Yamaha XT600E Owners Manual

OWNER’S MANUAL
XT500E
YAMAHA MOTOR CO., LTD.
XT600E
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2001·7–0.9×1(E) !
4PT-28199-E7
4PT-E7 (English) 6/29/01 9:13 AM Page 1
EAU03338
INTRODUCTION
Welcome to the Yamaha world of motorcycling!
As the owner of an XT500E/XT600E, you are benefiting from Yamaha’s vast experience and newest
technology regarding the design and manufacture of high-quality products, which have earned
Yamaha a reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your
XT500E/XT600E. The owner’s manual does not only instruct you in how to operate, inspect and
maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible
condition. If you have any further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
EAU00005
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
Q INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to

w
the motorcycle operator, a bystander, or a person inspecting or repairing the
motorcycle.
cC A CAUTION indicates special precautions that must be taken to avoid damage to

the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
NOTE:
8 This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
8 Yamaha continually seeks advancements in product design and quality. Therefore, while this
manual contains the most current product information available at the time of printing, there
may be minor discrepancies between your motorcycle and this manual. If you have any ques-
tions concerning this manual, please consult your Yamaha dealer.
IMPORTANT MANUAL INFORMATION

EW000002
w
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.
EAU04229
XT500E/XT600E
OWNER’S MANUAL
©2001 by Yamaha Motor Co., Ltd.
1st edition, June 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
EAU00009
TABLE OF CONTENTS
1 GIVE SAFETY THE RIGHT OF WAY 1
2 DESCRIPTION 2
3 INSTRUMENT AND CONTROL FUNCTIONS 3
4 PRE-OPERATION CHECKS 4
5 OPERATION AND IMPORTANT RIDING POINTS 5
6 PERIODIC MAINTENANCE AND MINOR REPAIR 6
7 MOTORCYCLE CARE AND STORAGE 7
8 SPECIFICATIONS 8
9 CONSUMER INFORMATION 9
INDEX
Q GIVE SAFETY THE RIGHT OF WAY
GIVE SAFETY THE RIGHT OF WAY .............................................. 1-1

1
EAU00021
Q GIVE SAFETY THE RIGHT OF WAY

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and free-
dom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
1
Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passen-
gers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic
materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum pro-
tective wear, however, should not encourage carelessness. Although full-coverage helmets and suits,
in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable.
Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is
even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensive-
ly—avoiding all dangers, including those caused by others.
Enjoy your ride!
1-1
DESCRIPTION
Left view ........................................................................................... 2-1

Right view ......................................................................................... 2-2
Controls and instruments .................................................................. 2-3
2
EAU00026
DESCRIPTION
Part locations
Left view
1 2 3 4 5
9 8 7 6
1. Headlight (page 6-33) 6. Shock absorber spring preload

2. Fuel cock (page 3-8) adjusting nut (page 3-10)
3. Battery (page 6-31) 7. Fuse (page 6-32)
4. Owner’s tool kit (page 6-1) 8. Starter (choke) knob (page 3-9)
5. Helmet holder (page 3-10) 9. Shift pedal (page 3-5)
2-1
DESCRIPTION
Right view
10 11 12
13
10. Air filter element (page 6-13)

11. Oil filter element (page 6-11)
12. Engine oil filler cap (page 6-10)
13. Brake pedal (page 3-5, 6-21)
2-2
DESCRIPTION
Controls and instruments
1 2 3 4 5 6 7
9 8
1. Clutch lever (page 3-4, 6-20) 6. Right handlebar switches (page 3-4)
2. Left handlebar switches (page 3-3) 7. Brake lever (page 3-5, 6-21)
3. Speedometer unit (page 3-2) 8. Throttle grip (page 6-16, 6-27)
4. Main switch/steering lock (page 3-1) 9. Fuel tank cap (page 3-6)
5. Tachometer (page 3-3)
2-3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock .................................................................. 3-1

Indicator lights .................................................................................. 3-2
Speedometer unit ............................................................................ 3-2
Tachometer ...................................................................................... 3-3
Handlebar switches .......................................................................... 3-3
Clutch lever ....................................................................................... 3-4 3
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
EAU00027

EW000016
ON w
1 2
OFF Never turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off,
LOCK
which may result in loss of control
. or an accident. Make sure that the
3
motorcycle is stopped before turn-
1. Push. ing the key to “OFF” or “LOCK”.
2. Turn.
EAU00029
EAU00040
Main switch/steering lock EAU01590
Main switch/steering lock
LOCK . (Parking)
The main switch/steering lock con- The steering is locked, and all electri-
trols the ignition and lighting systems, The steering is locked, and the tail-
cal systems are off. The key can be light and auxiliary light are on, but all
and is used to lock the steering. The removed.
various positions are described other electrical systems are off. The
To lock the steering key can be removed.
below. 1. Turn the handlebars all the way
EAU00036 The steering must be locked before
to the left. the key can be turned to “ .”.
ON
2. Push the key in from the “OFF” ECA00043
All electrical systems are supplied
with power, and the engine can be
position, and then turn it to cC
“LOCK” while still pushing it. Do not use the parking position for
started. The key cannot be removed.
EAU00038 3. Remove the key. an extended length of time, other-
OFF wise the battery may discharge.
All electrical systems are off. The key To unlock the steering
can be removed. Push the key in, and then turn it to
“OFF” while still pushing it.
3-1

EAU00057
1 2 1 2
Turn signal indicator light “5”
Turn signal indicator light
This indicator light flashes when the

& N
turn signal switch is pushed to the left 4
5
or right.
3
3 3
1. High beam indicator light “&” 1. Speedometer

2. Neutral indicator light “N” 2. Odometer
3. Turn signal indicator light “5” 3. Tripmeter
EAU00056 4. Reset knob
Indicator lights EAU00095
Indicator lights
Speedometer unit
EAU00063 Speedometer unit
High beam indicator light “&” The speedometer unit is equipped

High beam indicator light
with a speedometer, an odometer
This indicator light comes on when
and a tripmeter. The speedometer
the high beam of the headlight is
shows riding speed. The odometer
switched on.
EAU00061
shows the total distance traveled.
Neutral indicator light “N” The tripmeter shows the distance
Neutral indicator light
traveled since it was last set to zero

This indicator light comes on when
with the reset knob. The tripmeter
the transmission is in the neutral
can be used to estimate the distance
position.
that can be traveled with a full tank of
fuel. This information will enable you
to plan future fuel stops.
3-2

EAU03888
1 2 3
1 Dimmer switch “%/&”
Dimmer switch
Set this switch to “&” for the high

& N
beam and to “%” for the low beam.
a EAU03889
5
Turn signal switch “4/6”

Turn signal switch
*
To signal a right-hand turn, push this
3 switch to “6”. To signal a left-hand
5 4
turn, push this switch to “4”. When
1. Tachometer 1. Light switch “9 /'/:” released, the switch returns to the
a. Red zone 2. Pass switch “&”
3. Dimmer switch “%/&” center position. To cancel the turn
EAU00102
4. Turn signal switch “4/6” signal lights, push the switch in after
Tachometer 5. Horn switch “*”
Tachometer
EAU00118
it has returned to the center position.
The tachometer allows the rider to EAU00129
monitor the engine speed and keep it Handlebar switches

Handlebar switches Horn switch “*”
EAU03898 Horn switch
within the ideal power range. Press this switch to sound the horn.
Light switch “9/'/:”
Light switch
EC000003 Set this switch to “'” to turn on the

cC auxiliary light, meter lighting and tail-
Do not operate the engine in the light. Set the switch to “:” to turn on
tachometer red zone. the headlight also. Set the switch to
Red zone: 7,000 r/min and above “9” to turn off all the lights.
EAU00119
Pass switch “&”

Pass switch
Press this switch to flash the head-

light.
3-3

EAU00143
Start switch “,”

Start switch
Push this switch to crank the engine 1

with the starter.
EC000005
cC
,
1 See page 5-1 for starting instruc-

2 tions prior to starting the engine. 3
1. Engine stop switch “$/#” 1. Clutch lever

2. Start switch “,”
EAU00152
EAU03890
Clutch lever
Engine stop switch “$/#” Clutch lever
Engine stop switch

The clutch lever is located at the left
Set this switch to “#” before starting
handlebar grip. To disengage the
the engine. Set this switch to “$” to
clutch, pull the lever toward the han-
stop the engine in case of an emer-
dlebar grip. To engage the clutch,
gency, such as when the motorcycle
release the lever. The lever should
overturns or when the throttle cable is
be pulled rapidly and released slowly
stuck.
for smooth clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-12 for an explanation of the ignition
circuit cut-off system.)
3-4
1
1 1
1. Shift pedal 1. Brake lever 1. Brake pedal

EAU00157 EAU00158 EAU00162
Shift pedal
Shift pedal
Brake lever
Brake lever
Brake pedal
Brake pedal
The shift pedal is located on the left The brake lever is located at the right The brake pedal is on the right side
side of the engine and is used in handlebar grip. To apply the front of the motorcycle. To apply the rear
combination with the clutch lever brake, pull the lever toward the han- brake, press down on the brake
when shifting the gears of the dlebar grip. pedal.
5-speed constant-mesh transmission
equipped on this motorcycle.
3-5
NOTE:
The fuel tank cap cannot be installed 1
unless the key is in the lock. In addi-
2
a tion, the key cannot be removed if the
b
cap is not properly installed and
locked.
EW000023 3
w
a. Unlock. 1. Filler tube
b. Open. Make sure that the fuel tank cap is 2. Fuel level
EAU00177 properly closed and locked before EAU03753
Fuel tank cap

Fuel tank cap
riding. Fuel
Fuel
Make sure that there is sufficient fuel

To remove the fuel tank cap
in the tank. Fill the fuel tank to the
1. Insert the key into the lock and
bottom of the filler tube as shown.
turn it 1/4 turn counterclockwise. EW000130
2. Turn the fuel tank cap 1/3 turn w
counterclockwise and pull it off.
8 Do not overfill the fuel tank,
otherwise it may overflow
To install the fuel tank cap
when the fuel warms up and
1. Insert the fuel tank cap into the
expands.
tank opening with the key insert-
8 Avoid spilling fuel on the hot
ed in the lock, and then turn the
engine.
cap 1/3 turn clockwise.
2. Turn the key 1/4 turn clockwise,
and then remove it.
3-6

