2000 YAMAHA XT500E engine

5-6
EC000052
cCAfter 1,000 km of operation, be
sure to replace the engine oil and
oil filter.1,000 km and beyond
Full throttle can be used.
EC000053
cC8
8
Never let engine speeds enter
the red zone.
8 8
If any engine trouble should
occur during the break-in peri-
od, consult a Yamaha dealer
immediately.
EAU00457
ParkingWhen parking the motorcycle, stop
the engine and remove the ignition
key. Turn the fuel cock to ÒOFFÓ
whenever stopping the engine.
EW000058
wThe exhaust system is hot. Park
the motorcycle in a place where
pedestrians or children are not
likely to touch the motorcycle. Do
not park the motorcycle on a slope
or soft ground; the motorcycle
may overturn.OPERATION AND IMPORTANT RIDING POINTS
1
2
3
45
6
7
8
9
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 37

PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit ...................................................................6-1
Periodic maintenance and lubrication chart ...........6-3
Cowling and panel removal and installation...........6-6
Cowling A ...............................................................6-7
Panel A, B ..............................................................6-7
Spark plug ..............................................................6-8
Engine oil .............................................................6-10
Air filter .................................................................6-12
Carburetor adjustment .........................................6-13
Idle speed adjustment ..........................................6-14
Throttle cable free play adjustment ......................6-14
Valve clearance adjustment .................................6-15
Tires .....................................................................6-15
Wheels .................................................................6-17
Clutch lever free play adjustment.........................6-18
Front brake lever free play adjustment ................6-18
Rear brake pedal height adjustment ....................6-19
Brake light switch adjustment ..............................6-20
Checking the front and rear brake pads...............6-20
Inspecting the brake fluid level.............................6-21
Brake fluid replacement .......................................6-22
Drive chain slack check .......................................6-22
Drive chain slack adjustment ...............................6-23Drive chain lubrication............................................6-23
Cable inspection and lubrication ............................6-24
Throttle cable and grip lubrication ..........................6-24
Brake and shift pedal lubrication ............................6-25
Brake and clutch lever lubrication ..........................6-25
Sidestand lubrication..............................................6-25
Rear suspension lubrication...................................6-26
Front fork inspection ..............................................6-26
Steering inspection ................................................6-27
Wheel bearings ......................................................6-27
Battery....................................................................6-28
Fuse replacement ..................................................6-29
Headlight bulb replacement ...................................6-29
Turn signal light bulb replacement .........................6-31
Taillight bulb replacement ......................................6-32
Supporting the motorcycle .....................................6-32
Front wheel removal ..............................................6-33
Front wheel installation ..........................................6-34
Rear wheel removal ...............................................6-35
Rear wheel installation ...........................................6-36
Troubleshooting .....................................................6-36
Troubleshooting chart ............................................6-37
6
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 1

6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU03884
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
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 6

Inspection
The spark plug is an important
engine component and is easy to
inspect. The condition of the spark
plug can indicate the condition of the
engine.
The ideal color on the white insulator
around the center electrode is a
medium-to-light tan color for a motor-
cycle that is being ridden normally.
Do not attempt to diagnose such
problems yourself. Instead, take the
motorcycle to a Yamaha dealer. You
should periodically remove and
inspect the spark plug because heat
and deposits will cause any spark
plug to slowly break down and erode.
If electrode erosion becomes exces-
sive, or if carbon and other deposits
are excessive, you should replace
the spark plug with the specified plug.Installation
1.Measure the electrode gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2.Clean the gasket surface. Wipe
off any grime from the threads.
3.Install the spark plug and tighten
it to the specified torque.
NOTE:
If a torque wrench is not available
when you are installing a spark plug,
a good estimate of the correct torque
is 1/4 to 1/2 turn past finger tight.
Have the spark plug tightened to the
specified torque as soon as possible.4.Install the spark plug cap.
6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
Specified spark plug:
DPR8EA-9 or
DPR9EA-9 (NGK)
Spark plug gap:
0.8 ~ 0.9 mmTightening torque:
Spark plug:
17.5 Nm (1.75 m0kg)
1
1.Spark plug gap
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 10

