Yamaha 2007 XP500 Manuals

Yamaha 2007 XP500 Manuals

Manuals and User Guides for Yamaha 2007 XP500. We have 1 Yamaha 2007 XP500 manual available for free PDF download: Service Manual

Yamaha 2007 XP500 Service Manual

Yamaha 2007 XP500 Service Manual (450 pages)

Brand: Yamaha | Category: Scooter | Size: 19.49 MB

Table of Contents

Table of Contents

7
- General Information
  9
  - Identification
    10
  - Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of Fi System
    11
    
    Fi System
    12
    
    Outline of Anti-Lock Brake System (Xp500A)
    13
    
    Multi-Function Display
    24
  - Important Information
    27
    
    Preparation for Removal and Disassembly
    27
    
    Replacement Parts
    27
    
    Gaskets, Oil Seals and O-Rings
    27
    
    Lock Washers/Plates and Cotter Pins
    27
    
    Bearings and Oil Seals
    27
    
    Circlips
    28
  - Checking the Connections
    29
  - Special Tools
    30
Specifications

37
- General Specifications
  38
- Engine Specifications
  39
- Chassis Specifications
  46
- Electrical Specifications
  49
  - Tightening Torques
    52
- General Tightening Torque Specifications
  52
  - Engine Tightening Torques
    52
  - Chassis Tightening Torques
    56
- Lubrication Points and Lubricant Types
  58
  - Engine
    58
  - Chassis
    59
- Lubrication System Chart and Diagrams
  62
  - Engine Oil Lubrication Chart
    62
  - Lubrication Diagrams
    64
- Cooling System Diagrams
  70
- Cable Routing
  72
Periodic Checks and Adjustments

103
- Periodic Maintenance
  
  105
  - General Maintenance and Lubrication Chart
    105
  - Introduction
    105
  - Adjusting the Valve Clearance
    107
    
    Synchronizing the Throttle Bodies
    109
    
    Adjusting the Exhaust Gas Volume
    111
    
    Adjusting the Engine Idling Speed
    112
    
    Adjusting the Throttle Cable Free Play
    112
    
    Checking the Spark Plugs
    113
    
    Checking the Ignition Timing
    114
    
    Measuring the Compression Pressure
    115
    
    Checking the Engine Oil Level
    116
    
    Changing the Engine Oil
    117
    
    Measuring the Engine Oil Pressure
    118
    
    Cleaning the Air Filter Element
    119
    
    Cleaning the V-Belt Case Air Filter Element
    120
    
    Checking the Throttle Body Joints and Intake Manifolds
    120
    
    Checking the Fuel Hoses and Fuel Tank Breather Hose
    121
    
    Checking the Cylinder Head Breather Hose
    121
    
    Checking the Exhaust System
    121
    
    Checking the Coolant Level
    122
    
    Checking the Cooling System
    122
    
    Changing the Coolant
    123
- Engine
  
  107
- Chassis
  
  126
  - Checking the Brake Fluid Level
    126
    
    Checking the Front Brake Pads
    126
    
    Checking the Rear Brake Pads
    126
    
    Checking the Front Brake Hoses
    127
    
    Checking the Rear Brake Hose
    127
    
    Adjusting the Rear Brake Lock Lever Cable
    127
    
    Bleeding the Hydraulic Brake System (Xp500)
    128
    
    Checking the Chain Drive Oil Level
    130
    
    Changing the Chain Drive Oil
    130
    
    Checking and Adjusting the Steering Head
    131
    
    Checking the Front Fork
    133
    
    Checking the Tires
    133
    
    Checking the Wheels
    135
    
    Checking and Lubricating the Cables
    135
    
    Lubricating the Levers
    135
    
    Lubricating the Sidestand
    135
    
    Lubricating the Centerstand
    135
- Electrical System
  
  136
  - Checking and Charging the Battery
    136
  - Checking the Fuses
    136
Chassis

139
- General Chassis
  
  141
- Front Wheel
  
  146
- Rear Wheel
  
  156
- Front Brake
  
  161
- Rear Brake
  
  174
  - Introduction
    179
    
    Checking the Rear Brake Disc
    179
    
    Replacing the Rear Brake Pads
    179
    
    Removing the Rear Brake Caliper
    181
    
    Disassembling the Rear Brake Caliper
    181
    
    Checking the Rear Brake Caliper
    182
    
    Assembling the Rear Brake Caliper
    182
    
    Installing the Rear Brake Caliper
    183
    
    Removing the Rear Brake Master Cylinder
    184
    
    Checking the Rear Brake Master Cylinder
    184
    
    Assembling the Rear Brake Master Cylinder
    185
    
    Installing the Rear Brake Master Cylinder
    185
- ABS (Anti-Lock Brake System)
  