EAU00185 EAU04284
Your Yamaha engine has been
cC
Recommended fuel: designed to use regular unleaded
Immediately wipe off spilled fuel gasoline with a research octane num-
REGULAR UNLEADED
with a clean, dry, soft cloth, since ber of 91 or higher. If knocking (or
GASOLINE ONLY
fuel may deteriorate painted sur- pinging) occurs, use a gasoline of a
Fuel tank capacity:
faces or plastic parts. different brand or premium unleaded
Total amount:
15.0 L fuel. Use of unleaded fuel will extend
3 Reserve amount: spark plug life and reduce mainte-
2.0 L nance costs.
ECA00102
cC
Use only unleaded gasoline. The
use of leaded gasoline will cause
severe damage to internal engine
parts, such as the valves and pis-
ton rings, as well as to the exhaust
system.
3-7

OFF: closed position ON: normal position RES: reserve position
RES
RES
RES
RES
OFF
OFF
OFF
FUEL FUEL
ON 1
ON FUEL
ON
1 ON 1 3
1. Arrow mark pointing over “OFF” 1. Arrow mark pointing over “ON” 1. Arrow mark pointing over “RES”
EAU03050
ON RES
Fuel cock
Fuel cock With the lever in this position, fuel This indicates reserve. If you run out
The fuel cock supplies fuel from the flows to the carburetor. Normal riding of fuel while riding, move the lever to
tank to the carburetor while filtering it is done with the lever in this position. this position. Fill the tank at the first
also. opportunity. Be sure to set the lever
The fuel cock has three positions: back to “ON” after refueling!
OFF
With the lever in this position, fuel will
not flow. Always return the lever to
this position when the engine is not
running.
3-8
1
b a
2
1
3 1
1. Starter (choke) knob “1” 1. Bolt (×2) 1. Projection (×2)

2. Seat holder (×2)
EAU04038 EAU00240
Starter (choke) knob “1” Seat To install the seat

1. Insert the projections on the front
Starter (choke) knob Seat
Starting a cold engine requires a rich- To remove the seat

er air-fuel mixture, which is supplied Remove the bolts, and then pull the of the seat into the seat holders
by the starter (choke). seat off. as shown.
Move the knob in direction a to turn 2. Place the seat in the original
on the starter (choke). position, and then tighten the
Move the knob in direction b to turn bolts.
off the starter (choke).
NOTE:
Make sure that the seat is properly
secured before riding.
3-9
a
2
a b
1
1
A 3
1. Helmet holder 1. Locknut

a. Open. 2. Adjusting nut
EAU00260 EAU03591 2. To increase the spring preload
Helmet holder Adjusting the shock and thereby harden the suspen-
Helmet holder
To open the helmet holder, insert the absorber assembly sion, turn the adjusting nut in
direction a. To decrease the
Shock absorber assembly, adjusting
key into the lock, and then turn the This shock absorber assembly is
key as shown. equipped with a spring preload spring preload and thereby soft-
To lock the helmet holder, place it in adjusting nut. en the suspension, turn the
the original position, and then remove adjusting nut in direction b.
the key. EC000015
EW000030 cC NOTE:
w Never attempt to turn an adjusting
The spring preload setting is deter-
mined by measuring distance A,
Never ride with a helmet attached mechanism beyond the maximum
shown in the illustration. The shorter
to the helmet holder, since the hel- or minimum settings.
distance A is, the lower the spring
met may hit objects, causing loss
preload; the longer distance A is, the
of control and possibly an acci- Adjust the spring preload as follows.
higher the spring preload.
dent. 1. Loosen the locknut.
3-10

EAU00315 EAU00330
Spring preload: w Sidestand
Minimum (soft): Sidestand
This shock absorber contains The sidestand is located on the left

Distance A = 1 mm
highly pressurized nitrogen gas. side of the frame. Raise the side-
Standard:
For proper handling, read and stand or lower it with your foot while
Distance A = 5.5 mm
understand the following informa- holding the motorcycle upright.
Maximum (hard):
tion before handling the shock
Distance A = 12 mm NOTE:
3 absorber. The manufacturer can-
3. Tighten the locknut to the speci- not be held responsible for proper- The built-in sidestand switch is part of
fied torque. ty damage or personal injury that the ignition circuit cut-off system,
may result from improper han- which cuts the ignition in certain situ-
Tightening torque: dling. ations. (See further down for an
Locknut: 8 Do not tamper with or attempt explanation of the ignition circuit cut-
42 Nm (4.2 m0kgf) to open the gas cylinder. off system.)
EC000018 8 Do not subject the shock
cC absorber to an open flame or
Always tighten the locknut against other high heat sources, other-
the adjusting nut, and then tighten wise it may explode due to
the locknut to the specified torque. excessive gas pressure.
8 Do not deform or damage the
gas cylinder in any way, as
this will result in poor damp-
ing performance.
8 Always have a Yamaha dealer
service the shock absorber.
3-11

EW000044 EAU03720 EW000045
w Ignition circuit cut-off w

The motorcycle must not be ridden system
Ignition circuit cut-of system
If a malfunction is noted, have a
with the sidestand down, or if the The ignition circuit cut-off system Yamaha dealer check the system
sidestand cannot be properly (comprising the sidestand switch, before riding.
moved up (or does not stay up), clutch switch and neutral switch) has
otherwise the sidestand could con- the following functions.
tact the ground and distract the 8 It prevents starting when the 3
operator, resulting in a possible transmission is in gear and the
loss of control. Yamaha’s ignition sidestand is up, but the clutch
circuit cut-off system has been lever is not pulled.
designed to assist the operator in 8 It prevents starting when the
fulfilling the responsibility of rais- transmission is in gear and the
ing the sidestand before starting clutch lever is pulled, but the
off. Therefore, check this system sidestand is still down.
regularly as described below and 8 It cuts the running engine when
have a Yamaha dealer repair it if it the transmission is in gear and
does not function properly. the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
3-12
With the engine turned off: NOTE:

1. Move the sidestand down. This check is most reliable if performed with
2. Make sure that the engine stop switch is set to “#”. a warmed-up engine.
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective.
3 YES NO The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
The sidestand switch may be defective.
YES NO The motorcycle should not be ridden until
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The clutch switch may be defective.
YES NO The motorcycle should not be ridden until
The system is OK. The motorcycle can be ridden.
3-13
PRE-OPERATION CHECKS
Pre-operation check list .................................................................... 4-1
4
EAU01114
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list

Pre-operation check list
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel • Refuel if necessary. 3-6–3-7
• Check fuel line for leakage.
4 • Check oil level in engine.
Engine oil • If necessary, add recommended oil to specified level. 6-10–6-13
• Check vehicle for oil leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
Front brake • Adjust if necessary. 3-5, 6-21–6-24
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
Rear brake • Check fluid level in reservoir. 3-5, 6-21–6-24
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
4-1
ITEM CHECKS PAGE
• Lubricate cable if necessary.
Clutch 3-4, 6-20
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
Throttle grip • Check free play. 6-16, 6-27
• If necessary, have Yamaha dealer make adjustment or lubricate.
Control cables 6-27
• Lubricate if necessary.
• Check chain slack.
• Adjust if necessary.
Drive chain 6-25–6-26
• Check chain condition. 4
• Lubricate if necessary.
• Check for damage.
• Check tire condition and tread depth.
Wheels and tires 6-16–6-19
• Check air pressure.
• Correct if necessary.
Brake and shift pedals 6-28
• Lubricate pedal pivoting points if necessary.
Brake and clutch levers 6-28
• Lubricate lever pivoting points if necessary.
Sidestand 6-28
• Lubricate pivot if necessary.
4-2
ITEM CHECKS PAGE
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners —
• Tighten if necessary.
Instruments, lights, signals • Check operation.
3-1–3-4, 6-33–6-36
and switches • Correct if necessary.
• Check operation of ignition circuit cut-off system.
Sidestand switch 3-11–3-13
• If system is defective, have Yamaha dealer check vehicle.
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a
4 very short time; and the added safety it assures is more than worth the time involved.
EWA00033
w
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat-
ing the motorcycle.
4-3
OPERATION AND IMPORTANT RIDING POINTS
Starting the engine ........................................................................... 5-1

Starting a warm engine ..................................................................... 5-2
Shifting .............................................................................................. 5-3
Recommended shift points (for Switzerland only) ............................ 5-3
Tips for reducing fuel consumption .................................................. 5-4
Engine break-in ................................................................................ 5-4
Parking ............................................................................................. 5-5
5
EAU00372

EAU00373 EAU03515
1. Turn the fuel cock lever to “ON”.
w Starting the engine
Starting the engine 2. Turn the key to “ON” and make
8 Become thoroughly familiar In order for the ignition circuit cut-off sure that the engine stop switch
with all operating controls and system to enable starting, one of the is set to “#”.
their functions before riding. following conditions must be met: 3. Shift the transmission into the
Consult a Yamaha dealer 8 The transmission is in the neutral neutral position.
regarding any control or func- position.
tion that you do not thorough- 8 The transmission is in gear with NOTE:
ly understand. the clutch lever pulled and the When the transmission is in the neu-
8 Never start the engine or oper- sidestand up. tral position, the neutral indicator light
ate it in a closed area for any EW000054
should be on, otherwise have a
length of time. Exhaust fumes w Yamaha dealer check the electrical
5
are poisonous, and inhaling 8 Before starting the engine, circuit.
them can cause loss of con- check the function of the igni-
sciousness and death within a tion circuit cut-off system 4. Turn the starter (choke) on and
short time. Always make sure according to the procedure completely close the throttle.
that there is adequate ventila- described on page 3-13. (See page 3-9 for starter (choke)
tion. 8 Never ride with the sidestand operation.)
8 Before starting out, make sure down. 5. Start the engine by pushing the
that the sidestand is up. If the start switch.
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
5-1

EAU01258
NOTE: 7. When the engine is warm, turn
the starter (choke) off. Starting a warm engine
If the engine fails to start, release the Engine, starting a warm
Follow the same procedure as for

start switch, wait a few seconds, and
NOTE: starting a cold engine with the excep-
then try again. Each starting attempt
The engine is warm when it responds tion that the starter (choke) is not
should be as short as possible to pre-
normally to the throttle with the starter required when the engine is warm.
serve the battery. Do not crank the
(choke) turned off.
engine more than 10 seconds on any
one attempt.
6. After starting the engine, move

the starter (choke) knob back
halfway. 5
ECA00055
cC
For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when
the engine is cold!
5-2

EC000048 EAU02941
5
cC Recommended shift points
4 8 Even with the transmission in (for Switzerland only)
3 1 Shift points (for Switzerland only)
2 the neutral position, do not The recommended shift points during

N coast for long periods of time acceleration are shown in the table
1
with the engine off, and do not below.
tow the motorcycle for long
Shift point (km/h)
distances. The transmission is
properly lubricated only when 1st → 2nd 23
1. Shift pedal 2nd → 3rd 36
the engine is running.
N. Neutral position 3rd → 4th 50
EAU00423
Inadequate lubrication may 4th → 5th 60
Shifting damage the transmission.

