Yamaha TMAX XP530E-A 2017 Service Manual page 103

1. Brake master cylinder
2. Front brake hose (front brake master cylinder
to hydraulic unit)
3. OFF/LOCK switch coupler
4. Parking/Unlock switch coupler
5. Throttle cable (decelerator cable)
6. Throttle cable (accelerator cable)
7. Wire harness
8. Plate (throttle cable)
9. Grip warmer lead (right)
10.Plastic locking tie
11.Front brake master cylinder
12.Rear brake master cylinder
13.Bracket
14.Clamp
15.Handlebar switch lead (right)
16.Front brake light switch lead
17.Rear brake light switch lead
18.Handlebar switch lead (left)
19.Grip warmer lead (left)
20.Handlebar cover
A. Route the throttle cable (accelerator cable) in
front of the throttle cable (decelerator cable).
B. Route the rear brake hose behind the leads
around the handlebar and throttle cables.
C. Route the wire harness in front of the leads
around the handlebar.
D. Route the grip cancel switch lead between
the accelerator position sensor coupler and
the wire harness.
E. Clamp A
F. Clamp B
G. Route the rear brake hose on top of the front
brake hose.
H. Arrange the grip cancel switch coupler in
front of the brake hose and leads around the
handlebar.
I. Route the front brake hose behind the throttle
cables.
J. Route the grip warmer lead so that it does not
get caught between the front brake light
switch lead and the handlebar cover.
K. Route the grip warmer lead inside the han-
dlebar cover while routing it behind the front
brake light switch.
L. Align the blue tape end of the grip warmer
lead with the end of the plastic locking tie to
fasten it.
M. 3 mm (0.12 in) or less
N. The plastic locking tie should face downward
with the end cut to 3 mm (0.12 in) or less.
O. The metal part of the front brake hose should
come into contact with the guide section of
the brake master cylinder.
P. Install the front brake hose with the white
paint mark on the metal part facing the front.
Q. Install the rear brake hose with the yellow
paint mark on the metal part facing the front.
R. Route the metal part of the rear brake hose
between the guides of the brake master cylin-
der.
S. Consolidate the leads around the handlebar
and fasten them with the clamp. See the
clamp A fixed position details for more
details.
T. Face the end of the wire harness clamp
toward the left.
U. Clamp A fixed position details
V. Right side of the vehicle
W. Left side of the vehicle
X. 330–340 mm (12.99–13.39 in): Collar end
face
Y. 245–255 mm (9.65–10.04 in): Case end face
Z. 215–225 mm (8.46–8.86 in): Case end face
AA. 360–370 mm (14.17–14.57 in): Grommet
end face
AB. 285–295 mm (11.22–11.61 in): Case end
face
AC. 255–265 mm (10.04–10.43 in): Case end
face
AD. Interval between the clamp A end and the
clamp B end: 275–285 mm (10.83–11.22 in)
AE. Make sure there is no slack, break, entangl-
ing, etc., within this interval for each harness.
AF. 205–215 mm (8.07–8.46 in)
AG. Positioning white tape
AH. Clamp installing procedure
1. Mark the reference point on the lead of
each component.
2. Align the marking of each lead and fasten
with the clamp A.
3. Fasten the wire harness with the clamp B
at a position that is located 275–285 mm
(10.83–11.22 in) from the end of clamp A.
AI. Reference point
AJ. Fasten the grip warmer lead (left), grip
warmer lead (right), handlebar switch lead
(left), handlebar switch lead (right), front
brake light switch lead, and rear brake light
switch lead with the clamp.
AK. Relative angle between clamp A and clamp
B: –15–15
AL. The end of the clamp should face the right
without being cut.
AM. Route the throttle cables thorough the right
side opening in the handlebar cover as
shown in the illustration.
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CABLE ROUTING