clutch YAMAHA XT500E 2002 User Guide

6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03685
Periodic maintenance and lubrication chart
Periodic maintenance and lubrication chartNOTE:
8The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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
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6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
6 6. Remove and replace the oil filter
element.
7. Check the O-rings for damage
and replace them if necessary.
8. Install the oil filter element cover
by installing the bolts, then tight-
ening them to the specified
torque.
NOTE:
Make sure that the O-ring is properly
seated.9. Install the engine oil drain bolts,
and then tighten them to the
specified torques.
10. Add the specified amount of the
recommended engine oil, install
and tighten the oil filler cap, and
then install the oil filler cap cover.
ECA00105
cC8In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives
with the oil or use oils of grade
“CD” or higher. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.
8Make sure that no foreign
material enters the crankcase.
1
2
1. Oil filter element
2. O-ring (×2)
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m0kgf)
Tightening torques:
Engine oil drain bolt
(crankcase):
30 Nm (3.0 m0kgf)
Engine oil drain bolt (oil tank):
18 Nm (1.8 m0kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
2.7 L
With oil filter element
replacement:
2.8 L
Total amount (dry engine):
3.3 L
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6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00694
Adjusting the clutch lever
free playClutch lever free play, adjustingThe clutch lever free play should
measure 10–15 mm as shown.
Periodically check the clutch lever
free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in
direction a. To decrease the
clutch lever free play, turn the
adjusting bolt in direction b.
a
b 12
c1. Locknut (clutch lever)
2. Adjusting bolt
c. Free play
7. Tighten the locknut at the clutch
lever and the crankcase.
3. If the specified clutch lever free
play could be obtained as
described above, tighten the
locknut and skip the rest of the
procedure, otherwise proceed as
follows.
4. Fully turn the adjusting bolt at the
clutch lever in direction ato
loosen the clutch cable.
5. Loosen the locknut at the
crankcase.
6. To increase the clutch lever free
play, turn the adjusting nut in
direction a. To decrease the
clutch lever free play, turn the
adjusting nut in direction b.
b
a
2
1
1. Locknut (crankcase)
2. Adjusting nut
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6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03370
Checking and lubricating the
brake and shift pedalsBrake and shift pedals, checking and lubricatingThe operation of the brake and shift
pedals should be checked before
each ride, and the pedal pivots
should be lubricated if necessary.
EAU03164
Checking and lubricating the
brake and clutch leversBrake and clutch levers, checking and lubricatingThe operation of the brake and clutch
levers should be checked before
each ride, and the lever pivots should
be lubricated if necessary.
EAU03165
Checking and lubricating the
sidestandSidestand, checking and lubricatingThe operation of the sidestand
should be checked before each ride,
and the sidestand pivot and metal-to-
metal contact surfaces should be
lubricated if necessary.
EW000113
wIf the sidestand does not move up
and down smoothly, have a
Yamaha dealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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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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8-2
SPECIFICATIONS
8
Air filterDry type element
Fuel
Type REGULAR UNLEADED
GASOLINE ONLY
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 typeWet, 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 2.533 (XT500E)
3.000 (XT600E)
Number of drive chain 38/15 (XT500E)
sprocket teeth (rear/front) 45/15 (XT600E)
Transmission type Constant mesh 5-speed
Operation Left foot operationGear 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
Front
Type With tube
Size 90/90-21 54S or
90/90-21 M/C 54S
Manufacturer/ BRIDGESTONE / TW47
model DUNLOP / TRAIL MAX L
Rear
Type With tube
Size 120/90-17 64S or
120/90-17 M/C 64S
Manufacturer/ BRIDGESTONE / TW48
model DUNLOP / TRAIL MAX
Maximum load* 176 kg (XT500E)
180 kg (XT600E)
4PT-E7 (English) 6/29/01 9:13 AM Page 89

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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