5 NOTE:
Shifting
8 Always use the clutch while
Shifting gears lets you control the When shifting down two gears at a
changing gears to avoid dam-
amount of engine power available for time, reduce the speed accordingly
aging the engine, transmis-
starting off, accelerating, climbing (e.g., down to 35 km/h when shifting
sion, and drive train, which are
hills, etc. from 4th to 2nd gear).
not designed to withstand the
The gear positions are shown in the
shock of forced shifting.
illustration.
NOTE:
To shift the transmission into the neu-
tral position, press the shift pedal
down repeatedly until it reaches the
end of its travel, and then slightly
raise it.
5-3

EAU00424 EAU01128 EAU04315
Tips for reducing fuel Engine break-in

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

EC000053 EAU00457
cC Parking
Parking
8 Keep the engine speed out of When parking, stop the engine,
the tachometer red zone. remove the key from the main switch,
8 If any engine trouble should and then turn the fuel cock lever to
occur during the engine break- “OFF”.
in period, immediately have a EW000058
Yamaha dealer check the vehi- w

cle. 8 Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely
5
to touch them.
8 Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
5-5
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ................................................ 6-1 Checking and lubricating the throttle grip
Periodic maintenance and lubrication chart ..... 6-3 and cable .................................................... 6-27
Removing and installing the cowling Checking and lubricating the brake and
and panels .................................................... 6-6 shift pedals .................................................. 6-28
Checking the spark plug .................................. 6-8 Checking and lubricating the brake and
Engine oil and oil filter element ...................... 6-10 clutch levers ................................................ 6-28
Cleaning the air filter element ........................ 6-13 Checking and lubricating the sidestand ......... 6-28
Adjusting the carburetor ................................. 6-14 Lubricating the rear suspension ..................... 6-29
Adjusting the engine idling speed ................... 6-15 Checking the front fork ................................... 6-29
Adjusting the throttle cable free play .............. 6-16 Checking the steering .................................... 6-30
Adjusting the valve clearance ........................ 6-16 Checking the wheel bearings ......................... 6-30
Tires ............................................................... 6-16 Battery ............................................................ 6-31
Spoke wheels ................................................ 6-19 Replacing the fuse ......................................... 6-32 6
Adjusting the clutch lever free play ................ 6-20 Replacing the headlight bulb ......................... 6-33
Adjusting the brake lever free play ................. 6-21 Replacing a turn signal light bulb ................... 6-35
Adjusting the brake pedal position ................. 6-21 Replacing the tail/brake light bulb .................. 6-35
Adjusting the rear brake light switch .............. 6-22 Supporting the motorcycle ............................. 6-36
Checking the front and rear brake pads ........ 6-22 Front wheel ................................................... 6-37
Checking the brake fluid level ........................ 6-23 Rear wheel ..................................................... 6-39
Changing the brake fluid ................................ 6-24 Troubleshooting ............................................. 6-41
Drive chain slack ............................................ 6-25 Troubleshooting chart .................................... 6-42
Lubricating the drive chain ............................. 6-26
Checking and lubricating the cables .............. 6-27
EAU00462

EAU00464 EW000060
Safety is an obligation of the owner. w 1

Periodic inspection, adjustment and If you are not familiar with motor-
lubrication will keep your vehicle in cycle maintenance work, have a
the safest and most efficient condi- Yamaha dealer do it for you.
tion possible. The most important
points of inspection, adjustment, and
lubrication are explained on the fol-
lowing pages.
The intervals given in the periodic 1. Owner’s tool kit
maintenance and lubrication chart EAU01175
should be simply considered as a Owner’s tool kit

Tool kit
general guide under normal riding The owner’s tool kit is located behind
conditions. However, DEPENDING panel A. (See page 6-7 for panel
6 ON THE WEATHER, TERRAIN, removal and installation procedures.)
GEOGRAPHICAL LOCATION, AND The service information included in
INDIVIDUAL USE, THE MAINTE- this manual and the tools provided in
NANCE INTERVALS MAY NEED TO the owner’s tool kit are intended to
BE SHORTENED. assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be nec-
essary to perform certain mainte-
nance work correctly.
6-1
NOTE:
If you do not have the tools or experi-
ence required for a particular job,
have a Yamaha dealer perform it for
you.
EW000063
w
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any
changes. 6
6-2

EAU03685
Periodic maintenance and lubrication chart

Periodic maintenance and lubrication chart
NOTE:
8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8 From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
ODOMETER READING (× 1,000 km) ANNUAL

NO. ITEM CHECK OR MAINTENANCE JOB
1 10 20 30 40 CHECK
1 * Fuel line • Check fuel hoses for cracks or damage. √ √ √ √ √
• Check condition.
√ √
2 Spark plug • Clean and regap.
• Replace. √ √
6 3 Valves
• Check valve clearance.
√ √ √ √
* • Adjust.
• Clean. √ √
4 Air filter element
• Replace. √ √
5 Clutch √ √ √ √ √
• Adjust.
• Check operation, fluid level and vehicle for fluid leakage.
√ √ √ √ √ √
6 * Front brake (See NOTE on page 6-5.)
• Replace brake pads. Whenever worn to the limit
• Check operation, fluid level and vehicle for fluid leakage.
√ √ √ √ √ √
7 * Rear brake (See NOTE on page 6-5.)
• Replace brake pads. Whenever worn to the limit
6-3

1 10 20 30 40 CHECK
• Check for cracks or damage. √ √ √ √ √
8 * Brake hoses
• Replace. (See NOTE on page 6-5.) Every 4 years
• Check runout, spoke tightness and for damage.
9 * Wheels √ √ √ √
• Tighten spokes if necessary.
• Check tread depth and for damage.
• Replace if necessary.
10 * Tires √ √ √ √ √
• Check air pressure.
• Correct if necessary.
11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √
12 * Swingarm • Check operation and for excessive play. √ √ √ √
• Check chain slack.
Every 500 km and after washing
13 Drive chain • Make sure that the rear wheel is properly aligned.
the motorcycle or riding in the rain
• Clean and lubricate.
• Check bearing play and steering for roughness. √ √ √ √ √
14 * Steering bearings
• Lubricate with lithium-soap-based grease. Every 20,000 km 6
15 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √
16 Sidestand √ √ √ √ √
• Lubricate.
17 * Sidestand switch • Check operation. √ √ √ √ √ √
18 * Front fork • Check operation and for oil leakage. √ √ √ √
Shock absorber
19 * • Check operation and shock absorber for oil leakage. √ √ √ √
assembly
6-4

1 10 20 30 40 CHECK
Rear suspension relay • Check operation. √ √ √ √
20 * arm and connecting arm
pivoting points • Lubricate with molybdenum disulfide grease. √ √
• Check starter (choke) operation.
21 * Carburetor √ √ √ √ √ √
• Adjust engine idling speed.
• Change.
22 Engine oil √ √ √ √ √ √
• Check oil level and vehicle for oil leakage.
23 Engine oil filter element • Replace. √ √ √
Front and rear brake
24 * • Check operation. √ √ √ √ √ √
switches
25 Moving parts and cables • Lubricate. √ √ √ √ √
Lights, signals and • Check operation.
26 * √ √ √ √ √ √
switches • Adjust headlight beam.
EAU03884
6
NOTE:
8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8 Hydraulic brake service
9 Regularly check and, if necessary, correct the brake fluid level.
9 Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9 Replace the brake hoses every four years and if cracked or damaged.
6-5
1 1
1
1. Cowling A 1. Panel A 1. Panel B

EAU03516
Refer to this section each time the
Removing and installing the cowling or a panel needs to be
cowling and panels
Cowling and panels, removing and instal ing removed and installed.
The cowling and panels shown above
need to be removed to perform some 6
of the maintenance jobs described in
this chapter.
6-6
1
1. Screw 1. Panel A
2. Screw
EAU01145
To install the cowling EAU04003
Cowling A Place the cowling in the original posi- Panels A and B
To remove the cowling tion, and then install the screw. To remove one of the panels
Remove the screw, and then pull the
6 Remove the screw, and then pull the
cowling off as shown.
panel off as shown.
To install the panel

Place the panel in the original posi-
tion, and then install the screw.
6-7
1
1
2
1. Panel B 1. Spark plug cap 1. Spark plug wrench

2. Screw
EAU01833
2. Remove the spark plug as
Checking the spark plug
Spark plug, checking shown, with the spark plug
The spark plug is an important wrench included in the owner’s
engine component, which is easy to tool kit.
check. Since heat and deposits will 6
cause any spark plug to slowly erode,
the spark plug should be removed
and checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug

1. Remove the spark plug cap.
6-8

To check the spark plug 3. Install the spark plug with the
1. Check that the porcelain insula- spark plug wrench, and then
tor around the center electrode tighten it to the specified torque.
of the spark plug is a medium-to-
Tightening torque:
light tan (the ideal color when the
Spark plug:
motorcycle is ridden normally). a 17.5 Nm (1.75 m0kgf)
NOTE:
NOTE:
If the spark plug shows a distinctly
a. Spark plug gap If a torque wrench is not available
different color, the engine could be
when installing a spark plug, a good
defective. Do not attempt to diagnose To install the spark plug estimate of the correct torque is 1/4-
such problems yourself. Instead, 1. Measure the spark plug gap with 1/2 turn past finger tight. However,
have a Yamaha dealer check the a wire thickness gauge and, if the spark plug should be tightened to
motorcycle. necessary, adjust the gap to
6 the specified torque as soon as pos-
specification. sible.
2. Check the spark plug for elec-
trode erosion and excessive car- Spark plug gap:
0.8–0.9 mm 4. Install the spark plug cap.
bon or other deposits, and
replace it if necessary.
2. Clean the surface of the spark
Specified spark plug: plug gasket and its mating sur-
DPR8EA-9 or face, and then wipe off any grime
DPR9EA-9 (NGK) from the spark plug threads.
6-9

EAU04354
Engine oil and oil filter

element
Engine oil and oil filter element
The engine oil level should be

checked before each ride. In addition,
the oil must be changed and the oil 1
1 2
filter element replaced at the intervals
2 3
specified in the periodic maintenance
and lubrication chart.
1. Screw 1. Oil filler cap
2. Oil filler cap cover 2. Maximum level mark
To check the engine oil level 3. Minimum level mark
1. Place the motorcycle on a level 2. Remove the oil filler cap cover by
4. Wait a few minutes until the oil
surface and hold it in an upright removing the screw.
settles, remove the oil filler cap,
position. 3. Start the engine, warm it up for
wipe the dipstick clean, insert it 6
at least 10 seconds, and then
back into the oil filler hole (with-
NOTE: turn it off.
out screwing it in), and then
Make sure that the motorcycle is
remove it again to check the oil
positioned straight up when checking
level.
the oil level. A slight tilt to the side
can result in a false reading. NOTE:
The engine oil should be between the
minimum and maximum level marks.
6-10

