Yamaha K-600- Manuals

Q GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY .............................................. 1-1 1 4PT-E7 (English) 6/29/01 9:13 AM Page 7

DESCRIPTION Left view ........................................................................................... 2-1Right view ......................................................................................... 2-2Controls and instruments .........................................................

2-1 EAU00026 DESCRIPTION Part locations 2 1. Headlight (page 6-33) 2. Fuel cock (page 3-8) 3. Battery (page 6-31) 4. Owner’s tool kit (page 6-1) 5. Helmet holder (page 3-10) 6. Shock absorber spring preload adjusting nut (page 3-10) 7. Fuse (page 6-32) 8. Starter (choke) knob (page 3-9) 9. Shift ped...

2-2 DESCRIPTION 2 10. Air filter element (page 6-13) 11. Oil filter element (page 6-11) 12. Engine oil filler cap (page 6-10) 13. Brake pedal (page 3-5, 6-21) 10 11 13 12 Right view 4PT-E7 (English) 6/29/01 9:13 AM Page 11

2-3 DESCRIPTION 2 1. Clutch lever (page 3-4, 6-20) 2. Left handlebar switches (page 3-3) 3. Speedometer unit (page 3-2) 4. Main switch/steering lock (page 3-1) 5. Tachometer (page 3-3) 6. Right handlebar switches (page 3-4) 7. Brake lever (page 3-5, 6-21) 8. Throttle grip (page 6-16, 6-27) 9. Fuel t...

INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock .................................................................. 3-1Indicator lights .................................................................................. 3-2Speedometer unit ......................................................

3-1 EAU00029 Main switch/steering lock Main switch/steering lock The main switch/steering lock con-trols the ignition and lighting systems,and is used to lock the steering. Thevarious positions are describedbelow. EAU00036 ON All electrical systems are suppliedwith power, and the engine can bestarte...

3-2 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00056 Indicator lights Indicator lights EAU00063 High beam indicator light “ & ” High beam indicator light This indicator light comes on whenthe high beam of the headlight isswitched on. EAU00061 Neutral indicator light “N” Neutral indicator light This i...

3-3 EAU00102 Tachometer Tachometer The tachometer allows the rider tomonitor the engine speed and keep itwithin the ideal power range. EC000003 c C Do not operate the engine in thetachometer red zone.Red zone: 7,000 r/min and above EAU03888 Dimmer switch “ % / & ” Dimmer switch Set this switch t...

3-4 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU03890 Engine stop switch “ $ / # ” Engine stop switch Set this switch to “ # ” before starting the engine. Set this switch to “ $ ” to stop the engine in case of an emer-gency, such as when the motorcycleoverturns or when the throttle cable isstuck. EAU00143...

3-5 EAU00157 Shift pedal Shift pedal The shift pedal is located on the leftside of the engine and is used incombination with the clutch leverwhen shifting the gears of the 5-speed constant-mesh transmissionequipped on this motorcycle. INSTRUMENT AND CONTROL FUNCTIONS 3 1 1. Shift pedal EAU00158 Brak...

3-6 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00177 Fuel tank cap Fuel tank cap To remove the fuel tank cap 1. Insert the key into the lock and turn it 1/4 turn counterclockwise. 2. Turn the fuel tank cap 1/3 turn counterclockwise and pull it off. To install the fuel tank cap 1. Insert the fuel tank cap...

3-8 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU03050 Fuel cock Fuel cock The fuel cock supplies fuel from thetank to the carburetor while filtering italso.The fuel cock has three positions: OFF With the lever in this position, fuel willnot flow. Always return the lever tothis position when the engine is ...

3-9 EAU04038 Starter (choke) knob “ 1 ” Starter (choke) knob Starting a cold engine requires a rich-er air-fuel mixture, which is suppliedby 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). INSTRUMENT AND CO...

3-10 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00260 Helmet holder Helmet holder To open the helmet holder, insert thekey into the lock, and then turn thekey as shown.To lock the helmet holder, place it inthe original position, and then removethe key. EW000030 w Never ride with a helmet attachedto the h...

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...

OPERATION AND IMPORTANT RIDING POINTS Starting the engine ........................................................................... 5-1Starting a warm engine ..................................................................... 5-2Shifting .............................................................

