Yamaha XT500E, XT600E User Manual

OWNER’S MANUAL

XT500E
XT600E

4PT-28199-E6

Welcome to the Yamaha world of motorcycling!

INTRODUCTION

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As the owner of a XT500E/XT600E, you are benefiting from Yamaha’s vast experience in and
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
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.

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.

The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

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IMPORTANT MANUAL INFORMATION

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

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NOTE:

NOTE:

8 This manual should be considered a permanent part of this motorcycle and should remain

8 Yamaha continually seeks advancements in product design and quality. Therefore, while this

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

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

A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.

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

with it even if the motorcycle is subsequently sold.

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

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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.

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XT500E/XT600E

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OWNER’S MANUAL

© 2000 by Yamaha Motor Co., Ltd.

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1st Edition, December 2000

All rights reserved.

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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

2 DESCRIPTION

3 INSTRUMENT AND CONTROL FUNCTIONS

4 PRE-OPERATION CHECKS

5 OPERATION AND IMPORTANT RIDING POINTS

6 PERIODIC MAINTENANCE AND MINOR REPAIR

7 MOTORCYCLE CARE AND STORAGE

8 SPECIFICATIONS

9 CONSUMER INFORMATION

INDEX

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3

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GIVE SAFETY THE RIGHT OF WAY

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

1

Q GIVE 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

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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.

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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

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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.

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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

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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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DESCRIPTION

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6789

Left view

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2

3

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1. Headlight (page 6-29)

2. Fuel cock (page 3-7)

3. Battery (page 6-28)

4. Tool kit (page 6-1)

5. Helmet holder (page 3-9)

6. Rear shock absorber spring preload
adjusting nut (page 3-10)

7. Fuse (page 6-28)

8. Starter (choke) (page 3-8)

9. Shift pedal (page 3-5)

2-1

10 11

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Right view

DESCRIPTION

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2

3

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)

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2-2

DESCRIPTION

14 15

16 17 18

19 20

2122

Controls/Instruments

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14. Clutch lever (page 3-4, 6-18)

15. Left handlebar switches (page 3-3)

16. Speedometer (page 3-2)

17. Main switch/steering lock (page 3-1)

18. Tachometer (page 3-3)

19. Right handlebar switches (page 3-4)

20. Front brake lever (page 3-5, 6-18)

21. Throttle grip (page 6-24)

22. Fuel tank cap (page 3-6)

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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

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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ON

OFF

LOCK

P

INSTRUMENT AND CONTROL FUNCTIONS

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Main switch/steering lock

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

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described below.

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ON

Electrical circuits are switched on.

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The engine can be started. The key
cannot be removed in this position.

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OFF

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

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1. Push 2. Turn

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".

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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”.

..

(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.

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&

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N

INSTRUMENT AND CONTROL FUNCTIONS

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3

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High beam indicator light “&”

This indicator comes on when the
headlight high beam is used.

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1. High beam indicator light “&”

2. Neutral indicator light “N”

3. Turn indicator light “5”

Indicator lights

Turn indicator light “5”

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

Neutral indicator light “N”

This indicator comes on when the
transmission is in neutral.

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3-2

1. Speedometer

2. Odometer

3. Trip odometer

4. Reset knob

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Speedometer

The speedometer shows riding
speed. This speedometer is equipped
with an odometer and trip odometer.
The trip odometer can be reset to “0”
with the reset knob. Use the trip
odometer to estimate how far you
can ride on a tank of fuel. This infor­mation will enable you to plan fuel
stops in the future.

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INSTRUMENT AND CONTROL FUNCTIONS

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&

N

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*

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Dimmer switch

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

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1. Tachometer

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2. Red zone

Tachometer

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This model is equipped with a
tachometer so the rider can monitor

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the engine speed and keep it within
the ideal power range.

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Do not operate in the red zone.
Red zone: 7,000 r/min and above

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Turn signal switch

To signal a right-hand turn, push the
switch to “)”. To signal a left-hand
turn, push the switch to “(”. Once

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1. Lights switch

2. Pass switch “&”

3. Dimmer switch

4. Turn signal switch

5. Horn switch “*”

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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.

Handlebar switches

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Lights switch

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

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Pass switch “&”

Press the switch to operate the pass­ing light.

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Horn switch “*”

Press the switch to sound the horn.

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INSTRUMENT AND CONTROL FUNCTIONS

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Start switch “,”

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

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1. Engine stop switch

2. Start switch “,”

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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.

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See starting instructions prior to
starting the engine.

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1. Clutch lever

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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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N

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INSTRUMENT AND CONTROL FUNCTIONS

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1. Shift pedal

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N. Neutral

Shift pedal

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This motorcycle is equipped with a
constant-mesh 5-speed transmission.

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The shift pedal is located on the left
side of the engine and is used in

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combination with the clutch when
shifting.

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1. Front brake lever

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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

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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.

INSTRUMENT AND CONTROL FUNCTIONS

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2

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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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2

1. Unlock

2. Open

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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.

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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

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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

RES

ON

FUEL

OFF

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Always wipe off spilled fuel imme-

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diately with a dry and clean soft
cloth. Fuel may deteriorate painted

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surfaces or plastic parts.

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Recommended fuel:

Regular unleaded gasoline
with a research octane
number of 91 or higher.

Fuel tank capacity:

Total:

15.0 L

Reserve:

2.0 L

NOTE:

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

OFF: closed position

1. Arrow mark pointing to “OFF”

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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

OFF

ON

FUEL

RES

1

RES

INSTRUMENT AND CONTROL FUNCTIONS

1

b

a

ON

FUEL

RES

OFF

1

ON

ON: normal position RES: reserve position

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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.

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!

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1. Starter (choke) “1”

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Starter (choke) “1”

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

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INSTRUMENT AND CONTROL FUNCTIONS

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2

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Seat

To remove the seat, remove the

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bolts.

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1. Helmet holder

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

2. Open

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Helmet holder

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

NOTE:

Make sure that the seat is securely
fitted.

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.

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INSTRUMENT AND CONTROL FUNCTIONS

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a

b

2

1

1. Locknut

2. Adjusting nut

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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.

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

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)

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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

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highly pressurized nitrogen gas.
Read and understand the following

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information before handling the
shock absorber. The manufacturer
cannot be held responsible for

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property damage or personal
injury that may result from improp-

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er handling.

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

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Do 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.

88

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

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

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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

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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.

ENGINE WILL START.

CLUTCH SWITCH IS OK.

SIDESTAND IS DOWN.

ENGINE WILL STALL.

SIDESTAND SWITCH IS OK.

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

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3-12

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6

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8

9

PRE-OPERATION CHECKS

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

4

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 thor-

1

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

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2

3

Front brake

4

Rear brake

Clutch

5

Throttle grip and housing

6

Engine oil

Drive chain

7

Wheels and tires

8

Control and meter cable

9

Brake and shift pedal shafts

Brake and clutch lever pivots

PRE-OPERATION CHECK LIST

ITEM CHECKS PAGE

9 Check operation, free play, fluid level and vehicle for fluid leakage.
9 Fill with DOT 4 (or DOT 3) brake fluid if necessary.

9 Check operation, free play, fluid level and vehicle for fluid leakage.
9 Fill with DOT 4 brake fluid if necessary.

9 Check operation, condition and free play.
9 Adjust if necessary.

9 Check for smooth operation.
9 Lubricate.

9 Check oil level.
9 Fill with oil if necessary.

9 Check chain slack and condition.
9 Adjust if necessary.

9 Check tire pressure, wear, damage and spoke tightness.
9 Tighten spokes if necessary.

9 Check for smooth operation.
9 Lubricate if necessary.

9 Check for smooth operation.
9 Lubricate if necessary.

9 Check for smooth operation.
9 Lubricate if necessary.

3-5, 6-18 ~ 6-22

3-4, 6-18

6-24

6-10 ~ 6-12

6-22 ~ 6-24

6-15 ~ 6-17

6-24

6-25

6-25

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4-1

PRE-OPERATION CHECKS

ITEM CHECKS PAGE

Sidestand pivot

Chassis fasteners

Fuel tank
Lights, signals and

switches

NOTE:

Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a
very short time; and the added safety it assures is more than worth the time involved.

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If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating
the motorcycle.

9 Check for smooth operation.
9 Lubricate if necessary.

9 Make sure that all nuts, bolts, and screws are properly tightened.
9 Tighten if necessary.

9 Check fuel level.
9 Fill with fuel if necessary.

9 Check for proper operation. 6-29 ~ 6-32

6-25

—

3-6 ~ 3-7

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5

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4-2

9

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2

3

4

5

6

7

8

9

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

OPERATION AND IMPORTANT RIDING POINTS

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5

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9

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Before riding this motorcycle,
become thoroughly familiar
with all operating controls and
their functions. Consult a
Yamaha dealer regarding any
control or function that you do
not thoroughly understand.
Never start your engine or let
it run for any length of time in
a closed area. The exhaust
fumes are poisonous and can
cause loss of consciousness
and death within a short time.
Always operate your motorcy­cle in an area with adequate
ventilation.
Before starting out, always be
sure the sidestand is up.
Failure to retract the sidestand
completely can result in a seri­ous accident when you try to
turn a corner.

