Yamaha 2007 XP500 Service Manual

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2007

XP500

XP500A

SERVICE MANUAL

15B-28197-E0

Table of Contents

Chapters

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Troubleshooting

Summary of Contents for Yamaha 2007 XP500

Page 1 2007 XP500 XP500A SERVICE MANUAL 15B-28197-E0...
Page 3 EAS20040 XP500/XP500A 2007 SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. First edition, November 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 4 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
Page 5 EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. The manual is divided into chapters and each chapter is divided into sections.
Page 6 EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling ﬂuid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.
Page 7: Table Of Contents
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
GENERAL INFORMATION IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER ........... 1-1 MODEL LABEL..................1-1 FEATURES....................1-2 OUTLINE OF FI SYSTEM ............... 1-2 FI SYSTEM....................1-3 OUTLINE OF ANTI-LOCK BRAKE SYSTEM (XP500A) ......1-4 MULTI-FUNCTION DISPLAY..............1-15 IMPORTANT INFORMATION ............... 1-18 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-18 REPLACEMENT PARTS.................
Page 10: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
Page 11: Features
FEATURES EAS20170 FEATURES EAS15B1002 OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions. In a conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber.
Page 12: Fi System
FEATURES EAS15B1003 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump) maintains the fuel pressure that is applied to the fuel injector at 240 – 260 kPa (2.40 – 2.60 kg/cm 34.1 –...
Page 13: Outline Of Anti-Lock Brake System (Xp500A)
The operation of the Yamaha ABS brakes is the same as conventional vehicle, with a right hand brake lever for operating the front wheel brake and a left hand brake lever for operating the rear wheel brake.
Page 14 FEATURES ABS block diagram 8. Rear brake caliper 1. Rear brake master cylinder 9. Front brake caliper 2. Hydraulic unit 10. ECU (ABS) 3. Hydraulic pump 11. Rear wheel sensor 4. ABS motor 12. Front wheel sensor 5. Buffer chamber 13.
Page 15 FEATURES 0%: There is no slip between the wheel and the road surface. The chassis speed is equal to the wheel speed. 100%: The wheel speed is “0”, but the chassis is moving (i.e., wheel lock). EAS15B1006 Brake force and vehicle stability When the brake pressure is increased, wheel speed is reduced.
Page 16 FEATURES EAS15B1008 ABS operation and vehicle control If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the limit of control. To make the rider aware of this condition, the ABS has been designed to generate a reaction-force pulsating action in the brake lever.
Page 17 FEATURES sure. But, if there is a tendency of the wheel to lock on a slippery road surface, due to engine braking, the ABS may not be able to prevent the wheel from locking. EWA15B1004 WARNING The ABS controls only the tendency of the wheel to lock caused by applying the brakes. The ABS cannot prevent wheel lock on slippery surfaces, such as ice, when it is caused by engine braking, even if the ABS is operating.
Page 18 FEATURES Electronic control unit (ECU) The ECU (ABS) “1” controls the ABS and is located on the right side of the vehicle near the top of the front fork. To protect the ECU (ABS) from water damage, it is protected by a cover. ABS control operation The ABS control operation performed in the ECU (ABS) is divided into the following two parts.
Page 19 FEATURES 6. Receive signals 1. Software operation flow 7. Control operation 2. Set the main switch to “ON”. 8. Depressurize/pressurize 3. Initialize 4. Self-diagnosis (when static) A. 8/1,000 of a second 5. Self-diagnosis (when riding) Fail-safe relay The fail-safe relay controls the power supply of the hydraulic unit and is located upper the ECU (ABS). 1.
Page 20 FEATURES Composition and operation The fail-safe relay is composed of the solenoid relay “1” and fail-safe relay “2”. The solenoid relay is activated (continuous) by signals transmitted from the ECU (ABS). As a result, the solenoid valve “3” can be operated. If a malfunction occurs in the circuit, the solenoid relay is deactivated and it becomes impossible for the solenoid valve to reduce the hydraulic pressure of the brake fluid and normal braking is resumed.
Page 21 FEATURES ABS operation The ABS hydraulic circuit consists of two systems: the front wheel and rear wheel. The following de- scribes the front system only. Normal braking (ABS not activated) When the ABS is not activated port D “11” of the solenoid valve is closed because a control signal has not been transmitted from the ECU (ABS) and port A “7”...
Page 22 FEATURES Emergency braking (ABS activated) 1.Depressurized state When the front wheel is about to lockup, port D “11” of the solenoid valve is opened by the “depres- surization” signal transmitted from the ECU (ABS). When this occurs, the spool of the flow control valve compresses the return spring to close port B “9”.
Page 23 FEATURES 2.Pressurized state Port D “11” is closed by the “pressurization” signal transmitted from the ECU (ABS). Before this oc- curs, the spool of the flow control valve has compressed the return spring to close port B “9”. Brake fluid that has entered through port A “7” is further restricted by the orifice “10” and the brake fluid is sent to the brake calipers via port A “7”...
Page 24: Multi-Function Display
FEATURES EAS15B1001 NOTE: MULTI-FUNCTION DISPLAY Be sure to turn the key to “ON” before using the EWA12311 “SELECT” and “RESET” buttons. WARNING When the key is turned to “ON”, all of the dis- Be sure to stop the vehicle before making play segments of the multi-function display will any setting changes to the multi-function appear one after the other and then disappear,...
Page 25 FEATURES To reset a tripmeter, select it by pushing the “SELECT” button until “TRIP” or “TRIP F” begins flashing (“TRIP” or “TRIP F” will only flash for five seconds). While “TRIP” or “TRIP F” is flash- ing, push the “RESET” button for at least one second.
Page 26 FEATURES engine stop switch is set to “ON”. 2. Disconnect the V-belt replacement reset cou- pler “1” for two to ten seconds. 3. And then, connect the V-belt replacement re- set coupler, the V-belt replacement indicator will come on for 1.4 seconds. And the V-belt replacement indicator will go off.
Page 27: Important Information
Oil bearings liberally when installing, if appropri- EAS20200 ate. REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 28: Circlips
IMPORTANT INFORMATION ECA13300 CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfac- EAS20240 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Al- ways replace piston pin clips after one use. When installing a circlip “1”, make sure the sharp-edged corner “2”...
Page 29: Checking The Connections
CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: Lead NOTE: Coupler If there is no continuity, clean the terminals. Connector When checking the wire harness, perform 2.
Page 30: Special Tools
SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages T-handle 4-59, 4-61 90890-01326 T-handle 3/8" drive 60 cm long YM-01326 Damper rod holder 4-59, 4-61 90890-01460 Locknut wrench 5-55, 5-57 90890-01348 YM-01348 Flywheel puller 5-32 90890-01362 Heavy duty puller YU-33270-B Frok seal driver weight 4-62 90890-01367 Replacement hammer...
Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil ﬁlter wrench 3-13 90890-01469 Oil ﬁlter wrench YM-01469 66.8 Sheave holder 5-54 90890-01481 Clutch spring compressor 5-45 90890-01482 Sheave holder 5-32, 5-33 90890-01701 Primary clutch holder YS-01880-A Thickness gauge 90890-03079 Narrow gauge set YM-34483 Compression gauge 3-11...
Page 33 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pocket tester 1-20, 5-37, 90890-03112 8-103, 8-105, 8-106, 8-108, Analog pocket tester 8-110, 8-111, YU-03112-C 8-112, 8-113, 8-114, 8-115, 8-116, 8-117, 8-118, 8-119, 8-120, 8-121 Timing light 3-10 90890-03141 Inductive clamp timing light YU-03141 Test coupler adapter 4-50, 4-51...
Page 34 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor 5-18, 5-23 90890-04019 YM-04019 Valve spring compressor attachment 5-18, 5-23 90890-04114 Valve spring compressor adapter 19.5 YM-04114 Middle driven shaft bearing driver 6-10 90890-04058 Bearing driver 40 mm YM-04058 Mechanical seal installer 6-10 90890-04078...
Page 35 YM-04134 Sheave ﬁxed block 5-55, 5-57 90890-04135 Sheave ﬁxed bracket YM-04135 Plane bearing installer 5-62 90890-04139 Ignition checker 8-113 90890-06754 Opama pet-4000 spark checker YM-34487 Digital tachometer 90890-06760 YU-39951-B Yamaha bond No. 1215 (Three Bond 5-34, 5-68 No.1215®) 90890-85505 1-26...
Page 36 SPECIAL TOOLS 1-27...
Page 37: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................ 2-9 ELECTRICAL SPECIFICATIONS ..............2-12 TIGHTENING TORQUES ................2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-15 ENGINE TIGHTENING TORQUES............2-15 CHASSIS TIGHTENING TORQUES............2-19 LUBRICATION POINTS AND LUBRICANT TYPES ........2-21 ENGINE....................
Page 38: General Specifications
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model XP500 15B1 (EUR) XP500 15B4 (EUR) XP500A 15B2 (EUR) XP500A 15B5 (EUR) XP500W 15B3 (AUS) XP500W 15B6 (AUS) Dimensions Overall length 2235 mm (88.0 in) Overall width 775 mm (30.5 in) Overall height 1410 mm (55.5 in) Seat height 795 mm (31.3 in)
Page 39: Engine Specifications
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 499.0 cm Cylinder arrangement Forward-inclined parallel 2-cylinder Bore × stroke 66.0 × 73.0 mm (2.60 × 2.87 in) Compression ratio 11.00 :1 Standard compression pressure (at sea level) 1400 kPa/360 r/min (199.1 psi/360 r/min) (14.0 kgf/cm /360 r/min)
Page 40 ENGINE SPECIFICATIONS Thermostat Model/manufacturer 4JH/NIPPON THERMOSTAT 69.0–73.0 °C (156.20–163.40 °F) Valve opening temperature 85.0 °C (185.00 °F) Valve full open temperature Valve lift (full open) 8.0 mm (0.31 in) Radiator core Width 330.0 mm (12.99 in) Height 138.0 mm (5.43 in) Depth 24.0 mm (0.94 in) Water pump...
Page 41 ENGINE SPECIFICATIONS Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Model/number of links SCR-0409 SV/132 Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.15–0.20 mm (0.0059–0.0079 in) Exhaust 0.25–0.30 mm (0.0098–0.0118 in) Valve dimensions Valve head diameter A (intake) 24.90–25.10 mm (0.9803–0.9882 in) Valve head diameter A (exhaust) 21.90–22.10 mm (0.8622–0.8701 in)
Page 42 ENGINE SPECIFICATIONS Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout 0.040 mm (0.0016 in) Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.06 in) Cylinder head valve seat width (exhaust)
Page 43 ENGINE SPECIFICATIONS Wear limit 66.100 mm (2.6024 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.050 mm (0.0020 in) Piston Piston-to-cylinder clearance 0.020–0.045 mm (0.0008–0.0018 in) Limit 0.15 mm (0.0059 in) Diameter D 65.965–65.980 mm (2.5970–2.5976 in) Height H 9.0 mm (0.35 in) Offset...
Page 44 ENGINE SPECIFICATIONS End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in) Ring side clearance 0.040–0.160 mm (0.0016–0.0063 in) Connecting rod Oil clearance (using plastigauge®) 0.026–0.050 mm (0.0010–0.0020 in) Bearing color code 1.Blue 2.Black 3.Brown 4.Green Small end inside diameter 15.005–15.018 mm (0.5907–0.5913 in) Crankshaft Width A 50.00–50.60 mm (1.969–1.992 in)
Page 45 ENGINE SPECIFICATIONS V-belt V-belt width 32.0 mm (1.26 in) Limit 30.5 mm (1.20 in) Transmission Transmission type V-belt automatic Primary reduction system Spur gear/helical gear 52/32 × 36/22 (2.659) Primary reduction ratio Secondary reduction system Chain drive 41/25 × 40/29 (2.262) Secondary reduction ratio Operation Centrifugal automatic type...
Page 46: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 28.00 ° Caster angle Trail 95.0 mm (3.74 in) Front wheel Wheel type Cast wheel Rim size 14M/C x MT3.50 Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 47 CHASSIS SPECIFICATIONS Brake pad lining thickness (inner) 6.2 mm (0.24 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (outer) 6.2 mm (0.24 in) Limit 0.8 mm (0.03 in) Master cylinder inside diameter 14.00 mm (0.55 in) Caliper cylinder inside diameter 30.16 mm (1.19 in) Caliper cylinder inside diameter 25.40 mm (1.00 in)
Page 48 CHASSIS SPECIFICATIONS Spring rate K2 294.00 N/mm (1678.74 lb/in) (29.98 kgf/mm) Spring stroke K1 0.0–28.8 mm (0.00–1.13 in) Spring stroke K2 28.8–43.0 mm (1.13–1.69 in) Optional spring available Enclosed gas/air pressure (STD) 4900 kPa (696.9 psi) (49.0 kgf/cm Swingarm Swingarm end free play limit (radial) 1.0 mm (0.04 in) Swingarm end free play limit (axial) 1.0 mm (0.04 in)
Page 49: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Digital 10.0 °/1200 r/min Ignition timing (B.T.D.C.) 189–231 Ω (Gy-B) Crankshaft position sensor resistance Engine control unit Model/manufacturer XP500 TBDF48/DENSO XP500A TBDF49/DENSO XP500W TBDF07/DENSO Ignition coil...
Page 50 ELECTRICAL SPECIFICATIONS 12 V, 5.0 W × 1 License plate light 14 V, 2.0 W × 3 Meter lighting Indicator light 14 V, 1.4 W × 2 Turn signal indicator light 14 V, 1.4 W × 1 High beam indicator light 14 V, 1.4 W ×...
Page 51 ELECTRICAL SPECIFICATIONS Parking lighting fuse 10.0 A Fuel injection system fuse 10.0 A ABS motor fuse XP500A 30.0 A ABS control unit fuse XP500A 5.0 A Backup fuse 10.0 A Reserve fuse 30.0 A Reserve fuse XP500 20.0 A XP500A 15.0 A XP500W 20.0 A Reserve fuse XP500 15.0 A...
Page 52: Tightening Torques
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- A.
Page 53 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Chain guide (intake side) 10 Nm (1.0 m•kg, 7.2 ft•lb) Water pump housing cover 10 Nm (1.0 m•kg, 7.2 ft•lb) Water pump assembly 10 Nm (1.0 m•kg, 7.2 ft•lb) Coolant pipe 10 Nm (1.0 m•kg, 7.2 ft•lb) Radiator ﬁller neck 7 Nm (0.7 m•kg, 5.1 ft•lb)
Page 54 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Right crankcase cover 24 Nm (2.4 m•kg, 17 ft•lb) V-belt case air ﬁlter cover and V-belt 7 Nm (0.7 m•kg, 5.1 ft•lb) case air ﬁlter element (right) V-belt case air ﬁlter element (left) 7 Nm (0.7 m•kg, 5.1 ft•lb) Generator cover protector 7 Nm (0.7 m•kg, 5.1 ft•lb)
Page 55 TIGHTENING TORQUES Crankcase tightening sequence: Cylinder head tightening sequence: 2-18...
Page 56: Chassis Tightening Torques
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Upper bracket pinch bolt 30 Nm (3.0 m•kg, 22 ft•lb) Steering stem nut 110 Nm (11.0 m•kg, 80 ft•lb) Lower ring nut 20 Nm (2.0 m•kg, 14 ft•lb) NOTE.
