2002 YAMAHA XT500E light

5-4
OPERATION AND IMPORTANT RIDING POINTS
5
EAU00424
Tips for reducing fuel
consumptionFuel consumption, tips for reducingFuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
8Thoroughly warm up the engine.
8Turn the starter (choke) off as
soon as possible.
8Shift up swiftly, and avoid high
engine speeds during accelera-
tion.
8Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the
engine.
8Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad cross-
ings).
EAU01128
Engine break-inEngine break-inThere is never a more important peri-
od in the life of your engine than the
period between 0 and 1,600 km. For
this reason, you should read the fol-
lowing material carefully.
Since the engine is brand new, do
not put an excessive load on it for the
first 1,600 km. The various parts in
the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheat-
ing must be avoided.
EAU04315
0–1,000 km
Avoid prolonged operation above
4,000 r/min.
1,000–1,600 km
Avoid prolonged operation above
5,000 r/min.
ECA00058
cCAfter 1,000 km of operation, the
engine oil must be changed, and
the oil filter element replaced.1,600 km and beyond
The vehicle can now be operated
normally.
4PT-E7 (English) 6/29/01 9:13 AM Page 35

PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ................................................ 6-1
Periodic maintenance and lubrication chart ..... 6-3
Removing and installing the cowling
and panels .................................................... 6-6
Checking the spark plug .................................. 6-8
Engine oil and oil filter element ...................... 6-10
Cleaning the air filter element ........................ 6-13
Adjusting the carburetor ................................. 6-14
Adjusting the engine idling speed ................... 6-15
Adjusting the throttle cable free play .............. 6-16
Adjusting the valve clearance ........................ 6-16
Tires ............................................................... 6-16
Spoke wheels ................................................ 6-19
Adjusting the clutch lever free play ................ 6-20
Adjusting the brake lever free play ................. 6-21
Adjusting the brake pedal position ................. 6-21
Adjusting the rear brake light switch .............. 6-22
Checking the front and rear brake pads ........ 6-22
Checking the brake fluid level ........................ 6-23
Changing the brake fluid ................................ 6-24
Drive chain slack ............................................ 6-25
Lubricating the drive chain ............................. 6-26
Checking and lubricating the cables .............. 6-27Checking and lubricating the throttle grip
and cable .................................................... 6-27
Checking and lubricating the brake and
shift pedals .................................................. 6-28
Checking and lubricating the brake and
clutch levers ................................................ 6-28
Checking and lubricating the sidestand ......... 6-28
Lubricating the rear suspension ..................... 6-29
Checking the front fork ................................... 6-29
Checking the steering .................................... 6-30
Checking the wheel bearings ......................... 6-30
Battery ............................................................ 6-31
Replacing the fuse ......................................... 6-32
Replacing the headlight bulb ......................... 6-33
Replacing a turn signal light bulb ................... 6-35
Replacing the tail/brake light bulb .................. 6-35
Supporting the motorcycle ............................. 6-36
Front wheel ................................................... 6-37
Rear wheel ..................................................... 6-39
Troubleshooting ............................................. 6-41
Troubleshooting chart .................................... 6-42
6
4PT-E7 (English) 6/29/01 9:13 AM Page 37

6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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.√√√√
•Lubricate with molybdenum disulfide grease.√√
21*Carburetor•Check starter (choke) operation.
•Adjust engine idling speed.√√√√√ √
22 Engine oil•Change.
•Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter element•Replace.√√√
24*Front and rear brake
switches•Check operation.√√√√√ √
25 Moving parts and cables•Lubricate.√√√√ √
26*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
4PT-E7 (English) 6/29/01 9:13 AM Page 42

6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
6To check the spark plug
1. Check that the porcelain insula-
tor around the center electrode
of the spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).
NOTE:
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead,
have a Yamaha dealer check the
motorcycle.2. Check the spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and
replace it if necessary.3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4-
1/2 turn past finger tight. However,
the spark plug should be tightened to
the specified torque as soon as pos-
sible.4. Install the spark plug cap. To install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
a
a. Spark plug gap
Specified spark plug:
DPR8EA-9 or
DPR9EA-9 (NGK)
Spark plug gap:
0.8–0.9 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m0kgf)
4PT-E7 (English) 6/29/01 9:13 AM Page 46

6-10
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04354
Engine oil and oil filter
elementEngine oil and oil filter elementThe engine oil level should be
checked before each ride. In addition,
the oil must be changed and the oil
filter element replaced at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
Make sure that the motorcycle is
positioned straight up when checking
the oil level. A slight tilt to the side
can result in a false reading.
4. Wait a few minutes until the oil
settles, remove the oil filler cap,
wipe the dipstick clean, insert it
back into the oil filler hole (with-
out screwing it in), and then
remove it again to check the oil
level.NOTE:
The engine oil should be between the
minimum and maximum level marks.
1
2
3
1. Oil filler cap
2. Maximum level mark
3. Minimum level mark
2. Remove the oil filler cap cover by
removing the screw.
3. Start the engine, warm it up for
at least 10 seconds, and then
turn it off.
2
1
1. Screw
2. Oil filler cap cover
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6-14
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as
shown. If the air filter element is
damaged, replace it.
4. Insert the air filter element into
the air filter case with the arrow
mark on the top pointing inward.
EAU00629
Adjusting the carburetorCarburetor, adjustingThe carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most
carburetor adjustments should be left
to a Yamaha dealer, who has the
necessary professional knowledge
and experience. The adjustment
described in the following section,
however, may be serviced by the
owner as part of routine mainte-
nance.
EC000094
cCThe carburetor has been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine.
1
1. Mesh side
EC000082
cC8Make sure that the air filter ele-
ment is properly seated in the
air filter case.
8The engine should never be
operated without the air filter
element installed, otherwise
the piston and/or cylinder may
become excessively worn.5. Install the air filter case cover by
installing the screws.
6. Install the panel.
1
1. Arrow mark
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6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EW000109
wA soft or spongy feeling in the
brake pedal can indicate the pres-
ence of air in the hydraulic system.
If there is air in the hydraulic sys-
tem, have a Yamaha dealer bleed
the system before operating the
motorcycle. Air in the hydraulic
system will diminish the braking
performance, which may result in
loss of control and an accident.
EAU00721
Checking the front and rear
brake padsFront and rear brake pads, checkingThe front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU00713
Adjusting the rear brake light
switchRear brake light switch, adjustingThe rear brake light switch, which is
activated by the brake pedal, is prop-
erly adjusted when the brake light
comes on just before braking takes
effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding
the rear brake light switch in place.
To make the brake light come on ear-
lier, turn the adjusting nut in direction
a. To make the brake light come on
later, turn the adjusting nut in direc-
tion b.
21
a
b
1. Rear brake light switch
2. Adjusting nut
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6-33
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000103
cCDo not use a fuse of a higher
amperage rating than recommend-
ed to avoid causing extensive
damage to the electrical system
and possibly a fire.3. Turn the key to “ON” and turn on
the electrical circuits to check if
the devices operate.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.3. Disconnect the headlight coupler
and the auxiliary light leads, and
then remove the headlight bulb
cover.
3
1
2
1. Headlight coupler
2. Auxiliary light lead (×2)
3. Headlight bulb cover
EAU01146
Replacing the headlight bulbHeadlight bulb, replacingThis motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.
1. Remove cowling A. (See page
6-7 for cowling removal and
installation procedures.)
2. Remove the headlight unit by
removing the bolts.
1
1. Bolt (×3)
4PT-E7 (English) 6/29/01 9:13 AM Page 70