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Starting the engine

NOTE:

This motorcycle is equipped with an
ignition circuit cut-off system. The
engine can be started only under one
of the following conditions:

8 The transmission is in neutral.
8 The sidestand is up, the trans-

mission is in gear and the clutch

is disengaged.
The motorcycle must not be ridden
when the sidestand is down.

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Before going through the following
steps, check the function of the
sidestand switch and clutch
switch. (Refer to page 3-12.)

5-1

OPERATION AND IMPORTANT RIDING POINTS

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

1

IF THE TRANSMISSION IS IN NEUTRAL
AND THE SIDESTAND IS DOWN,
PUSH START SWITCH.

THE ENGINE WILL START.

RETRACT THE SIDESTAND AND PUT
THE TRANSMISSION IN GEAR.

IF THE TRANSMISSION IS IN GEAR
AND THE SIDESTAND IS UP,

PULL IN THE CLUTCH LEVER AND
PUSH THE START SWITCH.

THE ENGINE WILL START.

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

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6

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9

5-2

OPERATION AND IMPORTANT RIDING POINTS

1. Turn the fuel cock to “ON”.

2. Turn the main switch to “ON” and

1

the engine stop switch to “#”.

3. Shift the transmission into neu­tral.

2

NOTE:

When the transmission is in neutral,

3

the neutral indicator light should be
on. If the light does not come on, ask

4

a Yamaha dealer to inspect it.

5

4. Turn on the starter (choke) and

6

completely close the throttle grip.

5. Start the engine by pushing the
start switch.

7

8

9

NOTE:

If the engine fails to start, release the
start switch, wait a few seconds, then
try again. Each attempt should be as
short as possible to preserve the bat­tery. Do not crank the engine more
than 10 seconds on any one attempt.

6. After starting the engine, move
the starter (choke) to the halfway
position.

NOTE:

For maximum engine life, never
accelerate hard with a cold engine!

7. After warming up the engine,
turn off the starter (choke) com­pletely.

NOTE:

The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.

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Starting a warm engine

The starter (choke) is not required
when the engine is warm.

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See the “Engine break-in” section
prior to operating the motorcycle
for the first time.

5-3

OPERATION AND IMPORTANT RIDING POINTS

1

5
4
3
2

N

1

1. Shift pedal
N. Neutral

EAU00423

Shifting

The transmission lets you control the
amount of power you have available
at a given speed for starting, acceler­ating, climbing hills, etc. The use of
the shift pedal is shown in the illustra­tion.

To shift into neutral, depress the shift
pedal repeatedly until it reaches the
end of its travel, then raise the pedal
slightly.

cC

88

Do not coast for long periods
with the engine off, and do not
tow the motorcycle a long dis­tance. Even with gears in neu­tral, the transmission is only
properly lubricated when the
engine is running. Inadequate
lubrication may damage the
transmission.

88

Always use the clutch when
changing gears. The engine,
transmission, and driveline are
not designed to withstand the
shock of forced shifting and
can be damaged by shifting
without using the clutch.

EC000048

EAU02941

Recommended shift points
(for Switzerland only)

The recommended shift points are
shown in the table below.

Acceleration shift point

(km/h)

1st → 2nd 23

2nd → 3rd 36
3rd → 4th 50

4th → 5th 60

NOTE:

When shifting two gears down from
4th to 2nd, bring your motorcycle to a
speed of 35 km/h.

1

2

3

4

5

6

7

8

9

5-4

OPERATION AND IMPORTANT RIDING POINTS

Tips for reducing fuel
consumption

Your motorcycle’s fuel consumption

1

depends to a large extent on your rid­ing style. The following tips can help

2

reduce fuel consumption:

8 Warm up the engine before rid-

3

4

5

6

7

8

9

ing.

8 Turn off the starter (choke) as

soon as possible.

8 Shift up swiftly and avoid high

engine speeds during accelera­tion.

8 Do not double-clutch or rev the

engine while shifting down and
avoid high engine speeds with
no load on the engine.

8 Turn off the engine instead of let-

ting it idle for an extended length
of time, i.e. in traffic jams, at traf­fic lights or railroad crossings.

EAU00424

EAU00436

Engine break-in

There is never a more important peri­od in the life of your motorcycle than
the period between zero and 1,000
km. For this reason we ask that you
carefully read the following material.
Because the engine is brand new,
you must not put an excessive load
on it for the first 1,000 km. The vari­ous parts in the engine wear and pol­ish themselves to the correct operat­ing clearances. During this period,
prolonged full throttle operation, or
any condition which might result in
excessive heating of the engine,
must be avoided.

EAU00440

0 ~ 150 km

Avoid operation above 4,000 r/min.
Stop the engine and let it cool for 5 to
10 minutes after every hour of opera­tion. Vary the speed of the motorcy­cle from time to time. Do not operate
it at one set throttle position.

150 ~ 500 km

Avoid prolonged operation above
5,000 r/min. Rev the motorcycle
freely through the gears, but do not
use full throttle at any time.

500 ~ 1,000 km

Avoid prolonged full throttle opera­tion. Avoid cruising speeds in excess
of 6,000 r/min.

5-5

OPERATION AND IMPORTANT RIDING POINTS

EC000052

cC

After 1,000 km of operation, be
sure to replace the engine oil and
oil filter.

1,000 km and beyond

Full throttle can be used.

EC000053

cC

88

Never let engine speeds enter
the red zone.

88

If any engine trouble should
occur during the break-in peri­od, consult a Yamaha dealer
immediately.

EAU00457

Parking

When parking the motorcycle, stop
the engine and remove the ignition
key. Turn the fuel cock to “OFF”
whenever stopping the engine.

EW000058

w

The exhaust system is hot. Park
the motorcycle in a place where
pedestrians or children are not
likely to touch the motorcycle. Do
not park the motorcycle on a slope
or soft ground; the motorcycle
may overturn.

1

2

3

4

5

6

7

8

9

5-6

1

2

3

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

Tool kit ...................................................................6-1

Periodic maintenance and lubrication chart...........6-3

Cowling and panel removal and installation...........6-6

Cowling A...............................................................6-7

Panel A, B..............................................................6-7

Spark plug..............................................................6-8

Engine oil.............................................................6-10

Air filter.................................................................6-12

Carburetor adjustment.........................................6-13

Idle speed adjustment..........................................6-14

Throttle cable free play adjustment......................6-14

Valve clearance adjustment.................................6-15

Tires.....................................................................6-15

Wheels.................................................................6-17

Clutch lever free play adjustment.........................6-18

Front brake lever free play adjustment ................6-18

Rear brake pedal height adjustment....................6-19

Brake light switch adjustment ..............................6-20

Checking the front and rear brake pads...............6-20

Inspecting the brake fluid level.............................6-21

Brake fluid replacement.......................................6-22

Drive chain slack check .......................................6-22

Drive chain slack adjustment...............................6-23

Drive chain lubrication............................................6-23

Cable inspection and lubrication............................6-24

Throttle cable and grip lubrication..........................6-24

Brake and shift pedal lubrication............................6-25

Brake and clutch lever lubrication..........................6-25

Sidestand lubrication..............................................6-25

Rear suspension lubrication...................................6-26

Front fork inspection ..............................................6-26

Steering inspection ................................................6-27

Wheel bearings......................................................6-27

Battery....................................................................6-28

Fuse replacement..................................................6-29

Headlight bulb replacement...................................6-29

Turn signal light bulb replacement.........................6-31

Taillight bulb replacement......................................6-32

Supporting the motorcycle.....................................6-32

Front wheel removal ..............................................6-33

Front wheel installation..........................................6-34

Rear wheel removal...............................................6-35

Rear wheel installation...........................................6-36

Troubleshooting.....................................................6-36

Troubleshooting chart............................................6-37

6

PERIODIC MAINTENANCE AND MINOR REPAIR

1

EAU00462

Periodic inspection, adjustment and
lubrication will keep your motorcycle

1

in the safest and most efficient condi­tion possible. Safety is an obligation
of the motorcycle owner. The mainte-

2

nance and lubrication schedule chart
should be considered strictly as a

3

guide to general maintenance and
lubrication intervals.

4

YOU MUST TAKE INTO CONSIDER­ATION THAT WEATHER, TERRAIN,

5

GEOGRAPHICAL LOCATIONS, AND
A VARIETY OF INDIVIDUAL USES

6

ALL TEND TO DEMAND THAT
EACH OWNER ALTER THIS TIME
SCHEDULE TO SHORTER INTER-

7

VALS TO MATCH THE ENVIRON­MENT. The most important points of

8

motorcycle inspection, adjustment,
and lubrication are explained in the

9

following pages.

EAU00464

EW000060

w

If you are not familiar with motor­cycle service, this work should be
done by a Yamaha dealer.