Page 57 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size ECU (ABS) bracket (XP500A) 7 Nm (0.7 m•kg, 5.1 ft•lb) Hydraulic unit (XP500A) 16 Nm (1.6 m•kg, 11 ft•lb) Brake lever 7 Nm (0.7 m•kg, 5.1 ft•lb) Swingarm and pivot shaft 7 Nm (0.7 m•kg, 5.1 ft•lb) Pivot shaft and lock nut 100 Nm (10.0 m•kg, 72 ft•lb)
Page 58: Lubrication Points And Lubricant Types
LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearing and bushes Crankshaft pins Piston surfaces Piston pins and connecting rod small end Balancer surface Connecting rod big end thrust surface Connecting rod bolts and nuts Crankshaft thrust surface Crankshaft journals...
Page 59: Chassis
BEL-RAY assembly Secondary sheave lube® Swingarm pivot shaft bearing Crankcase mating surface Yamaha bond No.1215 A.C. magneto lead Yamaha bond No.1215 Cylinder head cover (gasket mating surface) Yamaha bond No.1215 Cylinder head cover (guide stopper mating surface) Yamaha bond No.1215 Right crankcase cover (air duct seal mating surface) Yamaha bond No.1215...
Page 60 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Rear shock absorber bearing and collar inner surface Swingarm, oil seal lip and collar inner surface Rear shock absorber bolt (front side) 2-23...
Page 61 LUBRICATION POINTS AND LUBRICANT TYPES 2-24...
Page 62: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-25...
Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Piston cooler 4. Crankshaft 5. Oil tank 6. Oil pan 7. Strainer 8. Suction oil pump 9. Flush oil pump 10. Check valve 11. Relief valve 12. Oil cooler 13.
Page 64: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27...
Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Oil tank 3. Oil strainer 4. Relief valve 5. Oil cooler 6. Oil ﬁlter cartridge 7. Exhaust camshaft 8. Intake camshaft 9. Oil pipe 10. Oil delivery pipe 2-28...
Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Crankshaft 2-30...
Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Clutch 2. Right main journal bearing 3. Main gallery plug 2-32...
Page 70: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-33...
Page 71 COOLING SYSTEM DIAGRAMS 1. Coolant reservoir 2. Thermostat 3. Radiator 4. Water pump 5. Radiator fan 6. Radiator cap 7. Fast idle plunger 2-34...
Page 72: Cable Routing
CABLE ROUTING EAS20430 CABLE ROUTING 2-35...
Page 73 CABLE ROUTING 1. Headlight sub-wire harness 2. Horn 3. Horn (H mark on the back of the horn) A. Securely fasten the wire strap to the front cowl- ing hook to prevent it from being pulled out by the headlight assembly. (left and right) B.
Page 74 CABLE ROUTING 2-37...
Page 75 CABLE ROUTING 1. Rear brake hose 2. Front brake hose 3. Rear brake lock lever cable 4. Left handlebar switch A. Route the rear brake lock lever cable in front of the handlebar, then down through the space between the handlebar and the upper bracket. B.
Page 76 CABLE ROUTING 2-39...
Page 77 CABLE ROUTING 1. Grommet 2. Fuel over ﬂow hose 3. Fuel tank 4. Fuel overﬂow tray 5. Fuel tank cap 6. Upper side cover moulding (left) 7. Hose guide 8. Grommet 9. Footrest board 10. Hose clamp 11. Fuel tank breather hose 12.
Page 78 CABLE ROUTING 2-41...
Page 79 CABLE ROUTING L. Route the ignition coil lead through the inside of 1. Main switch/immobilizer unit the ignition coil bracket. 2. Throttle cable M. Fasten the radiator fan motor lead and side- 3. Brake hose stand switch lead to the frame with a plastic 4.
Page 80 CABLE ROUTING 2-43...
Page 81 CABLE ROUTING 1. Rear brake lock lever cable 2. Throttle cable (decelerator cable, double lock- nut) 3. Fast idle inlet hose 4. Rear brake hose 5. A.C. magneto lead 6. Fuel tank breather hose 7. Coolant hose 8. Sidestand switch 9.
Page 82 CABLE ROUTING 2-45...
Page 83 CABLE ROUTING Q. Fasten the wire harness and seat lock cable to 1. Rear brake lock lever cable the frame with a plastic holder. 2. Coolant system air bleed hose R. Pass the wire harness, lead and cable the out- 3.
Page 84 CABLE ROUTING XP500 2-47...
Page 85 CABLE ROUTING 1. Cooling system air bleed hose 2. Storage box light switch lead 3. Coolant reservoir hose 4. Spark plug lead #2 5. Radiator fan motor lead 6. Sidestand switch lead 7. Spark plug lead #1 8. Rear brake lock lever cable 9.
Page 86 CABLE ROUTING 2-49...
Page 87 CABLE ROUTING 1. Brake hose holder 1 2. Front brake hose 3. Speed sensor 4. Plastic holder 5. Brake hose holder 2 6. Speed sensor lead 7. Stay 1 8. Brake hose holder 3 9. Rear brake hose 1 A. Fasten the speed sensor lead along the inside of the brake hose.
Page 88 CABLE ROUTING 2-51...
Page 89 CABLE ROUTING H. Fasten the wire harness and ECU (engine) lead 1. Main switch/immobilizer unit to the stay 1 with a holder. 2. ECU (ABS) I. After connecting the left headlight sub-wire har- 3. Throttle cable ness and wire harness (by matching the cou- 4.
Page 90 CABLE ROUTING 2-53...
Page 91 CABLE ROUTING AH. Fasten the rear wheel sensor lead to the swin- garm with the plastics holders. The open end of each holder should be facing downward. AI. Route the rear wheel sensor lead behind the relay leads. AJ. 10 – 20 mm (0.39 – 0.79 in) AK.
Page 92 CABLE ROUTING 2-55...
Page 93 CABLE ROUTING 1. Rear brake lock lever cable 2. Throttle cable (decelerator cable, double lock- nut) 3. Fast idle inlet hose 4. Rear brake hose 5. A.C. magneto lead 6. Fuel tank breather hose 7. Coolant hose 8. Sidestand switch 9.
Page 94 CABLE ROUTING 2-57...
Page 95 CABLE ROUTING P. Fasten the wire harness and seat lock cable to 1. Rear brake lock lever cable the frame with a plastic holder. 2. Cooling system air bleed hose Q. Pass the wire harness, lead and cable the out- 3.
Page 96 CABLE ROUTING 2-59...
Page 97 CABLE ROUTING 1. Throttle cable 2. Fail-safe relay 3. ECU (ABS) 4. ABS test coupler 5. Cooling system air bleed hose 6. Storage box light switch lead 7. Coolant reservoir hose 8. Spark plug lead #2 9. Radiator fan motor lead 10.
Page 98 CABLE ROUTING 2-61...
Page 99 CABLE ROUTING 1. Front wheel sensor 2. ABS motor coupler 3. Fail-safe relay 4. ECU (ABS) 5. Hydraulic unit solenoid coupler 6. Hydraulic unit overﬂow hose 7. Brake hose (front brake master cylinder to hydraulic unit) 8. Brake hose (rear brake master cylinder to hydraulic unit) 9.
Page 100 CABLE ROUTING 2-63...
Page 101 CABLE ROUTING 1. Plastic holder 2. Brake hose holder 2 3. Brake hose holder 1 4. Front brake hose 5. Front wheel sensor lead 6. Front wheel sensor 7. Front housing A. Engage the hose holder rib more than 3 notch.Face the hose holder projection to the back.
Page 102 CABLE ROUTING 2-65...
Page 103: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ..... 3-1 ENGINE ......................3-3 ADJUSTING THE VALVE CLEARANCE ..........3-3 SYNCHRONIZING THE THROTTLE BODIES........3-5 ADJUSTING THE EXHAUST GAS VOLUME ......... 3-7 ADJUSTING THE ENGINE IDLING SPEED ........... 3-8 ADJUSTING THE THROTTLE CABLE FREE PLAY ......
Page 104 REPLACING THE HEADLIGHT BULBS ..........3-32 ADJUSTING THE HEADLIGHT BEAMS..........3-32...
Page 105: Periodic Maintenance
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 50000 km, repeat the maintenance intervals starting from 10000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)
Page 106 PERIODIC MAINTENANCE ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Check bearing play and steer- √ √ √ √ √ ing for roughness. 13 * Steering bearings Lubricate with lith- Every 20000 km ium-soap-based grease. Make sure that all nuts, bolts √...
Page 107: Engine
ENGINE 6. Remove: EAS20470 ENGINE V-belt case cover “1” EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
Page 108 ENGINE In order to be sure that the piston is at TDC, the Exhaust camshaft alignment mark “c” on the intake camshaft ECA15B1015 CAUTION: sprocket and the alignment mark “d” on the ex- Before removing the camshafts from the cyl- haust camshaft sprocket must align with the inder head, tilt up the engine at least 25°.
Page 109: Synchronizing The Throttle Bodies
ENGINE 1.20–2.40 mm Valve pad thickness (0.0472–0.0945 in) 25 thicknesses in 0.05 Available valve pads mm (0.002 in) incre- ments NOTE: The thickness “a” of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Since valve pads of various sizes are originally installed, the valve pad number must be round- NOTE:...
Page 110 ENGINE should be properly adjusted and the ignition tim- Engine idling speed ing should be checked. 1100–1300 r/min 1. Stand the vehicle on a level surface. 7. Adjust: NOTE: Throttle body synchronization Place the vehicle on a suitable stand. MMMMMMMMMMMMMMMMMMMMMM 2.
Page 111: Adjusting The Exhaust Gas Volume
ENGINE Out of specification → Adjust. tion. Make sure that the vacuum pressure is within specification. 9. Stop the engine and remove the measuring equipment. 10.Adjust: Throttle cable free play Refer to “ADJUSTING THE THROTTLE CA- BLE FREE PLAY” on page 3-8. Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 5.
Page 112: Adjusting The Engine Idling Speed
ENGINE Direction “a” Engine idling speed is increased. Direction “b” Engine idling speed is decreased. 8. Release the switch to execute the selection. 9. Simultaneously press the “SELECT” and “RESET” buttons to return to the cylinder se- lection (step 5). 10.Turn the main switch to “OFF”...
Page 113: Checking The Spark Plugs
ENGINE Refer to “GENERAL CHASSIS” on page 4-1. b. Turn the adjusting nut “2” in direction “a” or 3. Adjust: “b” until the specified throttle cable free play Throttle cable free play is obtained. NOTE: Direction “a” When the throttle is opened, the accelerator ca- Throttle cable free play is increased.
Page 114: Checking The Ignition Timing
ENGINE into the cylinders. EAS20700 CHECKING THE IGNITION TIMING 4. Check: NOTE: Spark plug type Prior to checking the ignition timing, check the Incorrect → Change. wiring connections of the entire ignition system. Make sure all connections are tight and free of Manufacturer/model corrosion.
Page 115: Measuring The Compression Pressure
ENGINE MMMMMMMMMMMMMMMMMMMMMM Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-3. a. Start the engine, warm it up for several min- 3. Start the engine, warm it up for several min- utes, and then let it run at the specified en- utes, and then turn it off.
Page 116: Checking The Engine Oil Level
ENGINE b. With the throttle wide open, crank the engine 2. Start the engine, warm it up for several min- until the reading on the compression gauge utes, and then turn it off. stabilizes. 3. Wait two minutes until the oil settles, and then check the oil level through the check window EWA12940 WARNING...
Page 117: Changing The Engine Oil
ENGINE 4. Drain: Engine oil (completely from the crankcase) 5. If the oil filter cartridge is also to be replaced, perform the following procedure. MMMMMMMMMMMMMMMMMMMMMM a. Remove the oil filter cartridge “1” with an oil filter wrench “2”. Oil filter wrench 90890-01426 YU-38411 NOTE:...
Page 118: Measuring The Engine Oil Pressure
ENGINE 6. Check: button, otherwise repeat the procedure. Engine oil drain bolt gasket Damage → Replace. 7. Install: Engine oil drain bolt (along with the gasket) Engine oil drain bolt 43 Nm (4.3 m•kg, 31 ft•lb) 8. Fill: Crankcase (with the specified amount of the recom- mended engine oil) LLLLLLLLLLLLLLLLLLLLLL Engine oil quantity...
Page 119: Cleaning The Air Filter Element
ENGINE Adapter “2” EAS20920 CLEANING THE AIR FILTER ELEMENT Pressure gauge 1. Remove: 90890-03153 Front cowling upper cover Oil pressure adapter B Windshield 90890-03124 Front cowling inner panel Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: Air filter case cover “1” Air filter element 6.
Page 120: Cleaning The V-Belt Case Air Filter Element
ENGINE stalled in the air filter case. 4. Clean: Make sure the air filter is installed with its mesh V-belt case air filter element side facing towards the rear of the vehicle. Blow the compressed air to the outer surface of the V-belt case air filter element.
Page 121: Checking The Fuel Hoses And Fuel Tank Breather Hose
ENGINE 2. Check: EAS21070 CHECKING THE CYLINDER HEAD Throttle body joints “1” BREATHER HOSE Cracks/damage → Replace. 1. Remove: Intake manifolds “2” Leg shield Cracks/damage → Replace. Refer to “GENERAL CHASSIS” on page 4-1. Refer to “THROTTLE BODIES” on page 7-4. 2.
Page 122: Checking The Coolant Level
ENGINE 3. Start the engine, warm it up for several min- utes, and then turn it off. 4. Check: Coolant level NOTE: 4. Install: Before checking the coolant level, wait a few Inner fender minutes until it settles. Refer to “GENERAL CHASSIS” on page 4-1. Right rear side cover EAS21120 Refer to “GENERAL CHASSIS”...
Page 123: Changing The Coolant
ENGINE Lower side cover mole (left and right) Inner fender Refer to “GENERAL CHASSIS” on page 4-1. 2. Disconnect: Coolant reservoir hose “1” 3. Drain: Coolant (from the coolant reservoir) 4. Remove: Radiator cap “1” EWA13030 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot.
Page 124 ENGINE handled with special care. EWA13040 WARNING If coolant splashes in your eyes, thorough- ly wash them with water and consult a doc- tor. If coolant splashes on your clothes, quickly wash it away with water and then with soap and water.
Page 125 ENGINE 13.Install: Coolant reservoir cap 14.Start the engine, warm it up for several min- utes, and then stop it. 15.Check: Coolant level Refer to “CHECKING THE COOLANT LEV- EL” on page 3-18. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled.
Page 126: Chassis
CHASSIS the brake fluid and could cause vapor lock. EAS21140 CHASSIS ECA13540 CAUTION: EAS21240 CHECKING THE BRAKE FLUID LEVEL Brake fluid may damage painted surfaces 1. Stand the vehicle on a level surface. and plastic parts. Therefore, always clean up NOTE: any spilt brake fluid immediately.
Page 127: Checking The Front Brake Hoses
CHASSIS EAS21280 EAS21320 CHECKING THE FRONT BRAKE HOSES ADJUSTING THE REAR BRAKE LOCK The following procedure applies to all of the LEVER CABLE brake hoses and brake hose clamps. EWA15B2001 WARNING 1. Check: Do not apply the rear brake lock lever when Brake hose Cracks/damage/wear →...
Page 128: Bleeding The Hydraulic Brake System (Xp500)
CHASSIS EAS21350 BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500) EWA13100 WARNING Bleed the hydraulic brake system whenever: the system is disassembled. a brake hose is loosened, disconnected or replaced. the brake fluid level is very low. brake operation is faulty. A. Front NOTE: B.
Page 129 CHASSIS der. 1st: Front brake caliper 2nd: Rear brake caliper EWA15B1006 WARNING Bleed the ABS whenever: the system is disassembled. a brake hose is loosened, disconnected or replaced. the brake fluid level is very low. brake operation is faulty. A. Front NOTE: B.
Page 130: Checking The Chain Drive Oil Level
