check engine light YAMAHA XT500E 2002 Owners Manual

1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch
is set to “#”.
3. Shift the transmission into the
neutral position.NOTE:
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.4. Turn the starter (choke) on and
completely close the throttle.
(See page 3-9 for starter (choke)
operation.)
5. Start the engine by pushing the
start switch.
5-1
EAU00372
OPERATION AND IMPORTANT RIDING POINTS
5
EAU00373
w8Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or func-
tion that you do not thorough-
ly understand.
8Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
8Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU03515
Starting the engineStarting the engineIn order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
8The transmission is in the neutral
position.
8The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
w8Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-13.
8Never ride with the sidestand
down.
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PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ................................................ 6-1
Periodic maintenance and lubrication chart ..... 6-3
Removing and installing the cowling
and panels .................................................... 6-6
Checking the spark plug .................................. 6-8
Engine oil and oil filter element ...................... 6-10
Cleaning the air filter element ........................ 6-13
Adjusting the carburetor ................................. 6-14
Adjusting the engine idling speed ................... 6-15
Adjusting the throttle cable free play .............. 6-16
Adjusting the valve clearance ........................ 6-16
Tires ............................................................... 6-16
Spoke wheels ................................................ 6-19
Adjusting the clutch lever free play ................ 6-20
Adjusting the brake lever free play ................. 6-21
Adjusting the brake pedal position ................. 6-21
Adjusting the rear brake light switch .............. 6-22
Checking the front and rear brake pads ........ 6-22
Checking the brake fluid level ........................ 6-23
Changing the brake fluid ................................ 6-24
Drive chain slack ............................................ 6-25
Lubricating the drive chain ............................. 6-26
Checking and lubricating the cables .............. 6-27Checking and lubricating the throttle grip
and cable .................................................... 6-27
Checking and lubricating the brake and
shift pedals .................................................. 6-28
Checking and lubricating the brake and
clutch levers ................................................ 6-28
Checking and lubricating the sidestand ......... 6-28
Lubricating the rear suspension ..................... 6-29
Checking the front fork ................................... 6-29
Checking the steering .................................... 6-30
Checking the wheel bearings ......................... 6-30
Battery ............................................................ 6-31
Replacing the fuse ......................................... 6-32
Replacing the headlight bulb ......................... 6-33
Replacing a turn signal light bulb ................... 6-35
Replacing the tail/brake light bulb .................. 6-35
Supporting the motorcycle ............................. 6-36
Front wheel ................................................... 6-37
Rear wheel ..................................................... 6-39
Troubleshooting ............................................. 6-41
Troubleshooting chart .................................... 6-42
6
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6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03884
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.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.
•Check oil level and vehicle for oil leakage.√√√√√ √
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 JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
6To check the spark plug
1. Check that the porcelain insula-
tor around the center electrode
of the spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).
NOTE:
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead,
have a Yamaha dealer check the
motorcycle.2. Check the spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and
replace it if necessary.3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4-
1/2 turn past finger tight. However,
the spark plug should be tightened to
the specified torque as soon as pos-
sible.4. Install the spark plug cap. To install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
a
a. Spark plug gap
Specified spark plug:
DPR8EA-9 or
DPR9EA-9 (NGK)
Spark plug gap:
0.8–0.9 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m0kgf)
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6-10
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04354
Engine oil and oil filter
elementEngine oil and oil filter elementThe engine oil level should be
checked before each ride. In addition,
the oil must be changed and the oil
filter element replaced at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
Make sure that the motorcycle is
positioned straight up when checking
the oil level. A slight tilt to the side
can result in a false reading.
4. Wait a few minutes until the oil
settles, remove the oil filler cap,
wipe the dipstick clean, insert it
back into the oil filler hole (with-
out screwing it in), and then
remove it again to check the oil
level.NOTE:
The engine oil should be between the
minimum and maximum level marks.
1
2
3
1. Oil filler cap
2. Maximum level mark
3. Minimum level mark
2. Remove the oil filler cap cover by
removing the screw.
3. Start the engine, warm it up for
at least 10 seconds, and then
turn it off.
2
1
1. Screw
2. Oil filler cap cover
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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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