  187
  - Removing the Hydraulic Unit
    188
  - Checking the Hydraulic Unit
    188
  - Installing the Hydraulic Unit
    189
  - Hydraulic Unit Operation Test
    189
  - Trial Run
    192
- Handlebar
  
  193
  - Removing the Handlebars
    195
  - Checking the Handlebar
    195
  - Installing the Handlebar
    195
- Front Fork
  
  197
  - Removing the Front Fork Legs
    199
  - Disassembling the Front Fork Legs
    199
  - Checking the Front Fork Legs
    200
  - Assembling the Front Fork Legs
    201
  - Installing the Front Fork Legs
    203
- Steering Head
  
  204
  - Removing the Lower Bracket
    206
  - Checking the Steering Head
    206
  - Installing the Steering Head
    207
- Rear Shock Absorber Assembly
  
  208
Engine

211
- Engine Removal
  
  215
  - Installing the Engine
    218
- Camshafts
  
  219
  - Removing the Camshafts
    221
  - Checking the Camshafts
    222
  - Checking the Timing Chain Guides
    223
  - Checking the Timing Chain Tensioner
    224
  - Installing the Camshafts
    224
- Cylinder Head
  
  227
  - Removing the Cylinder Head
    228
  - Checking the Cylinder Head
    228
  - Installing the Cylinder Head
    228
- Valves and Valve Springs
  
  231
  - Removing the Valves
    231
  - Checking the Valves and Valve Guides
    231
  - Checking the Valve Seats
    233
  - Checking the Valve Springs
    234
  - Checking the Valve Lifters
    235
  - Installing the Valves
    235
- Cylinder and Pistons
  
  239
  - Removing the Piston
    239
  - Checking the Cylinders and Pistons
    239
  - Checking the Piston Rings
    240
  - Checking the Piston Pin
    241
  - Installing the Pistons and Cylinders
    241
- Generator and Starter Clutch
  
  243
  - Removing the A.C. Magneto Rotor
    245
  - Checking the Starter Clutch
    245
  - Installing the A.C. Magneto Rotor
    246
  - Electric Starter
    248
  - Checking the Starter Motor
    250
  - Assembling the Starter Motor
    251
  - Installing the Starter Motor
    251
- Oil Pump
  
  252
  - Checking the Oil Pump
    254
  - Checking the Relief Valve
    254
  - Checking the Oil Delivery Pipes
    255
  - Checking the Oil Strainer
    255
  - Checking the Oil Pump Drive Chain
    255
  - Assembling the Oil Pump
    255
- Clutch
  
  256
  - Removing the Clutch
    258
  - Disassembling the Clutch
    258
  - Checking the Friction Plates
    259
  - Checking the Clutch Plates
    259
  - Checking the Clutch Spring Plate
    259
  - Checking the Clutch Housing
    260
  - Checking the Clutch Boss
    260
  - Checking the Pressure Plate
    260
  - Checking the Weight
    260
  - Assembling the Clutch
    261
  - Installing the Clutch
    261
- V-Belt Automatic Transmission
  
  263
  - Removing the Primary Sheave
    267
  - Removing the Secondary Sheave
    267
  - Disassembling the Primary Sheave
    267
  - Disassembling the Secondary Sheave
    268
  - Checking the V-Belt
    268
  - Checking the Primary Sheave
    268
  - Checking the V-Belt Case Air Duct
    268
  - Checking the Primary Sheave Weights
    268
  - Checking the Slider
    269
  - Checking the Secondary Sheave
    269
  - Assembling the Primary Sheave
    269
  - Assembling the Secondary Sheave
    269
  - Installing the Primary Sheave Assembly, Secondary Sheave Assembly and V-Belt
    270
- Crankcase and Crankshaft
  
  272
  - Disassembling the Crankcase
    275
  - Removing the Crankshaft Journal Bearing
    275
  - Removing the Connecting Rods
    275
  - Checking the Crankcase
    275
  - Checking the Timing Chain
    276
  - Checking the Crankshaft and Connecting Rods
    276
  - Installing the Crankshaft Main Journal Bearing
    279
  - Installing the Connecting Rods
    280
  - Installing the Crankshaft
    281
  - Assembling the Crankcase
    281
- Transmission
  
