2000 YAMAHA XT500E brake

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EAU00685
WheelsTo ensure maximum performance,
long service, and safe operation, note
the following:
8Always inspect the wheels
before a ride. Check for cracks,
bends or warpage of the wheel.
Be sure the spokes are tight and
undamaged. If any abnormal
condition exists in a wheel, con-
sult a Yamaha dealer. Do not
attempt even small repairs to the
wheel. If a wheel is deformed or
cracked, it must be replaced.
8Tires and wheels should be bal-
anced whenever either one is
changed or replaced. Failure to
have a wheel balanced can
result in poor performance,
adverse handling characteristics,
and shortened tire life.
8Ride at moderate speeds after
changing a tire since the tire sur-
face must first be broken in for it
to develop its optimal character-
istics.
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w8 8
Operating the motorcycle with
excessively worn tires
decrease riding stability and
can lead to loss of control.
Have excessively worn tires
replaced by a Yamaha dealer
immediately. Brakes, tires, and
related wheel parts replace-
ment should be left to a
Yamaha Service Technician.
8 8
Patching a punctured tube is
not recommended. If it is
absolutely necessary to do so,
use great care and replace the
tube as soon as possible with
a good quality replacement.
NOTE:
These limits may be different by regu-
lation from country to country. If so,
conform to the limits specified by the
regulations of your own country.
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a
b 12
3
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Clutch lever free play
adjustmentThe clutch lever free play should be
adjusted to 10 ~ 15 mm.
1.Loosen the locknut at the clutch
lever.
2.Turn the adjusting bolt at the
clutch lever in direction ato
increase free play or in direction
bto decrease free play.
3.Tighten the locknut at the clutch
lever.
If the specified free play cannot be
obtained, proceed with the following
steps.1.Locknut
2.Adjusting bolt
3.Free play
b
a
1
2
4.Loosen the locknut at the clutch
lever.
5.Turn the adjusting bolt at the
clutch lever in direction ato
loosen the cable.
6.Loosen the locknut at the
crankcase side.
7.Turn the adjusting nut at the
crankcase in direction ato
increase free play or in direction
bto decrease free play.
8.Tighten the locknut at the
crankcase and the clutch lever.1.Adjusting nut
2.Locknut
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Front brake lever free play
adjustmentThe free play at the front brake lever
should be 2 ~ 5 mm.
1.Loosen the locknut.
2.Turn the adjusting bolt in direc-
tion ato increase free play or in
direction bto decrease free
play.
3.After adjusting, tighten the lock-
nut.
1
2
3
b
a
1.Locknut
2.Adjusting bolt
3.Free play
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EW000109
wA soft or spongy feeling in the
brake pedal can indicate the pres-
ence of air in the brake system.
This air must be removed by
bleeding the brake system before
the motorcycle is operated. Air in
the system will cause greatly
diminished braking capability and
can result in loss of control and an
accident. Have a Yamaha dealer
inspect and bleed the system if
necessary.
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Rear brake pedal height
adjustmentThe top of the brake pedal should be
positioned 12 mm below the top of
the footrest. If not, ask a Yamaha
dealer to adjust it.
a
a.Pedal height
EW000099
w8
8
Check the brake lever free
play. Be sure the brake is
working properly.
8 8
A soft or spongy feeling in the
brake lever can indicate the
presence of air in the brake
system. This air must be
removed by bleeding the brake
system before the motorcycle
is operated. Air in the system
will cause greatly diminished
braking capability and can
result in loss of control and an
accident. Have a Yamaha deal-
er inspect and bleed the sys-
tem if necessary.
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Brake light switch
adjustmentThe rear brake light switch is activat-
ed by the brake pedal and is properly
adjusted when the brake light comes
on just before braking takes effect.
To adjust the rear brake light switch,
hold the switch body so it does not
rotate while turning the adjusting nut.
Turn the adjusting nut in direction a
to make the brake light come on earli-
er.
Turn the adjusting nut in direction b
to make the brake light come on
later.
21
a
b
1.Brake light switch
2.Adjusting nut
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Checking the front and rear
brake padsA wear indicator is provided on each
brake. This indicator allows checking
of brake pad wear without disassem-
bling the brake. Apply the brake and
inspect the wear indicator. If the
brake pads are worn to wear limit,
have a Yamaha dealer to replace the
pads.
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Front brake
Wear indicator grooves are provided
on each brake pad. These indicators
allow checking of brake pad wear
without disassembling the brake.
Inspect the grooves. If they have
almost disappeared, ask a Yamaha
dealer to replace the pads.
1
1
1.Wear indicator groove (´3)
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8Use only the designated quality
brake fluid. Otherwise, the rub-
ber seals may deteriorate, caus-
ing leakage and poor brake per-
formance.NOTE:
If DOT 4 is not available, DOT 3 can
be used for the front brake only.1.Minimum level mark
Recommended brake fluid:
DOT 4
1
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Inspecting the brake fluid
levelInsufficient brake fluid may let air
enter the brake system, possibly
causing the brakes to become inef-
fective.
Before riding, check that the brake
fluid is above the minimum level and
replenish when necessary.
Observe these precautions:
8When checking the fluid level,
make sure the top of the master
cylinder is level by turning the
handlebars.1.Minimum level mark
1
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Rear brake
Remove the cap and inspect the
pads. If the thickness is less than the
specified value, have a Yamaha deal-
er replace the pads.1.Wear limit: 0.8 mm
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8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
8Be careful that water does not
enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8Have a Yamaha dealer check
the cause if the brake fluid level
goes down.
PERIODIC MAINTENANCE AND MINOR REPAIR
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Brake fluid replacementThe brake fluid should be replaced
only by trained Yamaha service per-
sonnel. Have the Yamaha dealer
replace the following components
during periodic maintenance or when
they are damaged or leaking:
8oil seals (every two years)
8brake hoses (every four years)
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Drive chain slack checkNOTE:
Spin the wheel several times and find
the tightest position of the chain.
Check and/or adjust the chain slack
while itÕs in this tightest position.To check the chain slack the motor-
cycle must be held straight up with
both wheels on the ground and with-
out rider. Check the slack at the posi-
tion shown in the illustration. Normal
slack is approximately 30 ~ 40 mm. If
the slack exceeds 40 mm, adjust.
a
a.Chain slack
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Brake and shift pedal
lubricationLubricate the pivoting parts.
Recommended lubricant:
Engine oil
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Sidestand lubricationLubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.
EW000113
wIf the sidestand does not move
smoothly, consult a Yamaha deal-
er.
Recommended lubricant:
Engine oil
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Brake and clutch lever
lubricationLubricate the pivoting parts.
Recommended lubricant:
Engine oil
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Rear suspension lubricationLubricate the pivoting parts.
Recommended lubricant:
Molybdenum disulfide grease
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1.Grease nipple (´2)
Operation check
1.Place the motorcycle on a level
place.
2.Hold the motorcycle in an upright
position and apply the front
brake.
3.Push down hard on the handle-
bars several times and check if
the fork rebounds smoothly.
EC000098
cCIf any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
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Front fork inspectionVisual check
EW000115
wSecurely support the motorcycle
so there is no danger of it falling
over.Check for scratches or damage on
the inner tube and excessive oil leak-
age from the front fork.
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