1. Tool kit

EAU01175

Tool kit

The tool kit is located behind panel A.
(See page 6-7 for panel removal and
installation procedures.) The tools
provided in the owner's tool kit are to
assist you in the performance of peri­odic maintenance. However, some
other tools such as a torque wrench
are also necessary to perform the
maintenance correctly.
The service information included in
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

NOTE:

If you do not have necessary tools
required during a service operation,
take your motorcycle to a Yamaha
dealer for service.

EW000063

w

Modifications to this motorcycle
not approved by Yamaha may
cause loss of performance, and
render it unsafe for use. Consult a
Yamaha dealer before attempting
any changes.

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

3

4

5

6

7

8

6-2

9

PERIODIC MAINTENANCE AND MINOR REPAIR

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING (× 1,000 km)

ANNUAL

CHECK

1 10 20 30 40

1

*

Fuel line • Check fuel hoses for cracks or damage. √ √ √ √ √

2 Spark plug

• Check condition.

• Clean and regap.

√ √

• Replace. √ √

3

*

Valves

• Check valve clearance.

• Adjust.

√ √ √ √

4 Air filter element

• Clean. √ √

• Replace. √ √

5 Clutch

• Check operation.

• Adjust.

√ √ √ √ √

6

*

Front brake

• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)

√ √ √ √ √ √

• Replace brake pads. Whenever worn to the limit

7

*

Rear brake

• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)

√ √ √ √ √ √

• Replace brake pads. Whenever worn to the limit

8

*

Brake hoses

• Check for cracks or damage. √ √ √ √ √

• Replace. (See NOTE on page 6-5.) Every 4 years

Periodic maintenance and lubrication chart

NOTE:

8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.

1

8 From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and

2

3

technical skills.

EAU03685

4

5

6

7

8

9

6-3

PERIODIC MAINTENANCE AND MINOR REPAIR

9*Wheels

• Check runout, spoke tightness and for damage.

• Tighten spokes if necessary.

√ √ √ √

10

*

Tires

• Check tread depth and for damage.

• Replace if necessary.

• Check air pressure.

• Correct if necessary.

√ √ √ √

11

*

Wheel bearings • Check bearing for looseness or damage. √ √ √ √

12*Swingarm • Check operation and for excessive play. √ √ √ √

13 Drive chain

• Check chain slack.

• Make sure that the rear wheel is properly aligned.

• Clean and lubricate.

Every 500 km and after washing

the motorcycle or riding in the rain.

14

*

Steering bearings

• Check bearing play and steering for roughness. √ √ √ √ √

• Lubricate with lithium-soap-based grease. Every 20,000 km

15*Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √
16 Sidestand

• Check operation.

• Lubricate.

√ √ √ √ √

17

*

Sidestand switch • Check operation. √ √ √ √ √ √

18*Front fork • Check operation and for oil leakage. √ √ √ √
19

*

Shock absorber
assembly

• Check operation and shock absorber for oil leakage. √ √ √ √

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING (× 1,000 km)

ANNUAL

CHECK

1 10 20 30 40

6

6-4

PERIODIC MAINTENANCE AND MINOR REPAIR

20

*

Rear suspension relay
arm and connecting arm
pivoting points

• Check operation. √ √ √ √

• Lubricate with molybdenum disulfide grease. √ √

21

*

Carburetor

• Check starter (choke) operation.

• Adjust engine idling speed.

√ √ √ √ √ √

22 Engine oil • Change. √ √ √ √ √ √
23 Engine oil filter element • Replace. √ √ √

24

*

Front and rear brake
switches

• Check operation. √ √ √ √ √ √

25 Moving parts and cables • Lubricate. √ √ √ √ √
26

*

Lights, signals and
switches

• Check operation.

• Adjust headlight beam.

√ √ √ √ √ √

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING (× 1,000 km)

ANNUAL

CHECK

1 10 20 30 40

1

2

3

4

5

NOTE:

6

8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

7

8

9

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

brake fluid.

9 Replace the brake hoses every four years and if cracked or damaged.

6-5

EAU03884

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1

1

1

2

3

1. Cowling A

EAU01139

Cowling and panel removal
and installation

The cowlings and panels illustrated
need to be removed to perform some
of the maintenance described in this
chapter.
Refer to this section each time a
cowling or panel has to be removed
or reinstalled.

1. Panel A

6-6

1. Panel B

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1

2

1

2

3

1. Screw

4

Cowling A

To remove

5

Remove the cowling screw and pull
outward on the areas shown.

6

7

8

9

EAU01145

To install

Place in the original position and
install the screw.

6-7

1. Panel A

2. Screw

EAU00488

Panel A

To remove

Remove the screw and pull outward
on the areas shown.

To install

Place the panel in the original posi­tion and install the screw.

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

1

2

1

2

3

1. Panel B

2. Screw

EAU00488

Panel B

To remove

Remove the screw and pull outward
on the areas shown.

To install

Place the panel in the original posi­tion and install the screw.

1. Spark plug cap

Spark plug

Removal

1. Remove the spark plug cap.

6-8

EAU01833

1. Spark plug wrench

2. Use the spark plug wrench in the
tool kit to remove the spark plug
as shown.

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

Inspection

The spark plug is an important
engine component and is easy to

1

inspect. The condition of the spark
plug can indicate the condition of the

2

engine.
The ideal color on the white insulator

3

around the center electrode is a
medium-to-light tan color for a motor­cycle that is being ridden normally.

4

Do not attempt to diagnose such
problems yourself. Instead, take the

5

motorcycle to a Yamaha dealer. You
should periodically remove and

6

inspect the spark plug because heat
and deposits will cause any spark

7

plug to slowly break down and erode.
If electrode erosion becomes exces-

8

sive, or if carbon and other deposits
are excessive, you should replace
the spark plug with the specified plug.

9

Specified spark plug:

DPR8EA-9 or
DPR9EA-9 (NGK)

1

1. Spark plug gap

Installation

1. Measure the electrode gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.

Spark plug gap:

0.8 ~ 0.9 mm

2. Clean the gasket surface. Wipe
off any grime from the threads.

3. Install the spark plug and tighten
it to the specified torque.

Tightening torque:

Spark plug:

17.5 Nm (1.75 m0kg)

NOTE:

If a torque wrench is not available
when you are installing a spark plug,
a good estimate of the correct torque
is 1/4 to 1/2 turn past finger tight.
Have the spark plug tightened to the
specified torque as soon as possible.

4. Install the spark plug cap.

6-9

2

1

1. Screw

1

2

3

2. Cover

EAU00526*

Engine oil

Oil level measurement

1. Place the motorcycle on a level
place and hold it in an upright
position.

2. Remove the screw and pull out­ward on the oil tank cap cover to
remove it.

3. Start the engine and warm it up.

PERIODIC MAINTENANCE AND MINOR REPAIR

EC000000

cC

Do not run the motorcycle until
you know it has sufficient engine
oil.

EW000065

w

1. Oil tank cap/dipstick

2. Maximum level mark

3. Minimum level mark

4. Idle the engine for at least 10
seconds and stop it. While keep­ing the motorcycle upright,
remove the dipstick (oil tank cap)
and check the oil level.

5. The oil level should be between
the minimum and maximum
marks. If the level is low, fill with
oil to the maximum level line.

Never remove the dipstick just
after high-speed operation. Hot oil
could spout out, causing danger.
Always wait until the oil cools
down before removing the dip­stick.

1

2

3

4

5

6

7

8

9

6-10

1

2

PERIODIC MAINTENANCE AND MINOR REPAIR

2

3

4

1

1

2

1

2

3

1. Drain bolt (oil tank)

4

2. Drain bolt (crankcase)

Engine oil and oil filter

5

element replacement

1. Warm up the engine for a few

6

minutes.

2. Place an oil pan under the

7

engine.

3. Remove the oil tank cap, drain

8

bolts.

9

1. Air bleed screw

2. Oil filter cover bolt (×2)

3. Oil filter drain bolt

4. Oil filter cover

4. Check each gasket. If damaged,
replace.

5. Remove the filter cover bolts and
the oil filter cover. Replace the oil

1. Oil filter element

2. O-ring (×2)

6. Check the O-rings for damage.
Replace if damaged.

7. Install the drain plugs, filter cover
and bolts. Tighten to the speci­fied torque.

filter element.

NOTE:

The oil filter cover is secured by three
bolts. The lower one should be
removed first so that the filter cavity
will drain.

6-11

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1

Tightening torque:

Drain plug (crankcase):

30 Nm (3.0 m0kg)

Drain plug (oil tank):

17.5 Nm (1.75 m0kg)

Filter cover bolt:

10 Nm (1.0 m0kg)

Air bleed screw:

5 Nm (0.5 m0kg)

8. Fill the engine with oil. Install the
oil tank cap.

Recommended oil:

See page 8-1

Oil quantity:

Total amount:

3.3 L

Periodic oil change:

2.7 L

With oil filter replacement:

2.8 L

9. Start the engine and warm it up
for a few minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for the
cause.

10. Stop the engine and check the
oil level.

EC000076

cC

After replacing the engine oil, be
sure to check the oil pressure as
described below.

