Yamaha XP500 2002 Supplementary Service Manual
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Yamaha XP500 2002 Supplementary Service Manual

Yamaha XP500 2002 Supplementary Service Manual

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  • Page 2 Service Manual together with the following manual. XP500 (N) 2001 SERVICE MANUAL: 5GJ1-AE1 XP500 (P) 2002 SUPPLEMENTARY SERVICE MANUAL E2001 by Yamaha Motor Co., Ltd. First Edition, September 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
  • Page 3 EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 4 EAS00007 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. 1 The manual is divided into chapters.
  • Page 5 EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Carburetor(-s) COOL 8 Electrical system...

  • Page 6: Table Of Contents

    ........CHECKING THE SIGNAL SYSTEM ......XP500 2002 WIRING DIAGRAM (for EUR)

  • Page 7: Specifications

    GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS/ SPEC ELECTRICAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code XP500 (P) : 5GJ5 (EUR) 5GJ7 (OCE) ENGINE SPECIFICATIONS Item Standard Limit Carburetors Model (manufacturer) quantity BS30 (MIKUNI) 3 X 5 mm Throttle cable free play (at the flange of the throttle grip) ID mark 5GJ1 20...

  • Page 8: Coolant Flow Diagrams

    SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS Coolant reservoir tank Thermostat Radiator Water pump Cooling fan Radiator cap –2–...

  • Page 9: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Headlight sub-harness F Connect the brake light switch lead through the Horn handlebar switch side. Horn (H mark on the back of the horn). G Route the throttle cables through the hole of the handle under cover. A Attach the wireharness clamp (protector terminal) H Fasten the handlebar switch lead to the handlebar to the T stud.
  • Page 10 SPEC CABLE ROUTING J Connect the taped headlight lead coupler to the headlight’s white marked side (left side: high beam side). (For UK, OCE the right side is the high beam side.) K Fasten the headlight sub-harness. (left and right) (For EUR) L Connect the turn signal light.
  • Page 11 SPEC CABLE ROUTING Rectifier/ regulator Fan motor lead Starting circuit cut-off relay V-belt reset coupler Pump relay Box 1 Flasher relay Fuel pump A Fasten the starter motor lead, battery negative lead Main switch and seat lock cable (left side) to the frame with a Meter assembly plastic clamp.
  • Page 12 SPEC CABLE ROUTING C Fasten the starter motor lead, battery negative G Through the seat lock cable between wireharness lead, V-belt reset coupler, and seat lock cable to the and frame. frame with a plastic band. H Use the clamp on the back of the frame to hold the Position the band clasp on the bottom of the frame side stand switch lead and fan motor lead.
  • Page 13 SPEC CABLE ROUTING N Fasten the headlight sub-harness to the stay 1 T Through the wireharness to the frame wireharness with a plastic clamp. holder. O Fasten the igniter lead to the stay 1 with a plastic U Route the wireharness and regulator lead through clamp.
  • Page 14 SPEC CABLE ROUTING AA After connecting the left headlight sub-harness and wireharness (by matching the coupler col- ors), fold back the lead facing to the right and in- sert it into the air filter case rib. AB Fasten the coolant reservoir hose to the stay with a plastic clamp.
  • Page 15 SPEC CABLE ROUTING Air vent pipe A Route the wireharness through the frame guide. Air vent hose At this time, place the protector (for the handle cov- Vacuum hose er inner side) on the bottom side. A.C. magneto lead B Fasten the rear brake hose and vacuum hose with Sidestand switch a plastic clamp.
  • Page 16 SPEC CABLE ROUTING D Fasten the wireharness to the frame with a plastic K Use this as a reference when adjusting the throttle clamp. cable. E Pass the box light lead by the front of the frame back stay pipe. F When tightening the leg shield stay 3, pull the gap of half-pierce and the hole to the arrow mark and tighten the bolt.
  • Page 17 SPEC CABLE ROUTING Fuel hose A Route the wireharness against the stay wire guide. Battery negative lead B Fasten the wireharness branch wiring to the frame Seat lock with a plastic clamp. Starter motor lead C Fasten the wireharness to the frame with a plastic Fuse box clamp.
  • Page 18 SPEC CABLE ROUTING H Install the box light to the box 1. N Route the wireharness through the guide. I Fasten the auto choke leads (left and right) and O Place the speed sensor lead between the ribs of throttle position sensor lead to the frame with a the air filter case.
  • Page 19 SPEC CABLE ROUTING U Align the plastic clamp with the white tape on the AA Pass the speed sensor lead under the stay and wireharness and fasten to the frame. cross pipe and then over the brake hose guide. V Fasten the wireharness and seat lock cable to the AB Route the lean angle cut-off switch lead through frame with a plastic clamp.
  • Page 20 SPEC CABLE ROUTING Rear brake hose A Route the throttle cable through the cable holder. Vacuum hose B Into the handle cover. Switch assembly lead C Route the main switch lead through over the seat Auto choke lead lock cable. Throttle position sensor lead D Fasten the sidestand switch lead and thermo Fan motor lead...
  • Page 21 SPEC CABLE ROUTING H Fasten the rear end of the carburetor air vent M Route the left carburetor drain hose through the hose to the frame with a plastic clamp. (The di- outside of the spark plug lead #1. stance from the end of clamp to the frame must range from 0 to 5 mm.) I Pass the spark plug lead #1 by the front side of the air vent pipe and right carburetor drain pipe.

