Yamaha TMAX XP530D-A 2017 Service Manual

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2017

SERVICE MANUAL

XP530E-A

XP530-A

XP530D-A

BV1-28197-E0

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Page 1 2017 SERVICE MANUAL XP530E-A XP530-A XP530D-A BV1-28197-E0...
Page 3 EAS20002 XP530E-A/XP530-A/XP530D-A SERVICE MANUAL ©2017 by Yamaha Motor Co., Ltd. First edition, March 2017 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 4 EAS20003 IMPORTANT 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 man- ual. 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 5 EAS20004 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. •...
Page 6 EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
Page 7 TABLE OF CONTENTS EAS10003 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9 GENERAL INFORMATION IDENTIFICATION....................1-1 VEHICLE IDENTIFICATION NUMBER ............1-1 MODEL LABEL...................1-1 FEATURES .......................1-2 YCC-T (Yamaha Chip Controlled Throttle)..........1-2 OUTLINE OF THE CRUISE CONTROL SYSTEM (for XP530D-A) ...1-4 OUTLINE OF THE TCS (Traction Control System)........1-9 MULTI-FUNCTION DISPLAY..............1-12 IMPORTANT INFORMATION .................1-22 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-22 REPLACEMENT PARTS................1-22...
Page 10 IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the frame. EAS30003 MODEL LABEL The model label “1” is affixed to the storage box. This information will be needed to order spare parts.
Page 11 Yamaha developed the YCC-T system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast- er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
Page 12 FEATURES YCC-T system outline 1. Accelerator position sensor 2. Throttle servo motor 3. Throttle position sensor 4. ECU (Engine Control Unit) 5. Sensor input 6. Crankshaft position sensor 7. Rear wheel sensor 8. Coolant temperature sensor...
Page 13 FEATURES EAS30940 OUTLINE OF THE CRUISE CONTROL SYSTEM (for XP530D-A) This model is equipped with a cruise control system designed to maintain a set cruising speed. Be- cause the vehicle is equipped with the YCC-T system, the cruise control system can be controlled elec- tronically.
Page 14 FEATURES The cruise control system is designed to maintain a set cruising speed between about 50 km/h (31 mi/h) and 140 km/h (87 mi/h). EWA17451 WARNING • Improper use of the cruise control system may result in loss of control, which could lead to an accident.
Page 15 FEATURES Deactivating the cruise control system Perform one of the following operations to cancel the set cruising speed. The “SET” indicator light will go off. • Turn the throttle grip past the closed position in the deceleration direction. b. Cruise control cancel direction a.
Page 16 FEATURES Meter displays during cruise control system operation A. Cruise control system is activated (cruising a. Condition for automatically deactivating speed is set) cruise control system is detected B. Cruise control system is turned off (cruise b. 4 seconds elapse (during this time, input from control setting indicator light “SET”...
Page 17 “ ” flashes) Yamaha diagnostic tool. C. Cruise control system is turned off (engine e. Cruising speed is set trouble warning light “...
Page 18 FEATURES This section explains the operation of the cruise control system according to the meter displays when a malfunction is detected in the fuel injection system. EAS30855 OUTLINE OF THE TCS (Traction Control System) The traction control system controls excessive spinning (slipping) of the rear wheel when accelerating on slippery surfaces, such as unpaved or wet roads.
Page 19 FEATURES TCS (Traction control system) block diagram The signals from the front and rear wheel sensors are sent to the ECU through the ABS ECU, and the ECU calculates the amount of slip according to the difference between the detected front and rear wheel speeds.
Page 20 FEATURES Traction control system The traction control system (TCS) helps maintain traction when accelerating on slippery surfaces, such as unpaved or wet roads. If sensors detect that the rear wheel is starting to slip (uncontrolled spinning), the traction control system assists by regulating engine power as needed until traction is restored. When traction control has engaged, the “...
Page 21 FEATURES The fuel meter indicates the amount of fuel in the EAS30618 MULTI-FUNCTION DISPLAY fuel tank. The display segments of the fuel meter disappear from “F” (full) towards “E” (empty) as the fuel level decreases. When the last segment starts flashing, refuel as soon as possible. If a problem is detected in the fuel meter electri- cal circuit, the fuel meter will flash repeatedly.