88

Remove the air bleed screw
from the oil filter cover.

88

Start the engine and keep it
idling until oil flows out of the
bleed hole. If no oil comes out
after one minute, turn off the
engine immediately so it will
not seize. In such a case go to
the nearest Yamaha dealer for
repairs.

88

After checking, tighten the air
bleed screw securely.

1. Screw (×7)

EAU01083

Air filter

The air filter should be cleaned at the
specified intervals. It should be
cleaned more frequently if you are
riding in unusually wet or dusty
areas.

1. Remove panel B. (See page 6-7
for panel removal and installation
procedures.)

2. Remove the air filter case fitting
screws and the filter case cover.

1

2

3

4

5

6

7

8

9

6-12

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1

2

3

1. Mesh side

4

3. Remove the air filter.

4. Tap the air filter lightly to remove

5

6

most of the dust and dirt and
blow out the remaining dirt with
compressed air from the mesh
side of the air filter. If it is dam-

7

aged, replace it.

8

9

5. Install the air filter with the arrow
mark on the top pointing inward.

6. Install the air filter case cover
and the panel.

cC

88

Make sure the air filter is prop­erly seated in the air filter
case.

88

The engine should never be
run without the air filter
installed. Excessive piston
and/or cylinder wear may
result.

EC000082

EAU00629

Carburetor adjustment

The carburetor is a vital part of the
engine and requires very sophisticat­ed adjustment. Most adjustments
should be left to a Yamaha dealer
who has the professional knowledge
and experience to do so. However,
the following may be serviced by the
owner as part of routine mainte­nance.

EC000094

cC

The carburetor was set at the
Yamaha factory after many tests. If
the settings are changed, poor
engine performance and damage
may result.

6-13

1

b

a

PERIODIC MAINTENANCE AND MINOR REPAIR

a

Standard idle speed:

1,200 ~ 1,400 r/min
(Except for CH)
1,300 ~ 1,400 r/min
(For CH)

1

2

1. Throttle stop screw

EAU00632

Idle speed adjustment

1. Start the engine and warm it up
for a few minutes at approxi­mately 1,000 to 2,000 r/min.
Occasionally rev the engine to
4,000 to 5,000 r/min. The engine
is warm when it quickly responds
to the throttle.

2. Set the idle to the specified
engine speed by adjusting the
throttle stop screw. Turn the
screw in direction a to increase
engine speed and in direction b
to decrease engine speed.

NOTE:

If the specified idle speed cannot be
obtained by performing the above
adjustment, consult a Yamaha deal­er.

6-14

a. Free play

EAU00635

Throttle cable free play
inspection

There should be a free play of 3 ~
5 mm at the throttle grip. If the free
play is incorrect, ask a Yamaha deal­er to make this adjustment.

3

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

Valve clearance adjustment

The correct valve clearance changes

1

with use, resulting in improper fuel/air
supply or engine noise. To prevent
this, the valve clearance must be

2

adjusted regularly. This adjustment
however, should be left to a profes-

3

sional Yamaha service technician.

4

5

6

7

8

9

EAU00637

EAU00652

Tires

To ensure maximum performance,
long service and safe operation, note
the following:

Tire air pressure

Always check and adjust the tire
pressure before operating the motor­cycle.

EW000082

w

Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla­tion pressure must be adjusted
according to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if
approved for this model), and vehi­cle speed.

Maximum load*
Cold tire pressure: Front Rear

Up to 90 kg (1.5 kg/cm

90 kg load ~
Maximum load*

Off-road riding (1.25 kg/cm

High speed riding (1.5 kg/cm

* Load is the total weight of cargo, rider, passenger

and accessories.

176 kg (XT500E)
180 kg (XT600E)

150 kPa 150 kPa

2

, (1.5 kg/cm2,

1.5 bar) 1.5 bar)

150 kPa 225 kPa

2

(1.5 kg/cm

1.25 bar) 1.25 bar)

, (2.25 kg/cm2,

1.5 bar) 2.25 bar)

125 kPa 125 kPa

2

, (1.25 kg/cm2,

150 kPa 150 kPa

2

, (1.5 kg/cm2,

1.5 bar) 1.5 bar)

6-15

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

EW000083

w

Proper loading of your motorcycle
is important for several character­istics of your motorcycle, such as
handling, braking, performance
and safety. Do not carry loosely
packed items that can shift.
Securely pack your heaviest items
close to the center of the motorcy­cle, and distribute the weight even­ly from side to side. Properly
adjust the suspension for your
load, and check the condition and
pressure of your tires. NEVER
OVERLOAD YOUR MOTORCYCLE.
Make sure the total weight of the
cargo, rider, passenger, and
accessories (fairing, saddlebags,
etc. if approved for this model)
does not exceed the maximum
load of the motorcycle. Operation
of an overloaded motorcycle could
cause tire damage, an accident, or
even injury.

1. Tread depth

2. Side wall

Tire inspection

Always check the tires before operat­ing the motorcycle. If center tread
depth reaches the limit as shown, if
the tire has a nail or glass fragments
in it, or if the side wall is cracked,
contact a Yamaha dealer immediate­ly and have the tire replaced.

EW000078

w

After extensive tests, the tires
mentioned below have been
approved by Yamaha Motor Co.,
Ltd. for this model. No guarantee
for handling characteristics can be
given if tire combinations other
than what is approved are used on
this motorcycle. The front and rear
tires should be of the same manu­facture and design.

FRONT

Manufacturer Size Type
BRIDGESTONE 90/90-21 54S TW47
DUNLOP 90/90-21 54S TRAIL MAX L

REAR

Manufacturer Size Type
BRIDGESTONE 120/90-17 64S TW48
DUNLOP 120/90-17 64S TRAIL MAX

Minimum tire tread
depth 0.8 mm
(front and rear)

1

2

3

4

5

6

7

8

9

6-16

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

These limits may be different by regu­lation from country to country. If so,

1

conform to the limits specified by the
regulations of your own country.

2

3

4

5

6

7

8

9

w

88

Operating the motorcycle with
excessively worn tires
decrease riding stability and
can lead to loss of control.
Have excessively worn tires
replaced by a Yamaha dealer
immediately. Brakes, tires, and
related wheel parts replace­ment should be left to a
Yamaha Service Technician.

88

Patching a punctured tube is
not recommended. If it is
absolutely necessary to do so,
use great care and replace the
tube as soon as possible with
a good quality replacement.

EAU00681

EAU00685

Wheels

To ensure maximum performance,
long service, and safe operation, note
the following:

8 Always inspect the wheels

before a ride. Check for cracks,
bends or warpage of the wheel.
Be sure the spokes are tight and
undamaged. If any abnormal
condition exists in a wheel, con­sult a Yamaha dealer. Do not
attempt even small repairs to the
wheel. If a wheel is deformed or
cracked, it must be replaced.

8 Tires and wheels should be bal-

anced whenever either one is
changed or replaced. Failure to
have a wheel balanced can
result in poor performance,
adverse handling characteristics,
and shortened tire life.

8 Ride at moderate speeds after

changing a tire since the tire sur­face must first be broken in for it
to develop its optimal character­istics.

6-17

PERIODIC MAINTENANCE AND MINOR REPAIR

a

b

1

2

3

b

a

1

2

1

2

3

b

a

1

2

3

1. Locknut

2. Adjusting bolt

3. Free play

Clutch lever free play
adjustment

The clutch lever free play should be
adjusted to 10 ~ 15 mm.

1. Loosen the locknut at the clutch
lever.

2. Turn the adjusting bolt at the
clutch lever in direction a to
increase free play or in direction
b to decrease free play.

3. Tighten the locknut at the clutch
lever.

If the specified free play cannot be
obtained, proceed with the following
steps.

EAU00694

1. Adjusting nut

2. Locknut

4. Loosen the locknut at the clutch
lever.

5. Turn the adjusting bolt at the
clutch lever in direction a to
loosen the cable.

6. Loosen the locknut at the
crankcase side.

7. Turn the adjusting nut at the
crankcase in direction a to
increase free play or in direction
b to decrease free play.

8. Tighten the locknut at the
crankcase and the clutch lever.

6-18

1. Locknut

2. Adjusting bolt

3. Free play

EAU00696

Front brake lever free play
adjustment

The free play at the front brake lever
should be 2 ~ 5 mm.

1. Loosen the locknut.

2. Turn the adjusting bolt in direc­tion a to increase free play or in
direction b to decrease free
play.

3. After adjusting, tighten the lock­nut.

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

a

w

88

1

2

88

3

4

5

6

7

8

9

EW000099

Check the brake lever free
play. Be sure the brake is
working properly.
A soft or spongy feeling in the
brake lever can indicate the
presence of air in the brake
system. This air must be
removed by bleeding the brake
system before the motorcycle
is operated. Air in the system
will cause greatly diminished
braking capability and can
result in loss of control and an
accident. Have a Yamaha deal­er inspect and bleed the sys­tem if necessary.

a. Pedal height

EAU00712

Rear brake pedal height
adjustment

The top of the brake pedal should be
positioned 12 mm below the top of
the footrest. If not, ask a Yamaha
dealer to adjust it.

