steering YAMAHA XT500E 2002 Owners Manual

2-3
DESCRIPTION
2
1. Clutch lever (page 3-4, 6-20)
2. Left handlebar switches (page 3-3)
3. Speedometer unit (page 3-2)
4. Main switch/steering lock (page 3-1)
5. Tachometer (page 3-3)6. Right handlebar switches (page 3-4)
7. Brake lever (page 3-5, 6-21)
8. Throttle grip (page 6-16, 6-27)
9. Fuel tank cap (page 3-6)
1
234
5
67
8 9
Controls and instruments
4PT-E7 (English) 6/29/01 9:13 AM Page 12

INSTRUMENT AND CONTROL FUNCTIONSMain switch/steering lock .................................................................. 3-1
Indicator lights .................................................................................. 3-2
Speedometer unit ............................................................................ 3-2
Tachometer ...................................................................................... 3-3
Handlebar switches .......................................................................... 3-3
Clutch lever ....................................................................................... 3-4
Shift pedal ......................................................................................... 3-5
Brake lever ....................................................................................... 3-5
Brake pedal ...................................................................................... 3-5
Fuel tank cap .................................................................................... 3-6
Fuel ................................................................................................... 3-6
Fuel cock .......................................................................................... 3-8
Starter (choke) knob ......................................................................... 3-9
Seat .................................................................................................. 3-9
Helmet holder ................................................................................. 3-10
Adjusting the shock absorber assembly ......................................... 3-10
Sidestand ........................................................................................ 3-11
Ignition circuit cut-off system .......................................................... 3-12
3
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3-1
EAU00029
Main switch/steering lockMain switch/steering lockThe main switch/steering lock con-
trols the ignition and lighting systems,
and is used to lock the steering. The
various positions are described
below.
EAU00036
ON
All electrical systems are supplied
with power, and the engine can be
started. The key cannot be removed.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
EW000016
wNever turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off,
which may result in loss of control
or an accident. Make sure that the
motorcycle is stopped before turn-
ing the key to “OFF” or “LOCK”.
EAU01590
.
(Parking)
The steering is locked, and the tail-
light and auxiliary light are on, but all
other electrical systems are off. The
key can be removed.
The steering must be locked before
the key can be turned to “
.
”.
ECA00043
cCDo not use the parking position for
an extended length of time, other-
wise the battery may discharge.
EAU00027
INSTRUMENT AND CONTROL FUNCTIONS
3
ON
OFF
LOCK.
EAU00040
LOCK
The steering is locked, and all electri-
cal systems are off. The key can be
removed.
To lock the steering1. Turn the handlebars all the way
to the left.
2. Push the key in from the “OFF”
position, and then turn it to
“LOCK” while still pushing it.
3. Remove the key.
To unlock the steeringPush the key in, and then turn it to
“OFF” while still pushing it.
12
1. Push.
2. Turn.
4PT-E7 (English) 6/29/01 9:13 AM Page 14

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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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
8
*Brake hoses•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-5.)Every 4 years
9*Wheels•Check runout, spoke tightness and for damage.
•Tighten spokes if necessary.√√√√
10*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
11*Wheel bearings•Check bearing for looseness or damage.√√√√
12*Swingarm•Check operation and for excessive play.√√√√
13 Drive chain•Check chain slack.
•Make sure that the rear wheel is properly aligned.
•Clean and lubricate.Every 500 km and after washing
the motorcycle or riding in the rain
14*Steering bearings•Check bearing play and steering for roughness.√√√√√
•Lubricate with lithium-soap-based grease.Every 20,000 km
15*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 Sidestand•Check operation.
•Lubricate.√√√√ √
17*Sidestand switch•Check operation.√√√√√ √
18*Front fork•Check operation and for oil leakage.√√√√
19*Shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00794
Checking the steeringSteering, checkingWorn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
wSecurely support the motorcycle
so that there is no danger of it
falling over.
EAU01144
Checking the wheel bearingsWheel bearings, checkingThe front and rear wheel bearings
must be checked at the intervals
specified in the periodic maintenance
and lubrication chart. If there is play
in the wheel hub or if the wheel does
not turn smoothly, have a Yamaha
dealer check the wheel bearings.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any
free play can be felt, have a
Yamaha dealer check or repair
the steering.
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9-1
EAU01039
CONSUMER INFORMATION
9
EAU02944
Identification numbersIdentification numbersRecord the key identification number,
vehicle identification number and
model label information in the spaces
provided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the
vehicle is stolen.
1. KEY IDENTIFICATION
NUMBER:
2. VEHICLE IDENTIFICATION
NUMBER:
3. MODEL LABEL INFORMATION:
EAU01043
Vehicle identification numberVehicle identification numberThe vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro-
vided.NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motor-
cycle with the licensing authority in
your area.
1
1. Vehicle identification number
EAU01041
Key identification numberKey identification numberThe key identification number is
stamped into the key tag.
Record this number in the space pro-
vided and use it for reference when
ordering a new key.
1
1. Key identification number
1
6
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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
4PT-E7 (English) 6/29/01 9:13 AM Page 96

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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