CHASSIS eration. LLLLLLLLLLLLLLLLLLLLLL EAS21480 CHECKING THE CHAIN DRIVE OIL LEVEL 1. Stand the vehicle on a level surface. NOTE: Place the vehicle on a suitable stand. Make sure that the vehicle up right. 4. Install: 2. Remove: Chain drive oil filler cap Chain drive case cover “1”...
Page 131: Checking And Adjusting The Steering Head
CHASSIS EAS21500 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.
Page 132 CHASSIS e. Install the rubber washer “3”. b. Install a plastic locking tie “1” loosely around f. Install the upper ring nut “2”. the end of the handlebar as shown. g. Finger tighten the upper ring nut “2”, then c. Hook a spring gauge “2” onto the plastic lock- align the slots of both ring nuts.
Page 133: Checking The Front Fork
CHASSIS equals the ambient air temperature. EAS21530 CHECKING THE FRONT FORK The tire pressure and the suspension must 1. Stand the vehicle on a level surface. be adjusted according to the total weight EWA13120 (including cargo, rider, passenger and ac- WARNING cessories) and the anticipated riding Securely support the vehicle so that there is...
Page 134 No guarantee con- cerning handling characteristics can be giv- 1. Tire tread depth en if a tire combination other than one 2. Side wall approved by Yamaha is used on this vehicle. Wear limit (front) Front tire 1.6 mm (0.06 in) Size...
Page 135: Checking The Wheels
CHASSIS EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. Recommended lubricant Lithium-soap-based grease EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. EAS21670 CHECKING THE WHEELS Recommended lubricant The following procedure applies to both of the Lithium-soap-based grease wheels.
Page 136: Electrical System
ELECTRICAL SYSTEM 6. Install: EAS21750 ELECTRICAL SYSTEM Headlight bulb Secure the new headlight bulb with the head- EAS21760 CHECKING AND CHARGING THE BATTERY light bulb holder. Refer to “ELECTRICAL COMPONENTS” on ECA13690 CAUTION: page 8-97. Avoid touching the glass part of the head- EAS21770 light bulb to keep it free from oil, otherwise CHECKING THE FUSES...
Page 137 ELECTRICAL SYSTEM Left headlight Direction “c” Headlight beam moves to the right. Direction “d” Headlight beam moves to the left. Right headlight Direction “c” Headlight beam moves to the left. Direction “d” Headlight beam moves to the right. LLLLLLLLLLLLLLLLLLLLLL 3-33...
Page 138 ELECTRICAL SYSTEM 3-34...
Page 139 CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEEL..................... 4-6 REMOVING THE FRONT WHEEL (XP500) ........... 4-10 Removing the front wheel (XP500A) ............4-10 CHECKING THE FRONT WHEEL ............4-10 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR (XP500A)..............4-11 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-12 INSTALLING THE FRONT WHEEL (XP500) ..........
Page 140 ABS (Anti-Lock Brake System)..............4-47 REMOVING THE HYDRAULIC UNIT............4-48 CHECKING THE HYDRAULIC UNIT ............4-48 INSTALLING THE HYDRAULIC UNIT ............ 4-49 HYDRAULIC UNIT OPERATION TEST ..........4-49 TRIAL RUN....................4-52 HANDLEBAR ....................4-53 REMOVING THE HANDLEBARS ............4-55 CHECKING THE HANDLEBAR .............. 4-55 INSTALLING THE HANDLEBAR ............
Page 141: General Chassis
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Seat Order Job/Parts to remove Q’ty Remarks Fuel tank cap Fuel lid Seat For installation, reverse the removal proce- dure.
Page 142 GENERAL CHASSIS Front cowling 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Parts to remove Q’ty Remarks Footrest board mat (left and right) Front side cover moulding (left and right) Rear view mirror (left and right) Front cowling upper cover Windshield Front cowling inner panel Headlight sub-wire harness coupler...
Page 143 GENERAL CHASSIS Side cover mouldings and leg shield 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Parts to remove Q’ty...
Page 144 GENERAL CHASSIS Rear covers and tail/brake light assembly 16 Nm (1.6 m • kg, 12 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Parts to remove Q’ty Remarks Seat...
Page 145 GENERAL CHASSIS Strage box 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 16 Nm (1.6 m • kg, 12 ft • Ib) 7 Nm (0.7 m •...
Page 146: Front Wheel
FRONT WHEEL EAS21880 FRONT WHEEL Removing the front wheel and brake disc (XP500) 40 Nm (4.0 m • kg, 29 ft • Ib) 40 Nm (4.0 m • kg, 29 ft • Ib) 59 Nm (5.9 m • kg, 43 ft • Ib) 23 Nm (2.3 m •...
Page 147 FRONT WHEEL Disassembling the front wheel (XP500) Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Collar For installation, reverse the removal proce- dure.
Page 148 FRONT WHEEL Removing the front wheel and brake disc (XP500A) 40 Nm (4.0 m • kg, 29 ft • Ib) 59 Nm (5.9 m • kg, 43 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) 40 Nm (4.0 m •...
Page 149 FRONT WHEEL Disassembling the front wheel (XP500A) Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Collar For installation, reverse the removal proce- dure.
Page 150: Removing The Front Wheel (Xp500)
FRONT WHEEL Bends → Replace. EAS21900 REMOVING THE FRONT WHEEL (XP500) EWA13460 1. Stand the vehicle on a level surface. WARNING EWA13120 Do not attempt to straighten a bent wheel ax- WARNING Securely support the vehicle so that there is no danger of it falling over.
Page 151: Maintenance Of The Front Wheel Sensor And Sensor Rotor (Xp500A)
FRONT WHEEL the wheel bearing outer race and oil seal. 5. Replace: Wheel bearings Oil seals LLLLLLLLLLLLLLLLLLLLLL MMMMMMMMMMMMMMMMMMMMMM a. Clean the outside of the front wheel hub. EAS22010 b. Remove the oil seals “1” with a flat-head MAINTENANCE OF THE FRONT WHEEL screwdriver.
Page 152: Adjusting The Front Wheel Static Balance
FRONT WHEEL b. When the front wheel stops, put an “X ” mark Regulated resistance at the bottom of the wheel. 1.2–1.6 kΩ at 20°C (68°F) Out of specification → Replace. c. Turn the front wheel 90° so that the “X ”...
Page 153: Installing The Front Wheel (Xp500)
FRONT WHEEL b. Turn the front wheel 90° so that the heavy NOTE: spot is positioned as shown. Make sure the speed sensor and the wheel hub are installed with the two projections meshed into the two slots respectively. c. If the heavy spot does not stay in that posi- tion, install a heavier weight.
Page 154: Installing The Front Wheel (Xp500A)
FRONT WHEEL 5. Install: 3. Tighten: Front brake calipers Front wheel axle “1” EWA15B1009 Use the damper rod holder “2” WARNING Front wheel axle pinch bolt “3” Make sure the brake cable is routed properly. Front wheel axle 6. Install: 59 Nm (5.9 m•kg, 43 ft•lb) Front brake caliper bracket bolt “1”...
Page 155 FRONT WHEEL NOTE: When installing the front wheel sensor, check the wheel sensor lead for twists and the sensor electrode for foreign materials. ECA14480 CAUTION: To route the front wheel sensor lead, refer to “CABLE ROUTING” on page 2-35. 5. Check: Front wheel sensor installation Check if the wheel sensor housing is installed properly.
Page 156: Rear Wheel
REAR WHEEL EAS22030 REAR WHEEL Removing the rear wheel (XP500) 40 Nm (4.0 m • kg, 29 ft • Ib) 17 Nm (1.7 m • kg, 12 ft • Ib) 100 Nm (10.0 m • kg, 72 ft • Ib) 7 Nm (0.7 m •...
Page 157 REAR WHEEL Removing the rear wheel (XP500A) 40 Nm (4.0 m • kg, 29 ft • Ib) 17 Nm (1.7 m • kg, 12 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 100 Nm (10.0 m • kg, 72 ft • Ib) 7 Nm (0.7 m •...
Page 158 REAR WHEEL Disassembling the rear wheel 18 Nm (1.8 m • kg, 13 ft • Ib) 69 Nm (6.9 m • kg, 50 ft • Ib) Order Job/Parts to remove Q’ty Remarks Brake disc Rear wheel drive hub O-ring Oil seal Bearing For installation, reverse the removal proce- dure.
Page 159: Removing The Rear Wheel (Xp500)
REAR WHEEL 3. Measure: EAS28760 REMOVING THE REAR WHEEL (XP500) Radial wheel runout 1. Stand the vehicle on a level surface. Lateral wheel runout EWA13120 Refer to “CHECKING THE FRONT WHEEL” WARNING on page 4-10. Securely support the vehicle so that there is no danger of it falling over.
Page 160 REAR WHEEL NOTE: Align the slot “a” of the sensor housing “1” with the projection “b” of the collar “2”, and then as- semble them. After installation, check that the projection “c” of the collar is inserted into the slot “d” of the sensor housing.
Page 161: Front Brake
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 27 Nm (2.7 m • kg, 20 ft • Ib) Order Job/Parts to remove Q’ty Remarks Front brake caliper retaining bolt (lower) Front brake caliper retaining bolt (upper) Brake caliper Brake pad Brake pad shim Brake pad spring...
Page 162 FRONT BRAKE Removing the front brake master cylinder 1 Nm (0.1 m • kg, 0.7 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Parts to remove Q’ty...
Page 163 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-23...
Page 164 FRONT BRAKE Removing the front brake calipers 27 Nm (2.7 m • kg, 20 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 40 Nm (4.0 m • kg, 29 ft • Ib) Order Job/Parts to remove Q’ty Remarks Drain.
Page 165 FRONT BRAKE Disassembling the front brake calipers 6 Nm (0.6 m • kg, 4.3 ft • Ib) Order Job/Parts to remove Q’ty Remarks Bleed screw Dust seal Brake caliper piston seal Brake caliper piston Brake caliper body For assembly, reverse the disassembly pro- cedure.
Page 166: Introduction
FRONT BRAKE EAS22220 INTRODUCTION Brake disc deflection limit 0.12 mm (0.0047 in) EWA14100 WARNING MMMMMMMMMMMMMMMMMMMMMM Disc brake components rarely require disas- sembly. Therefore, always follow these pre- a. Place the vehicle on a suitable stand so that ventive measures: the front wheel is elevated. Never disassemble brake components un- b.
Page 167: Replacing The Front Brake Pads
FRONT BRAKE d. Measure the brake disc deflection. 3. Measure: e. If out of specification, repeat the adjustment Brake pad wear limit “a” Out of specification → Replace the brake steps until the brake disc deflection is within specification. pads as a set. f.
Page 168: Removing The Front Brake Calipers
FRONT BRAKE MMMMMMMMMMMMMMMMMMMMMM 6. Install: Brake caliper “1” a. Connect a clear plastic hose “1” tightly to the Front brake caliper retaining bolts “2” bleed screw “2”. Put the other end of the hose into an open container. Brake caliper retaining bolt 27 Nm (2.7 m•kg, 19 ft•lb) b.
Page 169: Disassembling The Front Brake Calipers
FRONT BRAKE brake calipers. ton. NOTE: Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: Union bolt “1” Copper washers “2” Brake hose b. Remove the brake caliper piston seals. LLLLLLLLLLLLLLLLLLLLLL EAS22390 CHECKING THE FRONT BRAKE CALIPERS Recommended brake component replacement NOTE: schedule...
Page 170: Assembling The Front Brake Calipers
FRONT BRAKE 2. Check: 2. Install: Brake caliper brackets “1” Brake caliper bracket Cracks/damage → Replace. Brake caliper bracket bolt 40 Nm (4.0 m•kg, 29 ft•lb) EAS22440 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers.
Page 171: Removing The Front Brake Master Cylinder
FRONT BRAKE 3. Install: Brake pads Brake pad springs Brake caliper retaining bolt Brake caliper Brake hose holder Brake caliper retaining bolt 27 Nm (2.7 m•kg, 19 ft•lb) Refer to “REPLACING THE FRONT BRAKE PADS” on page 4-27. 7. Check: 4.
Page 172: Assembling The Front Brake Master Cylinder
FRONT BRAKE with clean or new brake fluid. Never use solvents on internal brake com- ponents. Recommended fluid DOT 4 1. Install: Master cylinder kit “1” Circlip “2” Dust boot “3” 2. Check: Brake master cylinder kit “1” Damage/scratches/wear → Replace. EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER...
Page 173 FRONT BRAKE any spilt brake fluid immediately. Brake hose union bolt 4. Bleed: 30 Nm (3.0 m•kg, 22 ft•lb) Brake system EWA13530 Refer to “BLEEDING THE HYDRAULIC WARNING BRAKE SYSTEM (XP500)” on page 3-24. Proper brake hose routing is essential to in- 5.
Page 174: Rear Brake
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 40 Nm (4.0 m • kg, 29 ft • Ib) 27 Nm (2.7 m • kg, 20 ft • Ib) Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt Rear brake caliper bracket bolt Brake caliper Brake pad...
Page 175 REAR BRAKE Removing the rear brake master cylinder 30 Nm (3.0 m • kg, 22 ft • Ib) 1 Nm (0.1 m • kg, 0.7 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Parts to remove Q’ty...
Page 176 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-36...
Page 177 REAR BRAKE Removing the rear brake calipers 30 Nm (3.0 m • kg, 22 ft • Ib) 40 Nm (4.0 m • kg, 29 ft • Ib) 27 Nm (2.7 m • kg, 20 ft • Ib) 22 Nm (2.2 m • kg, 16 ft • Ib) Order Job/Parts to remove Q’ty...
Page 178 REAR BRAKE Disassembling the rear brake calipers 6 Nm (0.6 m • kg, 4.3 ft • Ib) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Dust seal Piston seal Bleed screw Brake caliper body For assembly, reverse the disassembly pro- cedure.
Page 179: Introduction
REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit 4.5 mm (0.18 in) EWA14100 WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- Brake disc deflection Refer to “CHECKING THE FRONT BRAKE ventive measures: Never disassemble brake components un- DISCS”...
Page 180 REAR BRAKE MMMMMMMMMMMMMMMMMMMMMM pads as a set. a. Connect a suitable hose “1” tightly to the Brake pad lining thickness (inner) brake caliper bleed screw “2”. Put the other 8.3 mm (0.33 in) end of this hose into an open container. Limit 0.8 mm (0.03 in) Brake pad lining thickness (outer)
Page 181: Removing The Rear Brake Caliper
REAR BRAKE NOTE: Align the projection “c” on the piston side of the brake pad with the lower recess in the brake cal- iper piston. 9. Check: Brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC A.
Page 182: Checking The Rear Brake Caliper
REAR BRAKE (brake caliper body) Obstruction → Blow out with compressed air. EWA13610 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston seals. MMMMMMMMMMMMMMMMMMMMMM a. Operate the rear brake lock lever “4” continu- ously in the direction shown by the arrow until the piston comes out.
Page 183: Installing The Rear Brake Caliper
REAR BRAKE with the brake caliper body as shown in the illus- tration. 2. Remove: Brake caliper 3. Install: Brake pads Brake pad springs Brake caliper retaining bolt Brake caliper Brake hose holder Refer to “REPLACING THE REAR BRAKE PADS” on page 4-39. Brake caliper retaining bolt 27 Nm (2.7 m•kg, 19 ft•lb) EAS22670...
Page 184: Removing The Rear Brake Master Cylinder
REAR BRAKE 5. Bleed: Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” on page 3-24. 6. Check: Brake fluid level Below the minimum level mark “a”→ Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
Page 185: Assembling The Rear Brake Master Cylinder
REAR BRAKE Holder bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Install the brake master cylinder holder with the “UP” mark facing up “a”. Align the brake master cylinder with the projec- tion “b” on the handlebar. First, tighten the upper bolt, then the lower bolt. 4.