EW000109

w

A soft or spongy feeling in the
brake pedal can indicate the pres­ence of air in the brake system.
This air must be removed by
bleeding the brake system before
the motorcycle is operated. Air in
the system will cause greatly
diminished braking capability and
can result in loss of control and an
accident. Have a Yamaha dealer
inspect and bleed the system if
necessary.

6-19

2

1

a

b

1. Brake light switch

1

1

2. Adjusting nut

EAU00713

Brake light switch
adjustment

The rear brake light switch is activat­ed by the brake pedal and is properly
adjusted when the brake light comes
on just before braking takes effect.
To adjust the rear brake light switch,
hold the switch body so it does not
rotate while turning the adjusting nut.
Turn the adjusting nut in direction a
to make the brake light come on earli­er.
Turn the adjusting nut in direction b
to make the brake light come on
later.

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00716

Checking the front and rear
brake pads

A wear indicator is provided on each
brake. This indicator allows checking
of brake pad wear without disassem­bling the brake. Apply the brake and
inspect the wear indicator. If the
brake pads are worn to wear limit,
have a Yamaha dealer to replace the
pads.

1. Wear indicator groove (×3)

EAU01119

Front brake

Wear indicator grooves are provided
on each brake pad. These indicators
allow checking of brake pad wear
without disassembling the brake.
Inspect the grooves. If they have
almost disappeared, ask a Yamaha
dealer to replace the pads.

1

2

3

4

5

6

7

8

9

6-20

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1

1

2

3

1. Wear limit: 0.8 mm

4

Rear brake

5

Remove the cap and inspect the
pads. If the thickness is less than the

6

specified value, have a Yamaha deal­er replace the pads.

7

8

9

1

1. Minimum level mark

EAU00729

Inspecting the brake fluid

EAU00733

level

Insufficient brake fluid may let air
enter the brake system, possibly
causing the brakes to become inef­fective.
Before riding, check that the brake
fluid is above the minimum level and
replenish when necessary.
Observe these precautions:

8 When checking the fluid level,

make sure the top of the master
cylinder is level by turning the
handlebars.

1. Minimum level mark

8 Use only the designated quality

brake fluid. Otherwise, the rub­ber seals may deteriorate, caus­ing leakage and poor brake per­formance.

Recommended brake fluid:

DOT 4

NOTE:

If DOT 4 is not available, DOT 3 can
be used for the front brake only.

6-21

PERIODIC MAINTENANCE AND MINOR REPAIR

a

8 Refill with the same type of brake

fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.

8 Be careful that water does not

enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.

8 Brake fluid may deteriorate paint-

ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.

8 Have a Yamaha dealer check

the cause if the brake fluid level
goes down.

EAU00742

Brake fluid replacement

The brake fluid should be replaced
only by trained Yamaha service per­sonnel. Have the Yamaha dealer
replace the following components
during periodic maintenance or when
they are damaged or leaking:

8 oil seals (every two years)
8 brake hoses (every four years)

a. Chain slack

EAU00744

Drive chain slack check

NOTE:

Spin the wheel several times and find
the tightest position of the chain.
Check and/or adjust the chain slack
while it’s in this tightest position.

To check the chain slack the motor­cycle must be held straight up with
both wheels on the ground and with­out rider. Check the slack at the posi­tion shown in the illustration. Normal
slack is approximately 30 ~ 40 mm. If
the slack exceeds 40 mm, adjust.

1

2

3

4

5

6

7

8

9

6-22

PERIODIC MAINTENANCE AND MINOR REPAIR

a

b

2

1

3

1

2

3

1. Chain adjusting plate

4

2. Axle nut

3. Caliper bracket bolt

5

Drive chain slack adjustment

1. Loosen the axle nut and caliper

6

bracket bolt.

2. Turn both left and right chain

7

adjusting plates the same
amount. Make sure that they are

8

in the same position for proper
wheel alignment. To tighten the

9

chain, turn in direction a. To
loosen the chain, turn in direction
b.

EAU01134

EC000096

cC

Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits.

3. After adjusting, be sure to tighten
the axle nut and caliper bracket
bolt to the specified tightening
torque.

Tightening torque:

Axle nut:

105 Nm (10.5 m0kg)

Caliper bracket bolt:

48 Nm (4.8 m0kg)

EAU03006

Drive chain lubrication

The chain consists of many parts
which work with each other. If the
chain is not maintained properly, it
will wear out quickly. Therefore, the
chain must be serviced regularly.
This service is especially necessary
when riding in dusty areas. This
motorcycle is equipped with a sealed
type chain. Steam cleaning, high­pressure washers, and solvents can
damage the drive chain, so do not
use these for cleaning it. Use only
kerosene to clean the drive chain.
Wipe it dry, and thoroughly lubricate it
with SAE 30 ~ 50W motor oil. Do not
use any other lubricants on the drive
chain. They may contain solvents
that could damage the sealed chain.

6-23

PERIODIC MAINTENANCE AND MINOR REPAIR

EC000097

cC

Be sure to oil the chain after wash­ing the motorcycle or riding in the
rain.

EAU02962

Cable inspection and
lubrication

EW000112

w

Damage to the outer housing of
cables may lead to internal rusting
and interfere with the cable move­ment. Replace damaged cables as
soon as possible to prevent unsafe
conditions.

Lubricate the cables and cable ends.
If a cable does not operate smoothly,
ask a Yamaha dealer to replace it.

Recommended lubricant:

Engine oil

EAU00773

Throttle cable and grip
lubrication

The throttle twist grip assembly
should be greased at the time that
the cable is lubricated, since the grip
must be removed to get at the end of
the throttle cable. After removing the
screws, hold the end of the cable up
in the air and put in several drops of
lubricant. With the throttle grip disas­sembled, coat the metal surface of
the grip assembly with a suitable all­purpose grease.

1

2

3

4

5

6

7

8

9

6-24

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

3

4

Brake and shift pedal

5

lubrication

Lubricate the pivoting parts.

6

7

8

9

Recommended lubricant:

Engine oil

EAU02984

Brake and clutch lever
lubrication

Lubricate the pivoting parts.

Recommended lubricant:

Engine oil

6-25

EAU02985

EAU02986

Sidestand lubrication

Lubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.

Recommended lubricant:

Engine oil

EW000113

w

If the sidestand does not move
smoothly, consult a Yamaha deal­er.

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU02939

Front fork inspection

Visual check

EW000115

w

1

1

1

1. Grease nipple (×2)

EAU00790

Rear suspension lubrication

Lubricate the pivoting parts.

Recommended lubricant:

Molybdenum disulfide grease

Securely support the motorcycle
so there is no danger of it falling
over.

Check for scratches or damage on
the inner tube and excessive oil leak­age from the front fork.

6-26

Operation check

1. Place the motorcycle on a level
place.

2. Hold the motorcycle in an upright
position and apply the front
brake.

3. Push down hard on the handle­bars several times and check if
the fork rebounds smoothly.

EC000098

cC

If any damage or unsmooth move­ment is found with the front fork,
consult a Yamaha dealer.

2

3

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

3

4

Steering inspection

Periodically inspect the condition of

5

the steering. Worn out or loose steer­ing bearings may be dangerous.

6

Place a stand under the engine to
raise the front wheel off the ground.

7

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 eas­ier if the front wheel is removed.

EAU00794

EW000115

w

Securely support the motorcycle
so there is no danger of it falling
over.

EAU01144

Wheel bearings

If there is play in the front or rear
wheel hub or if the wheel does not
turn smoothly, have a Yamaha dealer
inspect the wheel bearings.

6-27

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00800

Battery

This motorcycle is equipped with a
sealed-type battery. Therefore it is
not necessary to check the elec­trolyte or fill the battery with distilled
water.

88

If the battery seems to have dis­charged, consult a Yamaha deal­er.

88

If the motorcycle is equipped
with optional electrical acces­sories, the battery tends to dis­charge more quickly, so be sure
to recharge it periodically.

EC000101

cC

Never try to remove the sealing
caps of the battery cells. The bat­tery will be damaged.

EW000116

w

Battery electrolyte is poisonous
and dangerous, causing severe
burns, etc. It contains sulfuric
acid. Avoid contact with skin, eyes
or clothing.
ANTIDOTE:

88

EXTERNAL: Flush with water.

88

INTERNAL: Drink large quanti­ties of water or milk. Follow
with milk of magnesia, beaten
egg, or vegetable oil. Call a
physician immediately.

88

EYES: Flush with water for 15
minutes and get prompt med-

ical attention.
Batteries produce explosive
gases. Keep sparks, flame, ciga­rettes etc., away. Ventilate when
charging or using in an enclosed
space. Always shield your eyes
when working near batteries.
KEEP OUT OF REACH OF CHIL­DREN.

