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Yamaha XT 600 E Manual

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XT500E XT600E


PRINTED IN JAPAN 200170.91(E) !


4PT-E7 (English)

6/29/01 9:13 AM

Page 1


Welcome to the Yamaha world of motorcycling! As the owner of an XT500E/XT600E, you are benefiting from Yamahas vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XT500E/XT600E. The owners manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury. In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer. The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

Page 2

Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.
NOTE: 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. 8 Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

Page 3


Page 4

XT500E/XT600E OWNERS MANUAL 2001 by Yamaha Motor Co., Ltd. 1st edition, June 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

Page 5




Page 6

Page 7

Page 8

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. Regular care and maintenance are essential for preserving value and operating condition of your motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Motorcycle ridersmore than car driversmust always be at their mental and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take dangerous risks. Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear, however, should not encourage carelessness. Although full-coverage helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensivelyavoiding all dangers, including those caused by others. Enjoy your ride!

(Parking) The steering is locked, and the taillight and auxiliary light are on, but all other electrical systems are off. The key can be removed. The steering must be locked before the key can be turned to .


OFF All electrical systems are off. The key can be removed.
Do not use the parking position for an extended length of time, otherwise the battery may discharge.

Page 15


& N

Turn signal indicator light 5
Turn signal indicator light
This indicator light flashes when the turn signal switch is pushed to the left or right.
1. High beam indicator light & 2. Neutral indicator light N 3. Turn signal indicator light 5


1. 2. 3. 4. Speedometer Odometer Tripmeter Reset knob


Indicator lights

Speedometer unit

High beam indicator light &
High beam indicator light
This indicator light comes on when the high beam of the headlight is switched on.


Neutral indicator light N

Neutral indicator light

This indicator light comes on when the transmission is in the neutral position.
The 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.

Page 16


Dimmer switch %/&

Dimmer switch
Set this switch to & for the high beam and to % for the low beam.


Turn signal switch 4/6

Turn signal switch

1. Tachometer a. Red zone


1. 2. 3. 4. 5.


Light switch 9 /'/: Pass switch & Dimmer switch %/& Turn signal switch 4/6 Horn switch *

ON: normal position

RES: reserve position
1. Arrow mark pointing over OFF


1. Arrow mark pointing over ON
1. Arrow mark pointing over RES

Fuel cock

The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.
ON With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.
RES This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to ON after refueling!

Page 22

1 b a 2 1
1. Starter (choke) knob 1


1. Bolt (2)


1. Projection (2) 2. Seat holder (2)

Starter (choke) knob 1

Starter (choke) knob
Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the knob in direction a to turn on the starter (choke). Move the knob in direction b to turn off the starter (choke).
To remove the seat Remove the bolts, and then pull the seat off.
To install the seat 1. Insert the projections on the front of the seat into the seat holders as shown. 2. Place the seat in the original position, and then tighten the bolts. NOTE: Make sure that the seat is properly secured before riding.

Page 23

1. Helmet holder a. Open.


1. Locknut 2. Adjusting nut


Helmet holder
To 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.
Adjusting the shock absorber assembly
Shock absorber assembly, adjusting

Page 25

EW000044 EAU03720
The 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 contact the ground and distract the operator, resulting in a possible loss of control. Yamahas ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising 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.
Ignition circuit cut-off system
Ignition circuit cut-of system


The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. 8 It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. 8 It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down. 8 It 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.
If a malfunction is noted, have a Yamaha dealer check the system before riding.

Page 26

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?
NOTE: This check is most reliable if performed with a warmed-up engine.
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?
The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
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.
The system is OK. The motorcycle can be ridden.

Page 27

Pre-operation check list... 4-1

Page 28

The condition of a vehicle is the owners responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.


Pre-operation check list
ITEM Fuel Check fuel level in fuel tank. Refuel if necessary. Check fuel line for leakage.