Page 186 REAR BRAKE Below the minimum level mark “a”→ Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-22. 6. Check: Brake lever operation Soft or spongy feeling → Bleed the brake system.
Page 187: Abs (Anti-Lock Brake System)
ABS (Anti-Lock Brake System) EAS22760 ABS (Anti-Lock Brake System) Removing the hydraulic unit 16 Nm (1.6 m • kg, 12 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 16 Nm (1.6 m •...
Page 188: Removing The Hydraulic Unit
ABS (Anti-Lock Brake System) Brake hose “4” (to the rear brake caliper) EAS22770 REMOVING THE HYDRAULIC UNIT ECA15B1020 CAUTION: Do not remove the hydraulic unit to check the resistance of the solenoid valves and the ABS motor for continuity. NOTE: Do not operate the brake lever while removing the brake hoses.
Page 189: Installing The Hydraulic Unit
ABS (Anti-Lock Brake System) EWA13940 EAS22770c WARNING INSTALLING THE HYDRAULIC UNIT Proceed in the reverse order of disassembly. The brake hoses to the front and rear brake Pay attention to the following items. calipers can be distinguished by the rubber 1.
Page 190 ABS (Anti-Lock Brake System) Hydraulic unit operation test 1 7. Set the main switch to “ON”. EWA15B1001 NOTE: WARNING After setting the main switch to “ON”, wait (ap- Securely support the vehicle so that there is proximately 2 seconds) until the ABS warning no danger of it falling over.
Page 191 ABS (Anti-Lock Brake System) 10.After the pulsating action has stopped in the Battery voltage Lower than 12.8 V → Charge or replace the front brake lever, it is generated in the rear brake lever “1” 0.5 second after and contin- battery.
Page 192: Trial Run
ABS (Anti-Lock Brake System) unit. If the operation of the hydraulic unit is normal, delete all of the malfunction codes. EAS22820 TRIAL RUN After all checks and services are completed, al- ways ensure the vehicle has no problems by performing the trial running at a speed of faster than 10 km/h.
Page 193: Handlebar
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 26 Nm (2.6 m • kg, 19 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 11 14 10 Nm (1.0 m • kg, 7.2 ft • Ib) 26 Nm (2.6 m •...
Page 194 HANDLEBAR Removing the handlebar 26 Nm (2.6 m • kg, 19 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 11 14 10 Nm (1.0 m • kg, 7.2 ft • Ib) 26 Nm (2.6 m •...
Page 195: Removing The Handlebars
HANDLEBAR Upper handlebar holders “2” EAS22860 REMOVING THE HANDLEBARS 1. Stand the vehicle on a level surface. Upper handlebar holder bolt 23 Nm (2.3 m•kg, 17 ft•lb) EWA13120 WARNING ECA14250 Securely support the vehicle so that there is CAUTION: no danger of it falling over. First, tighten the bolts on the front side of 2.
Page 196 HANDLEBAR Rear brake master cylinder holder bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Install the rear brake master cylinder holder with the “UP” mark facing up “a”. Align the rear brake master cylinder with the projection “b” in the handlebar. First, tighten the upper bolt, then the lower bolt.
Page 197: Front Fork
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 24 Nm (2.4 m • kg, 17 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 40 Nm (4.0 m •...
Page 198 FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m • kg, 17 ft • Ib) Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Spacer Fork spring seat Fork spring Damper rod assembly bolt Copper washer Damper rod assembly Rebound spring Oil ﬂow stopper Inner tube...
Page 199: Removing The Front Fork Legs
FRONT FORK (with a flat-head screwdriver) EAS22960 REMOVING THE FRONT FORK LEGS ECA14180 The following procedure applies to both of the CAUTION: front fork legs. Do not scratch the inner tube. 1. Stand the vehicle on a level surface. NOTE: EWA13120 Do not remove the fork leg protector from the WARNING...
Page 200: Checking The Front Fork Legs
FRONT FORK tube as this may dangerously weaken it. 4. Remove: Inner tube 2. Measure: MMMMMMMMMMMMMMMMMMMMMM Spring free length “a” a. Hold the front fork leg horizontally. Out of specification → Replace. b. Securely clamp the brake caliper bracket in a Fork spring free length vise with soft jaws.
Page 201: Assembling The Front Fork Legs
FRONT FORK Inner tube’s outer surface “2” Recommended oil Fork oil 7.5W or equivalent EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. EWA13660 4. Install: WARNING Outer tube (onto the inner tube) Make sure the oil levels in both front fork Copper washer legs are equal.
Page 202 FRONT FORK Frok seal driver weight 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø41) 90890-01381 Replacement 41 mm YM-A5142-2 8. Install: Oil seal clip “1” NOTE: Adjust the oil seal clip so that it fits into the outer tube’s groove. 7.
Page 203: Installing The Front Fork Legs
FRONT FORK Quantity Lower bracket pinch bolt 512.0 cm (17.31 US oz) (18.06 23 Nm (2.3 m•kg, 17 ft•lb) Imp.oz) Recommended oil Cap bolt “2” Fork oil 7.5W or equivalent Cap bolt 24 Nm (2.4 m•kg, 17 ft•lb) Level 109.0 mm (4.29 in) Upper bracket pinch bolt “3”...
Page 204: Steering Head
STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 110 Nm (11.0 m • kg, 80 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 52 Nm (5.2 m • kg, 38 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 20 Nm (2.0 m •...
Page 205 STEERING HEAD Removing the lower bracket 110 Nm (11.0 m • kg, 80 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 52 Nm (5.2 m • kg, 38 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 20 Nm (2.0 m •...
Page 206: Removing The Lower Bracket
STEERING HEAD EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: Upper bracket 3. Remove: Lock washer “1” 3.
Page 207: Installing The Steering Head
STEERING HEAD Refer to “FRONT FORK” on page 4-57. NOTE: LLLLLLLLLLLLLLLLLLLLLL Temporarily tighten the upper and lower bracket 4. Check: pinch bolts. Upper bracket 5. Tighten: Lower bracket Steering stem nut “2” (along with the steering stem) Bends/cracks/damage → Replace. Steering stem nut 110 Nm (11.0 m•kg, 80 ft•lb) EAS23140...
Page 208: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 53 Nm (5.3 m • kg, 38 ft • Ib) 68 Nm (6.8 m • kg, 49 ft • Ib) Order Job/Parts to remove Q’ty Remarks Mufﬂer Refer to “ENGINE REMOVAL”...
Page 209: Handling The Rear Shock Absorber
REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 rear wheel is elevated. WARNING This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling Rear shock absorber bolts “1”...
Page 210 REAR SHOCK ABSORBER ASSEMBLY 3. Tighten: Bolt (rear side) “1” Nut “3” Bolt (rear side) 53 Nm (5.3 m•kg, 38 ft•lb) 4. Install: Lock washer “1” 5. Tighten: Bolt (front side) “2” Bolt (front side) “2” 68 Nm (6.8 m•kg, 48 ft•lb) NOTE: When installing the rear shock absorber as- sembly, lift up the swingarm.
Page 211: Engine
ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE..............5-5 CAMSHAFTS....................5-6 REMOVING THE CAMSHAFTS.............. 5-8 CHECKING THE CAMSHAFTS .............. 5-9 CHECKING THE TIMING CHAIN GUIDES..........5-10 CHECKING THE TIMING CHAIN TENSIONER........5-11 INSTALLING THE CAMSHAFTS ............5-11 CYLINDER HEAD..................5-14 REMOVING THE CYLINDER HEAD............
Page 212 CLUTCH ......................5-43 REMOVING THE CLUTCH ..............5-45 DISASSEMBLING THE CLUTCH ............5-45 CHECKING THE FRICTION PLATES............. 5-46 CHECKING THE CLUTCH PLATES ............5-46 CHECKING THE CLUTCH SPRING PLATE........... 5-46 CHECKING THE CLUTCH HOUSING ............ 5-47 CHECKING THE CLUTCH BOSS............5-47 CHECKING THE PRESSURE PLATE ............
Page 213 INSTALLING THE CHAIN DRIVE ............5-75...
Page 214 ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe 10 Nm (1.0 m • kg, 7.2 ft • Ib) 45 Nm (4.5 m • kg, 33 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 31 Nm (3.1 m • kg, 22 ft • Ib) 20 Nm (2.0 m •...
Page 215: Engine Removal
ENGINE REMOVAL Disconnecting the leads and hoses 5 Nm (0.5 m • kg, 3.6 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 216 ENGINE REMOVAL Disconnecting the leads and hoses 5 Nm (0.5 m • kg, 3.6 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Parts to remove Q’ty Remarks Starter motor lead...
Page 217 ENGINE REMOVAL Removing the engine 87 Nm (8.7 m • kg, 63 ft • Ib) 48 Nm (4.8 m • kg, 35 ft • Ib) 48 Nm (4.8 m • kg, 35 ft • Ib) Order Job/Parts to remove Q’ty Remarks Front lower mounting bolt/Washer Spacer...
Page 218: Installing The Engine
ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: Rear mounting bolt/nut “1” Front upper mounting bolt/nut “2” Washers.spacer “3” Front lower mounting bolts “4” NOTE: Do not fully tighten the bolts. 2. Tighten: Rear mounting nut “1” Rear mounting nut 87 Nm (8.7 m•kg, 63 ft•lb) Front upper mounting nut “2”...
Page 219: Camshafts
CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 13 Nm (1.3 m • kg, 9.4 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Intake manifold Refer to “THROTTLE BODIES”...
Page 220 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Parts to remove Q’ty Remarks Timing chain tensioner Timing chain tensioner gasket Camshaft cap NOTE: During removal, the dowel pins may still be Dowel pin connected to the camshaft cap.
Page 221: Removing The Camshafts
CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: Timing plug “1” LLLLLLLLLLLLLLLLLLLLLL 3. Remove: 2. Align: Timing chain tensioner “1” “I”mark “a” on the A.C. magneto rotor (with Timing chain tensioner gasket “2” the stationary pointer “b” on the A.C. magne- to cover) MMMMMMMMMMMMMMMMMMMMMM a.
Page 222: Checking The Camshafts
CAMSHAFTS 5. Remove: Camshaft lobe dimension limit Intake camshaft “1” Intake A Exhaust camshaft “2” 33.252–33.352 mm NOTE: (1.3091–1.3131 in) To prevent the timing chain from falling into the Limit crankcase, faster it with a wire “3”. 33.152 mm (1.3052 in) Intake B 24.956–25.056 mm (0.9825–0.9865 in)
Page 223: Checking The Timing Chain Guides
CAMSHAFTS 4. Measure: Camshaft-journal-to-camshaft-cap clearance LLLLLLLLLLLLLLLLLLLLLL Out of specification → Measure the camshaft 5. Measure: journal diameter. Camshaft journal diameter “a” Out of specification → Replace the camshaft. Camshaft-journal-to-cam- shaft-cap clearance Within specification → Replace the cylinder 0.020–0.054 mm (0.0008–0.0021 head and the camshaft caps as a set.
Page 224: Checking The Timing Chain Tensioner
CAMSHAFTS b. Lock the timing chain tensioner rod “1” by set- a. 1/4 tooth ting the circlip “3” to groove“4” while pushing b. Correct the timing chain tensioner rod. 1. Timing chain roller 2. Camshaft sprocket 2. Check: Timing chain guide (intake side)“1” Timing chain guide (exhaust side)“2”...
Page 225 CAMSHAFTS LLLLLLLLLLLLLLLLLLLLLL 2. Install: Dowel pins Intake camshaft cap “1” Exhaust camshaft cap “2” Camshaft cap bolts Camshaft cap bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) MMMMMMMMMMMMMMMMMMMMMM ECA15B1025 a. Turn the crankshaft counterclockwise. CAUTION: b. When piston #1 is at TDC on the compres- The camshaft cap bolts must be tightened sion stroke, align the “I”...
Page 226 CAMSHAFTS ting the circlip “3” into groove“4” while push- ing the timing chain tensioner rod. LLLLLLLLLLLLLLLLLLLLLL 4. Turn: Crankshaft (several turns counterclockwise) 5. Check: “I”mark “a” Make sure that the “I” mark is aligned with the stationary pointer “b”. Camshaft sprocket alignment marks “c” Make sure that the camshaft sprocket align- ment mark is aligned with the cylinder head mating surface “d”.
Page 227: Cylinder Head
CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m • kg, 7.2 ft • Ib) 46 Nm (4.6 m • kg, 33 ft • Ib) 35 Nm (3.5 m • kg, 25 ft • Ib) Order Job/Parts to remove Q’ty Remarks...
Page 228: Removing The Cylinder Head
CYLINDER HEAD MMMMMMMMMMMMMMMMMMMMMM EAS15B420a REMOVING THE CYLINDER HEAD a. Place a straightedge “1” and a thickness 1. Remove: gauge “2” across the cylinder head. Cylinder head bolts Cylinder head nuts NOTE: Loosen the nuts and bolts in the proper se- quence as shown.
Page 229 CYLINDER HEAD Cylinder head nuts “2” Cylinder head nut 46 Nm (4.6 m•kg, 33 ft•lb) Cylinder head bolts “3” Cylinder head bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Apply engine oil onto the threads of the cylin- der head nuts. Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them in two stages.
Page 230 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-14. Valve lifter Valve pad Valve cotter Valve retainer Valve spring Valve stem seal Valve spring seat Valve guide...
Page 231: Valves And Valve Springs
VALVES AND VALVE SPRINGS 3. Remove: EAS24280 REMOVING THE VALVES Valve cotters “1” The following procedure applies to all of the NOTE: valves and related components. Remove the valve cotters by compressing the NOTE: valve spring with the valve spring compressor Before removing the internal parts of the cylin- “2”...
Page 232 VALVES AND VALVE SPRINGS 1. Measure: remover “1”. Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance Valve-stem-to-valve-guide clear- b. Install the new valve guide with the valve ance (intake) guide installer “2”...
Page 233: Checking The Valve Seats
VALVES AND VALVE SPRINGS place the oil seal. Valve stem runout Valve stem runout 0.040 mm (0.0016 in) LLLLLLLLLLLLLLLLLLLLLL 3. Eliminate: Carbon deposits (from the valve face and valve seat) 4. Check: EAS24300 Valve face CHECKING THE VALVE SEATS Pitting/wear → Grind the valve face. The following procedure applies to all of the Valve stem end valves and valve seats.
Page 234: Checking The Valve Springs
VALVES AND VALVE SPRINGS onto the valve face. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hands.
Page 235: Checking The Valve Lifters
VALVES AND VALVE SPRINGS Valve spring free length Free length (intake) 35.59 mm (1.40 in) Limit 33.81 mm (1.33 in) Free length (exhaust) 35.59 mm (1.40 in) Limit 33.81 mm (1.33 in) EAS24320 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters.
Page 236 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attach- ment 90890-04114 Valve spring compressor adapter 19.5 mm YM-04114 3. Install: Valve “1” Lower spring seat “2” Valve stem seal “3” Valve spring “4” Upper spring seat “5” (into the cylinder head) NOTE: Make sure each valve is installed in its original...
Page 237 VALVES AND VALVE SPRINGS so that the pads do not fall. NOTE: The valve lifter must move smoothly when ro- tated with a finger. Each valve lifter and valve pad must be rein- stalled in its original position. 5-24...
Page 238 CYLINDER AND PISTONS EAS24370 CYLINDER AND PISTONS Removing the cylinder and pistons Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-14. Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Piston ring set...
