Yamaha XP500N 2001 Manuals

Manuals and User Guides for Yamaha XP500N 2001. We have 1 Yamaha XP500N 2001 manual available for free PDF download: Service Manual

Yamaha XP500N 2001 Service Manual

Yamaha XP500N 2001 Service Manual (395 pages)

Yamaha XP500(N) 2001 Scooter Service manual

Brand: Yamaha | Category: Scooter | Size: 14.73 MB

Table of Contents

Table of Contents

7
- Important Information
  4
- Periodic Checks and
  5
- Carburetors
  6
- Chassis
  6
- Cooling System
  6
- Electrical System
  6
- Engine
  6
- General Information
  6
- Periodic Checks and Adjustments
  6
- Specifications
  6
- Troubleshooting
  6
  - Table of Contents
    7
  - Gen
    10
  - Info
    10
- Chapter 1 General Information
  12
- Scooter Identification
  12
  - Vehicle Identification Number
    12
  - Model Code
    12
- Features
  13
  - Crankshaft and Balancer Shaft
    13
  - Chain Drive
    13
  - Swingarm and Rear Suspension
    14
- Important Information
  15
  - Preparation for Removal and Disassembly
    15
  - Replacement Parts
    15
  - Gaskets, Oil Seals and O-Rings
    15
  - Lock Washers/Plates and Cotterpins
    16
  - Bearings and Oil Seals
    16
  - Circlips
    16
- Checking the Connections
  17
- Special Tools
  18
Spec

23
- Chapter 2 Specifications
  25
- General Specifications
  25
- Engine Specifications
  26
- Chassis Specifications
  34
- Electrical Specifications
  38
- Conversion Table
  40
- Tightening Torques
  40
- Lubrication Points and Lubricant Types
  47
- Oil Flow Diagrams
  48
- Coolant Flow Diagrams
  52
- Cable Routing
  53
Table of Contents

68
- Chapter 3 Periodic Checks and Adjustments
  70
- Chk Adj
  70
- Introduction
  70
- Periodic Maintenance and Lubrication Intervals
  70
- Seat
  72
- Cover and Panel
  73
  - Front Cowling
    73
  - Side Cover Moles
    74
  - Rear Covers and Taillight
    75
- Fuel Tank
  76
- Engine
  77
- Chassis
  105
  - Checking the Brake Fluid Level
    105
  - Checking the Brake Pads
    106
  - Checking the Brake Hoses
    106
  - Bleeding the Hydraulic Brake System
    107
  - Checking the Chain Drive Oil Level
    108
  - Changing the Chain Drive Oil
    109
  - Checking and Adjusting the Steering Head
    109
  - Checking the Front Fork
    112
  - Checking the Tires
    114
  - Checking the Wheels
    116
  - Checking and Lubricating the Cables
    117
Chas

129
- Chapter 4 Chassis
  131
- Front Wheel and Brake Disc
  131
  - Removing the Front Wheel
    133
  - Disassembling the Front Wheel
    133
  - Checking the Front Wheel
    134
  - Checking the Brake Disc
    135
  - Assembling the Front Wheel
    137
  - Installing the Front Wheel
    137
  - Adjusting the Front Wheel Static Balance
    139
- Rear Wheel and Brake Disc
  141
  - Rear Wheel
    141
  - Checking the Rear Wheel
    143
  - Checking the Rear Wheel Drive Hub
    143
  - Adjusting the Rear Wheel Static Balance
    143
- Front and Rear Brakes
  144
- Front Fork
  175
  - Removing the Front Fork Legs
    179
  - Disassemblilng the Front Fork Legs
    180
  - Checking the Front Fork Legs
    181
  - Assembling the Front Fork Legs
    182
  - Installing the Front Fork Legs
    185
- Handlebar
  186
  - Removing the Handlebar
    188
  - Checking the Handlebar
    188
  - Installing the Handlebar
    189
  - Lower Bracket
    192
  - Steering Head
    192
  - Removing the Lower Bracket
    194
  - Checking the Steering Head
    194
  - Installing the Steering Head
    195
- Rear Shock Absorber
  197
Eng