PAGE 3-63-7

Engine oil

Front brake

Rear brake

Check oil level in engine. If necessary, add recommended oil to specified level. Check vehicle for oil leakage. 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. 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, 6-216-24

Page 29

ITEM Clutch CHECKS Check operation. Lubricate cable if necessary. Check lever free play. Adjust if necessary. Make sure that operation is smooth. Check free play. If necessary, have Yamaha dealer make adjustment or lubricate. Make sure that operation is smooth. Lubricate if necessary. Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. Make sure that operation is smooth. Lubricate pedal pivoting points if necessary. Make sure that operation is smooth. Lubricate lever pivoting points if necessary. Make sure that operation is smooth. Lubricate pivot if necessary. PAGE 3-4, 6-20
Throttle grip Control cables

6-16, 6-27 6-27

Drive chain


Wheels and tires


Brake and shift pedals Brake and clutch levers Sidestand

6-28 6-28 6-28

Page 30
ITEM Chassis fasteners Instruments, lights, signals and switches Sidestand switch CHECKS Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary. Check operation. Correct if necessary. Check operation of ignition circuit cut-off system. If system is defective, have Yamaha dealer check vehicle. PAGE 3-13-4, 6-336-36 3-113-13
NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved.

There is never a more important period in the life of your engine than the period between 0 and 1,600 km. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1,600 km. The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided.
01,000 km Avoid prolonged operation above 4,000 r/min. 1,0001,600 km Avoid prolonged operation above 5,000 r/min.


After 1,000 km of operation, the engine oil must be changed, and the oil filter element replaced. 1,600 km and beyond The vehicle can now be operated normally.

Page 36

EC000053 EAU00457


8 Keep the engine speed out of the tachometer red zone. 8 If any engine trouble should occur during the engine breakin period, immediately have a Yamaha dealer check the vehicle.
When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to OFF.


8 Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. 8 Do not park on a slope or on soft ground, otherwise the motorcycle may overturn.

Page 37

Owners 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. 6-27

* Fuel line

Spark plug

* Valves

Air filter element Clutch
* Front brake * Rear brake
Whenever worn to the limit
Whenever worn to the limit

Page 41

NO. ITEM CHECK OR MAINTENANCE JOB Check for cracks or damage. Replace. (See NOTE on page 6-5.) Check runout, spoke tightness and for damage. Tighten spokes if necessary. Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. Check bearing for looseness or damage. Check operation and for excessive play. Check chain slack. Make sure that the rear wheel is properly aligned. Clean and lubricate. Check bearing play and steering for roughness. Lubricate with lithium-soap-based grease. Make sure that all nuts, bolts and screws are properly tightened. Check operation. Lubricate. Check operation. Check operation and for oil leakage. Check operation and shock absorber for oil leakage. ODOMETER READING ( 1,000 km) 40 Every 4 years ANNUAL CHECK
* Brake hoses * Wheels * Tires
* Wheel bearings 12 * Swingarm

19 Drive chain

Every 500 km and after washing the motorcycle or riding in the rain Every 20,000 km
* Steering bearings * Chassis fasteners
* Sidestand switch * Front fork * assembly

Shock absorber

Page 42
NO. 26 ITEM Rear suspension relay CHECK OR MAINTENANCE JOB Check operation. ODOMETER READING ( 1,000 km) 40


* arm and connecting arm Lubricate with molybdenum disulfide grease. pivoting points * Carburetor
Engine oil Check starter (choke) operation. Adjust engine idling speed. Change. Check oil level and vehicle for oil leakage.
Engine oil filter element Replace.

* switches *

Front and rear brake

Check operation.

Moving parts and cables Lubricate. Lights, signals and switches Check operation. Adjust headlight beam.
NOTE: 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 8 Hydraulic brake service 9 Regularly check and, if necessary, correct the brake fluid level. 9 Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. 9 Replace the brake hoses every four years and if cracked or damaged.

Page 43

1. Cowling A


1. Panel A

1. Panel B

Removing and installing the cowling and panels
Cowling and panels, removing and instal ing
Refer to this section each time the cowling or a panel needs to be removed and installed. 6
The cowling and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter.