EC000000
cC
Do not operate the motorcycle
until you know that the engine oil 1
level is sufficient.
1
2
EW000065
w 2
3
Never remove the engine oil tank
1. Drain bolt (oil tank) 1. Oil filter cover bolt (×2)
cap after high-speed operation, 2. Drain bolt (crankcase) 2. Oil filter cover
otherwise hot engine oil could 3. Oil filter drain bolt
spout out and cause damage or To change the engine oil (with or
4. Check the washers for damage
injury. Always let the engine oil without oil filter element replace-
and replace them if necessary.
cool down sufficiently before ment)
6 1. Start the engine, warm it up for NOTE:
removing the oil tank cap.
several minutes, and then turn it Skip steps 5–8 if the oil filter element
off. is not being replaced.
5. If the engine oil is below the min-
2. Place an oil pan under the
imum level mark, add sufficient
engine to collect the used oil. 5. Remove the oil filter element
oil of the recommended type to
3. Remove the oil filler cap cover, cover by removing the bolts.
raise it to the correct level.
the oil filler cap and the drain NOTE:
6. Install the oil filler cap and the oil
bolts to drain the oil from the The oil filter element cover is secured
filler cap cover.
crankcase and oil tank. by two bolts and a drain bolt. First,
remove the drain bolt to drain the oil
filter element cavity.
6-11

ECA00105
NOTE: cC
1 Make sure that the O-ring is properly
8 In order to prevent clutch slip-
seated.
page (since the engine oil also
lubricates the clutch), do not
9. Install the engine oil drain bolts,
mix any chemical additives
and then tighten them to the
with the oil or use oils of grade
specified torques.
2 “CD” or higher. In addition, do
Tightening torques: not use oils labeled “ENERGY
1. Oil filter element CONSERVING II” or higher.
2. O-ring (×2) Engine oil drain bolt
(crankcase): 8 Make sure that no foreign
6. Remove and replace the oil filter material enters the crankcase.
30 Nm (3.0 m0kgf)
element.
Engine oil drain bolt (oil tank):
7. Check the O-rings for damage
18 Nm (1.8 m0kgf)
and replace them if necessary. Recommended engine oil: 6
8. Install the oil filter element cover 10. Add the specified amount of the See page 8-1.
by installing the bolts, then tight- recommended engine oil, install Oil quantity:
ening them to the specified and tighten the oil filler cap, and Without oil filter element
torque. then install the oil filler cap cover. replacement:
2.7 L
Tightening torque:
With oil filter element
Oil filter element cover bolt:
replacement:
10 Nm (1.0 m0kgf)
2.8 L
Total amount (dry engine):
3.3 L
6-12

12. Start the engine, and then let it 1
1 idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the
engine off and check for the
cause.
1
13. Turn the engine off, and then
check the oil level and correct it if
necessary.
1. Air bleed screw 1. Screw (×7)
EC000076 EAU03514
cC Cleaning the air filter

After changing the engine oil, be element
Air filter element, cleaning
sure to check the oil pressure as The air filter element should be
6 described below. cleaned at the intervals specified in
the periodic maintenance and lubrica-
11. Remove the air bleed screw, and tion chart. Clean the air filter element
then start the engine. If oil does more frequently if you are riding in
not seep out of the hole after a unusually wet or dusty areas.
few minutes, immediately stop 1. Remove panel B. (See page 6-8
the engine and have a Yamaha for panel removal and installation
dealer check for the cause. If oil procedures.)
seeps out of the hole, turn the 2. Remove the air filter case cover
engine off and install the air by removing the screws, and
bleed screw. then pull the air filter element
out.
6-13

EAU00629
1 Adjusting the carburetor
Carburetor, adjusting
The carburetor is an important part of

the engine and requires very sophisti-
cated adjustment. Therefore, most
carburetor adjustments should be left
1 to a Yamaha dealer, who has the
necessary professional knowledge
and experience. The adjustment
1. Mesh side 1. Arrow mark described in the following section,
3. Lightly tap the air filter element to EC000082 however, may be serviced by the
cC owner as part of routine mainte-
remove most of the dust and dirt,
and then blow the remaining dirt 8 Make sure that the air filter ele- nance.
out with compressed air as ment is properly seated in the EC000094
air filter case.

cC 6
shown. If the air filter element is
damaged, replace it. 8 The engine should never be The carburetor has been set and
4. Insert the air filter element into operated without the air filter extensively tested at the Yamaha
the air filter case with the arrow element installed, otherwise factory. Changing these settings
mark on the top pointing inward. the piston and/or cylinder may without sufficient technical knowl-
become excessively worn. edge may result in poor perfor-
mance of or damage to the engine.
5. Install the air filter case cover by
installing the screws.
6. Install the panel.
6-14

EAU00632
NOTE:
Adjusting the engine idling
If the specified idling speed cannot
speed
Engine idling speed
be obtained as described above,
The engine idling speed must be
b have a Yamaha dealer make the
checked and, if necessary, adjusted a adjustment.
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart. 1
1. Start the engine and warm it up
for several minutes at 1,000– 1. Throttle stop screw
2,000 r/min while occasionally 2. Check the engine idling speed

revving it to 4,000–5,000 r/min. and, if necessary, adjust it to
specification by turning the throt-
NOTE: tle stop screw. To increase the
6 The engine is warm when it quickly engine idling speed, turn the
responds to the throttle. screw in direction a. To
decrease the engine idling
speed, turn the screw in direction
b.
Engine idling speed:

1,200–1,400 r/min
(Except for CH)
1,300–1,400 r/min
(For CH)
6-15

EAU00637 EAU04259
Adjusting the valve Tires

Tires
clearance
Valve clearance, adjusting
To maximize the performance, dura-
The valve clearance changes with bility, and safe operation of your
use, resulting in improper air-fuel mix- motorcycle, note the following points
ture and/or engine noise. To prevent regarding the specified tires.
a this from occurring, the valve clear-
ance must be adjusted by a Yamaha Tire air pressure
dealer at the intervals specified in the The tire air pressure should be
a. Throttle cable free play periodic maintenance and lubrication checked and, if necessary, adjusted
EAU00635 chart. before each ride.
Adjusting the throttle cable EW000082
free play w
Throt le cable free play, adjusting
The throttle cable free play should 8 The tire air pressure must be
measure 3–5 mm at the throttle grip. checked and adjusted on cold 6
Periodically check the throttle cable tires (i.e., when the tempera-
free play and, if necessary, have a ture of the tires equals the
Yamaha dealer adjust it. ambient temperature).
8 The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passen-
ger, cargo, and accessories
approved for this model.
6-16

Tire air pressure EWA00012
8 Adjust the suspension and tire
(measured on cold tires) w
air pressure with regard to the
Load* Front Rear
Because loading has an enormous load.
150 kPa 150 kPa
Up to 90 kg (1.50 kgf/cm2, (1.50 kgf/cm2, impact on the handling, braking, 8 Check the tire condition and
1.50 bar) 1.50 bar) performance and safety character- air pressure before each ride.
90 kg–
150 kPa 225 kPa istics of your motorcycle, you
(1.50 kgf/cm2, (2.25 kgf/cm2,
maximum
1.50 bar) 2.25 bar) should keep the following precau-
125 kPa 125 kPa tions in mind.
Off-road riding (1.25 kgf/cm2, (1.25 kgf/cm2, 8 NEVER OVERLOAD THE
1.25 bar) 1.25 bar)
MOTORCYCLE! Operation of
150 kPa 225 kPa
High speed riding (1.50 kgf/cm2, (2.25 kgf/cm2, an overloaded motorcycle may
1.50 bar) 2.25 bar) result in tire damage, loss of
control, or severe injury. Make
176 kg (XT500E)
Maximum load*
180 kg (XT600E)
sure that the total weight of
6 rider, passenger, cargo, and
* Total weight of rider, passenger, cargo and
accessories accessories does not exceed
the specified maximum load
for the vehicle.
8 Do not carry along loosely
packed items, which can shift
during a ride.
8 Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.
6-17

EW000078
NOTE: w
a The tire tread depth limits may differ
8 The front and rear tires should
from country to country. Always com-
be of the same make and
ply with the local regulations.
design, otherwise the handling
1
characteristics of the motorcy-
Tire information
cle cannot be guaranteed.
This motorcycle is equipped with tube
8 After extensive tests, only the
tires.
tires listed below have been
1. Side wall approved for this model by
a. Tire tread depth
Yamaha Motor Co., Ltd.
Tire inspection
The tires must be checked before FRONT
each ride. If the center tread depth Manufacturer Size Type
reaches the specified limit, if the tire 90/90-21 54S 6
BRIDGESTONE TW47
has a nail or glass fragments in it, or 90/90-21 M/C 54S
if the sidewall is cracked, have a 90/90-21 54S

DUNLOP TRAIL MAX L
90/90-21 M/C 54S
Yamaha dealer replace the tire imme-
diately. REAR
Manufacturer Size Type
Minimum tire tread depth
1.6 mm 120/90-17 64S
(front and rear) BRIDGESTONE TW48
120/90-17 M/C 64S
120/90-17 64S
DUNLOP TRAIL MAX
120/90-17 M/C 64S
6-18

EAU00681 EAU00685
8 Ride at moderate speeds after
w Spoke wheels
Wheels changing a tire since the tire sur-
8 Have a Yamaha dealer replace To maximize the performance, dura- face must first be “broken in” for
excessively worn tires. bility, and safe operation of your it to develop its optimal charac-
Besides being illegal, operat- motorcycle, note the following points teristics.
ing the motorcycle with exces- regarding the specified wheels.
sively worn tires decreases 8 The wheel rims should be
riding stability and can lead to checked for cracks, bends or
loss of control. warpage, and the spokes for
8 The replacement of all wheel- looseness or damage before
and brake-related parts, each ride. If any damage is
including the tires, should be found, have a Yamaha dealer
left to a Yamaha dealer, who replace the wheel. Do not
has the necessary profession- attempt even the smallest repair
6 al knowledge and experience. to the wheel. A deformed or
8 It is not recommended to cracked wheel must be replaced.
patch a punctured tube. If 8 The wheel should be balanced
unavoidable, however, patch whenever either the tire or wheel
the tube very carefully and has been changed or replaced.
replace it as soon as possible An unbalanced wheel can result
with a high-quality product. in poor performance, adverse
handling characteristics, and a
shortened tire life.
6-19

7. Tighten the locknut at the clutch
1 2 a b
lever and the crankcase.
b a
c 1 2
1. Locknut (clutch lever) 1. Locknut (crankcase)

