2000 YAMAHA XT500E brake

6-33
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
92.Loosen the wheel axle holder
nuts and wheel axle.
3.Elevate the front wheel by plac-
ing a suitable stand under the
engine.
4.Remove the wheel axle and the
front wheel. Make sure the
motorcycle is properly supported.
NOTE:
Do not depress the brake lever when
the disc and caliper are separated.
1
2
1.Axle holder nut (´4)
2.Wheel axle
EAU00897
Front wheel removal
EW000122
w8
8
It is advisable to have a
Yamaha dealer service the
wheel.
8 8
Securely support the motorcy-
cle so there is no danger of it
falling over.1.Remove the speedometer cable
from the front wheel side.
1
1.Speedometer cable
Rear wheel service
Use a motorcycle stand or motorcycle
jack to elevate the motorcycle so the
rear wheel is off the ground.
Alternatively, two jacks can be placed
under the frame or swingarm.
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 34

6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9 5.Before tightening the holder nuts,
push down on the handlebars
several times and check if the
fork rebounds smoothly.
6.Tighten the axle holder nuts to
the specified tightening torque.
Tighten the upper nuts first and
then lower ones. When tightened
in this sequence, there should be
a gap formed at the bottom of
the axle holder.
32 1
1.Upper nut (´2)
2.Lower nut (´2)
3.Gap
EAU01135
Front wheel installation1.Install the speedometer gear unit
housing into the wheel hub.
Make sure the speedometer gear
unit housing is installed with the
projections meshed into the
slots.
2.Lift up the wheel between the
front fork legs and guide the
brake disc between the brake
pads. Make sure there is enough
gap between the brake pads
before inserting the brake disc.
3.Make sure the slot in the
speedometer gear unit fits over
the stopper on the front fork
outer tube.
4.Install the wheel axle and tighten
it to the specified torque.
Tightening torque:
Wheel axle:
59 Nm (5.9 m
0kg)
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 35

6-36
INSTRUMENT AND CONTROL FUNCTIONS
1
2
4
56
7
8
9
EAU01008
TroubleshootingAlthough Yamaha motorcycles
receive a rigid inspection before ship-
ment from the factory, trouble may
occur during operation.
Any problem in the fuel, compres-
sion, or ignition systems can cause
poor starting and loss of power. The
troubleshooting chart describes a
quick, easy procedure for making
checks.
If your motorcycle requires any
repair, bring it to a Yamaha dealer.
The skilled technicians at a Yamaha
dealership have the tools, experi-
ence, and know-how to properly ser-
vice your motorcycle. Use only gen-
uine Yamaha parts on your
motorcycle. Imitation parts may look
like Yamaha parts, but they are often
inferior. Conse-quently, they have a
shorter service life and can lead to
expensive repair bills.
5.Push the wheel forward and
remove the drive chain.
6.Pull out the wheel axle, then
remove the wheel assembly by
pulling backwards.NOTE:
8Do not depress the brake pedal
when the disc and caliper are
separated.
8You do not have to disassemble
the chain in order to remove or
install the rear wheel.
EAU01136*
Rear wheel installation1.Install the rear wheel and chain.
Guide the brake disc between
the brake pads. Make sure there
is enough gap between the
brake pads before inserting the
brake disc.
2.Make sure the wheel axle is
inserted from the left-hand side
and that the chain adjusting
plates are installed with the
punched side outward.
3.Install the swingarm end bolts.
4.Adjust the drive chain.
5.Tighten the following parts to the
specified torque.
Tightening torque:
Axle nut:
105 Nm (10.5 m
0kg)
Caliper bracket bolt:
48 Nm (4.8 m
0kg)
Swingarm end bolt:
2.5 Nm (0.25 m0kg)
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 37

7-2
8 8
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent
and water to clean plastic.
8 8
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra-
sive cleaning products, sol-
vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec-
trolyte.8 8
Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the
following areas: seals (of
wheel bearings, swingarm
bearings, forks and brakes),
electric components (cou-
plers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
8 8
For motorcycles equipped
with a windshield: Do not use
strong cleaners or hard
sponges as they will cause
dulling or scratching. Some
cleaning compounds for plas-
tic may leave scratches on the
windshield. Test the product
on a small hidden part of the
windshield to make sure they
do not leave any marks. If the
windshield is scratched, use a
quality plastic polishing com-
pound after washing.
After riding in the rain, near the seaor on salt-sprayed roads.Since sea salt or salt sprayed on the
roads in the winter are extremely cor-
rosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads. (Salt sprayed
in the winter may remain on the roads
well into spring.)
1.Clean your motorcycle with cold
water and soap after the engine
has cooled down.
ECA00012
cCDo not use warm water since it
increases the corrosive action of
the salt.2.Be sure to apply a corrosion pro-
tection spray on all (even
chrome- and nickel-plated) metal
surfaces to prevent corrosion.
MOTORCYCLE CARE AND STORAGE
1
2
3
4
5
67
8
9
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 3

7-3
EWA00001
wMake sure that there is no oil or
wax on the brakes and tires. If nec-
essary, clean the brake discs and
linings with a regular brake disc
cleaner or acetone, and wash the
tires with warm water and mild
soap. Then, carefully test the
motorcycle for its braking perfor-
mance and cornering behavior.
ECA00013
cC8
8
Apply spray oil and wax spar-
ingly and wipe off any excess.
8 8
Never apply oil or wax on rub-
ber and plastic parts, but treat
them with a suitable care prod-
uct.
8 8
Avoid using abrasive polish-
ing compounds as they wear
away the paint.
MOTORCYCLE CARE AND STORAGE
1
2
3
4
5
67
8
9
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
After cleaning
1.Dry the motorcycle with a
chamois or an absorbing cloth.
2.Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3.Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
4.To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all (even
chrome- and nickel-plated) metal
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.
8.Let the motorcycle dry complete-
ly before storing it or covering it.
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 4

