maintenance YAMAHA XT600E 2000 Owner's Guide

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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00800
BatteryThis motorcycle is equipped with a
sealed-type battery. Therefore it is
not necessary to check the elec-
trolyte or fill the battery with distilled
water.
8 8
If the battery seems to have dis-
charged, consult a Yamaha deal-
er.
8 8
If the motorcycle is equipped
with optional electrical acces-
sories, the battery tends to dis-
charge more quickly, so be sure
to recharge it periodically.
EC000101
cCNever try to remove the sealing
caps of the battery cells. The bat-
tery will be damaged.
Battery storage
When the motorcycle is not used for
a month or longer, remove the bat-
tery, fully charge it and store it in a
cool, dry place.
EC000102
cC8
8
Completely recharge the bat-
tery before storing. Storing a
discharged battery can cause
permanent battery damage.
8 8
Use a battery charger
designed for a sealed-type
(MF) battery. Using a conven-
tional battery charger will
cause battery damage. If you
do not have a sealed-type bat-
tery charger, contact your
Yamaha dealer.
8 8
Always make sure the connec-
tions are correct when rein-
stalling the battery.
EW000116
wBattery electrolyte is poisonous
and dangerous, causing severe
burns, etc. It contains sulfuric
acid. Avoid contact with skin, eyes
or clothing.
ANTIDOTE:
8 8
EXTERNAL: Flush with water.
8 8
INTERNAL: Drink large quanti-
ties of water or milk. Follow
with milk of magnesia, beaten
egg, or vegetable oil. Call a
physician immediately.
8 8
EYES: Flush with water for 15
minutes and get prompt med-
ical attention.
Batteries produce explosive
gases. Keep sparks, flame, ciga-
rettes etc., away. Ventilate when
charging or using in an enclosed
space. Always shield your eyes
when working near batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
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EC000103
cCDo not use fuses of higher amper-
age rating than those recommend-
ed. Substitution of a fuse of
improper rating can cause exten-
sive electrical system damage and
possibly a fire.
EAU01146
Headlight bulb replacementThis motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows:
1.Remove cowling A. (See page
6-7 for cowling removal and
installation procedures.)
2.Remove the headlight unit.
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9Specified fuse:
20 A
1
1.Bolt (´3)
1
2
EAU01307
Fuse replacementThe fuse is located behind panel A.
(See page 6-7 for panel removal and
installation procedures.)
If the fuse is blown, turn off the main
switch and the switch of the circuit in
question. Install a new fuse of proper
amperage. Turn on the switches and
see if the electrical device operates.
If the fuse immediately blows again,
consult a Yamaha dealer.1.Main fuse
2.Spare fuse
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2
1
3.Remove the connectors and the
bulb holder cover.1.Connector (´3)
2.Bulb holder cover
5.Put a new bulb into position and
secure it in place with the bulb
holder.
EC000105
cCAvoid touching the glass part of a
bulb. Keep it free from oil; other-
wise, the transparency of the
glass, life of the bulb, and lumi-
nous flux will be adversely affect-
ed. If oil gets on a bulb, thoroughly
clean it with a cloth moistened
with alcohol or lacquer thinner.
4.Turn the bulb holder counter-
clockwise to remove it and
remove the defective bulb.
EW000119
wKeep flammable products and your
hands away from a bulb while it is
on, as it is hot. Do not touch a bulb
until it cools down.
1
1.Bulb holder
1
1.DonÕt touch
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EAU01095
Turn signal light bulb
replacement1.Remove the screw and the lens.2.Remove the defective bulb by
pushing it inward and turning it
counterclockwise.
3.Install a new bulb by pushing it
inward and turning it clockwise.
4.Install the lens and tighten the
screw.
1
2
1.Screw
2.Lens
1
1.Bulb
6.Install the bulb holder cover, con-
nectors and headlight unit.
7.Install the cowling.
8.If the headlight beam adjustment
is necessary, ask a Yamaha
dealer to make that adjustment.
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 32

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EAU01579
Supporting the motorcycleSince the Yamaha XT500E/XT600E
has no centerstand, follow these pre-
cautions when removing the front and
rear wheel or performing other main-
tenance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed
under the engine for added stability.
Front wheel service
To stabilize the rear of the motorcy-
cle, either use a motorcycle stand or
place a motorcycle jack under the
frame in front of the rear wheel to
prevent it from moving from side to
side. Then use a motorcycle stand to
elevate the front wheel off of the
ground.
EAU01623
Taillight bulb replacement1.Remove the screws and the
lens.
21
1.Screw (´2)
2.Lens
2.Remove the defective bulb by
pushing it inward and turning it
counterclockwise.
3.Install a new bulb by pushing it
inward and turning it clockwise.
4.Install the lens and tighten the
screws.
EC000108
cCDo not over-tighten the screws as
the lens may break.
1
1.Bulb
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92.Loosen the wheel axle holder
nuts and wheel axle.
3.Elevate the front wheel by plac-
ing a suitable stand under the
engine.
4.Remove the wheel axle and the
front wheel. Make sure the
motorcycle is properly supported.
NOTE:
Do not depress the brake lever when
the disc and caliper are separated.
1
2
1.Axle holder nut (´4)
2.Wheel axle
EAU00897
Front wheel removal
EW000122
w8
8
It is advisable to have a
Yamaha dealer service the
wheel.
8 8
Securely support the motorcy-
cle so there is no danger of it
falling over.1.Remove the speedometer cable
from the front wheel side.