Battery storage

When the motorcycle is not used for
a month or longer, remove the bat­tery, fully charge it and store it in a
cool, dry place.

EC000102

cC

88

Completely recharge the bat­tery before storing. Storing a
discharged battery can cause
permanent battery damage.

88

Use a battery charger
designed for a sealed-type
(MF) battery. Using a conven­tional battery charger will
cause battery damage. If you
do not have a sealed-type bat­tery charger, contact your
Yamaha dealer.

88

Always make sure the connec­tions are correct when rein­stalling the battery.

1

2

3

4

5

6

7

8

9

6-28

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

cC

Do not use fuses of higher amper-

1

2

3

age rating than those recommend­ed. Substitution of a fuse of
improper rating can cause exten­sive electrical system damage and
possibly a fire.

EC000103

1

1. Main fuse

4

2. Spare fuse

Fuse replacement

5

The fuse is located behind panel A.
(See page 6-7 for panel removal and

6

installation procedures.)
If the fuse is blown, turn off the main

7

switch and the switch of the circuit in
question. Install a new fuse of proper

8

amperage. Turn on the switches and
see if the electrical device operates.
If the fuse immediately blows again,

9

consult a Yamaha dealer.

EAU01307

Specified fuse:

20 A

1. Bolt (×3)

EAU01146

Headlight bulb replacement

This motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows:

1. Remove cowling A. (See page
6-7 for cowling removal and
installation procedures.)

2. Remove the headlight unit.

6-29

PERIODIC MAINTENANCE AND MINOR REPAIR

2

1

1

1

1

2

3

1. Connector (×3)

2. Bulb holder cover

3. Remove the connectors and the
bulb holder cover.

1. Bulb holder

4. Turn the bulb holder counter­clockwise to remove it and
remove the defective bulb.

EW000119

w

Keep flammable products and your
hands away from a bulb while it is
on, as it is hot. Do not touch a bulb
until it cools down.

6-30

1. Don’t touch

5. Put a new bulb into position and
secure it in place with the bulb
holder.

EC000105

cC

Avoid touching the glass part of a
bulb. Keep it free from oil; other­wise, the transparency of the
glass, life of the bulb, and lumi­nous flux will be adversely affect­ed. If oil gets on a bulb, thoroughly
clean it with a cloth moistened
with alcohol or lacquer thinner.

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

1

6. Install the bulb holder cover, con­nectors and headlight unit.

7. Install the cowling.

1

8. If the headlight beam adjustment
is necessary, ask a Yamaha

2

3

dealer to make that adjustment.

4

5

1. Screw

2. Lens

EAU01095

Turn signal light bulb
replacement

6

7

8

9

1. Remove the screw and the lens.

1. Bulb

2. Remove the defective bulb by
pushing it inward and turning it
counterclockwise.

3. Install a new bulb by pushing it
inward and turning it clockwise.

4. Install the lens and tighten the
screw.

6-31

2

1

1. Screw (×2)

1

2. Lens

EAU01623

Taillight bulb replacement

1. Remove the screws and the
lens.

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01579

Supporting the motorcycle

Since the Yamaha XT500E/XT600E
has no centerstand, follow these pre­cautions when removing the front and
rear wheel or performing other main­tenance requiring the motorcycle to
stand upright. Check that the motor­cycle is in a stable and level position

1. Bulb

2. Remove the defective bulb by
pushing it inward and turning it
counterclockwise.

3. Install a new bulb by pushing it
inward and turning it clockwise.

4. Install the lens and tighten the
screws.

EC000108

cC

Do not over-tighten the screws as
the lens may break.

before starting any maintenance. A
strong wooden box can be placed
under the engine for added stability.

Front wheel service

To stabilize the rear of the motorcy­cle, either use a motorcycle stand or
place a motorcycle jack under the
frame in front of the rear wheel to
prevent it from moving from side to
side. Then use a motorcycle stand to
elevate the front wheel off of the
ground.

1

2

3

4

5

6

7

8

9

6-32

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

1

Rear wheel service

Use a motorcycle stand or motorcycle
jack to elevate the motorcycle so the

1

rear wheel is off the ground.
Alternatively, two jacks can be placed

2

under the frame or swingarm.

3

4

1. Speedometer cable

EAU00897

Front wheel removal

5

EW000122

w

88

6

7

8

It is advisable to have a
Yamaha dealer service the
wheel.

88

Securely support the motorcy­cle so there is no danger of it
falling over.

1. Axle holder nut (×4)

2. Wheel axle

2. Loosen the wheel axle holder
nuts and wheel axle.

3. Elevate the front wheel by plac­ing a suitable stand under the
engine.

4. Remove the wheel axle and the
front wheel. Make sure the
motorcycle is properly supported.

NOTE:

9

1. Remove the speedometer cable
from the front wheel side.

Do not depress the brake lever when
the disc and caliper are separated.

6-33

PERIODIC MAINTENANCE AND MINOR REPAIR

3

2

1

1

2

3

EAU01135

Front wheel installation

1. Install the speedometer gear unit
housing into the wheel hub.
Make sure the speedometer gear
unit housing is installed with the
projections meshed into the
slots.

2. Lift up the wheel between the
front fork legs and guide the
brake disc between the brake
pads. Make sure there is enough
gap between the brake pads
before inserting the brake disc.

3. Make sure the slot in the
speedometer gear unit fits over
the stopper on the front fork
outer tube.

4. Install the wheel axle and tighten
it to the specified torque.

Tightening torque:

Wheel axle:

59 Nm (5.9 m0kg)

6-34

1. Upper nut (×2)

2. Lower nut (×2)

3. Gap

5. Before tightening the holder nuts,
push down on the handlebars
several times and check if the
fork rebounds smoothly.

6. Tighten the axle holder nuts to
the specified tightening torque.
Tighten the upper nuts first and
then lower ones. When tightened
in this sequence, there should be
a gap formed at the bottom of
the axle holder.

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1

2

1

Tightening torque:

Axle holder nut:

1

2

3

9 Nm (0.9 m0kg)

4

5

1. Axle nut

2. Caliper bracket bolt

EAU00963*

Rear wheel removal

EW000122

w

6

88

It is advisable to have a

1. Swingarm end bolt (×2)

3. Remove the swingarm end bolts.

4. Elevate the rear wheel by placing
a suitable stand under the
engine.

Yamaha dealer service the

7

8

wheel.

88

Securely support the motorcy­cle so there is no danger of it
falling over.

9

1. Remove the axle nut.

2. Loosen the caliper bracket bolt.

6-35

INSTRUMENT AND CONTROL FUNCTIONS

5. Push the wheel forward and
remove the drive chain.

6. Pull out the wheel axle, then
remove the wheel assembly by
pulling backwards.

NOTE:

8 Do not depress the brake pedal

when the disc and caliper are
separated.

8 You do not have to disassemble

the chain in order to remove or
install the rear wheel.

EAU01136*

Rear wheel installation

1. Install the rear wheel and chain.
Guide the brake disc between
the brake pads. Make sure there
is enough gap between the
brake pads before inserting the
brake disc.

2. Make sure the wheel axle is
inserted from the left-hand side
and that the chain adjusting
plates are installed with the
punched side outward.

3. Install the swingarm end bolts.

4. Adjust the drive chain.

5. Tighten the following parts to the
specified torque.

Tightening torque:

Axle nut:

105 Nm (10.5 m0kg)

Caliper bracket bolt:

48 Nm (4.8 m0kg)

Swingarm end bolt:

2.5 Nm (0.25 m0kg)

EAU01008

Troubleshooting

Although Yamaha motorcycles
receive a rigid inspection before ship­ment from the factory, trouble may
occur during operation.
Any problem in the fuel, compres­sion, or ignition systems can cause
poor starting and loss of power. The
troubleshooting chart describes a
quick, easy procedure for making
checks.
If your motorcycle requires any
repair, bring it to a Yamaha dealer.
The skilled technicians at a Yamaha
dealership have the tools, experi­ence, and know-how to properly ser­vice your motorcycle. Use only gen­uine Yamaha parts on your
motorcycle. Imitation parts may look
like Yamaha parts, but they are often
inferior. Conse-quently, they have a
shorter service life and can lead to
expensive repair bills.

1

2

4

5

6

7

8

9

6-36

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Fuel

2. Compression

3. Ignition

4. Battery

Use the electric starter.

There is compression.

Go to ignition check.

No compression.

Ask a Yamaha dealer to inspect.

Wet.

Dry.

Wipe clean with dry cloth and

Ask a Yamaha dealer to inspect.

Check if there is fuel

Enough fuel.

No fuel.

Go to compression check.

Supply fuel.

in the fuel tank.

Remove spark

electrodes.

plug and check

Open throttle half-way and start the

Engine doesn’t start, go to battery
check.

engine.

correct spark gap or replace spark plug.

Engine turns over

Engine turns over

Battery good.

Check connections

quickly.

slowly. or recharge.