202
- Chapter 5 Overhauling the Engine
  204
- Engine
  204
  - Muffler Assembly
    204
  - Engine
    207
  - Installing the Engine
    208
- Camshafts
  209
  - Cylinder Head Cover
    209
  - Camshafts
    210
  - Removing the Camshafts
    211
  - Checking the Camshafts
    212
  - Checking the Camshaft Sprockets, and Timing Chain Guides
    214
  - Checking the Timing Chain Tensioner
    214
  - Installing the Camshafts
    215
- Cylinder Head
  218
  - Removing the Cylinder Head
    219
  - Checking the Cylinder Head
    219
  - Installing the Cylinder Head
    220
- Valves and Valve Springs
  221
  - Removing the Valves
    222
  - Checking the Valves and Valve Guides
    223
  - Checking the Valve Seats
    225
  - Checking the Valve Springs
    227
  - Checking the Valve Lifters
    228
  - Installing the Valves
    228
- Starter Clutch and Generator
  231
  - Removing the Generator
    233
  - Checking the Starter Clutch
    234
  - Installing the Generator
    234
- Oil Pump
  236
  - Checking the Oil Pump
    239
  - Checking the Relief Valve
    239
  - Checking the Oil Delivery Pipes
    240
  - Checking the Oil Strainer
    240
  - Assembling the Oil Pump
    240
- Clutch
  241
  - Removing the Clutch
    244
  - Checking the Friction Plates
    245
  - Checking the Clutch Plates
    245
  - Checking the Springs and Clutch Springs
    245
  - Checking the Clutch Housing
    246
  - Checking the Clutch Boss
    246
  - Checking the Pressure Plate
    246
  - Checking the Weight
    246
- Belt Drive
  247
  - Belt Drive Cover
    247
  - Belt Drive
    248
  - Disassembly the Primary Sheave
    249
  - Disassembly the Secondary Sheave
    250
  - Checking the V-Belt
    252
  - Checking the Primary Sheave
    253
  - Checking the Weight
    253
  - Checking the Slider
    253
  - Checking the Secondary Sheave
    253
  - Assembling the Primary Sheave
    254
  - Assembling the Secondary Sheave
    255
  - Installing the Belt Drive
    256
- Cylinder and Piston
  258
  - Removing the Cylinder and Piston
    259
  - Checking the Cylinder and Piston
    260
  - Checking the Piston Rings
    261
  - Checking the Piston Pins
    262
  - Installing the Pistons and Cylinders
    263
- Crankcase and Crankshaft
  265
  - Crankshaft Assembly
    265
  - Connecting Rod
    267
  - Disassembling the Crankcase
    268
  - Checking the Crankcase
    268
  - Removing the Crankshaft Journal Bearing
    269
  - Removing the Connecting Rods
    269
  - Checking the Crankshaft and Connecting Rods
    269
  - Installing the Crankshaft Journal Bearing
    274
  - Installing the Connecting Rods
    274
  - Installing the Crankshaft
    274
  - Assembling the Crankcase
    276
- Transmission
  277
  - Removing the Transmission
    278
  - Checking the Transmission
    278
  - Assembling the Crankcase
    279
- Chain Drive
  280
  - Checking the Swingarm
    283
  - Checking the Chain Drive Assembly
    283
  - Installing the Chain Drive
    284
Cool

287
- Chapter 6 Cooling System
  289
- Radiator
  289
  - Radiator and Oil Cooler
    289
  - Checking the Radiator
    291
  - Installilng the Radiator
    292
  - Checking the Oil Cooler
    292
  - Installing the Oil Cooler
    292
- Thermostat
  294
  - Checking the Thermostat
    295
  - Installing the Thermostat
    295
- Water Pump
  297
  - Checking the Water Pump
    299
  - Assembling the Water Pump
    299
Carb

302
- Carburetors
  304
- Chapter 7
  308
- Checking the Carburetors
  308
- Assembling the Carburetors
  310
- Installilng the Carburetors
  311
- Measuring and Adjusting the Fuel Level
  312
- Checking and Adjusting the Throttle Position Sensor
  313
- Checking the Fuel Pump
  315
- Air Induction System
  316
  - Air Induction
    316
  - Air Cutoff Valve
    316
  - Air Induction System Diagrams
    317
  - Checking the Air Induction System
    318
Elec

321
- Chapter 8 Electrical
  323
- Electrical Components
  323
- Arrangement of the Electrical Components and Couplers
  324
- Instrument Functions Indicator Lights
  327
- Switches
  330
  - Checking the Switch Continuity
    330
- Checking the Switches
  331
- Checking the Bulbs and Bulb Sockets
  332
- Ignition System
  335
  - Circuit Diagram
    335
  - Troubleshooting
    336
- Electrical Starting System
  339
  - Circuit Diagram
    339
  - Starting Circuit Cut off System Operation
    341
  - Troubleshooting
    342
  - Electric Starting System
    342
  - Starter Motor
    345
  - Checking the Starter Motor
    347
- Charging System
  350
  - Circuit Diagram
    350
  - Troubleshooting
    351
- Lighting System
  353
  - Circuit Diagram
    353
  - Troubleshooting
    354
  - Checking the Lighting System
    356
- Signal System
  359
  - Circuit Diagram
    359
  - Troubleshooting
    361
  - Checking the Signal System
    361
- Cooling System
  368
  - Circuit Diagram
    368
  - Troubleshooting
    369
  - Circuit Diagram
    372
  - Fuel Pump Circuit Operation
    373
  - Troubleshooting
    374
  - Checking the Fuel Pump
    376
- Auto Choke System
  377
  - Circuit Diagram
    377
  - Troubleshooting
    378
- Self-Diagnosis
  380
Trbl Shtg

386
- Troubleshooting
  386
- Chapter 9
  388
- Electrical System
  388
- Engine
  388
- Fuel System
  388
- Incorrect Engine Idling Speed
  389
  - Engine
    389
  - Fuel System
    389
  - Electrical Systems
    389
- Poor Medium-And-High-Speed Performance
  389
- Faulty Clutch
  390
  - Poor Starting Performance
    390
  - Poor Speed Performance
    390
- Overcooling Cooling System
  390
- Overheating
  390
  - Engine
    390
  - Fuel System
    390
- Faulty Front Fork Legs
  391
  - Leaking Oil
    391
  - Malfunction
    391
- Poor Braking Performance
  391
- Unstable Handling
  391
- Faulty Signaling System
  392
  - Headlight Does Not Light
    392
  - Headlight Bulb Burnt out
    392
  - Turn Signal Does Not Light
    392
  - Turn Signal Blinks Slowly
    392
  - Turn Signal Remains Lit
    392
  - Turn Signal Blinks Quickly
    392
  - Horn Does Not Sound
    392

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