Page 239: Cylinder And Pistons
CYLINDER AND PISTONS EAS24380 NOTE: REMOVING THE PISTON When removing a piston ring, open the end gap The following procedure applies to all of the pis- with your fingers and lift the other side of the ring tons. over the piston crown. 1.
Page 240: Checking The Piston Rings
CYLINDER AND PISTONS cylinder, and replace the piston and piston Bore “C” rings as a set. Bore 66.000–66.010 mm LLLLLLLLLLLLLLLLLLLLLL (2.5984–2.5988 in) Taper limit “T” Taper limit EAS24430 CHECKING THE PISTON RINGS 0.050 mm (0.0020 in) Out of round “R” 1.
Page 241: Checking The Piston Pin
CYLINDER AND PISTONS 3. Measure: a. 10 mm (0.39 in) Piston pin bore diameter “b” 3. Measure: Out of specification → Replace the piston. Piston ring end gap Out of specification → Replace the piston Piston pin bore inside diameter ring.
Page 242 CYLINDER AND PISTONS Cylinder NOTE: Be sure to install the top and 2nd rings so that (with the recommended lubricant) the manufacturers marks or numbers face up. Recommended lubricant Engine oil 5. Offset: Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown. 2.
Page 243: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the starter clutch and A.C. magneto rotor 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 30 Nm (3.0 m •...
Page 244 GENERATOR AND STARTER CLUTCH Removing the starter clutch and A.C. magneto rotor 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 30 Nm (3.0 m •...
Page 245: Removing The A.c. Magneto Rotor
GENERATOR AND STARTER CLUTCH EAS24530 REMOVING THE A.C. MAGNETO ROTOR 1. Remove: A.C. magneto rotor cover NOTE: Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
Page 246: Installing The A.c. Magneto Rotor
GENERATOR AND STARTER CLUTCH Starter clutch gear “a” in the A.C magneto rotor. Burrs/chips/roughness/wear → Replace the defective part(s). 2. Tighten: A.C magneto rotor nut “1” 3. Check: Starter clutch operation A.C magneto rotor nut MMMMMMMMMMMMMMMMMMMMMM 60 Nm (6.0 m•kg, 43 ft•lb) a.
Page 247 GENERATOR AND STARTER CLUTCH 3. Apply: Sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 (Three Bond No.1215®) 90890-85505 4. Install: A.C. magneto rotor cover A.C. magneto rotor cover bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Tighten the A.C.
Page 248: Electric Starter
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m • kg, 7.2 ft • Ib) 5 Nm (0.5 m • kg, 3.6 ft • Ib) Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Negative battery lead Starter motor lead Starter motor...
Page 249 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Front bracket O-ring Shims Lock washer Oil seal Bearing Rear bracket Shims Brush holder set Armature assembly Starter motor yoke For assembly, reverse the disassembly pro- cedure. 5-36...
Page 250: Checking The Starter Motor
ELECTRIC STARTER with the pocket tester. EAS24790 CHECKING THE STARTER MOTOR 1. Check: Pocket tester 90890-03112 Commutator Dirt → Clean with 600 grit sandpaper. Analog pocket tester YU-03112-C 2. Measure: Digital circuit tester Commutator diameter “a” 90890-03174 Out of specification → Replace the starter Model 88 Multimeter with tachom- motor.
Page 251: Assembling The Starter Motor
ELECTRIC STARTER springs as a set. 2. Connect: Starter motor lead Brush spring force 7.65–10.01 N (27.54–36.03 oz) (780–1021 gf) 7. Check: Gear teeth Damage/wear → Replace the gear. 8. Check: Bearing“1” Oil seal“2” Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1.
Page 252: Oil Pump
OIL PUMP EAS24900 OIL PUMP Removing the oil pump 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Parts to remove Q’ty Remarks Left side panel/lower side cover moulding/foot- Refer to “GENERAL CHASSIS”...
Page 253 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing Oil pump outer rotor Oil pump inner rotor Dowel pin Oil pump housing center Washer Oil pump cover Oil pump driven gear For installation, reverse the removal proce- dure.
Page 254: Checking The Oil Pump
OIL PUMP EAS24960 CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip clearance 1. Check: 0.040–0.120 mm (0.0016–0.0047 Oil pump drive gear “1” Oil pump housing “2” Limit Oil pump cover “3” 0.20 mm (0.0079 in) Cracks/damage/wear → Replace the defec- Outer-rotor-to-oil-pump-housing tive part(s). clearance 0.045–0.085 mm (0.0018–0.0033 Limit...
Page 255: Checking The Oil Delivery Pipes
OIL PUMP 2. Install: EAS24980 CHECKING THE OIL DELIVERY PIPES Pins The following procedure applies to all of the oil Inner rotors delivery pipes. NOTE: 1. Check: When installing the inner rotor, align the pin “1” Oil delivery pipe “1” in the oil pump shaft with the groove “a”...
Page 256: Clutch
CLUTCH EAS25060 CLUTCH Removing the clutch 65 Nm (6.5 m • kg, 47 ft • Ib) Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER A.C. magneto cover CLUTCH” on page 5-30. Clutch assembly nut Clutch assembly Washer For installation, reverse the removal proce- dure.
Page 257 CLUTCH Disassembling the clutch 90 Nm (9.0 m • kg, 65 ft • Ib) Order Job/Parts to remove Q’ty Remarks Circlip Spring stopper plate Clutch damper spring “2” Pressure plate Clutch plate “2” Clutch damper spring “1” Friction plate Clutch plate “1” Clutch spring Thrust plate Clutch boss nut...
Page 258: Removing The Clutch
CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: Clutch assembly nut “1” Clutch assembly “2” NOTE: Before removal, apply “a” and “b” alignment marks. While holding the clutch assembly with the ro- tor holding tool “3”, loosen the clutch assembly nut. 2.
Page 259: Checking The Friction Plates
CLUTCH Warpage limit 0.10 mm (0.0039 in) EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates. EAS25130 1. Check: CHECKING THE CLUTCH SPRING PLATE Friction plate The following procedure applies to all of the Damage/wear →...
Page 260: Checking The Clutch Housing
CLUTCH EAS25160 Clutch spring height “c” CHECKING THE CLUTCH BOSS 4.70 mm (0.19 in) 1. Check: Minimum height Clutch boss splines 4.40 mm (0.17 in) Damage/pitting/wear → Replace the clutch Clutch spring height “b” boss. 3.30 mm (0.13 in) NOTE: Minimum height Pitting on the clutch boss splines will cause er- 2.9 mm (0.11 in)
Page 261: Assembling The Clutch
CLUTCH EAS15B4586b ASSEMBLING THE CLUTCH 1. Lubricate: Friction plates Clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: Clutch boss Primary drive gear Clutch boss nut “1” 3. Tighten: Clutch boss nut Clutch boss nut 90 Nm (9.0 m•kg, 65 ft•lb) NOTE: While holding the clutch boss “2”...
Page 262 CLUTCH 5-49...
Page 263: V-Belt Automatic Transmission
V-BELT AUTOMATIC TRANSMISSION EAS24610 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 11 Nm (1.1 m • kg, 8.0 ft • Ib) (M6) 10 Nm (1.0 m •...
Page 264 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt and primary/secondary sheave 24 Nm (2.4 m • kg, 17 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 24 Nm (2.4 m • kg, 17 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 90 Nm (9.0 m •...
Page 265 V-BELT AUTOMATIC TRANSMISSION Disassembling the primary sheave Order Job/Parts to remove Q’ty Remarks silinder Weight Primary sliding sheave Collar For installation, reverse the disassembly procedure. 5-52...
Page 266 V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave 90 Nm (9.0 m • kg, 65 ft • Ib) Order Job/Parts to remove Q’ty Remarks Secondary sheave spring seat nut Upper spring seat Compression spring Spring seat Secondary sliding sheave Oil seal O-ring Guide pin Secondary ﬁxed sheave...
Page 267: Removing The Primary Sheave
V-BELT AUTOMATIC TRANSMISSION EAS24620 EAS24630 REMOVING THE PRIMARY SHEAVE REMOVING THE SECONDARY SHEAVE 1. Remove: 1. Remove: Primary sheave nut “1” Secondary sheave assembly “1” Secondary sheave nut “2” Primary sheave assembly “2” V-belt “3” NOTE: While holding the primary and secondary NOTE: sheave with the sheave holder, loosen the nut.
Page 268: Disassembling The Secondary Sheave
V-BELT AUTOMATIC TRANSMISSION EAS24640 DISASSEMBLING THE SECONDARY SHEAVE 1. Remove: Spring seat “1” NOTE: Install the sheave spring compressor “2” onto the secondary sheave as shown. Then, com- press the spring, and remove the secondary sheave spring seat nut “1” with locknut wrench “3”.
Page 269: Checking The Slider
V-BELT AUTOMATIC TRANSMISSION EAS24720 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: Primary fixed sheave Primary sliding sheave Collar Weights Sliders 2. Install: Weights “1” Sliders “2” EAS24700 CHECKING THE SLIDER Cam “3” 1. Check: NOTE: Slider “1” Do not apply the grease inside of the primary Cracks/damage/wear →...
Page 270: Installing The Primary Sheave Assembly, Secondary Sheave Assembly And V-Belt
V-BELT AUTOMATIC TRANSMISSION 3. Install: Secondary sheave spring seat Guide pin “2” 4. Lubricate: 90 Nm (9.0 m•kg, 65 ft•lb) Guide pin groove “3” O-ring (with the recommended lubricant) Recommended lubricant BEL-RAY assembly lube EAS15B4009 INSTALLING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY SHEAVE ASSEMBLY AND V-BELT 1.
Page 271 V-BELT AUTOMATIC TRANSMISSION Install the V-belt and secondary sheave as- sembly onto the primary sheave side. Align the “a” and “b” during reassembly. 5. Tighten: Primary sheave nut “1” Primary sheave nut 160 Nm (16.0 m•kg, 115 ft•lb) ECA15B1005 CAUTION: Before tightening the nut to remount the primary sheave, make sure that the serra- tions of the cam are fitted firmly into the...
Page 272: Crankcase And Crankshaft
CRANKCASE AND CRANKSHAFT EAS25960 CRANKCASE AND CRANKSHAFT Removing the crankshaft assembly 10 Nm (1.0 m • kg, 7.2 ft • Ib) 58 Nm (5.8 m • kg, 42 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m •...
Page 273 CRANKCASE AND CRANKSHAFT Removing the crankshaft assembly 10 Nm (1.0 m • kg, 7.2 ft • Ib) 58 Nm (5.8 m • kg, 42 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 55 Nm (5.5 m •...
Page 274 CRANKCASE AND CRANKSHAFT Removing the connecting rod 16 Nm (1.6 m • kg, 12 ft • Ib) + 90˚ 16 Nm (1.6 m • kg, 12 ft • Ib) + 90˚ 60 Nm (6.0 m • kg, 43 ft • Ib) Order Job/Parts to remove Q’ty...
Page 275: Disassembling The Crankcase
CRANKCASE AND CRANKSHAFT EAS25560 DISASSEMBLING THE CRANKCASE 1. Remove: Crankcase bolts NOTE: Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.
Page 276: Checking The Timing Chain
CRANKCASE AND CRANKSHAFT 3. Check: Journal oil clearance (using plas- Crankcase tigauge®) Cracks/damage → Replace. 0.040–0.082 mm (0.0016–0.0032 Oil delivery passages Obstruction → Blow out with compressed air. MMMMMMMMMMMMMMMMMMMMMM EAS15B4207 CHECKING THE TIMING CHAIN The following procedure applies to all of the 1.
Page 277 CRANKCASE AND CRANKSHAFT LLLLLLLLLLLLLLLLLLLLLL 4. Select: Big end bearings (“P ”,“P ”,“P ”) NOTE: The numbers “A” stamped into the crankshaft web and the numbers “1” on the connecting rods are used to determine the replacement big end bearing sizes. “P ”,“P ”,“P...
Page 278 CRANKCASE AND CRANKSHAFT Bearing color code 1.Blue 2.Black 3.Brown 4.Green m. Measure the inside diameter “b” of each jour- nal bearing at two places. LLLLLLLLLLLLLLLLLLLLLL 5. Measure: Crankshaft-journal-to-crankshaft-journal bearing clearance. Out of specification → Replace the crank- shaft journal bearings. Crankshaft-journal-to-crank- n.
Page 279: Installing The Crankshaft Main Journal Bearing
CRANKCASE AND CRANKSHAFT LLLLLLLLLLLLLLLLLLLLLL EAS25630 INSTALLING THE CRANKSHAFT MAIN JOURNAL BEARING 1. Attach: Crankshaft main journal bearings NOTE: Attach the crankshaft main journal bearing to the plane bearing installer “1”. MMMMMMMMMMMMMMMMMMMMMM a. For example, if the crankcase “J1”and the Plane bearing installer crankshaft web “J1”...
Page 280: Installing The Connecting Rods
CRANKCASE AND CRANKSHAFT EAS26150 INSTALLING THE CONNECTING RODS 1. Install: Big end bearings “1” NOTE: Align the projections “a” on the big end bear- ings with the notches “b” in the connecting rods and connecting rod caps. Be sure to reinstall each big end bearing in its original place.
Page 281: Installing The Crankshaft
LLLLLLLLLLLLLLLLLLLLLL 2. Apply: Sealant 5. Install: (onto the crankcase mating surfaces) Balancer connecting rod Connecting rod cap Yamaha bond No. 1215 (Three Bond No.1215®) Connecting rod cap 90890-85505 60 Nm (6.0 m•kg, 43 ft•lb) NOTE: ECA15B1043 Do not allow any sealant to come into contact CAUTION: with the oil gallery.
Page 282 CRANKCASE AND CRANKSHAFT 5-69...
Page 283: Transmission
TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 Nm (1.2 m • kg, 8.7 ft • Ib) Order Job/Parts to remove Q’ty Remarks Refer to “CHECKING THE CRANKCASE” Left crankcase on page 5-62. Secondary shaft Main axle Primary driven gear First pinion gear...
Page 284: Removing The Transmission
TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: Left crankcase Refer to “CRANKCASE AND CRANK- SHAFT” on page 5-59. 2. Remove: Secondary shaft; “1” Main axle“2” Drive axle“3” Primary driven gear“4” 3. Measure: First wheel gear“5” Secondary shaft runout First pinion gear (with a centering device and dial gauge) Out of specification →...
Page 285: Chain Drive Transmission
CHAIN DRIVE TRANSMISSION EAS24750 CHAIN DRIVE TRANSMISSION Removing primary and secondary drive chains 23 Nm (2.3 m • kg, 17 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 100 Nm (10.0 m •...
Page 286 CHAIN DRIVE TRANSMISSION Removing primary and secondary drive chains 23 Nm (2.3 m • kg, 17 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 100 Nm (10.0 m • kg, 72 ft • Ib) 40 Nm (4.0 m •...
Page 287 CHAIN DRIVE TRANSMISSION Removing primary and secondary drive chains 8 10 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Parts to remove Q’ty Remarks Chain drive case (outer) Secondary drive chain Secondary drive gear Secondary driven gear Middle shaft Primary drive chain Primary drive gear...
Page 288: Checking The Swingarm
CHAIN DRIVE TRANSMISSION EAS15B4006 CHECKING THE SWINGARM 1. Check: swingarm “1” Damage/wear → Replace. 2. Check: Pivot shaft “1” Collar Bearing Oil seal Damage/wear → Replace. EAS15B4008 ASSEMBLING THE CHAIN DRIVE ASSEMBLY 1. Install: Chain drive case (outer) Chain drive case bolt 10 Nm (1.0 m E kg, 7.2 ft E lb) NOTE: First, tighten the chain drive case bolts that are...
Page 289 CHAIN DRIVE TRANSMISSION 2. Tighten: Swingarm bolt Swingarm bolt 40 Nm (4.0 m•kg, 29 ft•lb) 3. Adjust: Pivot shaft Pivot shaft 7 Nm (0.7 m•kg, 5.1 ft•lb) 100 Nm (10.0 m•kg, 72 ft•lb) NOTE: With your fingers, screw in the pivot shaft until it touches the collar and then tighten the pivot shaft to the tightening torque.
Page 290 CHAIN DRIVE TRANSMISSION 5-77...
Page 291: Cooling System
COOLING SYSTEM RADIATOR ....................6-1 CHECKING THE RADIATOR..............6-3 CHECKING THE OIL COOLER .............. 6-3 INSTALLING THE OIL COOLER AND RADIATOR ........ 6-3 THERMOSTAT ....................6-5 CHECKING THE THERMOSTAT............6-6 INSTALLING THE THERMOSTAT ASSEMBLY ........6-6 WATER PUMP....................6-7 DISASSEMBLING THE WATER PUMP..........6-9 CHECKING THE WATER PUMP ............