Page 44

1. Screw


1. Panel A 2. Screw
Cowling A To remove the cowling Remove the screw, and then pull the cowling off as shown.
To install the cowling Place the cowling in the original position, and then install the screw.


Panels A and B To remove one of the panels Remove the screw, and then pull the panel off as shown. To install the panel Place the panel in the original position, and then install the screw.

Page 45

1. Panel B 2. Screw 1. Spark plug cap


1. Spark plug wrench

Checking the spark plug

Spark plug, checking
The 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.
2. Remove the spark plug as shown, with the spark plug wrench included in the owners tool kit.

Page 46

To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-tolight 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 electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: DPR8EA-9 or DPR9EA-9 (NGK) 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. Tightening torque: Spark plug: 17.5 Nm (1.75 m0kgf) NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/41/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4. Install the spark plug cap.

Cleaning the air filter element
Air filter element, cleaning
The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication 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.

Page 51


Adjusting the carburetor

Carburetor, adjusting

1. Mesh side

1. Arrow mark
3. Lightly tap the air filter element to remove most of the dust and dirt, and then blow the remaining dirt out with compressed air as shown. If the air filter element is damaged, replace it. 4. Insert the air filter element into the air filter case with the arrow mark on the top pointing inward.


8 Make sure that the air filter element is properly seated in the air filter case. 8 The engine should never be operated without the air filter element installed, otherwise the piston and/or cylinder may become excessively worn. 5. Install the air filter case cover by installing the screws. 6. Install the panel.
The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in the following section, however, may be serviced by the owner as part of routine maintenance.


The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine.

Page 52

Adjusting the engine idling speed

Engine idling speed

The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Start the engine and warm it up for several minutes at 1,000 2,000 r/min while occasionally revving it to 4,0005,000 r/min. NOTE: The engine is warm when it quickly responds to the throttle.
NOTE: If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment.

1. Throttle stop screw

2. Check the engine idling speed and, if necessary, adjust it to specification by turning the throttle stop screw. To increase the engine idling speed, turn the screw in direction a. To decrease the engine idling speed, turn the screw in direction b. Engine idling speed: 1,2001,400 r/min (Except for CH) 1,3001,400 r/min (For CH)

Page 61

Observe these precautions: 8 When checking the fluid level, make sure that the top of the brake fluid reservoir is level. 8 Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4
8 Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. 8 Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. 8 Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. 8 As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.


Changing the brake fluid

Brake fluid, changing

Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking. 8 Oil seals: Replace every two years. 8 Brake hoses: Replace every four years.

Page 62


Drive chain slack

The drive chain slack should be checked before each ride and adjusted if necessary. To check the drive chain slack


1 a 2 b a
a. Drive chain slack 1. Adjusting plate 2. Axle nut 3. Brake caliper bracket bolt


1. 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.
3. Move the rear wheel by pushing the motorcycle to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown. Drive chain slack: 3040 mm 4. If the drive chain slack is incorrect, adjust it as follows.
To adjust the drive chain slack


1. 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 forward.

Page 63

NOTE: Make sure that both adjusting plates are in the same position for proper wheel alignment.

1. Fuse 2. Spare fuse


Replacing the fuse

Fuse, replacing
The fuse holder is located behind panel A. (See page 6-7 for panel removal and installation procedures.) If the fuse is blown, replace it as follows. 1. Turn the key to OFF and turn off all electrical circuits. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuse: 20 A

Page 70

Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. 3. Turn the key to ON and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.

1. Bolt (3)

Replacing the headlight bulb
Headlight bulb, replacing
1. Headlight coupler 2. Auxiliary light lead (2) 3. Headlight bulb cover
This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove cowling A. (See page 6-7 for cowling removal and installation procedures.) 2. Remove the headlight unit by removing the bolts.
3. Disconnect the headlight coupler and the auxiliary light leads, and then remove the headlight bulb cover.