5-2 OPERATION AND IMPORTANT RIDING POINTS 5 7. When the engine is warm, turn the starter (choke) off. NOTE: The engine is warm when it respondsnormally to the throttle with the starter(choke) turned off. EAU01258 Starting a warm engine Engine, starting a warm Follow the same procedure as forstarting...

5-4 OPERATION AND IMPORTANT RIDING POINTS 5 EAU00424 Tips for reducing fuel consumption Fuel consumption, tips for reducing Fuel consumption depends largely onyour riding style. Consider the follow-ing tips to reduce fuel consumption: 8 Thoroughly warm up the engine. 8 Turn the starter (choke) off a...

PERIODIC MAINTENANCE AND MINOR REPAIR Owner’s tool kit ................................................ 6-1Periodic maintenance and lubrication chart ..... 6-3Removing and installing the cowling and panels .................................................... 6-6 Checking the spark plug ................

6-1 EAU00462 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU01175 Owner’s tool kit Tool kit The owner’s tool kit is located behindpanel A. (See page 6-7 for panelremoval and installation procedures.)The service information included inthis manual and the tools provided inthe owner’s tool kit are intended...

6-5 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU03884 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 o...

6-6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU03516 Removing and installing thecowling and panels Cowling and panels, removing and installing The cowling and panels shown aboveneed to be removed to perform someof the maintenance jobs described inthis chapter. 1 1. Cowling A 1 1. Panel B Refer to th...

6-7 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU01145 Cowling A To remove the cowlingRemove the screw, and then pull thecowling off as shown. 1 1. Screw EAU04003 Panels A and B To remove one of the panelsRemove the screw, and then pull thepanel off as shown. To install the panelPlace the panel in the...

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 plugwrench included in the owner’stool kit. 1 1. Spark plug wrench EAU01833 Checking the spark plug Spark plug, checking The spark plug is an importantengine component, which is easy...

6-9 PERIODIC MAINTENANCE AND MINOR REPAIR 6 To check the spark plug 1. Check that the porcelain insula- tor around the center electrodeof the spark plug is a medium-to-light tan (the ideal color when themotorcycle is ridden normally). NOTE: If the spark plug shows a distinctlydifferent color, the en...

6-10 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU04354 Engine oil and oil filter element Engine oil and oil filter element The engine oil level should bechecked before each ride. In addition,the oil must be changed and the oilfilter element replaced at the intervalsspecified in the periodic maintenan...

6-11 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EC000000 c C Do not operate the motorcycleuntil you know that the engine oillevel is sufficient. EW000065 w Never remove the engine oil tankcap after high-speed operation,otherwise hot engine oil couldspout out and cause damage orinjury. Always let the en...

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 specifiedtorque. NOTE: Make sure that the O-ring is ...

6-13 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EC000076 c C After changing the engine oil, besure to check the oil pressure asdescribed below. 11. Remove the air bleed screw, and then start the engine. If oil doesnot seep out of the hole after afew minutes, immediately stopthe engine and have a Yamaha...

6-14 PERIODIC MAINTENANCE AND MINOR REPAIR 6 3. Lightly tap the air filter element to remove most of the dust and dirt,and then blow the remaining dirtout with compressed air asshown. If the air filter element isdamaged, replace it. 4. Insert the air filter element into the air filter case with the ...

6-15 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU00632 Adjusting the engine idlingspeed Engine idling speed The engine idling speed must bechecked and, if necessary, adjustedas follows at the intervals specified inthe periodic maintenance and lubrica-tion chart. 1. Start the engine and warm it up for...

6-16 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU00635 Adjusting the throttle cablefree play Throttle cable free play, adjusting The throttle cable free play shouldmeasure 3–5 mm at the throttle grip.Periodically check the throttle cablefree play and, if necessary, have aYamaha dealer adjust it. a a....

6-18 PERIODIC MAINTENANCE AND MINOR REPAIR 6 Tire inspection The tires must be checked beforeeach ride. If the center tread depthreaches the specified limit, if the tirehas a nail or glass fragments in it, orif the sidewall is cracked, have aYamaha dealer replace the tire imme-diately. a 1 1. Side w...

6-19 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU00681 w 8 Have a Yamaha dealer replaceexcessively worn tires.Besides being illegal, operat-ing the motorcycle with exces-sively worn tires decreasesriding stability and can lead toloss of control. 8 The replacement of all wheel-and brake-related parts,...

6-20 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU00694 Adjusting the clutch leverfree play Clutch lever free play, adjusting The clutch lever free play shouldmeasure 10–15 mm as shown.Periodically check the clutch leverfree play and, if necessary, adjust itas follows. 1. Loosen the locknut at the clu...

