2002 YAMAHA XT500E engine

6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
6 6. Remove and replace the oil filter
element.
7. Check the O-rings for damage
and replace them if necessary.
8. Install the oil filter element cover
by installing the bolts, then tight-
ening them to the specified
torque.
NOTE:
Make sure that the O-ring is properly
seated.9. Install the engine oil drain bolts,
and then tighten them to the
specified torques.
10. Add the specified amount of the
recommended engine oil, install
and tighten the oil filler cap, and
then install the oil filler cap cover.
ECA00105
cC8In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives
with the oil or use oils of grade
“CD” or higher. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.
8Make sure that no foreign
material enters the crankcase.
1
2
1. Oil filter element
2. O-ring (×2)
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m0kgf)
Tightening torques:
Engine oil drain bolt
(crankcase):
30 Nm (3.0 m0kgf)
Engine oil drain bolt (oil tank):
18 Nm (1.8 m0kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
2.7 L
With oil filter element
replacement:
2.8 L
Total amount (dry engine):
3.3 L
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6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000076
cCAfter changing the engine oil, be
sure to check the oil pressure as
described below.11. Remove the air bleed screw, and
then start the engine. If oil does
not seep out of the hole after a
few minutes, immediately stop
the engine and have a Yamaha
dealer check for the cause. If oil
seeps out of the hole, turn the
engine off and install the air
bleed screw.12. Start the engine, and then let it
idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the
engine off and check for the
cause.
13. Turn the engine off, and then
check the oil level and correct it if
necessary.
1
1. Air bleed screw
EAU03514
Cleaning the air filter
elementAir filter element, cleaningThe air filter element should be
cleaned at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean the air filter element
more frequently if you are riding in
unusually wet or dusty areas.
1. Remove panel B. (See page 6-8
for panel removal and installation
procedures.)
2. Remove the air filter case cover
by removing the screws, and
then pull the air filter element
out.
1
1
1. Screw (×7)
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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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6-15
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00632
Adjusting the engine idling
speedEngine idling speedThe engine idling speed must be
checked and, if necessary, adjusted
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Start the engine and warm it up
for several minutes at 1,000–
2,000 r/min while occasionally
revving it to 4,000–5,000 r/min.NOTE:
The engine is warm when it quickly
responds to the throttle.
NOTE:
If the specified idling speed cannot
be obtained as described above,
have a Yamaha dealer make the
adjustment.
2. Check the engine idling speed
and, if necessary, adjust it to
specification by turning the throt-
tle stop screw. To increase the
engine idling speed, turn the
screw in direction a. To
decrease the engine idling
speed, turn the screw in direction
b.
1
b
a
1. Throttle stop screw
Engine idling speed:
1,200–1,400 r/min
(Except for CH)
1,300–1,400 r/min
(For CH)
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6-16
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00635
Adjusting the throttle cable
free playThrottle cable free play, adjustingThe throttle cable free play should
measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
a
a. Throttle cable free play
EAU04259
TiresTiresTo maximize the performance, dura-
bility, and safe operation of your
motorcycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000082
w8The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the tempera-
ture of the tires equals the
ambient temperature).
8The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passen-
ger, cargo, and accessories
approved for this model.
EAU00637
Adjusting the valve
clearanceValve clearance, adjustingThe valve clearance changes with
use, resulting in improper air-fuel mix-
ture and/or engine noise. To prevent
this from occurring, the valve clear-
ance must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
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6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
Make sure that both adjusting plates
are in the same position for proper
wheel alignment.
EC000096
cCImproper drive chain slack will
overload the engine as well as
other vital parts of the motorcycle
and can lead to chain slippage or
breakage. To prevent this from
occurring, keep the drive chain
slack within the specified limits.3. Tighten the axle nut and the
brake caliper bracket bolt to the
specified torques.2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA00052
cCDo not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
EAU03006
Lubricating the drive chainDrive chain, lubricatingThe drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
EC000097
cCThe drive chain must be lubricated
after washing the motorcycle or
riding in the rain.1. Clean the drive chain with
kerosene and a small soft brush.
ECA00053
cCTo prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents.
Tightening torques:
Axle nut:
105 Nm (10.5 m0kgf)
Brake caliper bracket bolt:
48 Nm (4.8 m0kgf)
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6-27
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU02962
Checking and lubricating the
cablesCables, checking and lubricatingThe operation of all control cables
and the condition of the cables
should be checked before each ride,
and the cables and cable ends
should be lubricated if necessary. If a
cable is damaged or does not move
smoothly, have a Yamaha dealer
check or replace it.
EAU04034
Checking and lubricating the
throttle grip and cableThrottle grip and cable, checking and lubricatingThe operation of the throttle grip
should be checked before each ride.
In addition, the cable should be lubri-
cated or replaced at the intervals
specified in the periodic maintenance
chart.
EW000112
wDamage to the outer sheath may
interfere with proper cable opera-
tion and will cause the inner cable
to rust. Replace a damaged cable
as soon as possible to prevent
unsafe conditions.
Recommended lubricant:
Engine oil
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6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00794
Checking the steeringSteering, checkingWorn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
wSecurely support the motorcycle
so that there is no danger of it
falling over.
EAU01144
Checking the wheel bearingsWheel bearings, checkingThe front and rear wheel bearings
must be checked at the intervals
specified in the periodic maintenance
and lubrication chart. If there is play
in the wheel hub or if the wheel does
not turn smoothly, have a Yamaha
dealer check the wheel bearings.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any
free play can be felt, have a
Yamaha dealer check or repair
the steering.
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