Fork YAMAHA XT600E 2000 Owners Manual

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
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
9
*Wheels¥Check runout, spoke tightness and for damage.
¥Tighten spokes if necessary.ÖÖÖÖ
10*Tires¥Check tread depth and for damage.
¥Replace if necessary.
¥Check air pressure.
¥Correct if necessary.ÖÖÖÖ
11*Wheel bearings¥Check bearing for looseness or damage.ÖÖÖÖ
12*Swingarm¥Check operation and for excessive play.ÖÖÖÖ
13Drive 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.ÖÖÖÖÖ
¥Lubricate with lithium-soap-based grease.Every 20,000 km
15*Chassis fasteners¥Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖÖ
16Sidestand¥Check operation.
¥Lubricate.ÖÖÖÖÖ
17*Sidestand switch¥Check operation.ÖÖÖÖÖÖ
18*Front fork¥Check operation and for oil leakage.ÖÖÖÖ
19*Shock absorber
assembly¥Check operation and shock absorber for oil leakage.ÖÖÖÖ NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´ 1,000 km)
ANNUAL
CHECK
110203040
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6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00790
Rear suspension lubricationLubricate the pivoting parts.
Recommended lubricant:
Molybdenum disulfide grease
1
1
1.Grease nipple (´2)
Operation check
1.Place the motorcycle on a level
place.
2.Hold the motorcycle in an upright
position and apply the front
brake.
3.Push down hard on the handle-
bars several times and check if
the fork rebounds smoothly.
EC000098
cCIf any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
EAU02939
Front fork inspectionVisual check
EW000115
wSecurely support the motorcycle
so there is no danger of it falling
over.Check for scratches or damage on
the inner tube and excessive oil leak-
age from the front fork.
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 27

EW000115
wSecurely support the motorcycle
so there is no danger of it falling
over.
6-27
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU01144
Wheel bearingsIf there is play in the front or rear
wheel hub or if the wheel does not
turn smoothly, have a Yamaha dealer
inspect the wheel bearings.
EAU00794
Steering inspectionPeriodically inspect the condition of
the steering. Worn out or loose steer-
ing bearings may be dangerous.
Place a stand under the engine to
raise the front wheel off the ground.
Hold the lower end of the front forks
and try to move them forward and
backward. If any free play can be felt,
ask a Yamaha dealer to inspect and
adjust the steering. Inspection is eas-
ier if the front wheel is removed.
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 28

6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
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)
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 35

7-2
8 8
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent
and water to clean plastic.
8 8
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra-
sive cleaning products, sol-
vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec-
trolyte.8 8
Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the
following areas: seals (of
wheel bearings, swingarm
bearings, forks and brakes),
electric components (cou-
plers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
8 8
For motorcycles equipped
with a windshield: Do not use
strong cleaners or hard
sponges as they will cause
dulling or scratching. Some
cleaning compounds for plas-
tic may leave scratches on the
windshield. Test the product
on a small hidden part of the
windshield to make sure they
do not leave any marks. If the
windshield is scratched, use a
quality plastic polishing com-
pound after washing.
After riding in the rain, near the seaor on salt-sprayed roads.Since sea salt or salt sprayed on the
roads in the winter are extremely cor-
rosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads. (Salt sprayed
in the winter may remain on the roads
well into spring.)
1.Clean your motorcycle with cold
water and soap after the engine
has cooled down.
ECA00012
cCDo not use warm water since it
increases the corrosive action of
the salt.2.Be sure to apply a corrosion pro-
tection spray on all (even
chrome- and nickel-plated) metal
surfaces to prevent corrosion.
MOTORCYCLE CARE AND STORAGE
1
2
3
4
5
67
8
9
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SPECIFICATIONS
1
2
3
4
5
6
78
9
Air pressure (cold tire)
up to 90 kg load*
Front150 kPa (1.50 kg/cm
2, 1.50 bar)
Rear150 kPa (1.50 kg/cm2, 1.50 bar)
90 kg load ~ Maximum
load*
Front150 kPa (1.50 kg/cm2, 1.50 bar)
Rear225 kPa (2.25 kg/cm2, 2.25 bar)
Off-road riding
Front125 kPa (1.25 kg/cm2, 1.25 bar)
Rear125 kPa (1.25 kg/cm2, 1.25 bar)
High speed riding
Front150 kPa (1.50 kg/cm2, 1.50 bar)
Rear150 kPa (1.50 kg/cm2, 1.50 bar)
* Load is total weight of cargo, rider, passenger and accessories.
Wheels
Front
TypeSpoke wheel
Size21 ´1.85
Rear
TypeSpoke wheel
Size17 ´MT2.50 Brakes
Front
TypeSingle disc brake
OperationRight hand operation
FluidDOT 3 or DOT 4
Rear
TypeSingle disc brake
OperationRight foot operation
FluidDOT 4
Suspension
Front
TypeTelescopic fork
Rear
TypeSwingarm (new monocross)
Shock absorber
FrontCoil spring/oil damper
RearCoil spring/gas-oil damper
Wheel travel
Front225 mm
Rear200 mm
8-3
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 10

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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