1
1.Speedometer cable
Rear wheel service
Use a motorcycle stand or motorcycle
jack to elevate the motorcycle so the
rear wheel is off the ground.
Alternatively, two jacks can be placed
under the frame or swingarm.
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9 5.Before tightening the holder nuts,
push down on the handlebars
several times and check if the
fork rebounds smoothly.
6.Tighten the axle holder nuts to
the specified tightening torque.
Tighten the upper nuts first and
then lower ones. When tightened
in this sequence, there should be
a gap formed at the bottom of
the axle holder.
32 1
1.Upper nut (´2)
2.Lower nut (´2)
3.Gap
EAU01135
Front wheel installation1.Install the speedometer gear unit
housing into the wheel hub.
Make sure the speedometer gear
unit housing is installed with the
projections meshed into the
slots.
2.Lift up the wheel between the
front fork legs and guide the
brake disc between the brake
pads. Make sure there is enough
gap between the brake pads
before inserting the brake disc.
3.Make sure the slot in the
speedometer gear unit fits over
the stopper on the front fork
outer tube.
4.Install the wheel axle and tighten
it to the specified torque.
Tightening torque:
Wheel axle:
59 Nm (5.9 m
0kg)
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93.Remove the swingarm end bolts.
4.Elevate the rear wheel by placing
a suitable stand under the
engine.
1
1
1.Swingarm end bolt (´2)
EAU00963*
Rear wheel removal
EW000122
w8
8
It is advisable to have a
Yamaha dealer service the
wheel.
8 8
Securely support the motorcy-
cle so there is no danger of it
falling over.1.Remove the axle nut.
2.Loosen the caliper bracket bolt.
2
1
1.Axle nut
2.Caliper bracket bolt
Tightening torque:
Axle holder nut:
9 Nm (0.9 m
0kg)
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EAU01397
Troubleshooting chart
EW000125
wNever check the fuel system while smoking or in the vicinity of an open flame.1. Fuel
2. Compression
3. Ignition
4. Battery
Use the electric starter.
There is compression.
Go to ignition check.
No compression.
Ask a Yamaha dealer to inspect.Wet.
Dry.Wipe clean with dry cloth and
Ask a Yamaha dealer to inspect.
Check if there is fuel
Enough fuel.
No fuel.
Go to compression check.Supply fuel.
in the fuel tank.
Remove sparkelectrodes. plug and checkOpen throttle half-way and start the
Engine doesn’t start, go to batterycheck. engine. correct spark gap or replace spark plug.
Engine turns over
Engine turns overBattery good.
Check connections
quickly.
slowly.or recharge.Engine doesn’t start, ask a Yamaha
dealer to inspect.
Engine doesn’t start, go to compression check.
Use the electric
starter.
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INDEX
Front brake lever free play
adjustment..........................................6-18
Front fork inspection..............................6-26
Front wheel installation..........................6-34
Front wheel removal..............................6-33
Fuel.........................................................3-6
Fuel cock.................................................3-7
Fuel tank cap...........................................3-6
Fuse replacement..................................6-29
H
Handlebar switches.................................3-3
Dimmer switch......................................3-3
Engine stop switch................................3-4
Horn switch...........................................3-3
Lights switch.........................................3-3
Pass switch...........................................3-3
Start switch...........................................3-4
Turn signal switch.................................3-3
Headlight bulb replacement...................6-29
Helmet holder..........................................3-9
High beam indicator light.........................3-2
Horn switch..............................................3-3
How to use the conversion table.............9-3
I
Identification number records..................9-1
Idle speed adjustment...........................6-14
Indicator lights.........................................3-2
High beam indicator light......................3-2
Neutral indicator light............................3-2
Turn indicator light................................3-2
Inspecting the brake fluid level..............6-21
K
Key identification number........................9-1
L
Lights switch............................................3-3
M
Main switch/Steering lock........................3-1
Model label..............................................9-2
N
Neutral indicator light...............................3-2
P
Panel A, B...............................................6-7
Parking....................................................5-6
Pass switch.............................................3-3
Periodic maintenance and
lubrication chart....................................6-3
Pre-operation check list...........................4-1
R
Rear brake pedal.....................................3-5
Rear brake pedal height adjustment.....6-19
Rear shock absorber adjustment..........3-10
Rear suspension lubrication..................6-26
Rear wheel installation..........................6-36
Rear wheel removal..............................6-35
Recommended shift point
(for Switzerland only)............................5-4
S
Seat.........................................................3-9
Shift pedal ..............................................3-5
Shifting....................................................5-4
Sidestand..............................................3-11
Sidestand lubrication.............................6-25
A
Air filter..................................................6-12
B
Battery...................................................6-28
Brake and clutch lever lubrication.........6-25
Brake and shift pedal lubrication...........6-25
Brake fluid replacement.........................6-22
Brake light switch adjustment................6-20
C
Cable inspection and lubrication...........6-24
Carburetor adjustment...........................6-13
Care.........................................................7-1
Carrier (optional)...................................3-11
Checking the front and rear brake
pads....................................................6-20
Clutch lever.............................................3-4
Clutch lever free play adjustment..........6-18
Cowling A................................................6-7
Cowling and panel removal and
installation.............................................6-6
D
Description..............................................2-1
Dimmer switch.........................................3-3
Drive chain lubrication...........................6-23
Drive chain slack adjustment.................6-23
Drive chain slack check.........................6-22
E
Engine break-in.......................................5-5
Engine oil...............................................6-10
Engine stop switch..................................3-4
F
Front brake lever.....................................3-5
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