fuel filter YAMAHA XT500E 2002 Owners Manual

3-8
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU03050
Fuel cockFuel cockThe fuel cock supplies fuel from the
tank to the carburetor while filtering it
also.
The fuel cock has three positions:
OFF
With the lever in this position, fuel will
not flow. Always return the lever to
this position when the engine is not
running.
RES
ONFUEL
OFF
1
1. Arrow mark pointing over “OFF”
RES
This indicates reserve. If you run out
of fuel while riding, move the lever to
this position. Fill the tank at the first
opportunity. Be sure to set the lever
back to “ON” after refueling!
OFF
ONFUEL RES
1
RES
1. Arrow mark pointing over “RES”
ON
With the lever in this position, fuel
flows to the carburetor. Normal riding
is done with the lever in this position.
ON
FUEL
RES
OFF
1
ON
1. Arrow mark pointing over “ON”
RES: reserve position
ON: normal position
OFF: closed position
4PT-E7 (English) 6/29/01 9:13 AM Page 21

5-4
OPERATION AND IMPORTANT RIDING POINTS
5
EAU00424
Tips for reducing fuel
consumptionFuel consumption, tips for reducingFuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
8Thoroughly warm up the engine.
8Turn the starter (choke) off as
soon as possible.
8Shift up swiftly, and avoid high
engine speeds during accelera-
tion.
8Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the
engine.
8Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad cross-
ings).
EAU01128
Engine break-inEngine break-inThere is never a more important peri-
od in the life of your engine than the
period between 0 and 1,600 km. For
this reason, you should read the fol-
lowing material carefully.
Since the engine is brand new, do
not put an excessive load on it for the
first 1,600 km. The various parts in
the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheat-
ing must be avoided.
EAU04315
0–1,000 km
Avoid prolonged operation above
4,000 r/min.
1,000–1,600 km
Avoid prolonged operation above
5,000 r/min.
ECA00058
cCAfter 1,000 km of operation, the
engine oil must be changed, and
the oil filter element replaced.1,600 km and beyond
The vehicle can now be operated
normally.
4PT-E7 (English) 6/29/01 9:13 AM Page 35

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
4PT-E7 (English) 6/29/01 9:13 AM Page 40

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
4PT-E7 (English) 6/29/01 9:13 AM Page 88

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
4PT-E7 (English) 6/29/01 9:13 AM Page 96