2002 YAMAHA XT600E maintenance

6-6
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03516
Removing and installing the
cowling and panelsCowling and panels, removing and installingThe cowling and panels shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter.
1
1. Cowling A
1
1. Panel B
Refer to this section each time the
cowling or a panel needs to be
removed and installed.
1
1. Panel A
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6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01145
Cowling A
To remove the cowlingRemove the screw, and then pull the
cowling off as shown.
1
1. Screw
EAU04003
Panels A and B
To remove one of the panelsRemove the screw, and then pull the
panel off as shown.
To install the panelPlace the panel in the original posi-
tion, and then install the screw.
1
2
1. Panel A
2. Screw
To install the cowlingPlace the cowling in the original posi-
tion, and then install the screw.
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6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
6
1
2
1. Panel B
2. Screw
2. Remove the spark plug as
shown, with the spark plug
wrench included in the owner’s
tool kit.
1
1. Spark plug wrench
EAU01833
Checking the spark plugSpark plug, checkingThe spark plug is an important
engine component, which is easy to
check. Since heat and deposits will
cause any spark plug to slowly erode,
the spark plug should be removed
and checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1. Remove the spark plug cap.
1
1. Spark plug cap
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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)
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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)
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