engine YAMAHA XT600E 2000 User Guide

OPERATION AND IMPORTANT RIDING POINTS
Starting the engine.............................................................................5-1
Starting a warm engine.......................................................................5-3
Shifting................................................................................................5-4
Recommended shift point (for Switzerland only)................................5-4
Tips for reducing fuel consumption.....................................................5-5
Engine break-in..................................................................................5-5
Parking...............................................................................................5-6
5
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 31

5-1
EAU00373
w8 8
Before riding this motorcycle,
become thoroughly familiar
with all operating controls and
their functions. Consult a
Yamaha dealer regarding any
control or function that you do
not thoroughly understand.
8 8
Never start your engine or let
it run for any length of time in
a closed area. The exhaust
fumes are poisonous and can
cause loss of consciousness
and death within a short time.
Always operate your motorcy-
cle in an area with adequate
ventilation.
8 8
Before starting out, always be
sure the sidestand is up.
Failure to retract the sidestand
completely can result in a seri-
ous accident when you try to
turn a corner.
EAU03011
Starting the engineNOTE:
This motorcycle is equipped with an
ignition circuit cut-off system. The
engine can be started only under one
of the following conditions:
8The transmission is in neutral.
8The sidestand is up, the trans-
mission is in gear and the clutch
is disengaged.
The motorcycle must not be ridden
when the sidestand is down.
EW000054
wBefore going through the following
steps, check the function of the
sidestand switch and clutch
switch. (Refer to page 3-12.)
EAU00372
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
45
6
7
8
94PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 32

5-2
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
45
6
7
8
9
IF THE TRANSMISSION IS IN NEUTRAL
AND THE SIDESTAND IS DOWN,
PUSH START SWITCH.THE ENGINE WILL START.RETRACT THE SIDESTAND AND PUT
THE TRANSMISSION IN GEAR.
THE MOTORCYCLE CAN BE RIDDEN.
THE MOTORCYCLE CAN BE RIDDEN.
IF THE TRANSMISSION IS IN GEAR
AND THE SIDESTAND IS UP, PULL IN THE CLUTCH LEVER AND
PUSH THE START SWITCH.
TURN THE MAIN SWITCH TO ÒONÓ AND
THE ENGINE STOP SWITCH TO Ò#Ó.
THE ENGINE WILL START.
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 33

5-3
1.Turn the fuel cock to ÒONÓ.
2.Turn the main switch to ÒONÓ and
the engine stop switch to Ò#Ó.
3.Shift the transmission into neu-
tral.NOTE:
When the transmission is in neutral,
the neutral indicator light should be
on. If the light does not come on, ask
a Yamaha dealer to inspect it.4.Turn on the starter (choke) and
completely close the throttle grip.
5.Start the engine by pushing the
start switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, then
try again. Each attempt should be as
short as possible to preserve the bat-
tery. Do not crank the engine more
than 10 seconds on any one attempt.6.After starting the engine, move
the starter (choke) to the halfway
position.NOTE:
For maximum engine life, never
accelerate hard with a cold engine!7.After warming up the engine,
turn off the starter (choke) com-
pletely.NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
EAU01258
Starting a warm engineThe starter (choke) is not required
when the engine is warm.
EC000046
cCSee the ÒEngine break-inÓ section
prior to operating the motorcycle
for the first time.
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
45
6
7
8
94PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 34

5-4
EAU00423
ShiftingThe transmission lets you control the
amount of power you have available
at a given speed for starting, acceler-
ating, climbing hills, etc. The use of
the shift pedal is shown in the illustra-
tion.
To shift into neutral, depress the shift
pedal repeatedly until it reaches the
end of its travel, then raise the pedal
slightly.
EC000048
cC8
8
Do not coast for long periods
with the engine off, and do not
tow the motorcycle a long dis-
tance. Even with gears in neu-
tral, the transmission is only
properly lubricated when the
engine is running. Inadequate
lubrication may damage the
transmission.
8 8
Always use the clutch when
changing gears. The engine,
transmission, and driveline are
not designed to withstand the
shock of forced shifting and
can be damaged by shifting
without using the clutch.
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
45
6
7
8
9
1
5
4
3
2
N
1
1.Shift pedal
N.Neutral
EAU02941
Recommended shift points
(for Switzerland only)The recommended shift points are
shown in the table below.
Acceleration shift point
(km/h)
1st
®2nd23
2nd ®3rd36
3rd ®4th50
4th ®5th60
NOTE:
When shifting two gears down from
4th to 2nd, bring your motorcycle to a
speed of 35 km/h.
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 35

5-5
EAU00436
Engine break-inThere is never a more important peri-
od in the life of your motorcycle than
the period between zero and 1,000
km. For this reason we ask that you
carefully read the following material.
Because the engine is brand new,
you must not put an excessive load
on it for the first 1,000 km. The vari-
ous parts in the engine wear and pol-
ish themselves to the correct operat-
ing clearances. During this period,
prolonged full throttle operation, or
any condition which might result in
excessive heating of the engine,
must be avoided.
EAU00440
0 ~ 150 km
Avoid operation above 4,000 r/min.
Stop the engine and let it cool for 5 to
10 minutes after every hour of opera-
tion. Vary the speed of the motorcy-
cle from time to time. Do not operate
it at one set throttle position.
150 ~ 500 km
Avoid prolonged operation above
5,000 r/min. Rev the motorcycle
freely through the gears, but do not
use full throttle at any time.
500 ~ 1,000 km
Avoid prolonged full throttle opera-
tion. Avoid cruising speeds in excess
of 6,000 r/min.
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
45
6
7
8
9
EAU00424
Tips for reducing fuel
consumptionYour motorcycleÕs fuel consumption
depends to a large extent on your rid-
ing style. The following tips can help
reduce fuel consumption:
8Warm up the engine before rid-
ing.
8Turn off the starter (choke) as
soon as possible.
8Shift up swiftly and avoid high
engine speeds during accelera-
tion.
8Do not double-clutch or rev the
engine while shifting down and
avoid high engine speeds with
no load on the engine.
8Turn off the engine instead of let-
ting it idle for an extended length
of time, i.e. in traffic jams, at traf-
fic lights or railroad crossings.
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 36