Engine doesn’t start, ask a Yamaha
dealer to inspect.

Engine doesn’t start, go to
compression check.

Use the electric

starter.

Troubleshooting chart

w

1

Never check the fuel system while smoking or in the vicinity of an open flame.

2

3

4

5

6

7

8

9

EAU01397

EW000125

6-37

MOTORCYCLE CARE AND STORAGE

Care....................................................................................................7-1

Storage...............................................................................................7-4

7

MOTORCYCLE CARE AND STORAGE

EAU01518

Care

The exposure of its technology
makes a motorcycle charming but

1

also vulnerable. Although high-quality
components are used, they are not
all rust-resistant. While a rusty

2

exhaust pipe may remain unnoticed
on a car, it does look unattractive on

3

a motorcycle. Frequent and proper
care, however, will keep your motor-

4

cycle looking good, extend its life and
maintain its performance. Moreover,
the warranty states that the vehicle

5

must be properly taken care of. For
all these reasons, it is recommended

6

that you observe the following clean­ing and storing precautions.

7

8

9

Before cleaning

1. Cover up the muffler outlet with a
plastic bag.

2. Make sure that all caps and cov­ers as well as all electrical cou­plers and connectors, including
the spark plug cap, are tightly
installed.

3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
tooth or bottle brush, but never
apply such products onto seals,
gaskets, sprockets, the drive
chain and wheel axles. Always
rinse the dirt and degreaser off
with water.

Cleaning

After normal use
Remove dirt with warm water, a neu­tral detergent and a soft clean
sponge, then rinse with plenty of
clean water. Use a brush for hard-to­reach parts. Tougher dirt and insects
will come off more easily if the area is
covered with a wet cloth for a few
minutes before cleaning.

ECA00010

cC

88

Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If you do use
such products for hard-to­remove dirt, do not leave it on
any longer than instructed,
then thoroughly rinse it off
with water, immediately dry
the area and apply a corrosion
protection spray.

7-1

MOTORCYCLE CARE AND STORAGE

88

Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent
and water to clean plastic.

88

Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra­sive cleaning products, sol­vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec­trolyte.

88

Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep­age and deterioration in the
following areas: seals (of
wheel bearings, swingarm
bearings, forks and brakes),
electric components (cou­plers, connectors, instru­ments, switches and lights),
breather hoses and vents.

88

For motorcycles equipped
with a windshield: Do not use
strong cleaners or hard
sponges as they will cause
dulling or scratching. Some
cleaning compounds for plas­tic may leave scratches on the
windshield. Test the product
on a small hidden part of the
windshield to make sure they
do not leave any marks. If the
windshield is scratched, use a
quality plastic polishing com­pound after washing.

After riding in the rain, near the sea
or on salt-sprayed roads.
Since sea salt or salt sprayed on the
roads in the winter are extremely cor­rosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads. (Salt sprayed
in the winter may remain on the roads
well into spring.)

1. Clean your motorcycle with cold
water and soap after the engine
has cooled down.

ECA00012

cC

Do not use warm water since it
increases the corrosive action of
the salt.

2. Be sure to apply a corrosion pro­tection spray on all (even
chrome- and nickel-plated) metal
surfaces to prevent corrosion.

1

2

3

4

5

6

7

8

9

7-2

MOTORCYCLE CARE AND STORAGE

After cleaning

1. Dry the motorcycle with a
chamois or an absorbing cloth.

1

2. Immediately dry the drive chain
and lubricate it to prevent it from

2

rusting.

3. Use a chrome polish to shine

3

chrome, aluminum and stainless­steel parts, including the exhaust

4

system. (Even the thermally
induced discoloring of stainless­steel exhaust systems can be

5

removed through polishing.)

4. To prevent corrosion, it is recom-

6

mended to apply a corrosion pro­tection spray on all (even

7

chrome- and nickel-plated) metal
surfaces.

5. Use spray oil as a universal

8

cleaner to remove any remaining
dirt.

9

6. Touch up minor paint damage
caused by stones, etc.

7. Wax all painted surfaces.

8. Let the motorcycle dry complete­ly before storing it or covering it.

EWA00001

w

Make sure that there is no oil or
wax on the brakes and tires. If nec­essary, clean the brake discs and
linings with a regular brake disc
cleaner or acetone, and wash the
tires with warm water and mild
soap. Then, carefully test the
motorcycle for its braking perfor­mance and cornering behavior.

ECA00013

cC

88

Apply spray oil and wax spar­ingly and wipe off any excess.

88

Never apply oil or wax on rub­ber and plastic parts, but treat
them with a suitable care prod­uct.

88

Avoid using abrasive polish­ing compounds as they wear
away the paint.

NOTE:

Consult a Yamaha dealer for advice
on what products to use.

7-3

MOTORCYCLE CARE AND STORAGE

Storage

Short-term

Always store your motorcycle in a
cool, dry place and, if necessary, pro­tect it against dust with a porous
cover.

ECA00014

cC

88

Storing the motorcycle in a
poorly ventilated room or cov­ering it with a tarp while it is
still wet will allow water and
humidity to seep in and cause
rust.

88

To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi­cals are stored.

Long-term

Before storing your motorcycle for
several months:

1. Follow all the instructions in the
“Care” section of this chapter.

2. Drain the carburetor float cham­ber by loosening the drain bolt;
this will prevent fuel deposits
from building up. Pour the
drained fuel into the fuel tank.

3. Only for motorcycles equipped
with a fuel cock which has an
“OFF” position: Turn the fuel
cock to “OFF”.

4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.

5. Perform the following steps to
protect the cylinder, piston rings,
etc. from corrosion.

a. Remove the spark plug cap and

spark plug.

b. Pour a teaspoonful of engine oil

into the spark plug bore.

c. Install the spark plug cap onto

the spark plug and place the
spark plug on the cylinder head
so that the electrodes are
grounded. (This will limit spark­ing during the next step.)

d. Turn the engine over several

times with the starter. (This will
coat the cylinder wall with oil.)

e. Remove the spark plug cap from

the spark plug, install the spark
plug and then the spark plug
cap.

EWA00003

w

When turning the engine over, be
sure to ground the spark plug elec­trodes to prevent damage or injury
from sparking.

1

2

3

4

5

6

7

8

9

7-4

MOTORCYCLE CARE AND STORAGE

6. Lubricate all control cables and
the pivoting points of all levers

1

2

3

4

5

6

7

8

9

and pedals as well as of the
sidestand/centerstand.

7. Check and, if necessary, correct
the tire air pressure, then raise
the motorcycle so that both of its
wheels are off the ground.
Alternatively, turn the wheels a
little every month in order to pre­vent the tires from becoming
degraded in one spot.

8. Cover up the muffler outlet with a
plastic bag to prevent moisture
from entering.

9. Remove the battery and fully
charge it. Store it in a cool, dry
place and recharge it once a
month. Do not store the battery
in an excessively cold or warm
place (less than 0°C or more
than 30°C). For more informa­tion, see “Battery storage” in the
chapter “PERIODIC MAINTE­NANCE AND MINOR
REPAIRS”.

NOTE:

Make any necessary repairs before
storing the motorcycle.

7-5

SPECIFICATIONS

Specifications .....................................................................................8-1

HOW TO USE THE CONVERSION TABLE.......................................8-5

8

SPECIFICATIONS

–10° 0° 10° 20° 30°

40°

SAE 10W/30

SAE 10W/40

SAE 20W/40

SAE 20W/50

–20°

SAE 15W/40

50°C

SPECIFICATIONS

Specifications

EAU01038

1

2

Model XT500E/XT600E
Dimensions

Overall length 2,220 mm

Overall width 865 mm

3

Overall height 1,205 mm

4

5

6

7

8

9

Seat height 855 mm
Wheel base 1,440 mm
Minimum ground clearance 230 mm
Minimum turning radius 2,300 mm

Basic weight (with oil and full
fuel tank) 176 kg

Engine

Engine type Air-cooled 4-stroke, SOHC,

Cylinder arrangement Forward inclined single

Displacement 499 cm

Bore × Stroke 87.0 × 84.0 mm (XT500E)

Compression ratio 8.5:1
Starting system Electric starter
Lubrication system Dry sump

2.295 mm (N, S, CH only)

825 mm (CH only)

172 kg (CH only)

gasoline

cylinder

3
3

595 cm

95.0 × 84.0 mm (XT600E)

Engine oil

Type

Recommended engine oil
classification API Service SE, SF, SG type

or higher

cC

Be sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled
“Energy Conserving”) contain anti-friction additives which
will cause clutch and/or starter clutch slippage, resulting in
reduced component life and poor engine performance.