2. Adjusting bolt 2. Adjusting nut
c. Free play
EAU00694
3. If the specified clutch lever free
Adjusting the clutch lever play could be obtained as
free play described above, tighten the
Clutch lever free play, adjusting
locknut and skip the rest of the 6
The clutch lever free play should
procedure, otherwise proceed as
measure 10–15 mm as shown.
follows.
Periodically check the clutch lever
4. Fully turn the adjusting bolt at the
free play and, if necessary, adjust it
clutch lever in direction a to
as follows.
loosen the clutch cable.
1. Loosen the locknut at the clutch
5. Loosen the locknut at the
lever.
crankcase.
2. To increase the clutch lever free
6. To increase the clutch lever free
play, turn the adjusting bolt in
play, turn the adjusting nut in
clutch lever free play, turn the
clutch lever free play, turn the
adjusting bolt in direction b.
adjusting nut in direction b.
6-20

3. Tighten the locknut.
EW000099
w
b c
8 After adjusting the brake lever
free play, check the free play a
and make sure that the brake
a is working properly.
1 2
8 A soft or spongy feeling in the
brake lever can indicate the
1. Locknut a. Brake pedal position
2. Adjusting bolt presence of air in the
EAU00712
c. Free play hydraulic system. If there is air
EAU00696
in the hydraulic system, have Adjusting the brake pedal
Adjusting the brake lever a Yamaha dealer bleed the position
Brake pedal position, adjusting
free play system before operating the The top of the brake pedal should be
6 Brake lever free play, adjusting
positioned approximately 12 mm
The brake lever free play should motorcycle. Air in the
measure 2–5 mm as shown. hydraulic system will diminish below the top of the footrest as
Periodically check the brake lever the braking performance, shown. Periodically check the brake
free play and, if necessary, adjust it which may result in loss of pedal position and, if necessary,
as follows. control and an accident. have a Yamaha dealer adjust it.
1. Loosen the locknut at the brake
lever.
2. To increase the brake lever free
play, turn the adjusting bolt in
brake lever free play, turn the
adjusting bolt in direction b.
6-21

EW000109 EAU00721
w Checking the front and rear

A soft or spongy feeling in the 1
brake pads
Front and rear brake pads, checking
brake pedal can indicate the pres- The front and rear brake pads must
ence of air in the hydraulic system. a 2 be checked for wear at the intervals
If there is air in the hydraulic sys- b specified in the periodic maintenance
tem, have a Yamaha dealer bleed and lubrication chart.
the system before operating the
motorcycle. Air in the hydraulic
system will diminish the braking 1. Rear brake light switch
2. Adjusting nut
performance, which may result in EAU00713
loss of control and an accident. Adjusting the rear brake light
switch
Rear brake light switch, adjusting
The rear brake light switch, which is 6

activated by the brake pedal, is prop-
erly adjusted when the brake light
comes on just before braking takes
effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding
the rear brake light switch in place.
To make the brake light come on ear-
lier, turn the adjusting nut in direction
a. To make the brake light come on
later, turn the adjusting nut in direc-
tion b.
6-22
2 FRONT
1
1
1 1
1. Wear indicator groove (×3) 1. Check plug 1. Minimum level mark

2. Wear indicator
EAU03938 EAU03774
EAU04288
Front brake pads Checking the brake fluid
Rear brake pads
Each front brake pad is provided with level
The rear brake is provided with a Brake fluid level, checking
wear indicator grooves, which allow Insufficient brake fluid may allow air
6 check plug, which, if it is removed,
you to check the brake pad wear to enter the brake system, possibly
allows you to check the brake pad
without having to disassemble the causing it to become ineffective.
wear without having to disassemble
brake. To check the brake pad wear, Before riding, check that the brake
the brake. To check the brake pad
check the wear indicator grooves. If a fluid is above the minimum level mark
wear, check the position of the wear
brake pad has worn to the point that and replenish if necessary. A low
indicator while applying the brake. If
the wear indicator grooves have brake fluid level may indicate worn
a brake pad has worn to the point
almost disappeared, have a Yamaha brake pads and/or brake system
that the wear indicator almost touch-
dealer replace the brake pads as a leakage. If the brake level is low, be
es the brake disc, have a Yamaha
set. sure to check the brake pads for
dealer replace the brake pads as a
set. wear and the brake system for leak-
age.
6-23

REAR 8 Refill with the same type of brake EAU03976
fluid. Mixing fluids may result in a Changing the brake fluid

Brake fluid, changing
harmful chemical reaction and Have a Yamaha dealer change the

lead to poor braking perfor- brake fluid at the intervals specified in
1
mance. the NOTE after the periodic mainte-
8 Be careful that water does not nance and lubrication chart. In addi-
enter the brake fluid reservoir tion, have the oil seals of the master
when refilling. Water will signifi- cylinders and calipers as well as the
cantly lower the boiling point of brake hoses replaced at the intervals
1. Minimum level mark listed below or whenever they are
the fluid and may result in vapor
Observe these precautions: lock. damaged or leaking.
8 When checking the fluid level, 8 Brake fluid may deteriorate paint- 8 Oil seals: Replace every two
make sure that the top of the ed surfaces or plastic parts. years.
brake fluid reservoir is level. Always clean up spilled fluid 8 Brake hoses: Replace every four
years. 6
8 Use only the recommended qual- immediately.
ity brake fluid, otherwise the rub- 8 As the brake pads wear, it is nor-
ber seals may deteriorate, caus- mal for the brake fluid level to
ing leakage and poor braking gradually go down. However, if
performance. the brake fluid level goes down
suddenly, have a Yamaha dealer
Recommended brake fluid: check the cause.
DOT 4
6-24

EAU00744
Drive chain slack

Drive chain slack
1
The drive chain slack should be
checked before each ride and adjust-
ed if necessary. a
2 3
To check the drive chain slack b
Checking
1. Place the motorcycle on a level

a
surface and hold it in an upright
a. Drive chain slack 1. Adjusting plate
position. 2. Axle nut
3. Move the rear wheel by pushing 3. Brake caliper bracket bolt
NOTE: the motorcycle to locate the tight- EAU01134
When checking and adjusting the est portion of the drive chain, To adjust the drive chain slack
adjusting
drive chain slack, the motorcycle and then measure the drive 1. Loosen the axle nut and the
6 should be positioned straight up and chain slack as shown. brake caliper bracket bolt.
there should be no weight on it. 2. To tighten the drive chain, turn
Drive chain slack:
the adjusting plate on each side
30–40 mm
2. Shift the transmission into the of the swingarm in direction a.
neutral position. 4. If the drive chain slack is incor- To loosen the drive chain, turn
rect, adjust it as follows. the adjusting plate on each side
of the swingarm in direction b,
and then push the rear wheel for-
ward.
6-25

EAU03006
NOTE: 2. Wipe the drive chain dry.
Lubricating the drive chain 3. Thoroughly lubricate the drive
Make sure that both adjusting plates Drive chain, lubricating
The drive chain must be cleaned and chain with a special O-ring chain
are in the same position for proper
lubricated at the intervals specified in lubricant.
wheel alignment.
the periodic maintenance and lubrica- ECA00052
tion chart, otherwise it will quickly cC

EC000096
cC wear out, especially when riding in Do not use engine oil or any other
dusty or wet areas. Service the drive lubricants for the drive chain, as
Improper drive chain slack will
chain as follows. they may contain substances that
overload the engine as well as EC000097
could damage the O-rings.
other vital parts of the motorcycle cC
and can lead to chain slippage or
The drive chain must be lubricated
breakage. To prevent this from
after washing the motorcycle or
occurring, keep the drive chain
riding in the rain.
slack within the specified limits. 6
1. Clean the drive chain with
3. Tighten the axle nut and the
kerosene and a small soft brush.
brake caliper bracket bolt to the ECA00053
specified torques. cC
Tightening torques: To prevent damaging the O-rings,
Axle nut: do not clean the drive chain with
105 Nm (10.5 m0kgf) steam cleaners, high-pressure
Brake caliper bracket bolt: washers or inappropriate solvents.
48 Nm (4.8 m0kgf)
6-26

EW000112 EAU04034
w Checking and lubricating the

Damage to the outer sheath may throttle grip and cable
Throt le grip and cable, checking and lubricating
interfere with proper cable opera- The operation of the throttle grip
tion and will cause the inner cable should be checked before each ride.
to rust. Replace a damaged cable In addition, the cable should be lubri-
as soon as possible to prevent cated or replaced at the intervals
unsafe conditions. specified in the periodic maintenance
chart.
EAU02962
Checking and lubricating the

cables
Cables, checking and lubricating
The operation of all control cables

6 and the condition of the cables
should be checked before each ride,
and the cables and cable ends
should be lubricated if necessary. If a
cable is damaged or does not move
smoothly, have a Yamaha dealer
check or replace it.
Recommended lubricant:
Engine oil
6-27
EAU03370 EAU03164 EAU03165
Checking and lubricating the Checking and lubricating the Checking and lubricating the
brake and shift pedals
Brake and shift pedals, checking and lubricating
brake and clutch levers
Brake and clutch levers, checking and lubricating
sidestand
Sidestand, checking and lubricating
The operation of the brake and shift The operation of the brake and clutch The operation of the sidestand
pedals should be checked before levers should be checked before should be checked before each ride, 6
each ride, and the pedal pivots each ride, and the lever pivots should and the sidestand pivot and metal-to-
should be lubricated if necessary. be lubricated if necessary. metal contact surfaces should be
lubricated if necessary.
Recommended lubricant: Recommended lubricant: EW000113
Lithium-soap-based grease Lithium-soap-based grease w

(all-purpose grease) (all-purpose grease) If the sidestand does not move up
and down smoothly, have a
Yamaha dealer check or repair it.
Lithium-soap-based grease
(all-purpose grease)
6-28

EAU02939
Checking the front fork

Front fork, checking
The condition and operation of the

front fork must be checked as follows
at the intervals specified in the peri-
1 odic maintenance and lubrication
chart.
1
To check the condition
1. Grease nipple (×2) EW000115
EAU00790
w
To check the operation
Lubricating the rear Securely support the motorcycle 1. Place the motorcycle on a level
suspension
Rear suspension, lubricating
so that there is no danger of it surface and hold it in an upright
The pivoting points of the rear sus- falling over. position.
6 pension must be lubricated at the 2. While applying the front brake,
intervals specified in the periodic Check the inner tubes for scratches, push down hard on the handle-
maintenance and lubrication chart. damage and excessive oil leakage. bars several times to check if the
front fork compresses and
rebounds smoothly.
Molybdenum disulfide grease EC000098
cC
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
6-29