Page 22 FEATURES Oil change indicator “Oil” Consider the following tips to reduce fuel con- sumption: • Avoid high engine speeds during acceleration. • Travel at a constant speed. Drive mode display (XP530-A, XP530D-A) 1. Oil change indicator “Oil” This indicator flashes at the initial 1000 km (600 mi), then at 5000 km (3000 mi) and every 5000 km (3000 mi) thereafter to indicate that the en- gine oil should be changed.
Page 23 FEATURES or higher, do not set the seat heater to the push the “ ” side of the select switch. Adjusting the grip warmer high setting. • If the seat becomes worn or damaged, stop This vehicle can be equipped with grip warmers, which can only be used when the engine is run- using the seat heater and replace the seat.
Page 24 FEATURES bient temperature. • –9 C will be displayed even if the detected temperature is lower. • 50 C will be displayed even if the detected temperature is higher. When approximately 3.0 L (0.79 US gal, 0.66 • The accuracy of the temperature reading may Imp.gal) of fuel remains in the fuel tank, the last be affected when riding under 20 km/h (12 segment of the fuel meter starts flashing.
Page 25 FEATURES Instantaneous fuel consumption: return to the normal display, push the “MENU” switch again for at least 2 seconds. Display Description This function allows you to set Grip Warmer the low, middle, and high set- tings to 10 temperature levels. This function allows you to set Seat Heater the low, middle, and high set-...
Page 26 FEATURES 2. Push the “MENU” switch. The grip warmer 2. Push the “MENU” switch. The seat heater setting display will be shown and “High” will setting display will be shown and “High” will flash in the display. flash in the display. 3.
Page 27 FEATURES 2. Push the “MENU” switch. The traction control 2. Push the “MENU” switch, and then use the system setting display will be shown and select switch to select the item to reset. “ON” will flash in the display. 3. While the selected item is flashing, push the 3.
Page 28 FEATURES 2. Push the “MENU” switch, use the select switch to highlight the display to change, and then push the “MENU” switch again. 2. Push the “MENU” switch. The unit setting dis- play will be shown and “L/100km” will flash in the display.
Page 29 FEATURES push the “MENU” switch to return to the pre- vious display. 6. Use the select switch to highlight “ ”, and then push the “MENU” switch to return to the setting mode menu. Meter panel brightness 1. Use the select switch to highlight “Bright- ness”.
Page 30 FEATURES The odometer, clock, maintenance counter item “Oil” and maintenance counter item “V-Belt” will not be reset. To exit the setting mode 1. Use the select switch to highlight “Return”. 2. Push the “MENU” switch to exit the setting mode and return to the standard display mode.
Page 31 5. Keep all parts away from any source of fire. EAS30007 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 32 IMPORTANT INFORMATION When installing oil seals, lubricate the oil seal contact the parts. lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. ECA13300 NOTICE Do not spin the bearing with compressed air because this will damage the bearing surfac- EAS30011 CIRCLIPS Before reassembly, check all circlips carefully...
Page 33 BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30013 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.
Page 34 BASIC SERVICE INFORMATION ECA16760 EAS30014 ELECTRICAL SYSTEM NOTICE Electrical parts handling Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- ECA16600 NOTICE tery lead connections could damage the Never disconnect a battery lead while the en- electrical components.
Page 35 BASIC SERVICE INFORMATION Checking the electrical system ECA16620 NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA14371 ECA16630 NOTICE NOTICE...
Page 36 BASIC SERVICE INFORMATION Checking the connections 2. Check: • Lead Check the leads, couplers, and connectors for stains, rust, moisture, etc. • Coupler • Connector 1. Disconnect: Moisture  Dry with an air blower. • Lead • Coupler Rust/stains  Connect and disconnect sev- •...
Page 37 BASIC SERVICE INFORMATION 5. Check: • Resistance Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 The resistance values shown were obtained at 4. Check: the standard measuring temperature of 20 C • Continuity (68 F). If the measuring temperature is not 20 (with the digital circuit tester) C (68 F), the specified measuring conditions will be shown.
