2002 YAMAHA XT500E check oil

4-1
EAU01114
PRE-OPERATION CHECKS
4The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
Pre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-6–3-7
Engine oil•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-10–6-13
Front brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check lever free play.
•Adjust if necessary.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-5, 6-21–6-24
Rear brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-5, 6-21–6-24
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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
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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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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
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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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6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000000
cCDo not operate the motorcycle
until you know that the engine oil
level is sufficient.
EW000065
wNever remove the engine oil tank
cap after high-speed operation,
otherwise hot engine oil could
spout out and cause damage or
injury. Always let the engine oil
cool down sufficiently before
removing the oil tank cap.5. If the engine oil is below the min-
imum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
6. Install the oil filler cap and the oil
filler cap cover.4. Check the washers for damage
and replace them if necessary.
NOTE:
Skip steps 5–8 if the oil filter element
is not being replaced.5. Remove the oil filter element
cover by removing the bolts.NOTE:
The oil filter element cover is secured
by two bolts and a drain bolt. First,
remove the drain bolt to drain the oil
filter element cavity.
1
32
1. Oil filter cover bolt (×2)
2. Oil filter cover
3. Oil filter drain bolt
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the
engine to collect the used oil.
3. Remove the oil filler cap cover,
the oil filler cap and the drain
bolts to drain the oil from the
crankcase and oil tank.1. Drain bolt (oil tank)
2. Drain bolt (crankcase)1
2
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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)
4PT-E7 (English) 6/29/01 9:13 AM Page 50