2002 YAMAHA XT500E ABS

2-1
EAU00026
DESCRIPTIONPart locations
2
1. Headlight (page 6-33)
2. Fuel cock (page 3-8)
3. Battery (page 6-31)
4. Owner’s tool kit (page 6-1)
5. Helmet holder (page 3-10)6. Shock absorber spring preload
adjusting nut (page 3-10)
7. Fuse (page 6-32)
8. Starter (choke) knob (page 3-9)
9. Shift pedal (page 3-5)
1
2
3
45
6
7 8 9
Left view
4PT-E7 (English) 6/29/01 9:13 AM Page 10

INSTRUMENT AND CONTROL FUNCTIONSMain switch/steering lock .................................................................. 3-1
Indicator lights .................................................................................. 3-2
Speedometer unit ............................................................................ 3-2
Tachometer ...................................................................................... 3-3
Handlebar switches .......................................................................... 3-3
Clutch lever ....................................................................................... 3-4
Shift pedal ......................................................................................... 3-5
Brake lever ....................................................................................... 3-5
Brake pedal ...................................................................................... 3-5
Fuel tank cap .................................................................................... 3-6
Fuel ................................................................................................... 3-6
Fuel cock .......................................................................................... 3-8
Starter (choke) knob ......................................................................... 3-9
Seat .................................................................................................. 3-9
Helmet holder ................................................................................. 3-10
Adjusting the shock absorber assembly ......................................... 3-10
Sidestand ........................................................................................ 3-11
Ignition circuit cut-off system .......................................................... 3-12
3
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3-10
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU00260
Helmet holderHelmet holderTo open the helmet holder, insert the
key into the lock, and then turn the
key as shown.
To lock the helmet holder, place it in
the original position, and then remove
the key.
EW000030
wNever ride with a helmet attached
to the helmet holder, since the hel-
met may hit objects, causing loss
of control and possibly an acci-
dent.
1
a
1. Helmet holder
a. Open.
EAU03591
Adjusting the shock
absorber assemblyShock absorber assembly, adjustingThis shock absorber assembly is
equipped with a spring preload
adjusting nut.
EC000015
cCNever attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.Adjust the spring preload as follows.
1. Loosen the locknut.
a
b
1 2
1. Locknut
2. Adjusting nut
2. To increase the spring preload
and thereby harden the suspen-
sion, turn the adjusting nut in
direction a. To decrease the
spring preload and thereby soft-
en the suspension, turn the
adjusting nut in direction b.NOTE:
The spring preload setting is deter-
mined by measuring distance A,
shown in the illustration. The shorter
distance A is, the lower the spring
preload; the longer distance A is, the
higher the spring preload.
A
4PT-E7 (English) 6/29/01 9:13 AM Page 23