EAU00794 EAU01144
Checking the steering

Steering, checking
Checking the wheel bearings
Wheel bearings, checking
Worn or loose steering bearings may The front and rear wheel bearings
cause danger. Therefore, the opera- must be checked at the intervals
tion of the steering must be checked specified in the periodic maintenance
as follows at the intervals specified in and lubrication chart. If there is play
the periodic maintenance and lubrica- in the wheel hub or if the wheel does
tion chart. not turn smoothly, have a Yamaha
1. Place a stand under the engine dealer check the wheel bearings.
to raise the front wheel off the
ground. 2. Hold the lower ends of the front
EW000115
fork legs and try to move them
w
forward and backward. If any
Securely support the motorcycle free play can be felt, have a
so that there is no danger of it 6
Yamaha dealer check or repair
falling over. the steering.
6-30

EAU00800 EW000116
8 KEEP THIS AND ALL BATTER-
Battery w
Battery IES OUT OF THE REACH OF
This motorcycle is equipped with a 8 Electrolyte is poisonous and CHILDREN.
sealed-type (MF) battery, which does dangerous since it contains
not require any maintenance. There sulfuric acid, which causes
is no need to check the electrolyte or severe burns. Avoid any con-
to add distilled water. tact with skin, eyes or clothing
EC000101
and always shield your eyes
cC when working near batteries.
Never attempt to remove the bat- In case of contact, administer
tery cell seals, as this would per- the following FIRST AID.
manently damage the battery. 9 EXTERNAL: Flush with plen-
ty of water.
9 INTERNAL: Drink large quan-
6 tities of water or milk and
immediately call a physician.
9 EYES: Flush with water for
15 minutes and seek prompt
medical attention.
8 Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes,
etc., away from the battery and
provide sufficient ventilation
when charging it in an
enclosed space.
6-31

EC000102
To charge the battery
cC
Have a Yamaha dealer charge the
battery as soon as possible if it 8 Always keep the battery 1
seems to have discharged. Keep in charged. Storing a discharged
mind that the battery tends to dis- battery can cause permanent
2
charge more quickly if the motorcycle battery damage.
is equipped with optional electrical 8 To charge a sealed-type (MF)
accessories. battery, a special (constant-
voltage) battery charger is
required. Using a conventional 1. Fuse
To store the battery 2. Spare fuse
1. If the motorcycle will not be used battery charger will damage EAU01307
for more than one month, the battery. If you do not have Replacing the fuse
remove the battery, fully charge access to a sealed-type (MF) Fuse, replacing
The fuse holder is located behind

it, and then place it in a cool, dry battery charger, have a
panel A. (See page 6-7 for panel 6
place. Yamaha dealer charge your
removal and installation procedures.)
2. If the battery will be stored for battery.
If the fuse is blown, replace it as fol-
more than two months, check it lows.
at least once a month and fully 1. Turn the key to “OFF” and turn
charge it if necessary. off all electrical circuits.
3. Fully charge the battery before 2. Remove the blown fuse, and
installation. then install a new fuse of the
4. After installation, make sure that specified amperage.
the battery leads are properly
connected to the battery termi- Specified fuse:
nals. 20 A
6-32

EC000103
cC 1
3 2
Do not use a fuse of a higher
amperage rating than recommend- 1
ed to avoid causing extensive
damage to the electrical system
and possibly a fire.
3. Turn the key to “ON” and turn on

1. Bolt (×3) 1. Headlight coupler
the electrical circuits to check if 2. Auxiliary light lead (×2)
EAU01146
the devices operate. 3. Headlight bulb cover
4. If the fuse immediately blows Replacing the headlight bulb
Headlight bulb, replacing 3. Disconnect the headlight coupler
again, have a Yamaha dealer This motorcycle is equipped with a and the auxiliary light leads, and
check the electrical system. quartz bulb headlight. If the headlight then remove the headlight bulb
6 bulb burns out, replace it as follows. cover.
1. Remove cowling A. (See page
6-7 for cowling removal and
installation procedures.)
2. Remove the headlight unit by
removing the bolts.
6-33

6. Install the bulb cover, and then
connect the coupler and leads.
1
a 7. Install the headlight unit by
installing the bolts.
8. Install the cowling.
9. Have a Yamaha dealer adjust
the headlight beam if necessary.
1. Headlight bulb holder a. Do not touch this area.
4. Remove the headlight bulb hold- 5. Place a new bulb into position,
er by turning it counterclockwise, and then secure it with the bulb
and then remove the defective holder.
bulb. EC000105
EW000119 cC 6
w Do not touch the glass part of the
Headlight bulbs get very hot. headlight bulb to keep it free from
Therefore, keep flammable prod- oil, otherwise the transparency of
ucts away from a lit headlight bulb, the glass, the luminosity of the
and do not touch the bulb until it bulb, and the bulb life will be
has cooled down. adversely affected. Thoroughly
clean off any dirt and fingerprints
on the headlight bulb using a cloth
moistened with alcohol or thinner.
6-34
1
1
2 1
2
1. Screw 1. Bulb 1. Screw (×2)
2. Lens 2. Lens
EAU03497 2. Remove the defective bulb by EAU01623
Replacing a turn signal light pushing it in and turning it coun- Replacing the tail/brake light
bulb terclockwise. bulb
Turn signal light bulb, replacing Tail/brake light bulb, replacing
1. Remove the turn signal light lens 3. Insert a new bulb into the socket, 1. Remove the tail/brake light lens
6
by removing the screw. push it in, and then turn it clock- by removing the screws.
wise until it stops.
4. Install the lens by installing the
screw.
ECA00065
cC
Do not overtighten the screw, oth-
erwise the lens may break.
6-35

EAU01579
To service the rear wheel
Supporting the motorcycle Raise the rear wheel off the ground
1 Supporting the motorcycle
Since this model is not equipped with by using a motorcycle stand or, if a
a centerstand, follow these precau- motorcycle stand is not available, by
tions when removing the front and placing a jack either under each side
rear wheel or performing other main- of the frame in front of the rear wheel
tenance requiring the motorcycle to or under each side of the swingarm.
stand upright. Check that the motor-
cycle is in a stable and level position
1. Bulb before starting any maintenance. A
2. Remove the defective bulb by strong wooden box can be placed
pushing it in and turning it coun- under the engine for added stability.
terclockwise.
3. Insert a new bulb into the socket, To service the front wheel
1. Stabilize the rear of the motorcy- 6
push it in, and then turn it clock-
wise until it stops. cle by using a motorcycle stand
4. Install the lens by installing the or, if an additional motorcycle
screws. stand is not available, by placing
EC000108 a jack under the frame in front of
cC the rear wheel.
Do not overtighten the screws, 2. Raise the front wheel off the
otherwise the lens may break. ground by using a motorcycle
stand.
6-36
1
1
2
1. Speedometer cable 1. Wheel axle holder nut (×4) 1. Speedometer gear unit
2. Wheel axle
EAU00897 EAU03555
Front wheel 2. Loosen the wheel axle holder To install the front wheel
nuts, then the wheel axle.
Removing Instal ing
To remove the front wheel 1. Install the speedometer gear unit

EW000122 3. Lift the front wheel off the ground into the wheel hub so that the
6 w according to the procedure on projections mesh with the slots.
8 It is advisable to have a page 6-36. 2. Lift the wheel up between the
Yamaha dealer service the 4. Pull the wheel axle out, and then fork legs.
wheel. remove the wheel.
ECA00048
8 Securely support the motorcy- cC
cle so that there is no danger
of it falling over. Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
1. Disconnect the speedometer
brake pads will be forced shut.
cable from the front wheel.
6-37

7. After tightening the holder nuts,
while applying the front brake,
1 push down on the handlebars
several times to check if the front
2 fork compresses and rebounds
a smoothly.
8. Connect the speedometer cable.
1
1. Retainer 1. Upper nut (×2)
2. Lower nut (×2)
NOTE: a. Gap
Make sure that there is enough 6. Tighten the axle holder nuts to
space between the brake pads the specified tightening torque.
before inserting the brake disc and Tighten the upper nuts first and
6
that the slot in the speedometer gear then lower ones. When tightened
unit fits over the retainer on the fork in this sequence, there should be
leg. a gap formed at the bottom of
the axle holder.
3. Install the wheel axle. Tightening torque:
4. Lower the front wheel so that it is Axle holder nut:
on the ground. 9 Nm (0.9 m0kgf)
5. Tighten the wheel axle to the
specified torque.
Tightening torque:
Wheel axle:
59 Nm (5.9 m0kgf)
6-38
1 1
1
a
1 2
1. Axle nut 1. Swingarm end bolt (×2) 1. Chain adjusting plate

2. Brake caliper bracket bolt
EAU04314 3. Lift the rear wheel off the ground 5. Turn the drive chain adjusting
Rear wheel according to the procedure on plate on each side of the
page 6-36. swingarm fully in direction a.
To remove the rear wheel 4. Remove the swingarm end bolts.
6
EW000122
w
8 It is advisable to have a
Yamaha dealer service the
wheel.
8 Securely support the motorcy-
cle so that there is no danger
of it falling over.
1. Remove the axle nut.

2. Loosen the brake caliper bracket
bolt.
6-39

ECA00048 EAU01136
cC To install the rear wheel

Instal
Do not apply the brake after the 1. Install the drive chain onto the
wheel has been removed together rear sprocket, and then insert the
with the brake disc, otherwise the wheel axle from the left-hand
brake pads will be forced shut. side.
NOTE:
8 Make sure that there is enough
space between the brake pads
6. Push the wheel forward, and before inserting the brake disc
then remove the drive chain from between the brake pads.
the rear sprocket. 8 Make sure that the drive chain
adjusting plates are installed with
NOTE: the punched sides facing to the 6
The drive chain does not need to be outside.
disassembled in order to remove and
install the wheel. 2. Install the swingarm end bolts.
3. Adjust the drive chain slack.
7. Pull the wheel axle out, and then (See page 6-25 for drive chain
remove the wheel. slack adjustment procedures.)
4. Tighten the axle nut, brake
caliper bracket bolt and
swingarm end bolts to the speci-
fied torques.
6-40

EAU01008
Tightening torque: Troubleshooting
Axle nut: Troubleshooting
Although Yamaha motorcycles

105 Nm (10.5 m0kgf)
receive a thorough inspection before
Brake caliper bracket bolt:
shipment from the factory, trouble
48 Nm (4.8 m0kgf)
may occur during operation. Any
Swingarm end bolt:
problem in the fuel, compression, or
2.5 Nm (0.25 m0kgf)
ignition systems, for example, can
cause poor starting and loss of
power.
The following troubleshooting chart
represents a quick and easy proce-
dure for checking these vital systems
yourself. However, should your
6 motorcycle require any repair, take it
to a Yamaha dealer, whose skilled
technicians have the necessary tools,
experience, and know-how to service
the motorcycle properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life
and can lead to expensive repair
bills.
6-41

EAU01397
Troubleshooting chart
Troubleshooting chart
EW000125
w
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel Enough fuel Go to compression check.
Check if there is fuel

in the fuel tank.
Engine doesn’t start, go to
No fuel Supply fuel.
compression check.
2. Compression There is compression. Go to ignition check.