Capacity

Periodic oil change 2.7 L
With oil filter replacement 2.8 L
Total amount 3.3 L

8-1

SPECIFICATIONS

Air filter Dry type element
Fuel

Type Regular unleaded gasoline
Fuel tank capacity 15 L
Reserve amount 2 L

Carburetor

Type/quantity Y26PV/1
Manufacturer TEIKEI

Spark plug

Type/Manufacturer DPR8EA-9 or DPR9EA-9/NGK
Spark plug gap 0.8 ~ 0.9 mm

Clutch type Wet, multiple-disc
Transmission

Primary reduction system Spur gear
Primary reduction ratio 74/31 (2.387) (XT500E)

71/34 (2.088) (XT600E)
Secondary reduction system Chain drive
Secondary reduction ratio 38/15 (2.533) (XT500E)

45/15 (3.000) (XT600E)
Transmission type Constant mesh 5-speed
Operation Left foot operation

Gear ratio 1st 2.583

2nd 1.588
3rd 1.200
4th 0.954 (XT500E)

0.955 (XT600E)

5th 0.792

Chassis

Frame type Diamond
Caster angle 27.75° (XT500E)

27°45’ (XT600E)

Trail 120 mm

Tire

Type With tube
Front

Size 90/90-21 54S
Manufacturer/ BRIDGESTONE/TW47

model DUNLOP/TRAIL MAX L

Rear

Size 120/90/17 64S
Manufacturer/ BRIDGESTONE/TW48

model DUNLOP/TRAIL MAX

Maximum load* 176 kg (XT500E)

180 kg (XT600E)

1

2

3

4

5

6

7

8

9

8-2

SPECIFICATIONS

1

2

3

4

5

6

7

8

9

Air pressure (cold tire)
up to 90 kg load*

Front 150 kPa (1.50 kg/cm2, 1.50 bar)
Rear 150 kPa (1.50 kg/cm2, 1.50 bar)

90 kg load ~ Maximum
load*

Front 150 kPa (1.50 kg/cm2, 1.50 bar)
Rear 225 kPa (2.25 kg/cm2, 2.25 bar)

Off-road riding

Front 125 kPa (1.25 kg/cm2, 1.25 bar)
Rear 125 kPa (1.25 kg/cm2, 1.25 bar)

High speed riding

Front 150 kPa (1.50 kg/cm2, 1.50 bar)
Rear 150 kPa (1.50 kg/cm2, 1.50 bar)

* Load is total weight of cargo, rider, passenger and accessories.

Wheels

Front

Type Spoke wheel
Size 21 × 1.85

Rear

Type Spoke wheel
Size 17 × MT2.50

Brakes

Front

Type Single disc brake
Operation Right hand operation
Fluid DOT 3 or DOT 4

Rear

Type Single disc brake
Operation Right foot operation
Fluid DOT 4

Suspension

Front

Type Telescopic fork

Rear

Type Swingarm (new monocross)

Shock absorber

Front Coil spring/oil damper
Rear Coil spring/gas-oil damper

Wheel travel

Front 225 mm
Rear 200 mm

8-3

SPECIFICATIONS

Electrical

Ignition system T.C.I. (Digital)
Charging system

Type A.C. magneto
Standard output 14 V, 13.5A@5,000 rpm

Battery

Type YTX9-BS
Voltage, capacity 12 V, 8 AH

Headlight bulb type Halogen bulb
Bulb voltage, wattage × quantity

Headlight 12 V, 60/55W × 1
Tail / brake light 12 V, 5/21W × 1
Auxiliary light 12 V, 4W × 1

12 V, 3.4W × 1 (GB only)
Front flasher light 12 V, 21W × 2
Rear flasher light 12 V, 21W × 2
Meter light 12 V, 3.4W × 1
Neutral indicator light 12 V, 3.4W × 1
High beam indicator light 12 V, 3.4W × 1
Turn indicator light 12 V, 3.4W × 1

Fuse

Main 20A

1

2

3

4

5

6

7

8

9

8-4

SPECIFICATIONS

1

HOW TO USE THE CONVERSION TABLE

All specification data in this manual are listed in SI and
METRIC UNITS.

2

Use this table to convert METRIC unit data to
IMPERIAL unit data.

3

Ex.

4

5

6

7

8

METRIC MULTIPLIER IMPERIAL

** mm × 0.03937 = ** in

2 mm × 0.03937 = 0.08 in

EAU01064

CONVERSION TABLE

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

m•kg 7.233 ft• lb

Torque

Weight
Speed km/hr 0.6214 mph

Distance m 1.094 yd

Volume/ cc (cm3) 0.06102 cu•in
Capacity lt (liter) 0.8799 qt (IMP liq.)

Misc. kg/cm2 14.2234 psi (lb/in2)

m•kg 86.794 in•lb
cm•kg 0.0723 ft•lb
cm•kg 0.8679 in•lb

kg 2.205 lb
g 0.03527 oz

km 0.6214 mi
m 3.281 ft

cm 0.3937 in
mm 0.03937 in

cc (cm3) 0.03527 oz (IMP liq.)

lt (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in

Centigrade(°C)

9/5 + 32

Fahrenheit(°F)

9

8-5

CONSUMER INFORMATION

Identification number records.............................................................9-1

Key identification number...................................................................9-1

Vehicle identification number..............................................................9-1

Model label.........................................................................................9-2

9

1

CONSUMER INFORMATION

EAU02944

Identification number
records

1

Record the key identification number,
vehicle identification number and
model label information in the spaces

2

provided for assistance when order­ing spare parts from a Yamaha deal-

3

er or for reference in case the vehicle
is stolen.

4

1. KEY IDENTIFICATION

5

6

7

8

9

NUMBER:

2. VEHICLE IDENTIFICATION
NUMBER:

3. MODEL LABEL INFORMATION:

1
6

1

1. Key identification number 1. Vehicle identification number

EAU01041

Key identification number

The key identification number is
stamped on the key tag.
Record this number in the space pro­vided and use it for reference when
obtaining a new key.

Vehicle identification
number

The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro­vided.

NOTE:

The vehicle identification number is
used to identify your motorcycle and
may be used to register your motor­cycle with the licensing authority in
your state.

EAU01039

EAU01043

9-1

CONSUMER INFORMATION

1

1

2

1. Model label

EAU01050

Model label

The model label is affixed to the
frame under the seat. (See page
3-9 for seat removal procedures.)
Record the information on this label
in the space provided. This informa­tion will be needed to order spare
parts from your Yamaha dealer.

9-2

4

5

6

7

8

9

9

INDEX

A

Air filter..................................................6-12

B

Battery...................................................6-28

Brake and clutch lever lubrication .........6-25

Brake and shift pedal lubrication...........6-25

Brake fluid replacement.........................6-22

Brake light switch adjustment................6-20

C

Cable inspection and lubrication ...........6-24

Carburetor adjustment...........................6-13

Care.........................................................7-1

Carrier (optional) ...................................3-11

Checking the front and rear brake

pads....................................................6-20

Clutch lever .............................................3-4

Clutch lever free play adjustment..........6-18

Cowling A................................................6-7

Cowling and panel removal and

installation.............................................6-6

D

Description ..............................................2-1

Dimmer switch.........................................3-3

Drive chain lubrication...........................6-23

Drive chain slack adjustment.................6-23

Drive chain slack check.........................6-22

E

Engine break-in.......................................5-5

Engine oil...............................................6-10

Engine stop switch ..................................3-4

F

Front brake lever.....................................3-5

Front brake lever free play

adjustment ..........................................6-18

Front fork inspection..............................6-26

Front wheel installation..........................6-34

Front wheel removal..............................6-33

Fuel .........................................................3-6

Fuel cock.................................................3-7

Fuel tank cap...........................................3-6

Fuse replacement..................................6-29

H

Handlebar switches.................................3-3

Dimmer switch ......................................3-3

Engine stop switch................................3-4

Horn switch...........................................3-3

Lights switch .........................................3-3

Pass switch...........................................3-3

Start switch ...........................................3-4

Turn signal switch.................................3-3

Headlight bulb replacement...................6-29

Helmet holder..........................................3-9

High beam indicator light.........................3-2

Horn switch..............................................3-3

How to use the conversion table.............9-3

I

Identification number records..................9-1

Idle speed adjustment...........................6-14

Indicator lights.........................................3-2

High beam indicator light ......................3-2

Neutral indicator light............................3-2

Turn indicator light ................................3-2

Inspecting the brake fluid level..............6-21

K

Key identification number........................9-1

L

Lights switch............................................3-3

M

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

Model label..............................................9-2

N

Neutral indicator light...............................3-2

P

Panel A, B ...............................................6-7

Parking....................................................5-6

Pass switch .............................................3-3

Periodic maintenance and

lubrication chart ....................................6-3

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

R

Rear brake pedal.....................................3-5

Rear brake pedal height adjustment .....6-19

Rear shock absorber adjustment ..........3-10

Rear suspension lubrication..................6-26

Rear wheel installation..........................6-36

Rear wheel removal ..............................6-35

Recommended shift point

(for Switzerland only)............................5-4

S

Seat.........................................................3-9

Shift pedal ..............................................3-5

Shifting ....................................................5-4

Sidestand ..............................................3-11

Sidestand lubrication.............................6-25

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

INDEX

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN
2001·1–1.0×1(E)

!