2002 YAMAHA XT600E transmission

3-2
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU00056
Indicator lightsIndicator lights
EAU00063
High beam indicator light “&”High beam indicator lightThis indicator light comes on when
the high beam of the headlight is
switched on.
EAU00061
Neutral indicator light “N”Neutral indicator lightThis indicator light comes on when
the transmission is in the neutral
position.
EAU00057
Turn signal indicator light “5”Turn signal indicator lightThis indicator light flashes when the
turn signal switch is pushed to the left
or right.
12
3&
5
N
1. High beam indicator light “&”
2. Neutral indicator light “N”
3. Turn signal indicator light “5”
EAU00095
Speedometer unit Speedometer unitThe speedometer unit is equipped
with a speedometer, an odometer
and a tripmeter. The speedometer
shows riding speed. The odometer
shows the total distance traveled.
The tripmeter shows the distance
traveled since it was last set to zero
with the reset knob. The tripmeter
can be used to estimate the distance
that can be traveled with a full tank of
fuel. This information will enable you
to plan future fuel stops.
1
2
4
3
1. Speedometer
2. Odometer
3. Tripmeter
4. Reset knob
4PT-E7 (English) 6/29/01 9:13 AM Page 15

3-5
EAU00157
Shift pedalShift pedalThe shift pedal is located on the left
side of the engine and is used in
combination with the clutch lever
when shifting the gears of the
5-speed constant-mesh transmission
equipped on this motorcycle.INSTRUMENT AND CONTROL FUNCTIONS
3
1
1. Shift pedal
EAU00158
Brake leverBrake leverThe brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the han-
dlebar grip.
1
1. Brake lever
EAU00162
Brake pedalBrake pedalThe brake pedal is on the right side
of the motorcycle. To apply the rear
brake, press down on the brake
pedal.
1
1. Brake pedal
4PT-E7 (English) 6/29/01 9:13 AM Page 18

3-12
INSTRUMENT AND CONTROL FUNCTIONS
3
EW000044
wThe motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up),
otherwise the sidestand could con-
tact the ground and distract the
operator, resulting in a possible
loss of control. Yamaha’s ignition
circuit cut-off system has been
designed to assist the operator in
fulfilling the responsibility of rais-
ing the sidestand before starting
off. Therefore, check this system
regularly as described below and
have a Yamaha dealer repair it if it
does not function properly.
EAU03720
Ignition circuit cut-off
systemIgnition circuit cut-off systemThe ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
8It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
8It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the
sidestand is still down.
8It cuts the running engine when
the transmission is in gear and
the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
EW000045
wIf a malfunction is noted, have a
Yamaha dealer check the system
before riding.
4PT-E7 (English) 6/29/01 9:13 AM Page 25

3-13
INSTRUMENT AND CONTROL FUNCTIONS
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
#”.
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
NOTE:This check is most reliable if performed with
a warmed-up engine.
YESYES NO
The system is OK. The motorcycle can be ridden.
YES NO
4PT-E7 (English) 6/29/01 9:13 AM Page 26

1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch
is set to “#”.
3. Shift the transmission into the
neutral position.NOTE:
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.4. Turn the starter (choke) on and
completely close the throttle.
(See page 3-9 for starter (choke)
operation.)
5. Start the engine by pushing the
start switch.
5-1
EAU00372
OPERATION AND IMPORTANT RIDING POINTS
5
EAU00373
w8Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or func-
tion that you do not thorough-
ly understand.
8Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
8Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU03515
Starting the engineStarting the engineIn order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
8The transmission is in the neutral
position.
8The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
w8Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-13.
8Never ride with the sidestand
down.
4PT-E7 (English) 6/29/01 9:13 AM Page 32

5-3
OPERATION AND IMPORTANT RIDING POINTS
5
EAU00423
ShiftingShiftingShifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the
illustration.NOTE:
To shift the transmission into the neu-
tral position, press the shift pedal
down repeatedly until it reaches the
end of its travel, and then slightly
raise it.
EC000048
cC8Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long
distances. The transmission is
properly lubricated only when
the engine is running.
Inadequate lubrication may
damage the transmission.
8Always use the clutch while
changing gears to avoid dam-
aging the engine, transmis-
sion, and drive train, which are
not designed to withstand the
shock of forced shifting.
EAU02941
Recommended shift points
(for Switzerland only)Shift points (for Switzerland only)The recommended shift points during
acceleration are shown in the table
below.NOTE:
When shifting down two gears at a
time, reduce the speed accordingly
(e.g., down to 35 km/h when shifting
from 4th to 2nd gear).
1
5
4
3
2
N
1
1. Shift pedal
N. Neutral position
Shift point (km/h)
1st →2nd 23
2nd →3rd 36
3rd →4th 50
4th →5th 60
4PT-E7 (English) 6/29/01 9:13 AM Page 34

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

8-2
SPECIFICATIONS
8
Air filterDry type element
Fuel
Type REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity 15 L
Reserve amount 2 L
Carburetor
Type×quantity Y26PV×1
Manufacturer TEIKEI
Spark plug
Type/Manufacturer DPR8EA-9 or DPR9EA-9/NGK
Spark plug gap 0.8–0.9 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 74/31 (2.387) (XT500E)
71/34 (2.088) (XT600E)
Secondary reduction system Chain drive
Secondary reduction ratio 2.533 (XT500E)
3.000 (XT600E)
Number of drive chain 38/15 (XT500E)
sprocket teeth (rear/front) 45/15 (XT600E)
Transmission type Constant mesh 5-speed
Operation Left foot operationGear ratio 1st 2.583
2nd 1.588
3rd 1.200
4th 0.954 (XT500E)
0.955 (XT600E)
5th 0.792
Chassis
Frame type Diamond
Caster angle 27.75°(XT500E)
27°45’ (XT600E)
Trail 120 mm
Tire
Front
Type With tube
Size 90/90-21 54S or
90/90-21 M/C 54S
Manufacturer/ BRIDGESTONE / TW47
model DUNLOP / TRAIL MAX L
Rear
Type With tube
Size 120/90-17 64S or
120/90-17 M/C 64S
Manufacturer/ BRIDGESTONE / TW48
model DUNLOP / TRAIL MAX
Maximum load* 176 kg (XT500E)
180 kg (XT600E)
4PT-E7 (English) 6/29/01 9:13 AM Page 89