  • Page 22: Periodic Checks And Adjustments

    D From 50,000 km, repeat the maintenance intervals starting from 10,000 km. D Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING ( 1,000 km)
  • Page 23 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ODOMETER READING ( 1,000 km) ANNUAL ITEM ITEM CHECK OR MAINTENANCE JOB CHECK OR MAINTENANCE JOB CHECK 4,000 km after initial 1,000 km S Change. Engine oil When the oil change indicator light comes on (every 5,000 km) Engine oil filter S Replace.

  • Page 24: Chassis

    CHAS FRONT FORK CHASSIS FRONT FORK 24 Nm (2.4 mSkg) 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the front fork Remove the parts in the order listed. The following procedure applies to both of the front fork legs.
  • Page 25 CHAS FRONT FORK 24 Nm (2.4 mSkg) 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Brake hose holder Speed sensor holder Cap bolt Loosen. Upper bracket pinch bolt Loosen. Lower bracket pinch bolt Loosen.

  • Page 26: Overhauling The Engine Clutch

    CLUTCH OVERHAULING THE ENGINE CLUTCH REMOVING THE CLUTCH 1. Remove: S generator cover 1 Refer to “STARTER CLUTCH AND GENER- ATOR”. (Manual No.: 5GJ1-AE1) NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 27: Carburetors

    CARB CARBURETORS CARBURETORS CARBURETORS 5 Nm (0.5 mSkg) 10 Nm (1.0 mSkg) 8.5 Nm (0.85 mSkg) Order Job/Part Q’ty Remarks Removing the carburetors Remove the parts in the order listed. Footrest board Refer to “COVER AND PANEL” in Leg shield chapter 3.
  • Page 28 CARB CARBURETORS Order Job/Part Q’ty Remarks Separating the carburetors Remove the parts in the order listed. Bracket Throttle stop screw Throttle stop screw bracket Spring Pipe Hose joint Fuel drain hose Throttle position sensor For installation, reverse the removal procedure. –22–...
  • Page 29 CARB CARBURETORS Order Job/Part Q’ty Remarks Disassembling the carburetor Disassembly the parts in the order listed. NOTE: The following procedure applies to all of the carburetors. Starter plunger Vacuum chamber cover Piston valve spring Jet needle kit Piston valve Screw plug Pilot screw Fuel drain bolt Float chamber...
  • Page 30 CARB CARBURETORS Order Job/Part Q’ty Remarks Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet For assembly, reverse the disassembly procedure. –24–...

  • Page 31: Electrical Components

    ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS Front brake light switch Pickup coil Rear brake light switch Stator coil Thermo unit Thermo switch Fuel sender Radiator fan Starting circuit cut-off relay Speed sensor Fuel pump relay Horn Flasher relay Throttle position sensor Battery Ignition coil Fuse box...

  • Page 32: Arrangement Of The Electrical Components

    ARRANGEMENT OF THE ELECTRICAL ELEC COMPONENTS AND COUPLERS ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS Headlight couplers Handlebar switch couplers Lean angle cut-off switch Hazard relay (for EUR) Meter Horns Speed sensor Speed sensor coupler –26–...

  • Page 33: Checking The Switches

    ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. (Manual No.: 5GJ1-AE1) Damage/wear ! Repair or replace the switch. Improperly connected ! Properly connect.

  • Page 34: Signal System

    ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM (for EUR) –28–...
  • Page 35 ELEC SIGNAL SYSTEM Main switch Battery Main fuse Igniter unit Reset coupler Speed sensor Front brake light switch Horn switch Turn signal switch Hazard switch Rear brake light switch Horn Turn signal relay Hazard relay Front turn signal light (Left) Front turn signal light (Right) Rear turn signal light (Left) Rear turn signal light (Right)

  • Page 36: Troubleshooting

    ELEC SIGNAL SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery S Any of the following fail to come on: turn S Check the condition of the battery. signal light, brake light, hazard or indica- Refer to “CHECKING THE BATTERY” in tor light. CHAPTER 3.

  • Page 37: Checking The Signal System

    ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM EAS00799 1. The turn signal light, turn signal indicator light, hazard or both fail to blink. 1. Turn signal indicator light bulb and socket S Check the turn signal light bulb and socket for continuity.
  • Page 38 ELEC SIGNAL SYSTEM S Set the main switch to “ON”. 6. Voltage S Set the turn signal switch to “ ” or “ ”. S Connect the pocket tester (20 V DC) to the S Measure the voltage (12 V) on brown/white turn signal relay coupler (wire harness side) at the turn signal relay coupler (wire har- as shown.
  • Page 39 ELEC SIGNAL SYSTEM 9. Voltage S Connect the pocket tester (20 VDC) to the meter assembly coupler (wire harness side) as shown. Left turn signal indicator light Tester positive probe ! chocolate Tester negative probe ! ground Right turn signal indicator light Tester positive probe ! dark green Tester negative probe ! ground S Set the main switch to “ON”.

  • Page 40: Xp500 2002 Wiring Diagram (For Eur)

    XP500 2002 WIRING DIAGRAM (for EUR) 1 Pickup coil 39 Pass switch 2 A.C.magneto 40 Dimmer switch 3 Rectifier / regulator 41 Horn switch 4 Box light switch 42 Turn signal switch 5 Box light 43 Hazard switch 6 Main switch...

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Xp500 p 20025gj55gj7

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