6-21 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU00696 Adjusting the brake leverfree play Brake lever free play, adjusting The brake lever free play shouldmeasure 2–5 mm as shown.Periodically check the brake leverfree play and, if necessary, adjust itas follows. 1. Loosen the locknut at the brake lev...

6-22 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EW000109 w A soft or spongy feeling in thebrake pedal can indicate the pres-ence of air in the hydraulic system.If there is air in the hydraulic sys-tem, have a Yamaha dealer bleedthe system before operating themotorcycle. Air in the hydraulicsystem will ...

6-23 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU03938 Front brake pads Each front brake pad is provided withwear indicator grooves, which allowyou to check the brake pad wearwithout having to disassemble thebrake. To check the brake pad wear,check the wear indicator grooves. If abrake pad has worn t...

6-24 PERIODIC MAINTENANCE AND MINOR REPAIR 6 Observe these precautions: 8 When checking the fluid level,make sure that the top of thebrake fluid reservoir is level. 8 Use only the recommended qual-ity brake fluid, otherwise the rub-ber seals may deteriorate, caus-ing leakage and poor brakingperforma...

6-25 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU00744 Drive chain slack Drive chain slack The drive chain slack should bechecked before each ride and adjust-ed if necessary. To check the drive chain slack Checking 1. Place the motorcycle on a level surface and hold it in an uprightposition. NOTE: Wh...

6-26 PERIODIC MAINTENANCE AND MINOR REPAIR 6 NOTE: Make sure that both adjusting platesare in the same position for properwheel alignment. EC000096 c C Improper drive chain slack willoverload the engine as well asother vital parts of the motorcycleand can lead to chain slippage orbreakage. To preven...

6-27 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU02962 Checking and lubricating thecables Cables, checking and lubricating The operation of all control cablesand the condition of the cablesshould be checked before each ride,and the cables and cable endsshould be lubricated if necessary. If acable is ...

6-29 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU00790 Lubricating the rear suspension Rear suspension, lubricating The pivoting points of the rear sus-pension must be lubricated at theintervals specified in the periodicmaintenance and lubrication chart. 1 1 1. Grease nipple ( × 2) To check the opera...

6-30 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU00794 Checking the steering Steering, checking Worn or loose steering bearings maycause danger. Therefore, the opera-tion of the steering must be checkedas follows at the intervals specified inthe periodic maintenance and lubrica-tion chart. 1. Place a...

6-32 PERIODIC MAINTENANCE AND MINOR REPAIR 6 To charge the battery Have a Yamaha dealer charge thebattery as soon as possible if itseems to have discharged. Keep inmind that the battery tends to dis-charge more quickly if the motorcycleis equipped with optional electricalaccessories. To store the ba...

6-33 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EC000103 c C Do not use a fuse of a higheramperage rating than recommend-ed to avoid causing extensivedamage to the electrical systemand possibly a fire. 3. Turn the key to “ON” and turn on the electrical circuits to check ifthe devices operate. 4. If the...

6-34 PERIODIC MAINTENANCE AND MINOR REPAIR 6 4. Remove the headlight bulb hold- er by turning it counterclockwise,and then remove the defectivebulb. EW000119 w Headlight bulbs get very hot.Therefore, keep flammable prod-ucts away from a lit headlight bulb,and do not touch the bulb until ithas cooled...

6-35 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU03497 Replacing a turn signal lightbulb Turn signal light bulb, replacing 1. Remove the turn signal light lens by removing the screw. 1 2 1. Screw 2. Lens EAU01623 Replacing the tail/brake lightbulb Tail/brake light bulb, replacing 1. Remove the tail/b...

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 c C Do not overtighten the...

6-37 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU00897 Front wheel Removing To remove the front wheel EW000122 w 8 It is advisable to have aYamaha dealer service thewheel. 8 Securely support the motorcy-cle so that there is no dangerof it falling over. 1. Disconnect the speedometer cable from the fro...

6-38 PERIODIC MAINTENANCE AND MINOR REPAIR 6 NOTE: Make sure that there is enoughspace between the brake padsbefore inserting the brake disc andthat the slot in the speedometer gearunit fits over the retainer on the forkleg. 3. Install the wheel axle.4. Lower the front wheel so that it is on the gro...