Use electric starter.
No compression. Ask a Yamaha dealer to inspect. 6
3. Ignition
Wipe clean with dry cloth and Open throttle half-way and start the
Wet.
Remove spark correct spark gap or replace spark plug. engine.
plug and check
electrodes.
Dry. Ask a Yamaha dealer to inspect. Engine doesn’t start, go to battery
check.
4. Battery
Engine turns over
Battery good.
quickly.
Use the electric Engine doesn’t start, ask a Yamaha
starter. dealer to inspect.
Engine turns over Check connections
slowly. or recharge.
6-42
MOTORCYCLE CARE AND STORAGE
Care .................................................................................................. 7-1

Storage ............................................................................................. 7-4
7
EAU03521

Before cleaning Cleaning
Care
Care
1. Cover the muffler outlet with a ECA00010
While the open design of a motorcy- plastic bag after the engine has cC
cle reveals the attractiveness of the cooled down. 8 Avoid using strong acidic
technology, it also makes it more vul- 2. Make sure that all caps and cov- wheel cleaners, especially on
nerable. Rust and corrosion can ers as well as all electrical cou- spoked wheels. If such prod-
develop even if high-quality compo- plers and connectors, including ucts are used on hard-to-
nents are used. A rusty exhaust pipe the spark plug cap, are tightly remove dirt, do not leave the
may go unnoticed on a car, however, installed. cleaner on the affected area
it detracts from the overall appear- 3. Remove extremely stubborn dirt, any longer than instructed.
ance of a motorcycle. Frequent and like oil burnt onto the crankcase, Also, thoroughly rinse the area
proper care does not only comply with a degreasing agent and a off with water, immediately dry
with the terms of the warranty, but it brush, but never apply such it, and then apply a corrosion
will also keep your motorcycle looking products onto seals, gaskets, protection spray.
good, extend its life and optimize its sprockets, the drive chain and 8 Improper cleaning can damage
performance. wheel axles. Always rinse the dirt windshields, cowlings, panels
7 and degreaser off with water. and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent
and water to clean plastic.
7-1

8 Do not use any harsh chemical 8 For motorcycles equipped After riding in the rain, near the sea
products on plastic parts. Be with a windshield: Do not use or on salt-sprayed roads
sure to avoid using cloths or strong cleaners or hard Since sea salt or salt sprayed on
sponges which have been in sponges as they will cause roads during winter are extremely
contact with strong or abra- dulling or scratching. Some corrosive in combination with water,
sive cleaning products, sol- cleaning compounds for plas- carry out the following steps after
vent or thinner, fuel (gasoline), tic may leave scratches on the each ride in the rain, near the sea or
rust removers or inhibitors, windshield. Test the product on salt-sprayed roads.
brake fluid, antifreeze or elec- on a small hidden part of the
trolyte. windshield to make sure that it NOTE:
8 Do not use high-pressure does not leave any marks. If Salt sprayed on roads in the winter
washers or steam-jet cleaners the windshield is scratched, may remain well into spring.
since they cause water seep- use a quality plastic polishing
age and deterioration in the compound after washing. 1. Clean the motorcycle with cold
following areas: seals (of water and a mild detergent, after
wheel and swingarm bearings, After normal use the engine has cooled down.
fork and brakes), electric com- ECA00012 7
Remove dirt with warm water, a mild
ponents (couplers, connec-
cC
detergent, and a soft, clean sponge,
tors, instruments, switches and then rinse thoroughly with clean Do not use warm water since it
and lights), breather hoses water. Use a toothbrush or bottle- increases the corrosive action of
and vents. brush for hard-to-reach areas. the salt.
Stubborn dirt and insects will come
off more easily if the area is covered 2. Apply a corrosion protection
with a wet cloth for a few minutes spray on all metal, including
before cleaning. chrome- and nickel-plated, sur-
faces to prevent corrosion.
7-2

ECA00013
After cleaning 8. Let the motorcycle dry complete-
cC
1. Dry the motorcycle with a ly before storing or covering it.
chamois or an absorbing cloth. EWA00001 8 Apply spray oil and wax spar-
2. Immediately dry the drive chain w ingly and make sure to wipe
and lubricate it to prevent it from 8 Make sure that there is no oil off any excess.
rusting. or wax on the brakes or tires. 8 Never apply oil or wax to any
3. Use a chrome polish to shine If necessary, clean the brake rubber and plastic parts, but
chrome, aluminum and stainless- discs and brake linings with a treat them with a suitable care
steel parts, including the exhaust regular brake disc cleaner or product.
system. (Even the thermally acetone, and wash the tires 8 Avoid using abrasive polish-
induced discoloring of stainless- with warm water and a mild ing compounds as they will
steel exhaust systems can be detergent. wear away the paint.
removed through polishing.) 8 Before operating the motorcy-
4. To prevent corrosion, it is recom- cle test its braking perfor- NOTE:
mended to apply a corrosion pro- mance and cornering behav- Consult a Yamaha dealer for advice
tection spray on all metal, includ- ior. on what products to use.
7 ing chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal
cleaner to remove any remaining
dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
7-3

Storage Long-term c. Install the spark plug cap onto
Before storing your motorcycle for the spark plug, and then place
Storage
Short-term
Always store your motorcycle in a several months: the spark plug on the cylinder
cool, dry place and, if necessary, pro- 1. Follow all the instructions in the head so that the electrodes
tect it against dust with a porous “Care” section of this chapter. are grounded. (This will limit
cover. 2. For motorcycles equipped with a sparking during the next step.)
ECA00014 fuel cock that has an “OFF” posi- d. Turn the engine over several
cC tion: Turn the fuel cock lever to times with the starter. (This
8 Storing the motorcycle in a “OFF”. will coat the cylinder wall with
poorly ventilated room or cov- 3. Drain the carburetor float cham- oil.)
ering it with a tarp, while it is ber by loosening the drain bolt; e. Remove the spark plug cap
still wet, will allow water and this will prevent fuel deposits from the spark plug, and then
humidity to seep in and cause from building up. Pour the install the spark plug and the
rust. drained fuel into the fuel tank. spark plug cap.
8 To prevent corrosion, avoid 4. Fill up the fuel tank and add fuel EWA00003
stabilizer (if available) to prevent w

damp cellars, stables (because
the fuel tank from rusting and the To prevent damage or injury from 7
of the presence of ammonia)
and areas where strong chemi- fuel from deteriorating. sparking, make sure to ground the
cals are stored. 5. Perform the following steps to spark plug electrodes while turn-
protect the cylinder, piston rings, ing the engine over.
etc. from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine
oil into the spark plug bore.
7-4

6. Lubricate all control cables and 9. Remove the battery and fully
the pivoting points of all levers charge it. Store it in a cool, dry
and pedals as well as of the place and charge it once a
sidestand/centerstand. month. Do not store the battery
7. Check and, if necessary, correct in an excessively cold or warm
the tire air pressure, and then lift place (less than 0 °C) or more
the motorcycle so that both of its than 30 °C). For more informa-
wheels are off the ground. tion on storing the battery, see
Alternatively, turn the wheels a page 6-32.
little every month in order to pre-
vent the tires from becoming NOTE:
degraded in one spot. Make any necessary repairs before
8. Cover the muffler outlet with a storing the motorcycle.
plastic bag to prevent moisture
from entering it.
7-5
SPECIFICATIONS
Specifications ................................................................................... 8-1

Conversion table ............................................................................... 8-5
8
EAU01038
SPECIFICATIONS
Specifications
Specifications
Engine oil
Model XT500E/XT600E Type
–20° –10° 0° 10° 20° 30° 40° 50°C
Dimensions
Overall length 2,220 mm SAE 10W/30
2.295 mm (N, S, CH only)
SAE 10W/40
Overall width 865 mm
825 mm (CH only) SAE 15W/40
Overall height 1,205 mm SAE 20W/40

Seat height 855 mm SAE 20W/50
Wheel base 1,440 mm
Recommended engine oil
Ground clearance 230 mm classification API Service SE, SF, SG type
Minimum turning radius 2,300 mm or higher
Basic weight (with oil and full
fuel tank) 176 kg cC
172 kg (CH only) Be sure to use motor oils that do not contain anti-friction
Engine
modifiers. Passenger car motor oils (often labeled
Engine type Air-cooled 4-stroke, SOHC, “ENERGY CONSERVING II”) contain anti-friction additives
gasoline which will cause clutch and/or starter clutch slippage, result-
8
Cylinder arrangement Forward inclined single ing in reduced component life and poor engine performance.
cylinder
Displacement 499 cm3
595 cm3 Capacity
Bore × Stroke 87.0 × 84.0 mm (XT500E) Without oil filter element

95.0 × 84.0 mm (XT600E) replacement 2.7 L
Compression ratio 8.5:1 With oil filter element

replaced 2.8 L
Starting system Electric starter
Total amount (dry engine) 3.3 L
Lubrication system Dry sump
8-1
SPECIFICATIONS
Air filter Dry type element Gear ratio 1st 2.583

