YAMAHA XT500E 2000 Workshop Manual

6-11
1
2
6.Check the O-rings for damage.
Replace if damaged.
7.Install the drain plugs, filter cover
and bolts. Tighten to the speci-
fied torque.1.Oil filter element
2.O-ring (´2)
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94.Check each gasket. If damaged,
replace.
5.Remove the filter cover bolts and
the oil filter cover. Replace the oil
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.
2
34
1
1.Air bleed screw
2.Oil filter cover bolt (´2)
3.Oil filter drain bolt
4.Oil filter cover
11.Drain bolt (oil tank)
2.Drain bolt (crankcase)Engine oil and oil filter
element replacement
1.Warm up the engine for a few
minutes.
2.Place an oil pan under the
engine.
3.Remove the oil tank cap, drain
bolts.
2
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9 8.Fill the engine with oil. Install the
oil tank cap. 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)
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
cCAfter replacing the engine oil, be
sure to check the oil pressure as
described below.8 8
Remove the air bleed screw
from the oil filter cover.
8 8
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.
8 8
After checking, tighten the air
bleed screw securely.
1
1
EAU01083
Air filterThe 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.Screw (´7)
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EAU00629
Carburetor adjustmentThe carburetor is a vital part of the
engine and requires very sophisticat-
ed 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 mainte-
nance.
EC000094
cCThe carburetor was set at the
Yamaha factory after many tests. If
the settings are changed, poor
engine performance and damage
may result.
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5.Install the air filter with the arrow
mark on the top pointing inward.
6.Install the air filter case cover
and the panel.
EC000082
cC8
8
Make sure the air filter is prop-
erly seated in the air filter
case.
8 8
The engine should never be
run without the air filter
installed. Excessive piston
and/or cylinder wear may
result.
1
3.Remove the air filter.
4.Tap the air filter lightly to remove
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-
aged, replace it.1.Mesh side
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b
a
EAU00632
Idle speed adjustment1.Start the engine and warm it up
for a few minutes at approxi-
mately 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 ato increase
engine speed and in direction b
to decrease engine speed.1.Throttle stop screw
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NOTE:
If the specified idle speed cannot be
obtained by performing the above
adjustment, consult a Yamaha deal-
er.
Standard idle speed:
1,200 ~ 1,400 r/min
(Except for CH)
1,300 ~ 1,400 r/min
(For CH)
EAU00635
Throttle cable free play
inspectionThere should be a free play of 3 ~
5 mm at the throttle grip. If the free
play is incorrect, ask a Yamaha deal-
er to make this adjustment.
a
a.Free play
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* Load is the total weight of cargo, rider, passenger
and accessories.Maximum load*176 kg (XT500E)
180 kg (XT600E)
Cold tire pressure:FrontRear
150 kPa150 kPa
Up to 90 kg(1.5 kg/cm
2, (1.5 kg/cm
2,
1.5 bar)1.5 bar)
90 kg load ~150 kPa225 kPa
Maximum load*(1.5 kg/cm
2, (2.25 kg/cm
2,
1.5 bar) 2.25 bar)
125 kPa125 kPa
Off-road riding(1.25 kg/cm
2, (1.25 kg/cm
2,
1.25 bar) 1.25 bar)
150 kPa150 kPa
High speed riding(1.5 kg/cm
2, (1.5 kg/cm
2,
1.5 bar) 1.5 bar)
EAU00652
TiresTo ensure maximum performance,
long service and safe operation, note
the following:
Tire air pressure
Always check and adjust the tire
pressure before operating the motor-
cycle.
EW000082
wTire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla-
tion pressure must be adjusted
according to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if
approved for this model), and vehi-
cle speed.
EAU00637
Valve clearance adjustmentThe correct valve clearance changes
with use, resulting in improper fuel/air
supply or engine noise. To prevent
this, the valve clearance must be
adjusted regularly. This adjustment
however, should be left to a profes-
sional Yamaha service technician.
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6-16
EW000083
wProper loading of your motorcycle
is important for several character-
istics 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 motorcy-
cle, and distribute the weight even-
ly 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.
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Tire inspection
Always check the tires before operat-
ing 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 immediate-
ly and have the tire replaced.1.Tread depth
2.Side wall
EW000078
wAfter 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 manu-
facture and design.ManufacturerSizeTypeBRIDGESTONE90/90-21 54STW47
DUNLOP90/90-21 54STRAIL MAX LFRONTManufacturerSizeTypeBRIDGESTONE120/90-17 64STW48
DUNLOP120/90-17 64STRAIL MAXREAR
Minimum tire tread
depth 0.8 mm
(front and rear)
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EAU00685
WheelsTo ensure maximum performance,
long service, and safe operation, note
the following:
8Always 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, con-
sult a Yamaha dealer. Do not
attempt even small repairs to the
wheel. If a wheel is deformed or
cracked, it must be replaced.
8Tires 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.
8Ride at moderate speeds after
changing a tire since the tire sur-
face must first be broken in for it
to develop its optimal character-
istics.
EAU00681
w8 8
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 replace-
ment should be left to a
Yamaha Service Technician.
8 8
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.
NOTE:
These limits may be different by regu-
lation from country to country. If so,
conform to the limits specified by the
regulations of your own country.
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a
b 12
3
EAU00694
Clutch lever free play
adjustmentThe 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 ato
increase free play or in direction
bto decrease free play.
3.Tighten the locknut at the clutch
lever.
If the specified free play cannot be
obtained, proceed with the following
steps.1.Locknut
2.Adjusting bolt
3.Free play
b
a
1
2
4.Loosen the locknut at the clutch
lever.
5.Turn the adjusting bolt at the
clutch lever in direction ato
loosen the cable.
6.Loosen the locknut at the
crankcase side.
7.Turn the adjusting nut at the
crankcase in direction ato
increase free play or in direction
bto decrease free play.
8.Tighten the locknut at the
crankcase and the clutch lever.1.Adjusting nut
2.Locknut
EAU00696
Front brake lever free play
adjustmentThe free play at the front brake lever
should be 2 ~ 5 mm.
1.Loosen the locknut.
2.Turn the adjusting bolt in direc-
tion ato increase free play or in
direction bto decrease free
play.
3.After adjusting, tighten the lock-
nut.
1
2
3
b
a
1.Locknut
2.Adjusting bolt
3.Free play
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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.
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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.
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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)
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