6-39 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU04314 Rear wheel To remove the rear wheel EW000122 w 8 8 It is advisable to have aYamaha dealer service thewheel. 8 Securely support the motorcy-cle so that there is no dangerof it falling over. 1. Remove the axle nut.2. Loosen the brake caliper bracke...

6-40 PERIODIC MAINTENANCE AND MINOR REPAIR 6 6. Push the wheel forward, and then remove the drive chain fromthe rear sprocket. NOTE: The drive chain does not need to bedisassembled in order to remove andinstall the wheel. 7. Pull the wheel axle out, and then remove the wheel. ECA00048 c C Do not app...

6-41 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU01008 Troubleshooting Troubleshooting Although Yamaha motorcyclesreceive a thorough inspection beforeshipment from the factory, troublemay occur during operation. Anyproblem in the fuel, compression, orignition systems, for example, cancause poor start...

MOTORCYCLE CARE AND STORAGE Care .................................................................................................. 7-1Storage ............................................................................................. 7-4 7 4PT-E7 (English) 6/29/01 9:13 AM Page 81

7-1 EAU03521 MOTORCYCLE CARE AND STORAGE 7 Care Care While the open design of a motorcy-cle reveals the attractiveness of thetechnology, it also makes it more vul-nerable. Rust and corrosion candevelop even if high-quality compo-nents are used. A rusty exhaust pipemay go unnoticed on a car, however,...

7-2 MOTORCYCLE CARE AND STORAGE 7 8 8 Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abra-sive cleaning products, sol-vent or thinner, fuel (gasoline),rust removers or inhibitors,brake fluid, antifreeze or elec-...

7-3 MOTORCYCLE CARE AND STORAGE 7 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Immediately dry the drive chain and lubricate it to prevent it fromrusting. 3. Use a chrome polish to shine chrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even t...

7-5 MOTORCYCLE CARE AND STORAGE 7 6. Lubricate all control cables and the pivoting points of all leversand pedals as well as of thesidestand/centerstand. 7. Check and, if necessary, correct the tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground.Alternatively,...

SPECIFICATIONS Specifications ................................................................................... 8-1Conversion table ............................................................................... 8-5 8 4PT-E7 (English) 6/29/01 9:13 AM Page 87

8-1 EAU01038 SPECIFICATIONS 8 Specifications Specifications Model XT500E/XT600E Dimensions Overall length 2,220 mm 2.295 mm (N, S, CH only) Overall width 865 mm825 mm (CH only) Overall height 1,205 mm Seat height 855 mm Wheel base 1,440 mm Ground clearance 230 mm Minimum turning radius 2,300 mm Basi...

8-4 SPECIFICATIONS 8 Electrical Ignition system T.C.I. (Digital) Charging system Type A.C. magneto Standard output 14 V, 13.5A @ 5,000 rpm Battery Type YTX9-BS Voltage, capacity 12 V, 8 AH Headlight bulb type Halogen bulb Bulb voltage, wattage × quantity Headlight 12 V, 60/55W × 1 Tail/brake light 1...

8-5 SPECIFICATIONS 8 EAU03941 Conversion table Conversion tableConversion table All specification data in this manual are listed in SI andMETRIC UNITS.Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MULTIPLIER IMPERIAL ** mm × 0.03937 = ** in 2 mm × 0.03937 = 0.08 in MET...

CONSUMER INFORMATION Identification numbers ...................................................................... 9-1Key identification number ................................................................. 9-1Vehicle identification number ............................................................

9-1 EAU01039 CONSUMER INFORMATION 9 EAU02944 Identification numbers Identification numbers Record the key identification number,vehicle identification number andmodel label information in the spacesprovided below for assistance whenordering spare parts from a Yamahadealer or for reference in case th...

9-2 CONSUMER INFORMATION 9 EAU01050 Model label Model label The model label is affixed to theframe under the seat. (See page 3-9for seat removal and installation pro-cedures.) Record the information onthis label in the space provided. Thisinformation will be needed whenordering spare parts from a Ya...

INDEX E Engine break-in ..................................... 5-4Engine idling speed ............................. 6-15Engine oil and oil filter element ........... 6-10Engine, starting a warm ......................... 5-2 F Front and rear brake pads, checking ... 6-22Front fork, checking .............

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001·7–0.9 × 1(E) ! 4PT-28199-E7 OWNER’S MANUAL YAMAHA MOTOR CO., LTD. XT600E XT500E