ 6-24
		9	Adjust if necessary.
	Wheels and tires	9Check tire pressure, wear, damage and spoke tightness.		6-15 ~ 6-17
		9	Tighten spokes if necessary.
	Control and meter cable	9Check for smooth operation.		6-24
		9	Lubricate if necessary.
	Brake and shift pedal shafts	9Check for smooth operation.		6-25
		9	Lubricate if necessary.
	Brake and clutch lever pivots	9Check for smooth operation.		6-25
		9	Lubricate if necessary.

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