Page 292: Radiator
RADIATOR EAS26380 RADIATOR Removing the radiator 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 63 Nm (6.3 m • kg, 45 ft • Ib) 17 Nm (1.7 m • kg, 12 ft • Ib) Order Job/Parts to remove Q’ty...
Page 293 RADIATOR Removing the radiator 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 63 Nm (6.3 m • kg, 45 ft • Ib) 17 Nm (1.7 m • kg, 12 ft • Ib) Order Job/Parts to remove Q’ty...
Page 294: Checking The Radiator
RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
Page 295 RADIATOR NOTE: Radiator cap tester Before installing the oil cooler, lubricate the oil 90890-01325 cooler bolt with engine oil. Radiator pressure tester Make sure that the O-ring is positioned proper- YU-24460-01 Radiator cap tester adapter Align the projection “a” on the oil cooler with 90890-01352 the slot “b”...
Page 296: Thermostat
THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly 18 Nm (1.8 m • kg, 13 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q’ty Remarks Refer to “GENERAL CHASSIS” on page Center cover/side cover 4-1.
Page 297: Checking The Thermostat
THERMOSTAT EAS26450 CHECKING THE THERMOSTAT LLLLLLLLLLLLLLLLLLLLLL 1. Check: Thermostat 2. Check: Does not open at 70.5–73.5°C (159–164°F) Thermostat housing cover → Replace. Cracks/tears → Replace. EAS26480 INSTALLING THE THERMOSTAT ASSEMBLY 1. Install: Thermostat Thermostat cover Bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: MMMMMMMMMMMMMMMMMMMMMM Install the thermostat with its breather hole “a”...
Page 298: Water Pump
WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Parts to remove Q’ty Remarks Left upper side cover moulding/left footrest Refer to “GENERAL CHASSIS”...
Page 299 WATER PUMP Disassembling the water pump 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Parts to remove Q’ty Remarks NOTE: It is not necessary to remove the impeller shaft, unless the coolant level is extremely low or coolant contains engine oil.
Page 300: Disassembling The Water Pump
WATER PUMP 4. Remove: EAS26510 DISASSEMBLING THE WATER PUMP Rubber damper holder “1” 1. Remove: Rubber damper “2” Water pump seal “1” (from the impeller, with a thin, flat-head NOTE: screwdriver) Remove the water pump seal from the inside of NOTE: the water pump housing.
Page 301 NOTE: Install the water pump seal with the special tools. Before installing the water pump seal, apply Yamaha bond No.1215 or Sealant (Quick Gas- ketR) “2” to the water pump housing “3”. Mechanical seal installer 90890-04078 Water pump seal installer YM-33221-A 5.
Page 302: Installing The Water Pump
WATER PUMP 1. Straightedge 2. Impeller EAS26600 INSTALLING THE WATER PUMP 1. Install: Water pump assembly Water pump assembly bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Align the projection “a” at the oil pump shaft and water pump shaft groove “b”. 2.
Page 303: Fuel System
FUEL SYSTEM FUEL TANK....................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ............... 7-2 INSTALLING THE FUEL PUMP.............. 7-2 INSTALLING THE FUEL TANK............... 7-2 THROTTLE BODIES ..................7-4 CHECKING THE INJECTORS ..............7-7 CHECKING THE THROTTLE BODIES........... 7-7 CHECKING THE PRESSURE REGULATOR OPERATION ....
Page 304: Fuel Tank
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 4 Nm (0.4 m • kg, 2.9 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Strage box 4-1.
Page 305: Removing The Fuel Tank
FUEL TANK EAS26630 EAS26710 REMOVING THE FUEL TANK INSTALLING THE FUEL PUMP 1. Extract the fuel in the fuel tank through the 1. Install: fuel tank cap with a pump. Fuel pump gasket 2. Remove: Fuel pump Fuel hose connector cover “1” Fuel pump bracket 3.
Page 306 FUEL TANK Fuel breather hose Fuel pump coupler ECA15B1032 CAUTION: Be sure to connect the fuel hose by hand. Do not forcefully connect the hose with tools. When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct posi- tion, otherwise the fuel hose will not be properly installed.
Page 307: Throttle Bodies
THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies 10 Nm (1.0 m • kg, 7.2 ft • Ib) 12 Nm (1.2 m • kg, 8.7 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 9 Nm (0.9 m • kg, 6.5 ft • Ib) Order Job/Parts to remove Q’ty...
Page 308 THROTTLE BODIES Removing the throttle bodies 10 Nm (1.0 m • kg, 7.2 ft • Ib) 12 Nm (1.2 m • kg, 8.7 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 9 Nm (0.9 m • kg, 6.5 ft • Ib) Order Job/Parts to remove Q’ty...
Page 309 THROTTLE BODIES Disassembling the throttle bodies Order Job/Parts to remove Q’ty Remarks NOTE: Before disassembling the throttle body, make sure to note the number of times the air screw is turned out from the seated position to its set position. Throttle position sensor Fast idle plunger Idle adjust screw...
Page 310: Checking The Injectors
THROTTLE BODIES EAS26980 CHECKING THE INJECTORS 1. Check: Injectors Damage → Replace. d. Set the main switch to “ON” and the engine stop switch to “ ”. e. Start the engine. f. Measure the fuel pressure. Out of specification → Check the fuel hose EAS26990 connection or replace the fuel pump.
Page 311 THROTTLE BODIES Tester positive probe Yellow “1” Negative tester probe Black/Blue “2” d. Measure the throttle position sensor voltage. e. Loosen the throttle position sensor screws “3”. f. Adjust the throttle position sensor angle so that the voltage is within the specified range. Throttle position sensor voltage (closed position) 0.63–0.73V (Yellow–Black/Blue )
Page 312 THROTTLE BODIES...
Page 313: Electrical System
ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM ................8-1 TROUBLESHOOTING ................8-3 ELECTRIC STARTING SYSTEM ..............8-5 CIRCUIT DIAGRAM ................8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......8-9 TROUBLESHOOTING ................8-13 CHARGING SYSTEM..................8-15 CIRCUIT DIAGRAM ................8-15 TROUBLESHOOTING ................8-17 LIGHTING SYSTEM ..................
Page 314 [D-1] MAINTENANCE OF THE ECU (ABS) ..........8-72 [D-2] MAINTENANCE OF THE ABS FAIL-SAFE RELAY ....... 8-72 [D-3] MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR ................. 8-73 [D-5] MAINTENANCE OF THE HYDRAULIC UNIT ........ 8-73 ABS TROUBLESHOOTING OUTLINE............ 8-75 BASIC INSTRUCTION FOR TROUBLESHOOTING ......
Page 315 CHECKING THE COOLANT TEMPERATURE SENSOR....... 8-118 CHECKING THE THROTTLE POSITION SENSOR ....... 8-119 CHECKING THE INTAKE AIR PRESSURE SENSOR ......8-120 CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....8-120 CHECKING THE V-BELT RESET COUPLER ........8-121...
Page 316: Ignition System
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
Page 317 IGNITION SYSTEM 1. Crankshaft position sensor 4. Main switch 13. Ignition fuse 16. Battery 17. Main fuse 21. Starting circuit cut-off relay 1 26. Engine stop switch 29. Sidestand switch 30. ECU (engine) 31. Ignition coil 32. Spark plug 40. Lean angle sensor...
Page 318: Troubleshooting
IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: Before troubleshooting, remove the following part(s): 1.Battery cover 2.Rear cover 3.Front cowling 4.Leg shield 5.Footrest board 6.Inner fender 1. Check the fuses. (Main and ignition) NG→...
Page 319 IGNITION SYSTEM 10. Check the sidestand switch. NG→ Replace the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 8-101. OK↓ 11. Check the starting circuit cut-off relay 1 (Diode). NG→ Replace the starting circuit cut-off relay 1. Refer to “CHECKING THE RELAYS” on page 8-110.
Page 320: Electric Starting System
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM XP500...
Page 321 ELECTRIC STARTING SYSTEM 4. Main switch 11. Signaling system fuse 13. Ignition fuse 16. Battery 17. Main fuse 18. Starter relay 19. Starter motor 20. Diode 21. Starting circuit cut-off relay 1 25. Start switch 26. Engine stop switch 28. Front brake light switch 29.
Page 322 ELECTRIC STARTING SYSTEM XP500A...
Page 323 ELECTRIC STARTING SYSTEM 4. Main switch 12. Signaling system fuse 14. Ignition fuse 17. Battery 19. Main fuse 20. Starter relay 21. Starter motor 22. Diode 23. Starting circuit cut-off relay 2 24. Starting circuit cut-off relay 1 28. Start switch 29.
Page 324: Starting Circuit Cut-Off System Operation
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: A brake lever is pulled to the handlebar (the brake light switch is closed) and the side-stand is up (the sidestand switch is closed).
Page 325 ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Starting circuit cut-off relay 1 7. Sidestand switch 8. Signaling system fuse 9. Front brake switch 10. Rear brake switch 11. Start switch 12.
Page 326 ELECTRIC STARTING SYSTEM 8-11...
Page 327 ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Signaling system fuse 5. Ignition fuse 6. Engine stop switch 7. Starting circuit cut-off relay 1 8. Front brake switch 9. Rear brake switch 10. Sidestand switch 11. Starting circuit cut-off relay 2 12.
Page 328: Troubleshooting
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: Before troubleshooting, remove the following part(s): 1.Front cowling 2.Leg shield 3.Fotrest board 4.Fuel tank 1. Check the fuses. (Main and ignition) NG→ Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-106.
Page 329 ELECTRIC STARTING SYSTEM OK↓ 11. Check the sidestand switch. NG→ Replace the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 8-101. OK↓ 12. Check the brake light switch. NG→ Replace the brake light switch. Refer to “CHECKING THE SWITCHES” on page 8-101. OK↓...
Page 330: Charging System
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-15...
Page 331 CHARGING SYSTEM 2. AC magneto 3. Rectiﬁer/regulator 16. Battery 17. Main fuse 8-16...
Page 332: Troubleshooting
CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. NOTE: Before troubleshooting, remove the following part(s): 1.Rear cover 2.Battery cover 3.Left side cover moulding 4.Left side cover 1. Check the fuse. (Main) NG→ Replace the fuse. Refer to “CHECKING THE FUSES” on page 8-106.
Page 333 CHARGING SYSTEM 8-18...
Page 334: Lighting System
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-19...
Page 335 LIGHTING SYSTEM 4. Main switch 6. Strage box light switch 7. Strage box light 10. Back-up fuse 11. Signal fuse 12. Headlight fuse 15. Lighting system fuse 16. Battery 17. Main fuse 30. ECU (engine) 51. Headlight relay 53. Pass switch 54.
Page 336: Troubleshooting
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, strage box light, license light or meter light. NOTE: Before troubleshooting, remove the following part(s): 1.Battery cover 2.Rear cover 3.Front cowling 4.Handlebar cover 1.
Page 337 LIGHTING SYSTEM 8-22...
Page 338: Signaling System
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-23...
Page 339 SIGNALING SYSTEM 4. Main switch 10. Backup fuse (storage box light, immobilizer unit and meter assembly) 11. Signaling system fuse 15. Lighting system fuse 16. Battery 17. Main fuse 23. Fuel pump 27. Hazard switch 28. Front brake light switch 30.
Page 340: Troubleshooting
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING Any of the following fail to light: turn signal light, brake light or an indicator light. The horn fails to sound. The speedometer fails to operate. The V-belt replacement indicator fails to come on. The fuel meter(meter assembly) fails to operate. NOTE: Before troubleshooting, remove the following part(s): 1.Battery cover...
Page 341 SIGNALING SYSTEM The tail/brake light fails to come on. 1. Check the tail/brake light bulb and socket. NG→ Replace the tail/brake light bulb, socket or both. Refer to “CHECKING THE BULBS AND BULB SOCKETS” on page 8-105. OK↓ 2. Check the brake light switch. NG→...
Page 342 SIGNALING SYSTEM 2. Check the entire signaling system’s Properly connect or repair the signaling system’s wiring. NG→ Refer to “CIRCUIT DIAGRAM” on wiring. page 8-23. OK↓ Replace the meter assembly. The fuel meter fails to come. 1. Check the fuel sender. NG→...
Page 343 SIGNALING SYSTEM 8-28...
Page 344: Cooling System
COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-29...
Page 345 COOLING SYSTEM 4. Main switch 13. Ignition fuse 14. Radiator fan motor fuse 16. Battery 17. Main fuse 30. ECU (engine) 33. Coolant temperature sensor 47. Radiator fan motor relay 48. Radiator fan motor 72. Multi-function display 8-30...
Page 346: Troubleshooting
COOLING SYSTEM EAS27320 TROUBLESHOOTING NOTE: Before troubleshooting, remove the following part(s): 1.Battery cover 2.Rear cover 3.Footrest board 4.Leg shield 5.Inner fender 1. Check the fuses. (Main, ignition and radiator fan motor) NG→ Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-106.
Page 347 COOLING SYSTEM 8-32...
Page 348: Fuel Injection System
FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-33...
Page 349 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 4. Main switch 9. Electrical fuel injection fuse 12. Headlight fuse 13. Ignition fuse 16. Battery 17. Main fuse 21. Starter circuit cut-off relay 1 22. Fuel injection system relay 23. Fuel pump 26.
Page 350: Ecu Self-Diagnostic Function
FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU (engine) is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately oper- ates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 351 FUEL INJECTION SYSTEM that enable the engine to continue to operate or stop operating, depending on the conditions. The ECU (engine) takes fail-safe actions in two ways: one in which the sensor output is set to a pre- scribed value, and the other in which the ECU (engine) directly operates an actuator. Details on the fail-safe actions are given in the table below.
Page 352 FUEL INJECTION SYSTEM Communication error with the meter Able / Able / Fault code Item Symptom unable to unable to start drive ECU (engine) internal No signals are received from the ECU Er-1 malfunction Unable Unable (engine). (output signal error) ECU (engine) internal No signals are received from the ECU Er-2...
Page 353: Troubleshooting Method
FUEL INJECTION SYSTEM If malfunction the sensors or actuators, repair EAS27400 TROUBLESHOOTING METHOD or replace it. The engine operation is not normal and the If not malfunction the sensors and actuators, engine trouble warning light comes on. check and repair the engine inner parts. 1.
Page 354 FUEL INJECTION SYSTEM bers. 8. Verify the operation of the sensor or actuator. Sensor operation The data representing the operating condi- tions of the sensor appears on the trip LCD. Actuator operation Set the engine stop switch to “ ” to operate the actuator.