Fuel 2nd 1.588
Type REGULAR UNLEADED 3rd 1.200
GASOLINE ONLY
4th 0.954 (XT500E)
Fuel tank capacity 15 L 0.955 (XT600E)
Reserve amount 2L 5th 0.792
Carburetor Chassis
Type×quantity Y26PV×1 Frame type Diamond
Manufacturer TEIKEI Caster angle 27.75° (XT500E)
27°45’ (XT600E)
Spark plug
Trail 120 mm
Type/Manufacturer DPR8EA-9 or DPR9EA-9/NGK
Tire
Spark plug gap 0.8–0.9 mm
Front
Clutch type Wet, multiple-disc
Type With tube
Transmission
Size 90/90-21 54S or
Primary reduction system Spur gear 90/90-21 M/C 54S
Primary reduction ratio 74/31 (2.387) (XT500E) Manufacturer/ BRIDGESTONE / TW47 8
71/34 (2.088) (XT600E) model DUNLOP / TRAIL MAX L
Secondary reduction system Chain drive Rear
Secondary reduction ratio 2.533 (XT500E) Type With tube
3.000 (XT600E)
Size 120/90-17 64S or
Number of drive chain 38/15 (XT500E) 120/90-17 M/C 64S
sprocket teeth (rear/front) 45/15 (XT600E)
Manufacturer/ BRIDGESTONE / TW48
Transmission type Constant mesh 5-speed model DUNLOP / TRAIL MAX
Operation Left foot operation Maximum load* 176 kg (XT500E)
180 kg (XT600E)
8-2
SPECIFICATIONS
Air pressure (cold tire) Brakes

up to 90 kg load* Front
Front 150 kPa (1.50 kgf/cm2, 1.50 bar) Type Single disc brake
Rear 150 kPa (1.50 kgf/cm2, 1.50 bar) Operation Right hand
90 kg load–Maximum Fluid DOT 4
load*
Rear
Front 150 kPa (1.50 kgf/cm2, 1.50 bar)
Type Single disc brake
Rear 225 kPa (2.25 kgf/cm2, 2.25 bar)
Operation Right foot
Off-road riding
Fluid DOT 4
Suspension
Front
High speed riding
Type Telescopic fork
Rear
Type Swingarm (new monocross)
* Total weight of rider, passenger, cargo and accessories
Shock absorber
Wheels
8 Front Coil spring/oil damper
Front
Rear Coil spring/gas-oil damper
Type Spoke wheel
Wheel travel
Size 21 × 1.85
Front 225 mm
Rear
Rear 200 mm
Type Spoke wheel
Size 17 × MT2.50 or
17 M/C × MT2.50
8-3
SPECIFICATIONS
Electrical
Ignition system T.C.I. (Digital)
Charging system
Type A.C. magneto
Standard output 14 V, 13.5A @ 5,000 rpm
Battery
Type YTX9-BS
Voltage, capacity 12 V, 8 AH
Headlight bulb type Halogen bulb
Bulb voltage, wattage × quantity
Headlight 12 V, 60/55W × 1
Tail/brake light 12 V, 5/21W × 1
Auxiliary light 12 V, 4W × 1
12 V, 3.4W × 1 (GB only)
Front flasher light 12 V, 21W × 2
Rear flasher light 12 V, 21W × 2 8
Meter lighting 12 V, 3.4W × 1
Neutral indicator light 12 V, 3.4W × 1
High beam indicator light 12 V, 3.4W × 1
Turn indicator light 12 V, 3.4W × 1
Fuse 20A
8-4
SPECIFICATIONS
EAU03941
Conversion table
Conversion table
CONVERSION TABLE
Conversion table
All specification data in this manual are listed in SI and METRIC TO IMPERIAL
Metric unit Multiplier Imperial unit
METRIC UNITS.
m • kgf 7.233 ft • lb
Use this table to convert METRIC unit data to m • kgf 86.794 in • lb
Torque
IMPERIAL unit data. cm • kgf 0.0723 ft • lb
cm • kgf 0.8679 in • lb
kg 2.205 lb
Weight
Ex. g 0.03527 oz
Speed km/hr 0.6214 mph
km 0.6214 mi
METRIC MULTIPLIER IMPERIAL m 3.281 ft
Distance m 1.094 yd
cm 0.3937 in
** mm × 0.03937 = ** in mm 0.03937 in
2 mm × 0.03937 = 0.08 in cc (cm3) 0.03527 oz (IMP liq.)
Volume, cc (cm3) 0.06102 cu • in
capacity L (liter) 0.8799 qt (IMP liq.)
L (liter) 0.2199 gal (IMP liq.)
kgf/mm 55.997 lb/in
Misc. kgf/cm2 14.2234 psi (lb/in2)
Centigrade (°C) 9/5 + 32 Fahrenheit (°F)
8-5
CONSUMER INFORMATION
Identification numbers ...................................................................... 9-1

Key identification number ................................................................. 9-1
Vehicle identification number ............................................................ 9-1
Model label ....................................................................................... 9-2
9
EAU01039
EAU02944
Identification numbers
Identification numbers
Record the key identification number,

vehicle identification number and
model label information in the spaces 1
provided below for assistance when 1
ordering spare parts from a Yamaha
dealer or for reference in case the
vehicle is stolen.
1. Key identification number 1. Vehicle identification number
1. KEY IDENTIFICATION EAU01041 EAU01043
NUMBER: Key identification number

Key identification number
Vehicle identification number
Vehicle identification number
The key identification number is The vehicle identification number is

stamped into the key tag. stamped into the steering head pipe.
Record this number in the space pro- Record this number in the space pro-
2. VEHICLE IDENTIFICATION vided and use it for reference when vided.
NUMBER: ordering a new key.
NOTE:
The vehicle identification number is
used to identify your motorcycle and
9 3. MODEL LABEL INFORMATION: may be used to register your motor-
cycle with the licensing authority in
1 your area.
6
9-1
1
1. Model label
EAU01050
Model label
Model label
The model label is affixed to the

frame under the seat. (See page 3-9
for seat removal and installation pro-
cedures.) Record the information on
this label in the space provided. This
information will be needed when
ordering spare parts from a Yamaha
dealer.
9
9-2
INDEX
A E Indicator lights ....................................... 3-2

Air filter element, cleaning ................... 6-13 Engine break-in ..................................... 5-4 High beam indicator light .................... 3-2
Engine idling speed ............................. 6-15 Neutral indicator light .......................... 3-2
B Engine oil and oil filter element ........... 6-10 Turn signal indicator light .................... 3-2
Battery ................................................. 6-31 Engine, starting a warm ......................... 5-2
Brake and clutch levers, checking and K
lubricating ......................................... 6-28 F Key identification number ...................... 9-1
Brake and shift pedals, checking and Front and rear brake pads, checking ... 6-22
lubricating ......................................... 6-28 Front fork, checking ............................. 6-29 M
Brake fluid level, checking ................... 6-23 Front wheel........................................... 6-37 Main switch/steering lock ...................... 3-1
Brake fluid, changing ........................... 6-24 Installing ............................................ 6-37 Model label ............................................ 9-2
Brake lever ............................................ 3-5 Removing .......................................... 6-37
Brake lever free play, adjusting ........... 6-21 Fuel ....................................................... 3-6 P
Brake pedal ........................................... 3-5 Fuel cock ............................................... 3-8 Parking .................................................. 5-5
Brake pedal position, adjusting ........... 6-21 Fuel consumption, tips for reducing ...... 5-4 Part locations ......................................... 2-1
Fuel tank cap ......................................... 3-6 Periodic maintenance and lubrication
C Fuse, replacing .................................... 6-32 chart .................................................... 6-3
Cables, checking and lubricating ......... 6-27 Pre-operation check list ......................... 4-1
Carburetor, adjusting ........................... 6-14 H
Care ....................................................... 7-1 Handlebar switches ............................... 3-3 R
Clutch lever ........................................... 3-4 Light switch ......................................... 3-3 Rear brake light switch, adjusting ........ 6-22
Clutch lever free play, adjusting .......... 6-20 Pass switch ......................................... 3-3 Rear suspension, lubricating ............... 6-29
Conversion table ................................... 8-5 Dimmer switch .................................... 3-3 Rear wheel ........................................... 6-39
Cowling and panels, removing and Turn signal switch ............................... 3-3 Removing .......................................... 6-39
installing .............................................. 6-6 Horn switch ......................................... 3-3 Install ................................................ 6-40
Engine stop switch .............................. 3-4
D Start switch ......................................... 3-4 S
Drive chain slack ................................. 6-25 Headlight bulb, replacing ..................... 6-33 Seat ....................................................... 3-9
Checking ........................................... 6-25 Helmet holder ...................................... 3-10 Shift pedal ............................................. 3-5
Adjusting ........................................... 6-25 Shift points (for Switzerland only) .......... 5-3
Drive chain, lubricating ........................ 6-26 I Shifting .................................................. 5-3
Identification numbers ........................... 9-1 Shock absorber assembly, adjusting ... 3-10
Ignition circuit cut-off system ............... 3-12 Sidestand ............................................ 3-11
INDEX
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
OWNER’S MANUAL
XT500E
YAMAHA MOTOR CO., LTD.
XT600E
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2001·7–0.9×1(E) !
4PT-28199-E7

Yamaha XT600E Owners Manual

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Yamaha XT600E Owners Manual

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OWNER’S MANUAL

Welcome to the Yamaha world of motorcycling!

IMPORTANT MANUAL INFORMATION

Failure to follow WARNING instructions could result in severe injury or death to

cC A CAUTION indicates special precautions that must be taken to avoid damage to

NOTE: A NOTE provides key information to make procedures easier or clearer.

IMPORTANT MANUAL INFORMATION

1 GIVE SAFETY THE RIGHT OF WAY 1

3 INSTRUMENT AND CONTROL FUNCTIONS 3

5 OPERATION AND IMPORTANT RIDING POINTS 5

6 PERIODIC MAINTENANCE AND MINOR REPAIR 6

7 MOTORCYCLE CARE AND STORAGE 7

Q GIVE SAFETY THE RIGHT OF WAY

GIVE SAFETY THE RIGHT OF WAY .............................................. 1-1

Q GIVE SAFETY THE RIGHT OF WAY

Enjoy your ride!

Left view ........................................................................................... 2-1

1. Headlight (page 6-33) 6. Shock absorber spring preload

10. Air filter element (page 6-13)

INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock .................................................................. 3-1

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

This indicator light flashes when the

1. High beam indicator light “&” 1. Speedometer

High beam indicator light “&” The speedometer unit is equipped

traveled since it was last set to zero

INSTRUMENT AND CONTROL FUNCTIONS

Set this switch to “&” for the high

Turn signal switch “4/6”

monitor the engine speed and keep it Handlebar switches

EC000003 Set this switch to “'” to turn on the

Pass switch “&”

Press this switch to flash the head-

INSTRUMENT AND CONTROL FUNCTIONS

Start switch “,”

Push this switch to crank the engine 1

1 See page 5-1 for starting instruc-

1. Engine stop switch “$/#” 1. Clutch lever

Engine stop switch

INSTRUMENT AND CONTROL FUNCTIONS

1. Shift pedal 1. Brake lever 1. Brake pedal

INSTRUMENT AND CONTROL FUNCTIONS

Fuel tank cap

Make sure that there is sufficient fuel

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

1. Starter (choke) knob “1” 1. Bolt (×2) 1. Projection (×2)

Starter (choke) knob “1” Seat To install the seat

Starting a cold engine requires a rich- To remove the seat

INSTRUMENT AND CONTROL FUNCTIONS

1. Helmet holder 1. Locknut

INSTRUMENT AND CONTROL FUNCTIONS

This shock absorber contains The sidestand is located on the left

INSTRUMENT AND CONTROL FUNCTIONS

w Ignition circuit cut-off w

INSTRUMENT AND CONTROL FUNCTIONS

With the engine turned off: NOTE:

Pre-operation check list .................................................................... 4-1

Pre-operation check list

OPERATION AND IMPORTANT RIDING POINTS

Starting the engine ........................................................................... 5-1

OPERATION AND IMPORTANT RIDING POINTS