3-11
3. Tighten the locknut to the speci-
fied torque.
EC000018
cCAlways tighten the locknut against
the adjusting nut, and then tighten
the locknut to the specified torque.
EAU00315
wThis shock absorber contains
highly pressurized nitrogen gas.
For proper handling, read and
understand the following informa-
tion before handling the shock
absorber. The manufacturer can-
not be held responsible for proper-
ty damage or personal injury that
may result from improper han-
dling.
8Do not tamper with or attempt
to open the gas cylinder.
8Do not subject the shock
absorber to an open flame or
other high heat sources, other-
wise it may explode due to
excessive gas pressure.
8Do not deform or damage the
gas cylinder in any way, as
this will result in poor damp-
ing performance.
8Always have a Yamaha dealer
service the shock absorber.
EAU00330
SidestandSidestandThe sidestand is located on the left
side of the frame. Raise the side-
stand or lower it with your foot while
holding the motorcycle upright.NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situ-
ations. (See further down for an
explanation of the ignition circuit cut-
off system.)
INSTRUMENT AND CONTROL FUNCTIONS
3Spring preload:
Minimum (soft):
Distance A = 1 mm
Standard:
Distance A = 5.5 mm
Maximum (hard):
Distance A = 12 mm
Tightening torque:
Locknut:
42 Nm (4.2 m
0kgf)
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
8
*Brake hoses•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-5.)Every 4 years
9*Wheels•Check runout, spoke tightness and for damage.
•Tighten spokes if necessary.√√√√
10*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
11*Wheel bearings•Check bearing for looseness or damage.√√√√
12*Swingarm•Check operation and for excessive play.√√√√
13 Drive chain•Check chain slack.
•Make sure that the rear wheel is properly aligned.
•Clean and lubricate.Every 500 km and after washing
the motorcycle or riding in the rain
14*Steering bearings•Check bearing play and steering for roughness.√√√√√
•Lubricate with lithium-soap-based grease.Every 20,000 km
15*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 Sidestand•Check operation.
•Lubricate.√√√√ √
17*Sidestand switch•Check operation.√√√√√ √
18*Front fork•Check operation and for oil leakage.√√√√
19*Shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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7-3
MOTORCYCLE CARE AND STORAGE
7After cleaning
1. Dry the motorcycle with a
chamois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, includ-
ing chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal
cleaner to remove any remaining
dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.8. Let the motorcycle dry complete-
ly before storing or covering it.
EWA00001
w8Make sure that there is no oil
or wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
8Before operating the motorcy-
cle test its braking perfor-
mance and cornering behav-
ior.
ECA00013
cC8Apply spray oil and wax spar-
ingly and make sure to wipe
off any excess.
8Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
8Avoid using abrasive polish-
ing compounds as they will
wear away the paint.NOTE:
Consult a Yamaha dealer for advice
on what products to use.
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8-3
SPECIFICATIONS
8
Air pressure (cold tire)
up to 90 kg load*
Front 150 kPa (1.50 kgf/cm
2, 1.50 bar)
Rear 150 kPa (1.50 kgf/cm2, 1.50 bar)
90 kg load–Maximum
load*
Front 150 kPa (1.50 kgf/cm2, 1.50 bar)
Rear 225 kPa (2.25 kgf/cm2, 2.25 bar)
Off-road riding
Front 125 kPa (1.25 kgf/cm2, 1.25 bar)
Rear 125 kPa (1.25 kgf/cm2, 1.25 bar)
High speed riding
Front 150 kPa (1.50 kgf/cm2, 1.50 bar)
Rear 225 kPa (2.25 kgf/cm2, 2.25 bar)
* Total weight of rider, passenger, cargo and accessories
Wheels
Front
Type Spoke wheel
Size 21 ×1.85
Rear
Type Spoke wheel
Size 17 ×MT2.50 or
17 M/C ×MT2.50Brakes
Front
Type Single disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Single disc brake
Operation Right foot
Fluid DOT 4
Suspension
Front
Type Telescopic fork
Rear
Type Swingarm (new monocross)
Shock absorber
Front Coil spring/oil damper
Rear Coil spring/gas-oil damper
Wheel travel
Front 225 mm
Rear 200 mm
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INDEX
E
Engine break-in ..................................... 5-4
Engine idling speed ............................. 6-15
Engine oil and oil filter element ........... 6-10
Engine, starting a warm ......................... 5-2
F
Front and rear brake pads, checking ... 6-22
Front fork, checking ............................. 6-29
Front wheel........................................... 6-37
Installing ............................................ 6-37
Removing .......................................... 6-37
Fuel ....................................................... 3-6
Fuel cock ............................................... 3-8
Fuel consumption, tips for reducing ...... 5-4
Fuel tank cap ......................................... 3-6
Fuse, replacing .................................... 6-32
H
Handlebar switches ............................... 3-3
Light switch ......................................... 3-3
Pass switch ......................................... 3-3
Dimmer switch .................................... 3-3
Turn signal switch ............................... 3-3
Horn switch ......................................... 3-3
Engine stop switch .............................. 3-4
Start switch ......................................... 3-4
Headlight bulb, replacing ..................... 6-33
Helmet holder ...................................... 3-10
I
Identification numbers ........................... 9-1
Ignition circuit cut-off system ............... 3-12
Indicator lights ....................................... 3-2
High beam indicator light .................... 3-2
Neutral indicator light .......................... 3-2
Turn signal indicator light .................... 3-2
K
Key identification number ...................... 9-1
M
Main switch/steering lock ...................... 3-1
Model label ............................................ 9-2
P
Parking .................................................. 5-5
Part locations ......................................... 2-1
Periodic maintenance and lubrication
chart .................................................... 6-3
Pre-operation check list ......................... 4-1
R
Rear brake light switch, adjusting ........ 6-22
Rear suspension, lubricating ............... 6-29
Rear wheel ........................................... 6-39
Removing .......................................... 6-39
Install ................................................ 6-40
S
Seat ....................................................... 3-9
Shift pedal ............................................. 3-5
Shift points (for Switzerland only) .......... 5-3
Shifting .................................................. 5-3
Shock absorber assembly, adjusting ... 3-10
Sidestand ............................................ 3-11
A
Air filter element, cleaning ................... 6-13
B
Battery ................................................. 6-31
Brake and clutch levers, checking and
lubricating ......................................... 6-28
Brake and shift pedals, checking and
lubricating ......................................... 6-28
Brake fluid level, checking ................... 6-23
Brake fluid, changing ........................... 6-24
Brake lever ............................................ 3-5
Brake lever free play, adjusting ........... 6-21
Brake pedal ........................................... 3-5
Brake pedal position, adjusting ........... 6-21
C
Cables, checking and lubricating ......... 6-27
Carburetor, adjusting ........................... 6-14
Care ....................................................... 7-1
Clutch lever ........................................... 3-4
Clutch lever free play, adjusting .......... 6-20
Conversion table ................................... 8-5
Cowling and panels, removing and
installing .............................................. 6-6
D
Drive chain slack ................................. 6-25
Checking ........................................... 6-25
Adjusting ........................................... 6-25
Drive chain, lubricating ........................ 6-26
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