2000 YAMAHA XT600E brake fluid

4-1
EAU01114
PRE-OPERATION CHECKS
1
2
34
5
6
7
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.
EAU00340
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
6
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 1

6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU03685
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
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 4

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

6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
1
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
EAU00733
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
EAU00729
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
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 22

6-22
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
1
2
3
4
56
7
8
9
EAU00742
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)
EAU00744
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
4PT-9-E6 (ENG) 6 12/27/00 1:29 PM Page 23

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

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