5-6
EC000052
cCAfter 1,000 km of operation, be
sure to replace the engine oil and
oil filter.1,000 km and beyond
Full throttle can be used.
EC000053
cC8
8
Never let engine speeds enter
the red zone.
8 8
If any engine trouble should
occur during the break-in peri-
od, consult a Yamaha dealer
immediately.
EAU00457
ParkingWhen parking the motorcycle, stop
the engine and remove the ignition
key. Turn the fuel cock to ÒOFFÓ
whenever stopping the engine.
EW000058
wThe exhaust system is hot. Park
the motorcycle in a place where
pedestrians or children are not
likely to touch the motorcycle. Do
not park the motorcycle on a slope
or soft ground; the motorcycle
may overturn.OPERATION AND IMPORTANT RIDING POINTS
1
2
3
45
6
7
8
9
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 37

PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit ...................................................................6-1
Periodic maintenance and lubrication chart ...........6-3
Cowling and panel removal and installation...........6-6
Cowling A ...............................................................6-7
Panel A, B ..............................................................6-7
Spark plug ..............................................................6-8
Engine oil .............................................................6-10
Air filter .................................................................6-12
Carburetor adjustment .........................................6-13
Idle speed adjustment ..........................................6-14
Throttle cable free play adjustment ......................6-14
Valve clearance adjustment .................................6-15
Tires .....................................................................6-15
Wheels .................................................................6-17
Clutch lever free play adjustment.........................6-18
Front brake lever free play adjustment ................6-18
Rear brake pedal height adjustment ....................6-19
Brake light switch adjustment ..............................6-20
Checking the front and rear brake pads...............6-20
Inspecting the brake fluid level.............................6-21
Brake fluid replacement .......................................6-22
Drive chain slack check .......................................6-22
Drive chain slack adjustment ...............................6-23Drive chain lubrication............................................6-23
Cable inspection and lubrication ............................6-24
Throttle cable and grip lubrication ..........................6-24
Brake and shift pedal lubrication ............................6-25
Brake and clutch lever lubrication ..........................6-25
Sidestand lubrication..............................................6-25
Rear suspension lubrication...................................6-26
Front fork inspection ..............................................6-26
Steering inspection ................................................6-27
Wheel bearings ......................................................6-27
Battery....................................................................6-28
Fuse replacement ..................................................6-29
Headlight bulb replacement ...................................6-29
Turn signal light bulb replacement .........................6-31
Taillight bulb replacement ......................................6-32
Supporting the motorcycle .....................................6-32
Front wheel removal ..............................................6-33
Front wheel installation ..........................................6-34
Rear wheel removal ...............................................6-35
Rear wheel installation ...........................................6-36
Troubleshooting .....................................................6-36
Troubleshooting chart ............................................6-37
6
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 1

6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
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.ÖÖÖÖ
¥Lubricate with molybdenum disulfide grease.ÖÖ
21*Carburetor¥Check starter (choke) operation.
¥Adjust engine idling speed.ÖÖÖÖÖÖ
22Engine oil¥Change.ÖÖÖÖÖÖ
23Engine oil filter element¥Replace.ÖÖÖ
24*Front and rear brake
switches¥Check operation.ÖÖÖÖÖÖ
25Moving parts and cables¥Lubricate.ÖÖÖÖÖ
26*Lights, signals and
switches¥Check operation.
¥Adjust headlight beam.ÖÖÖÖÖÖ NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´ 1,000 km)
ANNUAL
CHECK
110203040
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 6

Inspection
The spark plug is an important
engine component and is easy to
inspect. The condition of the spark
plug can indicate the condition of the
engine.
The ideal color on the white insulator
around the center electrode is a
medium-to-light tan color for a motor-
cycle that is being ridden normally.
Do not attempt to diagnose such
problems yourself. Instead, take the
motorcycle to a Yamaha dealer. You
should periodically remove and
inspect the spark plug because heat
and deposits will cause any spark
plug to slowly break down and erode.
If electrode erosion becomes exces-
sive, or if carbon and other deposits
are excessive, you should replace
the spark plug with the specified plug.Installation
1.Measure the electrode gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2.Clean the gasket surface. Wipe
off any grime from the threads.
3.Install the spark plug and tighten
it to the specified torque.
NOTE:
If a torque wrench is not available
when you are installing a spark plug,
a good estimate of the correct torque
is 1/4 to 1/2 turn past finger tight.
Have the spark plug tightened to the
specified torque as soon as possible.4.Install the spark plug cap.
6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
Specified spark plug:
DPR8EA-9 or
DPR9EA-9 (NGK)
Spark plug gap:
0.8 ~ 0.9 mmTightening torque:
Spark plug:
17.5 Nm (1.75 m0kg)
1
1.Spark plug gap
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 10