Page 38 8-240, 8-241, 8-241, 8-242, 8-242, 8-243, 8-244, 8-244, 8-245, 8-246, 8-246, 8-248, 8-248, 8-249, 8-249, 8-250, 8-250 Yamaha diagnostic tool USB 3-4, 3-13, 4-75, 90890-03256 4-77, 8-62, 8-171, 8-191 Yamaha diagnostic tool (A/I) 3-4, 3-13, 4-75, 90890-03254 4-77, 8-62, 8-171, 8-191...
Page 39 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Vacuum gauge 3-10 90890-03094 Vacuummate YU-44456 YU-44456 Carburetor angle driver 2 3-10 90890-03173 Tension meter (TEXA) 3-22 90890-03258 Steering nut wrench 3-24, 4-98 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-28, 6-6 90890-01426 Oil filter wrench...
Page 40 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pressure gauge 3-29, 7-12, 7-12 90890-03153 Pressure gauge YU-03153 Thickness gauge 4-30, 4-39, 5-16, 90890-03180 5-55 Feeler gauge set YU-26900-9 Fork spring compressor 4-89, 4-94 90890-01441 Fork spring compressor YM-01441 Rod holder 4-89, 4-94 90890-01434 Damper rod holder double ended...
Page 41 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Yamaha bond No. 1215 5-14, 5-41, 5-49, 90890-85505 5-65 (Three bond No.1215®) Valve spring compressor 5-19, 5-24 90890-04019 Valve spring compressor YM-04019...
Page 42 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover (ø4) 5-21 90890-04111 Valve guide remover (4.0 mm) YM-04111 Valve guide installer (ø4) 5-21 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide reamer (ø4) 5-21 90890-04113 Valve guide reamer (4.0 mm) YM-04113 Piston pin puller set 5-26...
Page 43 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Sheave spring compressor 5-38, 5-41 90890-04134 Sheave spring compressor YM-04134 Sheave fixed block 5-38, 5-41 90890-04135 Sheave fixed bracket YM-04135 Sheave holder 5-47, 5-47, 5-48, 90890-01701 5-49 Primary clutch holder YS-01880-A Flywheel puller 5-47 90890-01362 Heavy duty puller...
Page 44 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-54, 5-57 90890-04086 Universal clutch holder YM-91042 Plane bearing installer 5-69, 5-73 90890-04139 Radiator cap tester 6-3, 6-3 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 6-3, 6-3 90890-01352 Pressure tester adapter...
Page 45 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Middle driven shaft bearing driver 6-12 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Fuel injector pressure adapter 7-12 90890-03210 Fuel injector pressure adapter YU-03210 Fuel pressure adapter 7-12 90890-03186 Fuel pressure adapter YM-03186 OBD/ GST Leadwire kit...
Page 46 SPECIAL TOOLS 1-37...
Page 47 SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-9 TIGHTENING TORQUES ................2-11 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-11 ENGINE TIGHTENING TORQUES............2-12 CHASSIS TIGHTENING TORQUES............2-12 LUBRICATION POINTS AND LUBRICANT TYPES........2-14 ENGINE....................2-14 CHASSIS....................2-15 LUBRICATION SYSTEM CHART AND DIAGRAMS ........2-17 ENGINE OIL LUBRICATION CHART ............2-17 LUBRICATION DIAGRAMS ..............2-19 COOLING SYSTEM DIAGRAMS ..............2-27 CABLE ROUTING ..................2-31...
