2000 YAMAHA XT600E check engine

3-12
INSTRUMENT AND CONTROL FUNCTIONS
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23
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EAU00331
Sidestand/clutch switch
operation checkCheck the operation of the sidestand
switch and clutch switch against the
information below.
EW000045
wIf improper operation is noted,
consult a Yamaha dealer immedi-
ately.
TURN THE MAIN SWITCH TO ÒONÓ AND
THE ENGINE STOP SWITCH TO Ò#Ó.TRANSMISSION IS IN GEAR AND
SIDESTAND IS UP.PULL IN CLUTCH LEVER AND
PUSH THE START SWITCH.ENGINE WILL START.CLUTCH SWITCH IS OK.
SIDESTAND IS DOWN.ENGINE WILL STALL.SIDESTAND SWITCH IS OK.
4PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 25

4-1
EAU01114
PRE-OPERATION CHECKS
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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.
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5-1
EAU00373
w8 8
Before riding this motorcycle,
become thoroughly familiar
with all operating controls and
their functions. Consult a
Yamaha dealer regarding any
control or function that you do
not thoroughly understand.
8 8
Never start your engine or let
it run for any length of time in
a closed area. The exhaust
fumes are poisonous and can
cause loss of consciousness
and death within a short time.
Always operate your motorcy-
cle in an area with adequate
ventilation.
8 8
Before starting out, always be
sure the sidestand is up.
Failure to retract the sidestand
completely can result in a seri-
ous accident when you try to
turn a corner.
EAU03011
Starting the engineNOTE:
This motorcycle is equipped with an
ignition circuit cut-off system. The
engine can be started only under one
of the following conditions:
8The transmission is in neutral.
8The sidestand is up, the trans-
mission is in gear and the clutch
is disengaged.
The motorcycle must not be ridden
when the sidestand is down.
EW000054
wBefore going through the following
steps, check the function of the
sidestand switch and clutch
switch. (Refer to page 3-12.)
EAU00372
OPERATION AND IMPORTANT RIDING POINTS
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2
3
45
6
7
8
94PT-9-E6 (ENG) 1~5 12/27/00 1:28 PM Page 32

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
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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

6-10
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
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2
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1.Screw
2.Cover
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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
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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
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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.
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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
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6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
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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