2000 YAMAHA XT500E brake

DESCRIPTION
12
3
4
5
6
7
8
9
2-2
10.Air filter (page 6-12)
11.Oil filter (page 6-11)
12.Engine oil dipstick(page 6-10)
13.Rear brake pedal (page 3-5, 6-19)
10
11
13
12
Right view
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12
3
4
5
6
7
8
9
EAU00026
DESCRIPTION
2-3
14.Clutch lever (page 3-4, 6-18)
15.Left handlebar switches (page 3-3)
16.Speedometer (page 3-2)
17.Main switch/steering lock (page 3-1)
18.Tachometer (page 3-3)19.Right handlebar switches (page 3-4)
20.Front brake lever (page 3-5, 6-18)
21.Throttle grip (page 6-24)
22.Fuel tank cap (page 3-6)
14
15161718
1920
21 22
Controls/Instruments
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 12

INSTRUMENT AND CONTROL FUNCTIONSMain switch/steering lock.......................................................................3-1
Indicator lights.......................................................................................3-2
Speedometer.........................................................................................3-2
Tachometer...........................................................................................3-3
Handlebar switches...............................................................................3-3
Clutch lever............................................................................................3-4
Shift pedal..............................................................................................3-5
Front brake lever...................................................................................3-5
Rear brake pedal...................................................................................3-5
Fuel tank cap.........................................................................................3-6
Fuel........................................................................................................3-6
Fuel cock...............................................................................................3-7
Starter (choke) Ò
1Ó...............................................................................3-8
Seat.......................................................................................................3-9
Helmet holder........................................................................................3-9
Rear shock absorber adjustment.........................................................3-10
Sidestand.............................................................................................3-11
Sidestand/clutch switch operation check.............................................3-12
3
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3-5
1
5
4
3
2
N
1
1.Shift pedal
N.Neutral
EAU00157
Shift pedalThis motorcycle is equipped with a
constant-mesh 5-speed transmission.
The shift pedal is located on the left
side of the engine and is used in
combination with the clutch when
shifting.INSTRUMENT AND CONTROL FUNCTIONS
1
23
4
5
6
7
8
9
1
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Front brake leverThe front brake lever is located on
the right handlebar. Pull it toward the
handlebar to apply the front brake.
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Rear brake pedalThe rear brake pedal is on the right
side of the motorcycle. Press down
on the brake pedal to apply the rear
brake.
1.Front brake lever
1
1.Rear brake pedal
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 18

4-1
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PRE-OPERATION CHECKS
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2
34
5
6
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8
9Owners are personally responsible for their vehicleÕs condition. Your motorcycleÕs vital functions can start to deteriorate
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid
leak or loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thor-
ough visual inspection, you check the following points before each ride.
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PRE-OPERATION CHECK LIST
ITEMCHECKSPAGE
Front brake9Check operation, free play, fluid level and vehicle for fluid leakage.
9Fill with DOT 4 (or DOT 3) brake fluid if necessary.
Rear brake9Check operation, free play, fluid level and vehicle for fluid leakage.3-5, 6-18 ~ 6-22
9Fill with DOT 4 brake fluid if necessary.
Clutch9Check operation, condition and free play.
3-4, 6-18
9Adjust if necessary.
Throttle grip and housing9Check for smooth operation.
6-24
9Lubricate.
Engine oil9Check oil level.
6-10 ~ 6-12
9Fill with oil if necessary.
Drive chain9Check chain slack and condition.
6-22 ~ 6-24
9Adjust if necessary.
Wheels and tires9Check tire pressure, wear, damage and spoke tightness.
6-15 ~ 6-17
9Tighten spokes if necessary.
Control and meter cable9Check for smooth operation.
6-24
9Lubricate if necessary.
Brake and shift pedal shafts9Check for smooth operation.
6-25
9Lubricate if necessary.
Brake and clutch lever pivots9Check for smooth operation.
6-25
9Lubricate if necessary.
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 28

PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit ...................................................................6-1
Periodic maintenance and lubrication chart ...........6-3
Cowling and panel removal and installation...........6-6
Cowling A ...............................................................6-7
Panel A, B ..............................................................6-7
Spark plug ..............................................................6-8
Engine oil .............................................................6-10
Air filter .................................................................6-12
Carburetor adjustment .........................................6-13
Idle speed adjustment ..........................................6-14
Throttle cable free play adjustment ......................6-14
Valve clearance adjustment .................................6-15
Tires .....................................................................6-15
Wheels .................................................................6-17
Clutch lever free play adjustment.........................6-18
Front brake lever free play adjustment ................6-18
Rear brake pedal height adjustment ....................6-19
Brake light switch adjustment ..............................6-20
Checking the front and rear brake pads...............6-20
Inspecting the brake fluid level.............................6-21
Brake fluid replacement .......................................6-22
Drive chain slack check .......................................6-22
Drive chain slack adjustment ...............................6-23Drive chain lubrication............................................6-23
Cable inspection and lubrication ............................6-24
Throttle cable and grip lubrication ..........................6-24
Brake and shift pedal lubrication ............................6-25
Brake and clutch lever lubrication ..........................6-25
Sidestand lubrication..............................................6-25
Rear suspension lubrication...................................6-26
Front fork inspection ..............................................6-26
Steering inspection ................................................6-27
Wheel bearings ......................................................6-27
Battery....................................................................6-28
Fuse replacement ..................................................6-29
Headlight bulb replacement ...................................6-29
Turn signal light bulb replacement .........................6-31
Taillight bulb replacement ......................................6-32
Supporting the motorcycle .....................................6-32
Front wheel removal ..............................................6-33
Front wheel installation ..........................................6-34
Rear wheel removal ...............................................6-35
Rear wheel installation ...........................................6-36
Troubleshooting .....................................................6-36
Troubleshooting chart ............................................6-37
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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
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2
3
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7
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9
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Periodic maintenance and lubrication chart
NOTE:
8The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´ 1,000 km)
ANNUAL
CHECK
110203040
1
*Fuel line¥Check fuel hoses for cracks or damage.ÖÖÖÖÖ
2Spark plug¥Check condition.
¥Clean and regap.ÖÖ
¥Replace.ÖÖ
3*Valves¥Check valve clearance.
¥Adjust.ÖÖÖÖ
4Air filter element¥Clean.ÖÖ
¥Replace.ÖÖ
5Clutch¥Check operation.
¥Adjust.ÖÖÖÖÖ
6*Front brake¥Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)ÖÖÖÖÖÖ
¥Replace brake pads.Whenever worn to the limit
7*Rear brake¥Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)ÖÖÖÖÖÖ
¥Replace brake pads.Whenever worn to the limit
8*Brake hoses¥Check for cracks or damage.ÖÖÖÖÖ
¥Replace. (See NOTE on page 6-5.)Every 4 years
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6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
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2
3
4
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7
8
9
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NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.20
*Rear suspension relay
arm and connecting arm
pivoting points¥Check operation.ÖÖÖÖ
¥Lubricate with molybdenum disulfide grease.ÖÖ
21*Carburetor¥Check starter (choke) operation.
¥Adjust engine idling speed.ÖÖÖÖÖÖ
22Engine oil¥Change.ÖÖÖÖÖÖ
23Engine oil filter element¥Replace.ÖÖÖ
24*Front and rear brake
switches¥Check operation.ÖÖÖÖÖÖ
25Moving parts and cables¥Lubricate.ÖÖÖÖÖ
26*Lights, signals and
switches¥Check operation.
¥Adjust headlight beam.ÖÖÖÖÖÖ NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´ 1,000 km)
ANNUAL
CHECK
110203040
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