Page 48 GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model BC31 (XP530D-A) BV11 (XP530E-A) BX31 (XP530-A) Dimensions Overall length 2200 mm (86.6 in) Overall width 765 mm (30.1 in) Overall height 1420/1475 mm (55.9/58.1 in) (XP530-A, XP530E-A) 1420/1555 mm (55.9/61.2 in) (XP530D-A) Wheelbase 1575 mm (62.0 in) Ground clearance 125 mm (4.92 in)
Page 49 ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 530 cm³ Cylinder arrangement Inline Number of cylinders 2-cylinder Bore  stroke 68.0  73.0 mm (2.68  2.87 in) Compression ratio 10.9 : 1 Compression pressure 1696–2184 kPa/470 r/min (17.0–21.8 kgf/cm²/470 r/min, 241.3–310.6 psi/470 r/min)
Page 50 ENGINE SPECIFICATIONS Spark plug(s) Manufacturer/model NGK/CR7E Spark plug gap 0.7–0.8 mm (0.028–0.031 in) Cylinder head Warpage limit 0.03 mm (0.0012 in) Camshaft Camshaft cap inside diameter 23.000–23.021 mm (0.9055–0.9063 in) Camshaft journal diameter 22.959–22.972 mm (0.9039–0.9044 in) Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) Limit 0.080 mm (0.0032 in) Camshaft lobe dimensions...
Page 51 ENGINE SPECIFICATIONS Piston Diameter 67.975–67.990 mm (2.6762–2.6768 in) Measuring point (from piston skirt bottom) 9.0 mm (0.35 in) Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in) Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in) Limit 16.043 mm (0.6316 in) Piston pin outside diameter 15.995–16.000 mm (0.6297–0.6299 in) Limit 15.975 mm (0.6289 in)
Page 52 ENGINE SPECIFICATIONS Clutch plate 1 thickness 1.30–1.50 mm (0.051–0.059 in) Plate quantity 5 pcs Warpage limit 0.10 mm (0.004 in) Clutch plate 2 thickness 1.80–2.00 mm (0.071–0.079 in) Plate quantity 2 pcs Warpage limit 0.20 mm (0.008 in) Clutch spring free length 31.90 mm (1.26 in) Limit 24.80 mm (0.98 in)
Page 53 ENGINE SPECIFICATIONS 60–80 C (140–176 F) Engine oil temperature Intake vacuum 32.0 kPa (240 mmHg, 9.4 inHg) Difference in vacuum pressure between the 0 kPa–1.3 kPa (0 mmHg–10 mmHg, 0 inHg–0.4 cylinders inHg) 0.0–2.0 % Fuel line pressure (at idle) 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi) Throttle grip free play 1.0–3.0 mm (0.04–0.12 in)
Page 54 CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 26.0  Caster angle Trail 98 mm (3.9 in) Front wheel Wheel type Cast wheel Rim size 15M/C x MT3.5 Rim material Aluminum Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Rear wheel...
Page 55 297.1 mm (11.70 in) Limit 291.1 mm (11.46 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil 01 Quantity (left) 447.0 cm³ (15.11 US oz, 15.77 Imp.oz) Quantity (right) 437.0 cm³ (14.77 US oz, 15.41 Imp.oz) Level (left) 114 mm (4.5 in)
Page 56 ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Digital 5.0 1200 r/min Ignition timing (B.T.D.C.) Engine control unit Model TBDF0H (XP530-A) TBDF0K (XP530E-A) TBDFT6 (XP530D-A) Ignition coil 1.87–2.53  Primary coil resistance Secondary coil resistance 12.00–18.00 k...
Page 57 ELECTRICAL SPECIFICATIONS Smart key system indicator light Traction control system indicator/warning light Starter motor Power output 0.70 kW 0.0105–0.0195  Armature coil resistance Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force 6.02–6.51 N (614–664 gf, 21.69–23.45 oz) Mica undercut (depth) 0.70 mm (0.03 in) Fuel sender unit...
Page 58 TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30015 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- tern and progressive stages until the specified tightening torque is reached.
Page 59 TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 N·m (2.0 kgf·m, 15 lb·ft) Muffler protector bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Front muffler protector bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Cylinder head cover bolt...
Page 60 TIGHTENING TORQUES Front wheel axle pinch bolt 1. Insert the front wheel axle from the right side, temporarily install the front wheel axle bolt “1” from the left side, and then tighten the front wheel axle to 91 N·m (9.1 kgf·m, 67 lb·ft). 2.
Page 61 LUBRICATION POINTS AND LUBRICANT TYPES EAS20018 LUBRICATION POINTS AND LUBRICANT TYPES EAS30018 ENGINE Lubrication point Lubricant Oil seal lips O-rings Coolant hose insertion part Water or Bearings and bushings Cylinder head nut seats and washers Camshaft cap bolt seats Crankshaft big ends Piston surfaces Piston pins Crankshaft journals...