SPECIFICATIONS
1
2
3
4
5
6
78
9
Air pressure (cold tire)
up to 90 kg load*
Front150 kPa (1.50 kg/cm
2, 1.50 bar)
Rear150 kPa (1.50 kg/cm2, 1.50 bar)
90 kg load ~ Maximum
load*
Front150 kPa (1.50 kg/cm2, 1.50 bar)
Rear225 kPa (2.25 kg/cm2, 2.25 bar)
Off-road riding
Front125 kPa (1.25 kg/cm2, 1.25 bar)
Rear125 kPa (1.25 kg/cm2, 1.25 bar)
High speed riding
Front150 kPa (1.50 kg/cm2, 1.50 bar)
Rear150 kPa (1.50 kg/cm2, 1.50 bar)
* Load is total weight of cargo, rider, passenger and accessories.
Wheels
Front
TypeSpoke wheel
Size21 ´1.85
Rear
TypeSpoke wheel
Size17 ´MT2.50 Brakes
Front
TypeSingle disc brake
OperationRight hand operation
FluidDOT 3 or DOT 4
Rear
TypeSingle disc brake
OperationRight foot operation
FluidDOT 4
Suspension
Front
TypeTelescopic fork
Rear
TypeSwingarm (new monocross)
Shock absorber
FrontCoil spring/oil damper
RearCoil spring/gas-oil damper
Wheel travel
Front225 mm
Rear200 mm
8-3
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 10

SPECIFICATIONS
1
2
3
4
5
6
78
9
8-4 Electrical
Ignition systemT.C.I. (Digital)
Charging system
TypeA.C. magneto
Standard output14 V, 13.5A@5,000 rpm
Battery
TypeYTX9-BS
Voltage, capacity12 V, 8 AH
Headlight bulb typeHalogen bulb
Bulb voltage, wattage ´quantity
Headlight12 V, 60/55W ´1
Tail / brake light12 V, 5/21W ´1
Auxiliary light12 V, 4W ´1
12 V, 3.4W ´1 (GB only)
Front flasher light12 V, 21W ´2
Rear flasher light12 V, 21W ´2
Meter light12 V, 3.4W ´1
Neutral indicator light12 V, 3.4W ´1
High beam indicator light12 V, 3.4W ´1
Turn indicator light12 V, 3.4W ´1
Fuse
Main20A
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 11

INDEX
Front brake lever free play
adjustment..........................................6-18
Front fork inspection..............................6-26
Front wheel installation..........................6-34
Front wheel removal..............................6-33
Fuel.........................................................3-6
Fuel cock.................................................3-7
Fuel tank cap...........................................3-6
Fuse replacement..................................6-29
H
Handlebar switches.................................3-3
Dimmer switch......................................3-3
Engine stop switch................................3-4
Horn switch...........................................3-3
Lights switch.........................................3-3
Pass switch...........................................3-3
Start switch...........................................3-4
Turn signal switch.................................3-3
Headlight bulb replacement...................6-29
Helmet holder..........................................3-9
High beam indicator light.........................3-2
Horn switch..............................................3-3
How to use the conversion table.............9-3
I
Identification number records..................9-1
Idle speed adjustment...........................6-14
Indicator lights.........................................3-2
High beam indicator light......................3-2
Neutral indicator light............................3-2
Turn indicator light................................3-2
Inspecting the brake fluid level..............6-21
K
Key identification number........................9-1
L
Lights switch............................................3-3
M
Main switch/Steering lock........................3-1
Model label..............................................9-2
N
Neutral indicator light...............................3-2
P
Panel A, B...............................................6-7
Parking....................................................5-6
Pass switch.............................................3-3
Periodic maintenance and
lubrication chart....................................6-3
Pre-operation check list...........................4-1
R
Rear brake pedal.....................................3-5
Rear brake pedal height adjustment.....6-19
Rear shock absorber adjustment..........3-10
Rear suspension lubrication..................6-26
Rear wheel installation..........................6-36
Rear wheel removal..............................6-35
Recommended shift point
(for Switzerland only)............................5-4
S
Seat.........................................................3-9
Shift pedal ..............................................3-5
Shifting....................................................5-4
Sidestand..............................................3-11
Sidestand lubrication.............................6-25
A
Air filter..................................................6-12
B
Battery...................................................6-28
Brake and clutch lever lubrication.........6-25
Brake and shift pedal lubrication...........6-25
Brake fluid replacement.........................6-22
Brake light switch adjustment................6-20
C
Cable inspection and lubrication...........6-24
Carburetor adjustment...........................6-13
Care.........................................................7-1
Carrier (optional)...................................3-11
Checking the front and rear brake
pads....................................................6-20
Clutch lever.............................................3-4
Clutch lever free play adjustment..........6-18
Cowling A................................................6-7
Cowling and panel removal and
installation.............................................6-6
D
Description..............................................2-1
Dimmer switch.........................................3-3
Drive chain lubrication...........................6-23
Drive chain slack adjustment.................6-23
Drive chain slack check.........................6-22
E
Engine break-in.......................................5-5
Engine oil...............................................6-10
Engine stop switch..................................3-4
F
Front brake lever.....................................3-5
4PT-9-E6 (ENG) 7~9 12/27/00 1:30 PM Page 16