brake YAMAHA XT500E 2000 User Guide

EW000109
wA soft or spongy feeling in the
brake pedal can indicate the pres-
ence 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
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00712
Rear brake pedal height
adjustmentThe 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.
a
a.Pedal height
EW000099
w8
8
Check the brake lever free
play. Be sure the brake is
working properly.
8 8
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 deal-
er inspect and bleed the sys-
tem if necessary.
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 20

6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00713
Brake light switch
adjustmentThe rear brake light switch is activat-
ed 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 earli-
er.
Turn the adjusting nut in direction b
to make the brake light come on
later.
21
a
b
1.Brake light switch
2.Adjusting nut
EAU00716
Checking the front and rear
brake padsA wear indicator is provided on each
brake. This indicator allows checking
of brake pad wear without disassem-
bling 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.
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
1
1.Wear indicator groove (´3)
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 21

6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
1
8Use only the designated quality
brake fluid. Otherwise, the rub-
ber seals may deteriorate, caus-
ing leakage and poor brake per-
formance.NOTE:
If DOT 4 is not available, DOT 3 can
be used for the front brake only.1.Minimum level mark
Recommended brake fluid:
DOT 4
1
EAU00733
Inspecting the brake fluid
levelInsufficient brake fluid may let air
enter the brake system, possibly
causing the brakes to become inef-
fective.
Before riding, check that the brake
fluid is above the minimum level and
replenish when necessary.
Observe these precautions:
8When checking the fluid level,
make sure the top of the master
cylinder is level by turning the
handlebars.1.Minimum level mark
1
EAU00729
Rear brake
Remove the cap and inspect the
pads. If the thickness is less than the
specified value, have a Yamaha deal-
er replace the pads.1.Wear limit: 0.8 mm
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 22

6-22
8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
8Be 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.
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8Have a Yamaha dealer check
the cause if the brake fluid level
goes down.
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00742
Brake fluid replacementThe brake fluid should be replaced
only by trained Yamaha service per-
sonnel. Have the Yamaha dealer
replace the following components
during periodic maintenance or when
they are damaged or leaking:
8oil seals (every two years)
8brake hoses (every four years)
EAU00744
Drive chain slack checkNOTE:
Spin the wheel several times and find
the tightest position of the chain.
Check and/or adjust the chain slack
while itÕs in this tightest position.To check the chain slack the motor-
cycle must be held straight up with
both wheels on the ground and with-
out rider. Check the slack at the posi-
tion shown in the illustration. Normal
slack is approximately 30 ~ 40 mm. If
the slack exceeds 40 mm, adjust.
a
a.Chain slack
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 23

6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU02984
Brake and shift pedal
lubricationLubricate the pivoting parts.
Recommended lubricant:
Engine oil
EAU02986
Sidestand lubricationLubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.
EW000113
wIf the sidestand does not move
smoothly, consult a Yamaha deal-
er.
Recommended lubricant:
Engine oil
EAU02985
Brake and clutch lever
lubricationLubricate the pivoting parts.
Recommended lubricant:
Engine oil
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 26

6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00790
Rear suspension lubricationLubricate the pivoting parts.
Recommended lubricant:
Molybdenum disulfide grease
1
1
1.Grease nipple (´2)
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 handle-
bars several times and check if
the fork rebounds smoothly.
EC000098
cCIf any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
EAU02939
Front fork inspectionVisual check
EW000115
wSecurely support the motorcycle
so there is no danger of it falling
over.Check for scratches or damage on
the inner tube and excessive oil leak-
age from the front fork.
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 27

6-33
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
92.Loosen the wheel axle holder
nuts and wheel axle.
3.Elevate the front wheel by plac-
ing a suitable stand under the
engine.
4.Remove the wheel axle and the
front wheel. Make sure the
motorcycle is properly supported.
NOTE:
Do not depress the brake lever when
the disc and caliper are separated.
1
2
1.Axle holder nut (´4)
2.Wheel axle
EAU00897
Front wheel removal
EW000122
w8
8
It is advisable to have a
Yamaha dealer service the
wheel.
8 8
Securely support the motorcy-
cle so there is no danger of it
falling over.1.Remove the speedometer cable
from the front wheel side.
1
1.Speedometer cable
Rear wheel service
Use a motorcycle stand or motorcycle
jack to elevate the motorcycle so the
rear wheel is off the ground.
Alternatively, two jacks can be placed
under the frame or swingarm.
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 34

6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9 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.
32 1
1.Upper nut (´2)
2.Lower nut (´2)
3.Gap
EAU01135
Front wheel installation1.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 m
0kg)
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 35

6-36
INSTRUMENT AND CONTROL FUNCTIONS
1
2
4
56
7
8
9
EAU01008
TroubleshootingAlthough Yamaha motorcycles
receive a rigid inspection before ship-
ment from the factory, trouble may
occur during operation.
Any problem in the fuel, compres-
sion, 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, experi-
ence, and know-how to properly ser-
vice your motorcycle. Use only gen-
uine 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.
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:
8Do not depress the brake pedal
when the disc and caliper are
separated.
8You do not have to disassemble
the chain in order to remove or
install the rear wheel.
EAU01136*
Rear wheel installation1.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 m
0kg)
Caliper bracket bolt:
48 Nm (4.8 m
0kg)
Swingarm end bolt:
2.5 Nm (0.25 m0kg)
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 37

7-2
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.
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 bearings, swingarm
bearings, forks and brakes),
electric components (cou-
plers, connectors, instru-
ments, 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 they
do not leave any marks. If the
windshield is scratched, use a
quality plastic polishing com-
pound after washing.
After riding in the rain, near the seaor on salt-sprayed roads.Since sea salt or salt sprayed on the
roads in the winter are extremely cor-
rosive 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
cCDo not use warm water since it
increases the corrosive action of
the salt.2.Be sure to apply a corrosion pro-
tection spray on all (even
chrome- and nickel-plated) metal
surfaces to prevent corrosion.
MOTORCYCLE CARE AND STORAGE
1
2
3
4
5
67
8
9
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 3