Page 355 FUEL INJECTION SYSTEM Diagnostic code table Fault Diagnostic code Symptom Probable cause of malfunction code No. Open or short circuit in wire harness. Defective crankshaft position sensor. No normal signals are Malfunction in pickup rotor. received from the crankshaft — position sensor.
Page 356 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Open or short circuit in wire harness. Malfunction in ignition coil. Malfunction detected in the Malfunction in ECU (engine). primary wire of the ignition coil. Malfunction in a component of ignition cut-off circuit system.
Page 357 FUEL INJECTION SYSTEM Sensor operation table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “DIAGNOSTIC MONITORING MODE”. Diagnos monitori Item Meter display Checking method ng code Throttle angle Fully closed position (15–16) Check with throttle fully closed.
Page 358 FUEL INJECTION SYSTEM Diagnos monitori Item Meter display Checking method ng code Malfunction history code dis- — play No history History exists 12-50 (Fault detection code) (If code numbers more than one are detected, the display alternates every two seconds to show all the detected code numbers.
Page 359 FUEL INJECTION SYSTEM Diagnos monitori Item Actuation Checking method ng code Actuates the radiator fan motor relay for ﬁve cycles every Check the operating sound of ﬁve-second. (ON 2 seconds, Radiator fan motor relay the Radiator fan motor relay OFF 3 seconds) ﬁve times.
Page 360: Troubleshooting Details
FUEL INJECTION SYSTEM EAS27471 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the meter display ac- cording to the reinstatement method.
Page 361 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor-open or short circuit detected. Diagnostic code No. Intake air pressure sensor Reinstatement Order Item/components and probable cause Check or maintenance job method Connected state of connector Check the coupler for any pins Cranking the Intake air pressure sensor coupler engine.
Page 362 FUEL INJECTION SYSTEM Intake air pressure sensor-pipe system malfunction (clogged or Fault code No. Symptom detached hose). Diagnostic code No. Intake air pressure sensor Reinstatement Order Item/components and probable cause Check or maintenance job method Intake air pressure sensor hose Check the Intake air pressure Starting the engine and oper-...
Page 363 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor-open or short circuit detected. Diagnostic code No. Throttle position sensor Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of throttle position sen- Check the installed area for Turning the main sor.
Page 364 FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Diagnostic monitoring Throttle position sensor code No. Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of throttle position sen- Check the installed area for Reinstated by sor.
Page 365 FUEL INJECTION SYSTEM Fault code No. Symptom Coolant temperature sensor-open or short circuit detected. Diagnostic code No. Coolant temperature sensor Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of coolant temperature Check the installed area for loose- Turning the main sensor ness or pinching.
Page 366 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air temperature sensor-open or short circuit detected. Diagnostic code No. Intake air temperature sensor Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of intake air tempera- Check the installed area for loose- Turning the main ture sensor ness or pinching.
Page 367 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of O sensor Check the installed area for loose- As the returning ness or pinching.
Page 368 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the ignition coil. Diagnostic code No. Ignition coil Reinstatement Order Item/components and probable cause Check or maintenance job method Connected state of connector Check the coupler for any pins Starting the Ignition coil primary side coupler engine and oper-...
Page 369 FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor-open or short circuit detected. Diagnostic code No. Lean angle sensor Reinstatement Order Item/components and probable cause Check or maintenance job method Connected state of connector Check the coupler for any pins Reinstated imme- Lean angle sensor coupler diately when it...
Page 370 FUEL INJECTION SYSTEM Error is detected while reading or writing on EEPROM (CO Fault code No. Symptom adjustment value). Diagnostic code No. EEPROM improper cylinder indication Reinstatement Order Item/components and probable cause Check or maintenance job method Malfunction in ECU (engine) Execute the diagnostic monitor- Turning the main switch ON...
Page 371 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the FI system relay is not normal. Diagnostic monitoring — — code No. Reinstatement Order Item/components and probable cause Check or maintenance job method Connected state of connector. Check the coupler for any pins Starting the Main wire harness ECU (engine) engine and oper-...
Page 372: Immobilizer System
IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-57...
Page 373 IMMOBILIZER SYSTEM 4. Main switch 5. Immobilizer unit 10. Backup fuse (storage box light, immobilizer unit and meter assembly) 13. Ignition fuse 16. Battery 17. Main fuse 30. ECU (engine) 71. Immobilizer system indicator light 72. Multi-function meter 8-58...
Page 374: General Information
IMMOBILIZER SYSTEM EAS27671 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: a code re-registering key (with a red bow) two standard keys (with a black bow) that can be re-registered with new codes a transponder (installed in the red key bow) an immobilizer unit the ECU...
Page 375 IMMOBILIZER SYSTEM Parts to be replaced Main switch/ Key registration immobilizer unit Accessory requirement Standard lock* and Main Immobilize switch r unit √ Standard key is lost New standard key All keys have been lost Code re-registering √ √ √ √...
Page 376 IMMOBILIZER SYSTEM the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. NOTE: Do not start the engine with a standard key that has not been registered. If the main switch is turned “ON” with a standard key that has not been registered, the immobilizer system indicator light flashes to indicate fault code “52”.
Page 377: Troubleshooting
IMMOBILIZER SYSTEM Standard key code voiding method g. Remaining standard key a. Main switch “ON” h. Registration mode b. Main switch “OFF” c. LED on A. If the immobilizer system indicator light d. LED off stops ﬂashing 5 seconds after the ﬁrst stan- e.
Page 378 IMMOBILIZER SYSTEM Fault code Part Symptom Cause Action IMMOBILIZER Code cannot be trans- Radio wave interfer- Keep magnets, UNIT mitted between the ence caused by metal objects, key and immobilizer objects around the and other immobi- unit. keys and antennas. lizer system keys Immobilizer unit mal- away form the...
Page 379 IMMOBILIZER SYSTEM Fault code Part Symptom Cause Action Undeﬁnition code is Noise interference or dis- Check the wire received. connected lead/cable. harness and con- nector. Replace the main switch/immobi- lizer unit. Replace the ECU. Immobilizer system indicator light fault code indication Digit of 10 : Cycles of “1”...
Page 380: Abs (Anti-Lock Brake System) (Xp500A)
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27730 CIRCUIT DIAGRAM 8-65...
Page 381 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 4. Main switch 9. ABS control unit fuse 12. Signaling system fuse 17. Battery 18. ABS motor fuse 19. Main fuse 23. Starting circuit cut-off relay 2 24. Starting circuit cut-off relay 1 28. Start switch 29.
Page 382: Abs Components Chart
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27740 ABS COMPONENTS CHART 8-67...
Page 383 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 1. ABS warning light 2. Fail-safe relay 3. Electronic control unit (ECU) 4. Hydraulic unit 5. Rear disc rotor 6. Rear brake caliper 7. Rear wheel sensor 8. Front brake caliper 9. Front wheel sensor 10.
Page 384: Abs Connector Location Chart
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27750 ABS CONNECTOR LOCATION CHART 8-69...
Page 385 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 1. ABS test coupler 2. ECU (ABS) coupler 3. Front wheel sensor coupler 4. Fail-safe relay coupler 5. Hydraulic unit coupler 6. Rear wheel sensor coupler 7. Multi-function coupler 8-70...
Page 386: Ecu (Abs) And Fail-Safe Relay Chart
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27760 ECU (ABS) AND FAIL-SAFE RELAY CHART Removing the ECU (ABS) and fail-safe relay 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Parts to remove Q’ty Remarks “GENERAL CHASSIS” on page Refer to Front cowling Fail-safe relay coupler Disconnect.
Page 387: [D-1] Maintenance Of The Ecu (Abs)
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27770 [D-1] MAINTENANCE OF THE ECU (ABS) Solenoid relay resistance 150–450 Ω Checking the ECU (ABS) 1. Check: Tester reading is “∞”. → Replace the fail-safe Terminals “1” of the ECU (ABS) Cracks/damages → Replace ECU (ABS) relay.
Page 388: [D-3] Maintenance Of The Front Wheel Sensor And
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Connect the positive battery terminal to termi- EAS15B4887d [D-5] MAINTENANCE OF THE HYDRAULIC nal “6” and the negative battery terminal to UNIT terminal “1”, and then check for continuity be- ECA15B1006 tween terminals “2” and “5” of the ABS motor CAUTION: relay.
Page 389 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Positive tester probe Terminal “1” Negative tester probe Terminal “2” There is continuity. No continuity → Replace the hydraulic unit. 8-74...
Page 390: Abs Troubleshooting Outline
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27790 ABS TROUBLESHOOTING OUTLINE This section describes the troubleshooting about ABS in details. Read carefully this service manual be- fore repairing various malfunctions, understand and perform the service. Electronic control unit (ECU) has the self diagnostic function. When failures occur in the system, the ABS warning light on the meter assembly indicates a malfunction.
Page 391: Basic Instruction For Troubleshooting
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Malfunction history in ECU (ABS) is recorded. Delete it when the service is finished. (This is because the past malfunction contents will be redundantly displayed when the same malfunction occurred again.) EAS27800 BASIC INSTRUCTION FOR TROUBLESHOOTING EWA14030 WARNING Execute the troubleshooting on each malfunction from [A] to [D] in sequence.
Page 392: Basic Process For Troubleshooting
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING 8-77...
Page 393: [A] Abs Malfunction Check Using The Abs Warning Light
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) NOTE: Do not delete the malfunction code during the troubleshooting procedures. Be sure to delete it when the service is finished. EWA14050 WARNING Always execute the “final check” when the components related to ABS are checked and ser- viced.
Page 394: [B-4] Malfunction Check By The Abs Self Diagnosis (Past Malfunction)
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) NOTE: When the test coupler adaptor is connected to test coupler, the T/C terminal is grounded. 2. No → [C-3] Arrangement and the function of test couplers ECU becomes the malfunction diagnostic mode when the T/C terminal is grounded. Malfunction code which the ECU generated in the malfunction diagnostic mode (rise and fall of volt- age) is output at the T/F terminal.
Page 395: [B-5] Malfunction Check By The Abs Self Diagnosis (Present Malfunction)
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) ABS warning light flashes every 0.5 second for more than 6 seconds. → [C-4, C-5] If the ABS warning light flashes every 0.5 second, the malfunction code of a past malfunction has not been stored in the memory of the ECU (ABS). If a malfunction code is displayed on the multifunction display, the ABS warning light flashes.
Page 396 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 7. ABS warning light terminal (white/red) 1. ABS test coupler 8. Test coupler adapter 2. Lock plate 9. (Light green) 3. Protective cap 4. Grounding 10. (Black) 11. (White/red) 5. T/C terminal 6. T/F terminal As an example, “10 digits/1 digit pattern”...
Page 397: [C] Determining The Cause And Location Of The Malfunction
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) C. Time (second) A. This example is the pattern which shows malfunction code 12. B. This example is the pattern which shows malfunction code 21. EAS15B3011 [C] DETERMINING THE CAUSE AND LOCATION OF THE MALFUNCTION EAS15B3012 [C-1] ONLY THE ABS WARNING LIGHT DOES NOT COME ON WHEN THE MAIN SWITCH IS SET TO “ON”...
Page 398: [C-3] Abs Warning Light Flashes
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Check the battery voltage. (Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-107.) Check if the main fuse or signal fuse is blown. If the main fuse is blown, determine the cause and repair. Replace with a new fuse.
Page 399 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Malfunction Problem Check point Reference code Front wheel sensor signal is not Installation of the front wheel received properly. sensor Front wheel sensor lead and Malfunction code 11 coupler ABS wireharness circuit Front wheel sensor rotor Rear wheel sensor signal is not Installation of the rear wheel received properly.
Page 400 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Malfunction Problem Check point Reference code Defective operation of the ABS motor Fail-safe relay is detected. (ABS motor keeps run- ABS wireharness circuit ning and will not stop.) Malfunction ABS motor circuit code 34 Brake dragging Front wheel will not recover from the locking tendency even though the sig- Hydraulic unit operation test 2...
Page 401 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Front wheel sensor lead or internal circuit is broken. → [D-3] Wire harness (ABS) sensor circuit is broken. → (Refer to “CIRCUIT DIAGRAM” on page 8-65.) ECU (ABS) coupler terminal is disconnected. → [D-1] 2. ABS warning light goes on for 2 seconds then goes off. With the front wheel stopped, the rear wheel was rotated for more than 20 seconds.
Page 402 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Check for flaws on the teeth surfaces of the front or rear wheel sensor rotors. Also, check for any foreign materials. → [D-3, 4] 3. Sensor output has dropped. Sensor signal output may drop due to failure of the bearings, wheel axle, rear brake caliper bracket wheel or sensor housing of (front) the front or rear wheel.