6-10
EAU00526*
Engine oilOil level measurement
1.Place the motorcycle on a level
place and hold it in an upright
position.
2.Remove the screw and pull out-
ward on the oil tank cap cover to
remove it.
3.Start the engine and warm it up.
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
2
1
1.Screw
2.Cover
1
2
3
4.Idle the engine for at least 10
seconds and stop it. While keep-
ing the motorcycle upright,
remove the dipstick (oil tank cap)
and check the oil level.
5.The oil level should be between
the minimum and maximum
marks. If the level is low, fill with
oil to the maximum level line.1.Oil tank cap/dipstick
2.Maximum level mark
3.Minimum level mark
EC000000
cCDo not run the motorcycle until
you know it has sufficient engine
oil.
EW000065
wNever remove the dipstick just
after high-speed operation. Hot oil
could spout out, causing danger.
Always wait until the oil cools
down before removing the dip-
stick.
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 11

6-11
1
2
6.Check the O-rings for damage.
Replace if damaged.
7.Install the drain plugs, filter cover
and bolts. Tighten to the speci-
fied torque.1.Oil filter element
2.O-ring (´2)
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
94.Check each gasket. If damaged,
replace.
5.Remove the filter cover bolts and
the oil filter cover. Replace the oil
filter element.
NOTE:
The oil filter cover is secured by three
bolts. The lower one should be
removed first so that the filter cavity
will drain.
2
34
1
1.Air bleed screw
2.Oil filter cover bolt (´2)
3.Oil filter drain bolt
4.Oil filter cover
11.Drain bolt (oil tank)
2.Drain bolt (crankcase)Engine oil and oil filter
element replacement
1.Warm up the engine for a few
minutes.
2.Place an oil pan under the
engine.
3.Remove the oil tank cap, drain
bolts.
2
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 12

6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9 8.Fill the engine with oil. Install the
oil tank cap. Tightening torque:
Drain plug (crankcase):
30 Nm (3.0 m0kg)
Drain plug (oil tank):
17.5 Nm (1.75 m0kg)
Filter cover bolt:
10 Nm (1.0 m0kg)
Air bleed screw:
5 Nm (0.5 m0kg)
Recommended oil:
See page 8-1
Oil quantity:
Total amount:
3.3 L
Periodic oil change:
2.7 L
With oil filter replacement:
2.8 L
9.Start the engine and warm it up
for a few minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for the
cause.
10.Stop the engine and check the
oil level.
EC000076
cCAfter replacing the engine oil, be
sure to check the oil pressure as
described below.8 8
Remove the air bleed screw
from the oil filter cover.
8 8
Start the engine and keep it
idling until oil flows out of the
bleed hole. If no oil comes out
after one minute, turn off the
engine immediately so it will
not seize. In such a case go to
the nearest Yamaha dealer for
repairs.
8 8
After checking, tighten the air
bleed screw securely.
1
1
EAU01083
Air filterThe air filter should be cleaned at the
specified intervals. It should be
cleaned more frequently if you are
riding in unusually wet or dusty
areas.
1.Remove panel B. (See page 6-7
for panel removal and installation
procedures.)
2.Remove the air filter case fitting
screws and the filter case cover.1.Screw (´7)
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 13

EAU00629
Carburetor adjustmentThe carburetor is a vital part of the
engine and requires very sophisticat-
ed adjustment. Most adjustments
should be left to a Yamaha dealer
who has the professional knowledge
and experience to do so. However,
the following may be serviced by the
owner as part of routine mainte-
nance.
EC000094
cCThe carburetor was set at the
Yamaha factory after many tests. If
the settings are changed, poor
engine performance and damage
may result.
6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
5.Install the air filter with the arrow
mark on the top pointing inward.
6.Install the air filter case cover
and the panel.
EC000082
cC8
8
Make sure the air filter is prop-
erly seated in the air filter
case.
8 8
The engine should never be
run without the air filter
installed. Excessive piston
and/or cylinder wear may
result.
1
3.Remove the air filter.
4.Tap the air filter lightly to remove
most of the dust and dirt and
blow out the remaining dirt with
compressed air from the mesh
side of the air filter. If it is dam-
aged, replace it.1.Mesh side
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 14