wheel YAMAHA XT500E 2002 User Guide

6-39
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04314
Rear wheelTo remove the rear wheel
EW000122
w8 8
It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so that there is no danger
of it falling over.1. Remove the axle nut.
2. Loosen the brake caliper bracket
bolt.
2
1
1. Axle nut
2. Brake caliper bracket bolt
5. Turn the drive chain adjusting
plate on each side of the
swingarm fully in direction a.
1
a
1. Chain adjusting plate
3. Lift the rear wheel off the ground
according to the procedure on
page 6-36.
4. Remove the swingarm end bolts.
1
1
1. Swingarm end bolt (×2)
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6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
6 6. Push the wheel forward, and
then remove the drive chain from
the rear sprocket.
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the wheel.7. Pull the wheel axle out, and then
remove the wheel.
ECA00048
cCDo not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU01136
To install the rear wheelInstall1. Install the drive chain onto the
rear sprocket, and then insert the
wheel axle from the left-hand
side.NOTE:
8Make sure that there is enough
space between the brake pads
before inserting the brake disc
between the brake pads.
8Make sure that the drive chain
adjusting plates are installed with
the punched sides facing to the
outside.2. Install the swingarm end bolts.
3. Adjust the drive chain slack.
(See page 6-25 for drive chain
slack adjustment procedures.)
4. Tighten the axle nut, brake
caliper bracket bolt and
swingarm end bolts to the speci-
fied torques.
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7-1
EAU03521
MOTORCYCLE CARE AND STORAGE
7
CareCareWhile the open design of a motorcy-
cle reveals the attractiveness of the
technology, it also makes it more vul-
nerable. Rust and corrosion can
develop even if high-quality compo-
nents are used. A rusty exhaust pipe
may go unnoticed on a car, however,
it detracts from the overall appear-
ance of a motorcycle. Frequent and
proper care does not only comply
with the terms of the warranty, but it
will also keep your motorcycle looking
good, extend its life and optimize its
performance.Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and cov-
ers as well as all electrical cou-
plers 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
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
ECA00010
cC8
8
Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If such prod-
ucts are used on hard-to-
remove dirt, do not leave the
cleaner on the affected area
any longer than instructed.
Also, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection spray.
8 8
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.
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7-2
MOTORCYCLE CARE AND STORAGE
7 8 8
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra-
sive cleaning products, sol-
vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec-
trolyte.
8 8
Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the
following areas: seals (of
wheel and swingarm bearings,
fork and brakes), electric com-
ponents (couplers, connec-
tors, instruments, switches
and lights), breather hoses
and vents.8 8
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 plas-
tic may leave scratches on the
windshield. Test the product
on a small hidden part of the
windshield to make sure that it
does not leave any marks. If
the windshield is scratched,
use a quality plastic polishing
compound after washing.
After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottle-
brush for hard-to-reach areas.
Stubborn dirt and insects will come
off more easily if the area is covered
with a wet cloth for a few minutes
before cleaning.After riding in the rain, near the sea
or on salt-sprayed roadsSince sea salt or salt sprayed on
roads during 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.NOTE:
Salt sprayed on roads in the winter
may remain well into spring.1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
cCDo not use warm water since it
increases the corrosive action of
the salt.2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, sur-
faces to prevent corrosion.
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7-5
MOTORCYCLE CARE AND STORAGE
76. Lubricate all control cables and
the pivoting points of all levers
and pedals as well as of the
sidestand/centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground.
Alternatively, turn the wheels a
little every month in order to pre-
vent the tires from becoming
degraded in one spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge 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 informa-
tion on storing the battery, see
page 6-32.
NOTE:
Make any necessary repairs before
storing the motorcycle.
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8-1
EAU01038
SPECIFICATIONS
8
SpecificationsSpecifications
Model XT500E/XT600E
Dimensions
Overall length 2,220 mm
2.295 mm (N, S, CH only)
Overall width 865 mm
825 mm (CH only)
Overall height 1,205 mm
Seat height 855 mm
Wheel base 1,440 mm
Ground clearance 230 mm
Minimum turning radius 2,300 mm
Basic weight (with oil and full
fuel tank)176 kg
172 kg (CH only)
Engine
Engine type Air-cooled 4-stroke, SOHC,
gasoline
Cylinder arrangement Forward inclined single
cylinder
Displacement 499 cm
3
595 cm
3
Bore ×Stroke 87.0 ×84.0 mm (XT500E)
95.0 ×84.0 mm (XT600E)
Compression ratio 8.5:1
Starting system Electric starter
Lubrication system Dry sump
Engine oil
Type
Recommended engine oil
classification API Service SE, SF, SG type
or highercCBe sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled
“ENERGY CONSERVING II”) contain anti-friction additives
which will cause clutch and/or starter clutch slippage, result-
ing in reduced component life and poor engine performance.