Page 403 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Check if the hydraulic unit solenoid coupler located in the front cowling is connected properly. 3. Wire harness (ABS system circuit) Check the pink/white leads between the ECU (ABS) and the fail-safe relay for continuity. (Refer to “CIRCUIT DIAGRAM”.) ECU (ABS) coupler terminal (pink/white) is disconnected.
Page 404 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Malfunction code 32 (Circuit malfunction of ECU (ABS) is detected. Upstream side of the so- lenoid relay.) NOTE: Check following the steps in sequence. 1. Fail-safe relay Check if the fail-safe relay operates correctly. → [D-2] 2.
Page 405 Check the brake hose lines for kinks and deterioration. EWA15B3005 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and to the front brake caliper from the hydraulic unit are correct.
Page 406 EWA15B3005 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and to the rear brake caliper from the hydraulic unit are correct.
Page 407 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 5. Hydraulic unit solenoid coupler terminal Check if the front and rear hydraulic unit solenoid coupler terminals (hydraulic unit and wire harness [ABS]) are reversed. Terminal color Solenoid side Wire harness side (ABS) Front Red, green Red, white Rear Red, white...
Page 408: [D-6-4] Deleting The Malfunction Code
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 4. Brake hose lines Refer to “Malfunction code 42”. 5. Hydraulic unit solenoid coupler terminals Refer to “Malfunction code 42”. 6. Hydraulic unit Refer to “Malfunction code 42”. 7. Battery voltage Measure the battery voltage. EAS15B3036 [D-6-4] DELETING THE MALFUNCTION CODE 1.
Page 409: [D-6-6] Delete Function Test
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) e. Flashing a. ABS warning light f. 2 seconds b. ON g. 3 seconds c. Main switch on h. 0.5 seconds d. Main switch off 7. Turn the main switch off. 8. Disconnect the test coupler adaptor from the test coupler and install the protective cap onto the test coupler.
Page 410: [D-6] Final Check
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 6. Check: ECU (ABS)-to-start-switch-lead continuity Connect the pocket tester (Ω × 1) to the ECU (ABS) coupler and start switch coupler. Tester positive probe → Green/White “1” (ECU (ABS)) Tester negative probe → Green/White “2” (start switch) No continuity →...
Page 411 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 8-96...
Page 412: Electrical Components
ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-97...
Page 413 ELECTRICAL COMPONENTS 1. Front brake light switch 2. Rear brake light switch 3. Turn signal/hazard relay 4. Starting circuit cut-off relay 1 5. Starting circuit cut-off relay 2 (XP500A) 6. Battery 7. Fuse box 8. Main fuse 9. Starter relay 10.
Page 414 ELECTRICAL COMPONENTS 8-99...
Page 415 ELECTRICAL COMPONENTS 1. ECU (ABS) (XP500A) 2. Fail-safe relay (XP500A) 3. Main switch/immobilizer unit 4. Intake air pressure sensor 5. Coolant temperature sensor 6. ABS motor fuse 7. Fuel pump 8. Rear wheel sensor (XP500A) 9. O sensor 10. Hydraulic unit (XP500A) 11.
Page 416: Checking The Switches
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES L W B Br/R Br/L Br/R – / L B – PASS Br/L R/W R/B Br/W Br/W DgL/Y Br/L – Br/W Br/W Ch B/Y Br/L (BLUE) (BLACK) (BROWN) (BLUE) R L/G 8-101...
Page 417 ELECTRICAL COMPONENTS 1. Pass switch 2. Dimmer switch 3. Turn signal switch 4. Horn switch 5. Rear brake light switch 6. Sidestand switch 7. Storage box light switch 8. Main switch 9. Start switch 10. Engine stop switch 11. Hazard switch 12.
Page 418 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 419 ELECTRICAL COMPONENTS 8-104...
Page 420: Checking The Bulbs And Bulb Sockets
ELECTRICAL COMPONENTS 1. Remove: EAS27990 CHECKING THE BULBS AND BULB Bulb SOCKETS EWA13320 Check each bulb and bulb socket for damage or WARNING wear, proper connections, and also for continu- Since the headlight bulb gets extremely hot, ity between the terminals. keep flammable products and your hands Damage/wear →...
Page 421: Checking The Fuses
ELECTRICAL COMPONENTS 2. Check: Fuse MMMMMMMMMMMMMMMMMMMMMM a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester Checking the condition of the bulb sockets YU-03112-C The following procedure applies to all of the bulb sockets.
Page 422: Checking And Charging The Battery
ELECTRICAL COMPONENTS and contain electrolyte which is made of poi- Amperage Fuses Q’ty sonous and highly caustic sulfuric acid. rating Therefore, always follow these preventive Main measures: Wear protective eye gear when handling or Headlight working near batteries. Charge batteries in a well-ventilated area. (XP500) Signal Keep batteries away from fire, sparks or...
Page 423 ELECTRICAL COMPONENTS 2. Disconnect: 5. Charge: Battery leads Battery (from the battery terminals) (refer to the appropriate charging method il- lustration) ECA13640 CAUTION: EWA13300 WARNING First, disconnect the negative battery lead “1”, and then positive battery lead “2”. Do not quick charge a battery. ECA13670 CAUTION: Never remove the MF battery sealing caps.
Page 424 ELECTRICAL COMPONENTS the machine is stopped. c. Make sure that the current is higher than the standard charging current written on the bat- b. Connect a charged and AMP meter to the tery. battery and start charging. NOTE: NOTE: If the current is lower than the standard charging Set the charging voltage at 16–17 V.If the setting current written on the battery, This type of bat- is lower, charging will be insufficient.
Page 425: Checking The Relays
ELECTRICAL COMPONENTS Refer to “GENERAL CHASSIS” on page 4-1. Result Continuity → OK EAS28040 No continuity → Replace. CHECKING THE RELAYS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- Starting circuit cut-off relay 2 (XP500A) place the relay.
Page 426: Checking The Turn Signal/Hazard Relay
ELECTRICAL COMPONENTS Headlight relay b. Turn the main switch to “ON”. c. Measure the turn signal/hazard relay input 1. Positive battery terminal voltage. 2. Negative battery terminal 3. Tester positive probe 4. Negative tester probe LLLLLLLLLLLLLLLLLLLLLL 2. Check: Result Turn signal/hazard relay output voltage Continuity →...
Page 427: Checking The Diode
ELECTRICAL COMPONENTS LLLLLLLLLLLLLLLLLLLLLL EAS28050 CHECKING THE DIODE 1. Check: Starting circuit cut-off relay 1 diode Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester NOTE: YU-03112-C When you switch the positive and negative tester probes, the readings in the above chart will be reversed.
Page 428: Checking The Ignition Coil
ELECTRICAL COMPONENTS EAS28080 CHECKING THE IGNITION COIL Pocket tester 90890-03112 1. Check: Analog pocket tester Primary coil resistance YU-03112-C Out of specification → Replace. Primary coil resistance 1.87–2.53 Ω MMMMMMMMMMMMMMMMMMMMMM a. Disconnect the ignition coil connectors from the ignition coil terminals. b.
Page 429: Checking The Crankshaft Position Sensor
ELECTRICAL COMPONENTS b. Measure the crankshaft position sensor re- 1. Spark plug gap sistance. e. Crank the engine by pushing the starter switch and gradually increase the spark gap LLLLLLLLLLLLLLLLLLLLLL until a misfire occurs. EAS28130 LLLLLLLLLLLLLLLLLLLLLL CHECKING THE LEAN ANGLE SENSOR 1.
Page 430: Checking The Starter Motor Operation
ELECTRICAL COMPONENTS b. Check the starter motor operation. c. When turn the lean angle sensor to 45°. d. Measure the lean angle sensor out put volt- age. LLLLLLLLLLLLLLLLLLLLLL EAS28150 CHECKING THE STATOR COIL 1. Disconnect: Stator coil coupler (from the wire harness) 2.
Page 431: Checking The Charging Voltage
ELECTRICAL COMPONENTS b. Measure the stator coil resistance. c. Start the engine and let it run at approximate- ly 5000 r/min. d. Measure the charging voltage. LLLLLLLLLLLLLLLLLLLLLL LLLLLLLLLLLLLLLLLLLLLL EAS28170 CHECKING THE CHARGING VOLTAGE 1. Check: EAS28180 Charging voltage CHECKING THE HORN Out of specification →...
Page 432: Checking The Fuel Sender
ELECTRICAL COMPONENTS Positive tester probe LLLLLLLLLLLLLLLLLLLLLL Green “1” Negative tester probe 2. Check: Black “2” Operation of the horn The horn fails to sound → check the step (3). MMMMMMMMMMMMMMMMMMMMMM a. Disconnect the horn coupler at the horn. b. Connect a jumper lead “1” to the brown termi- nal in the horn coupler and the horn terminal.
Page 433: Checking The Radiator Fan Motor
ELECTRICAL COMPONENTS Tester positive probe LLLLLLLLLLLLLLLLLLLLLL White “1” Negative tester probe EAS28260 Black/Blue “2” CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: Coolant temperature sensor Refer to “THERMOSTAT” on page 6-5. EWA14130 WARNING Handle the coolant temperature sensor with special care. Never subject the coolant temperature sen- sor to strong shocks.
Page 434: Checking The Throttle Position Sensor
ELECTRICAL COMPONENTS Tester positive probe Blue “1” Negative tester probe Black/Blue “2” b. Immerse the coolant temperature sensor in a d. Measure the throttle position sensor resis- container filled with coolant “2”. tance. Out of specification → Replace the throttle NOTE: Make sure the coolant temperature sensor ter- position sensor.
Page 435: Checking The Intake Air Pressure Sensor
ELECTRICAL COMPONENTS abruptly → Replace the throttle position sen- sor. The slot is worn or broken → Replace the throttle position sensor. NOTE: Check mainly that the resistance changes grad- ually when turning the throttle, since the read- ings (from closed to wide-open throttle) may differ slightly from those specified.
Page 436: Checking The V-Belt Reset Coupler
ELECTRICAL COMPONENTS Tester positive probe Pink/White “1” Negative tester probe Black/Blue “2” LLLLLLLLLLLLLLLLLLLLLL 2. Check: V-belt reset coupler voltage Out of specification → Replace. b. Set the main switch to “ON”. V-belt reset coupler voltage c. Measure the intake air temperature sensor voltage.
Page 437: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING................... 9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURE/HARD STARTING..........9-1 INCORRECT ENGINE IDLING SPEED ..........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY CLUTCH ................... 9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............9-3 FAULTY FRONT FORK LEGS..............9-3 UNSTABLE HANDLING ................
Page 438: Troubleshooting
TROUBLESHOOTING Faulty battery EAS28450 TROUBLESHOOTING 2. Fuse(s) Blown, damaged or incorrect fuse EAS28460 GENERAL INFORMATION Improperly installed fuse 3. Spark plug(s) NOTE: Incorrect spark plug gap The following guide for troubleshooting does not cover all the possible causes of trouble. It should Incorrect spark plug heat range Fouled spark plug be helpful, however, as a guide to basic trouble-...
Page 439: Poor Medium-And-High-Speed Performance
TROUBLESHOOTING 2. Spark plug(s) Bent, damaged or worn clutch shoe Incorrect spark plug gap Poor speed performance Incorrect spark plug heat range 1. V-belt Fouled spark plug Oil or grease on the V-belt Worn or damaged electrode 2. Primary pulley weight(s) Worn or damaged insulator Faulty operation Faulty spark plug cap...
Page 440: Overcooling
TROUBLESHOOTING Incorrect spark plug gap 3. Front fork leg(s) Incorrect spark plug heat range Uneven oil levels (both front fork legs) 2. Ignition system Unevenly tensioned fork spring (both front Faulty ECU (engine) fork legs) Broken fork spring EAS28610 Bent or damaged inner tube OVERCOOLING Bent or damaged outer tube Cooling system...
Page 441 TROUBLESHOOTING Incorrectly adjusted rear brake light switch Tail/brake light bulb life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt-out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown, damaged or incorrect fuse Turn signal blinks slowly...
Page 442 EAS28740 48.Radiator fan motor WIRING DIAGRAM 49.Turn signal/hazard relay 2007 XP500 WIRING DIA- 50.Horn GRAM 51.Headlight relay 1.Crankshaft position sensor 52.Left handlebar switch 2.A.C. magneto 53.Pass switch 3.Rectifier/regulator 54.Dimmer switch 4.Main switch 55.Horn switch 5.Immobilizer unit 56.Turn signal switch 6.Storage box light switch 57.Rear brake light switch 7.Storage box light 58.Tail/brake light assembly...
Page 443 2007 XP500A WIRING DIA- 50.Grip warmer switch (optional) GRAM 51.Grip warmer relay (optional) 1.Crankshaft position sensor 52.Grip warmer (optional) 2.A.C. magneto 53.Auxiliary DC jack fuse 3.Rectifier/regulator 54.Auxiliary DC jack 4.Main switch 55.Radiator fan motor relay 5.Immobilizer unit 56.Radiator fan motor 6.Storage box light switch 57.Turn signal/hazard relay 7.Storage box light...
Page 444 EAS28750 Red/White COLOR CODE Red/Yellow Black Sb/W Sky blue/White Brown White/Black Chocolate White/Red Dark green White/Yellow Green Yellow/Black Gray Yellow/Green Blue Yellow/Blue Orange Yellow/Red Pink Sky blue White Yellow Black/Green Black/Blue Black/Red Black/White Black/Yellow Br/G Brown/Green Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White Green/Black...
Page 446 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
Page 447 XP500 2007 XP500 2007 XP500 2007 SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO DE LA WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN XP500 2007 XP500 2007...
Page 448 XP500A 2007 XP500A 2007 XP500A 2007 SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO DE LA WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN XP500A 2007 XP500A 2007...
Page 449 XP500 2007 XP500 2007 XP500 2007 SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO DE LA WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN XP500 2007 XP500 2007...
Page 450 XP500A 2007 XP500A 2007 XP500A 2007 SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO DE LA WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN XP500A 2007 XP500A 2007...

This manual is also suitable for:

2007 xp500a

Yamaha 2007 XP500 Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Periodic Maintenance

Engine

Chassis

Electrical System

Chassis

General Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

ABS (Anti-Lock Brake System)

Handlebar

Front Fork

Steering Head

Rear Shock Absorber Assembly

Engine

Engine Removal

Camshafts

Cylinder Head

Valves and Valve Springs

Cylinder and Pistons

Generator and Starter Clutch

Oil Pump

Clutch

V-Belt Automatic Transmission

Crankcase and Crankshaft

Transmission

Chain Drive Transmission

Cooling System

Radiator

Thermostat

Water Pump

Fuel System

Fuel Tank

Throttle Bodies

Electrical System

Ignition System

Electric Starting System

Charging System

Lighting System

Signaling System

Cooling System

Fuel Injection System

Immobilizer System

Abs (Anti-Lock Brake System) (Xp500A)

Electrical Components

Quick Links

Chapters

Troubleshooting

Related Manuals for Yamaha 2007 XP500

Summary of Contents for Yamaha 2007 XP500