Page 71

6. Install the bulb cover, and then connect the coupler and leads. 7. Install the headlight unit by installing the bolts. 8. Install the cowling. 9. Have a Yamaha dealer adjust the headlight beam if necessary.

1. Headlight bulb holder

a. Do not touch this area.
4. Remove the headlight bulb holder by turning it counterclockwise, and then remove the defective bulb.
5. Place a new bulb into position, and then secure it with the bulb holder.


Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down.
Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner.

Page 72

1. Screw 2. Lens


1. Bulb

1. Screw (2) 2. Lens

Replacing a turn signal light bulb
Turn signal light bulb, replacing
1. Remove the turn signal light lens by removing the screw.
2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screw.

Be sure to use motor oils that do not contain anti-friction modifiers. Passenger car motor oils (often labeled ENERGY CONSERVING II) contain anti-friction additives which will cause clutch and/or starter clutch slippage, resulting in reduced component life and poor engine performance.
Cylinder arrangement Displacement Bore Stroke Compression ratio Starting system Lubrication system
Capacity Without oil filter element replacement With oil filter element replaced Total amount (dry engine) 2.7 L 2.8 L 3.3 L

Page 89

Air filter Fuel Type Fuel tank capacity Reserve amount Carburetor Typequantity Manufacturer Spark plug Type/Manufacturer Spark plug gap Clutch type Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Number of drive chain sprocket teeth (rear/front) Transmission type Operation

Dry type element

Gear ratio

1st 2nd

2.583 1.588 1.200 0.954 (XT500E) 0.955 (XT600E) 0.792
REGULAR UNLEADED GASOLINE ONLY 15 L 2L Chassis Y26PV1 TEIKEI Frame type Caster angle Trail Tire Front Type Size

3rd 4th 5th

Diamond 27.75 (XT500E) 2745 (XT600E) 120 mm
DPR8EA-9 or DPR9EA-9/NGK 0.80.9 mm Wet, multiple-disc
With tube 90/90-21 54S or 90/90-21 M/C 54S BRIDGESTONE / TW47 DUNLOP / TRAIL MAX L With tube 120/90-17 64S or 120/90-17 M/C 64S BRIDGESTONE / TW48 DUNLOP / TRAIL MAX 176 kg (XT500E) 180 kg (XT600E)
Spur gear 74/31 (2.387) (XT500E) 71/34 (2.088) (XT600E) Chain drive 2.533 (XT500E) 3.000 (XT600E) 38/15 (XT500E) 45/15 (XT600E) Constant mesh 5-speed Left foot operation 8-2 Rear
Manufacturer/ model Type Size Manufacturer/ model Maximum load*

Page 90

Air pressure (cold tire) up to 90 kg load* Front Rear 90 kg loadMaximum load* Front Rear Off-road riding Front Rear High speed riding Front Rear 150 kPa (1.50 kgf/cm2, 1.50 bar) 225 kPa (2.25 kgf/cm2, 2.25 bar) 125 kPa (1.25 kgf/cm2, 1.25 bar) 125 kPa (1.25 kgf/cm2, 1.25 bar) 150 kPa (1.50 kgf/cm2, 1.50 bar) 225 kPa (2.25 kgf/cm2, 2.25 bar) 150 kPa (1.50 kgf/cm2, 1.50 bar) 150 kPa (1.50 kgf/cm2, 1.50 bar)
Brakes Front Type Operation Fluid Rear Type Operation Fluid Suspension Front Type Rear Type Shock absorber Front Coil spring/oil damper Coil spring/gas-oil damper Swingarm (new monocross) Telescopic fork Single disc brake Right foot DOT 4 Single disc brake Right hand DOT 4
Wheels Front Type Size Rear Type Size Spoke wheel 17 MT2.50 or 17 M/C MT2.50 8-3 Spoke wheel 21 1.85
Rear Wheel travel Front Rear

Page 95

1. Model label


Model label
The model label is affixed to the frame under the seat. (See page 3-9 for seat removal and installation procedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. 9

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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 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



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