  283
  - Removing the Transmission
    284
  - Checking the Transmission
    284
- Chain Drive Transmission
  
  285
  - Checking the Swingarm
    288
  - Checking the Chain Drive Assembly
    288
  - Assembling the Chain Drive Assembly
    288
Cooling System

291
- Radiator
  
  292
  - Checking the Oil Cooler
    294
  - Checking the Radiator
    294
  - Installing the Oil Cooler and Radiator
    294
- Thermostat
  
  296
  - Checking the Thermostat
    297
  - Installing the Thermostat Assembly
    297
- Water Pump
  
  298
  - Disassembling the Water Pump
    300
  - Checking the Water Pump
    300
  - Assembling the Water Pump
    300
  - Installing the Water Pump
    302
Fuel System

303
- Fuel Tank
  
  304
  - Installing the Fuel Pump
    305
  - Installing the Fuel Tank
    305
  - Removing the Fuel Pump
    305
  - Removing the Fuel Tank
    305
- Throttle Bodies
  
  307
  - Checking the Injectors
    310
    
    Checking the Throttle Bodies
    310
    
    Checking the Pressure Regulator Operation
    310
    
    Adjusting the Throttle Position Sensor
    310
Electrical System

313
- Ignition System
  
  316
  - Circuit Diagram
    316
  - Troubleshooting
    318
- Electric Starting System
  
  320
  - Circuit Diagram
    320
  - Starting Circuit Cut-Off System Operation
    324
  - Troubleshooting
    328
- Charging System
  
  330
  - Circuit Diagram
    330
  - Troubleshooting
    332
- Lighting System
  
  334
  - Circuit Diagram
    334
  - Troubleshooting
    336
- Signaling System
  
  338
  - Circuit Diagram
    338
  - Troubleshooting
    340
- Cooling System
  
  344
  - Circuit Diagram
    344
  - Troubleshooting
    346
- Fuel Injection System
  
  348
  - Circuit Diagram
    348
  - Ecu Self-Diagnostic Function
    350
  - Fail-Safe Actions (Substitute Characteristics Operation Control)
    350
  - Troubleshooting Method
    353
  - Diagnostic Mode
    353
  - Troubleshooting Details
    360
- Immobilizer System
  
  372
  - Circuit Diagram
    372
  - General Information
    374
  - Part Replacement and Key Code Registration Requirements
    374
  - Troubleshooting
    377
  - Self-Diagnosis Fault Code Indication
    377
- Abs (Anti-Lock Brake System) (Xp500A)
  
  380
- Electrical Components
  
  412
  - Checking the Switches
    416
  - Checking the Bulbs and Bulb Sockets
    420
  - Checking the Fuses
    421
  - Checking and Charging the Battery
    422
  - Checking the Relays
    425
  - Checking the Turn Signal/Hazard Relay
    426
  - Checking the Diode
    427
  - Checking the Spark Plug Caps
    427
  - Checking the Ignition Coil
    428
  - Checking the Spark Plug Gap
    428
  - Checking the Crankshaft Position Sensor
    429
  - Checking the Lean Angle Sensor
    429
  - Checking the Starter Motor Operation
    430
  - Checking the Stator Coil
    430
  - Checking the Charging Voltage
    431
  - Checking the Horn
    431
  - Checking the Fuel Sender
    432
  - Checking the Speed Sensor
    432
  - Checking the Radiator Fan Motor
    433
  - Checking the Coolant Temperature Sensor
    433
  - Checking the Throttle Position Sensor
    434
  - Checking the Intake Air Pressure Sensor
    435
  - Checking the Intake Air Temperature Sensor
    435
  - Checking the V-Belt Reset Coupler
    436
  - Troubleshooting
    437
    
    Troubleshooting
    438
    
    General Information
    438
    
    Starting Failure/Hard Starting
    438
    
    Incorrect Engine Idling Speed
    438
    
    Poor Medium-And-High-Speed Performance
    439
    
    Faulty Clutch
    439
    
    Overheating
    439
    
    Overcooling
    440
    
    Poor Braking Performance
    440
    
    Faulty Front Fork Legs
    440
    
    Unstable Handling
    440
    
    Faulty Lighting or Signaling System
    440

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