Capacity
Without oil filter element
replacement 2.7 L
With oil filter element
replaced 2.8 L
Total amount (dry engine) 3.3 L
–10° 0° 10° 20° 30°
40°
SAE 10W/30
SAE 10W/40
SAE 20W/40
SAE 20W/50
–20°
SAE 15W/40 50°C
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8-3
SPECIFICATIONS
8
Air pressure (cold tire)
up to 90 kg load*
Front 150 kPa (1.50 kgf/cm
2, 1.50 bar)
Rear 150 kPa (1.50 kgf/cm2, 1.50 bar)
90 kg load–Maximum
load*
Front 150 kPa (1.50 kgf/cm2, 1.50 bar)
Rear 225 kPa (2.25 kgf/cm2, 2.25 bar)
Off-road riding
Front 125 kPa (1.25 kgf/cm2, 1.25 bar)
Rear 125 kPa (1.25 kgf/cm2, 1.25 bar)
High speed riding
Front 150 kPa (1.50 kgf/cm2, 1.50 bar)
Rear 225 kPa (2.25 kgf/cm2, 2.25 bar)
* Total weight of rider, passenger, cargo and accessories
Wheels
Front
Type Spoke wheel
Size 21 ×1.85
Rear
Type Spoke wheel
Size 17 ×MT2.50 or
17 M/C ×MT2.50Brakes
Front
Type Single disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Single disc brake
Operation Right foot
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
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INDEX
E
Engine break-in ..................................... 5-4
Engine idling speed ............................. 6-15
Engine oil and oil filter element ........... 6-10
Engine, starting a warm ......................... 5-2
F
Front and rear brake pads, checking ... 6-22
Front fork, checking ............................. 6-29
Front wheel........................................... 6-37
Installing ............................................ 6-37
Removing .......................................... 6-37
Fuel ....................................................... 3-6
Fuel cock ............................................... 3-8
Fuel consumption, tips for reducing ...... 5-4
Fuel tank cap ......................................... 3-6
Fuse, replacing .................................... 6-32
H
Handlebar switches ............................... 3-3
Light switch ......................................... 3-3
Pass switch ......................................... 3-3
Dimmer switch .................................... 3-3
Turn signal switch ............................... 3-3
Horn switch ......................................... 3-3
Engine stop switch .............................. 3-4
Start switch ......................................... 3-4
Headlight bulb, replacing ..................... 6-33
Helmet holder ...................................... 3-10
I
Identification numbers ........................... 9-1
Ignition circuit cut-off system ............... 3-12
Indicator lights ....................................... 3-2
High beam indicator light .................... 3-2
Neutral indicator light .......................... 3-2
Turn signal indicator light .................... 3-2
K
Key identification number ...................... 9-1
M
Main switch/steering lock ...................... 3-1
Model label ............................................ 9-2
P
Parking .................................................. 5-5
Part locations ......................................... 2-1
Periodic maintenance and lubrication
chart .................................................... 6-3
Pre-operation check list ......................... 4-1
R
Rear brake light switch, adjusting ........ 6-22
Rear suspension, lubricating ............... 6-29
Rear wheel ........................................... 6-39
Removing .......................................... 6-39
Install ................................................ 6-40
S
Seat ....................................................... 3-9
Shift pedal ............................................. 3-5
Shift points (for Switzerland only) .......... 5-3
Shifting .................................................. 5-3
Shock absorber assembly, adjusting ... 3-10
Sidestand ............................................ 3-11
A
Air filter element, cleaning ................... 6-13
B
Battery ................................................. 6-31
Brake and clutch levers, checking and
lubricating ......................................... 6-28
Brake and shift pedals, checking and
lubricating ......................................... 6-28
Brake fluid level, checking ................... 6-23
Brake fluid, changing ........................... 6-24
Brake lever ............................................ 3-5
Brake lever free play, adjusting ........... 6-21
Brake pedal ........................................... 3-5
Brake pedal position, adjusting ........... 6-21
C
Cables, checking and lubricating ......... 6-27
Carburetor, adjusting ........................... 6-14
Care ....................................................... 7-1
Clutch lever ........................................... 3-4
Clutch lever free play, adjusting .......... 6-20
Conversion table ................................... 8-5
Cowling and panels, removing and
installing .............................................. 6-6
D
Drive chain slack ................................. 6-25
Checking ........................................... 6-25
Adjusting ........................................... 6-25
Drive chain, lubricating ........................ 6-26
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Sidestand, checking and lubricating .... 6-28
Spark plug, checking ............................. 6-8
Specifications ........................................ 8-1
Speedometer unit .................................. 3-2
Starter (choke) knob .............................. 3-9
Starting the engine ................................ 5-1
Steering, checking ............................... 6-30
Storage .................................................. 7-4
Supporting the motorcycle ................... 6-36
T
Tachometer ........................................... 3-3
Tail/brake light bulb, replacing ............. 6-35
Throttle cable free play, adjusting ....... 6-16
Throttle grip and cable, checking and
lubricating ......................................... 6-27
Tires .................................................... 6-16
Tool kit ................................................... 6-1
Troubleshooting ................................... 6-41
Troubleshooting chart .......................... 6-42
Turn signal light bulb, replacing ........... 6-35
V
Valve clearance, adjusting .................. 6-16
Vehicle identification number ................ 9-1
W
Wheel bearings, checking ................... 6-30
Wheels ................................................ 6-19
INDEX
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