2002 YAMAHA XT500E wheel

4-2
PRE-OPERATION CHECKS
4
Clutch•Check operation.
•Lubricate cable if necessary.
•Check lever free play.
•Adjust if necessary.3-4, 6-20
Throttle grip•Make sure that operation is smooth.
•Check free play.
•If necessary, have Yamaha dealer make adjustment or lubricate.6-16, 6-27
Control cables•Make sure that operation is smooth.
•Lubricate if necessary.6-27
Drive chain•Check chain slack.
•Adjust if necessary.
•Check chain condition.
•Lubricate if necessary.6-25–6-26
Wheels and tires•Check for damage.
•Check tire condition and tread depth.
•Check air pressure.
•Correct if necessary.6-16–6-19
Brake and shift pedals•Make sure that operation is smooth.
•Lubricate pedal pivoting points if necessary.6-28
Brake and clutch levers•Make sure that operation is smooth.
•Lubricate lever pivoting points if necessary.6-28
Sidestand•Make sure that operation is smooth.
•Lubricate pivot if necessary.6-28 ITEM CHECKS PAGE
4PT-E7 (English) 6/29/01 9:13 AM Page 29

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

6-4
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
4PT-E7 (English) 6/29/01 9:13 AM Page 41

6-19
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00681
w8Have a Yamaha dealer replace
excessively worn tires.
Besides being illegal, operat-
ing the motorcycle with exces-
sively worn tires decreases
riding stability and can lead to
loss of control.
8The replacement of all wheel-
and brake-related parts,
including the tires, should be
left to a Yamaha dealer, who
has the necessary profession-
al knowledge and experience.
8It is not recommended to
patch a punctured tube. If
unavoidable, however, patch
the tube very carefully and
replace it as soon as possible
with a high-quality product.
8Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for
it to develop its optimal charac-
teristics.
EAU00685
Spoke wheelsWheelsTo maximize the performance, dura-
bility, and safe operation of your
motorcycle, note the following points
regarding the specified wheels.
8The wheel rims should be
checked for cracks, bends or
warpage, and the spokes for
looseness or damage before
each ride. If any damage is
found, have a Yamaha dealer
replace the wheel. Do not
attempt even the smallest repair
to the wheel. A deformed or
cracked wheel must be replaced.
8The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
4PT-E7 (English) 6/29/01 9:13 AM Page 56

6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00744
Drive chain slackDrive chain slackThe drive chain slack should be
checked before each ride and adjust-
ed if necessary.
To check the drive chain slackChecking1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
When checking and adjusting the
drive chain slack, the motorcycle
should be positioned straight up and
there should be no weight on it.2. Shift the transmission into the
neutral position.
EAU01134
To adjust the drive chain slackadjusting1. Loosen the axle nut and the
brake caliper bracket bolt.
2. To tighten the drive chain, turn
the adjusting plate on each side
of the swingarm in direction a.
To loosen the drive chain, turn
the adjusting plate on each side
of the swingarm in direction b,
and then push the rear wheel for-
ward.
a
b2 1
3
1. Adjusting plate
2. Axle nut
3. Brake caliper bracket bolt
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain,
and then measure the drive
chain slack as shown.
4. If the drive chain slack is incor-
rect, adjust it as follows.
a
a. Drive chain slack
Drive chain slack:
30–40 mm
4PT-E7 (English) 6/29/01 9:13 AM Page 62

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)
4PT-E7 (English) 6/29/01 9:13 AM Page 63

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.
4PT-E7 (English) 6/29/01 9:13 AM Page 67

6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
6 2. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screws.
EC000108
cCDo not overtighten the screws,
otherwise the lens may break.
1
1. Bulb
To service the rear wheel
Raise the rear wheel off the ground
by using a motorcycle stand or, if a
motorcycle stand is not available, by
placing a jack either under each side
of the frame in front of the rear wheel
or under each side of the swingarm.
EAU01579
Supporting the motorcycleSupporting the motorcycleSince this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and
rear wheel or performing other main-
tenance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed
under the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing
a jack under the frame in front of
the rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
4PT-E7 (English) 6/29/01 9:13 AM Page 73