Page 62 YAMAHA GREASE “H” Secondary sheave nut (Polyurea Grease®) Secondary shaft right end bearing Pivot shaft taper roller bearing Yamaha bond No. 1215 Stopper (generator cover and water pump assembly) (Three bond No.1215®) Yamaha bond No. 1215 Crankcase mating surface (Three bond No.1215®) Yamaha bond No.
Page 63 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Passenger footrest pivoting point Centerstand pivoting point and metal-to-metal moving parts Centerstand hook and spring contact point Sidestand pivoting point and metal-to-metal moving parts Sidestand hook and spring contact point Front wheel oil seal lip Rear wheel oil seal lip Front wheel axle bolt mating surface Brake caliper piston seal...
Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-17...
Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Timing chain tensioner 4. Connecting rod 5. To piston 6. Starter clutch gear 7. Crankshaft 8. Balancer connecting rod 9. To balancer piston 10.Oil pipe 11.Check valve 12.Relief valve 13.Oil filter 14.Oil cooler 15.Oil tank...
Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS 2-19...
Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Delivery pipe 4. Oil pump assembly 5. Scavenge pump 6. Feed pump 7. Oil pipe 8. Oil cooler 9. Oil filter 10.Relief valve 11.Check valve 2-20...
Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-21...
Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Crankshaft 2. Secondary shaft 3. Drive axle 4. Clutch 5. Generator cover 2-22...
Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-23...
Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Intake camshaft 3. Exhaust camshaft 2-24...
Page 72 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
Page 73 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Generator cover 2. Oil strainer 3. Main gallery 4. Crankcase (right) A. Forward 2-26...
Page 74 COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-27...
Page 75 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator filler hose 3. Cooling system air bleed hose 4. Coolant reservoir hose 5. Coolant pipe 6. Oil cooler outlet hose 7. Thermostat 8. Oil cooler 9. Oil cooler inlet hose 10.Coolant hose 11.Water pump outlet pipe 12.Radiator outlet hose 13.Radiator bracket...
Page 76 COOLING SYSTEM DIAGRAMS 2-29...
Page 77 COOLING SYSTEM DIAGRAMS 1. Thermostat 2. Cooling system air bleed hose 3. Coolant reservoir hose 4. Radiator cap 5. Radiator filler hose 6. Radiator 7. Radiator bracket 8. Coolant pipe 9. Oil cooler 10.Oil cooler outlet hose 2-30...
Page 78 CABLE ROUTING EAS20021 CABLE ROUTING Headlight stay (front view) 2-31...
Page 79 CABLE ROUTING 1. Handlebar switch coupler 1 (left) (black) 2. Front brake light switch coupler (black) (for XP530D-A) 3. Rear brake light switch coupler (white) (for XP530D-A) 4. Handlebar switch coupler 2 (right) (white) 5. Handlebar switch lead (left/right)/Grip warmer lead (left/right) (for XP530D-A)/Front brake light switch lead (for XP530D-A)/Rear brake light switch lead (for XP530D-A)
Page 80 CABLE ROUTING Front cowling assembly (rear view) 2-33...
Page 81 CABLE ROUTING 1. Headlight control unit 2. Clamp 3. Front turn signal light coupler 4. Headlight assembly lead 5. Headlight sub-wire harness A. Route the headlight sub-wire harness so that the blue tape section is aligned with the rib section of the headlight assembly. B.
Page 82 CABLE ROUTING Frame (right side view) 2-35...
Page 83 CABLE ROUTING Q. Front of the vehicle 1. Storage compartment lid lock solenoid cou- pler (except for XP530E-A) R. Range of arrangement of the end of the plas- tic locking tie 2. Remote control unit lead S. Left side of the vehicle 3.
Page 84 CABLE ROUTING Frame (right side view) 2-37...
Page 85 CABLE ROUTING 1. Tail/brake light lead (right) 2. Storage box light switch lead 3. Rear wheel sensor lead 4. Fuel pump lead 5. O sensor lead 6. Storage box light lead 7. Storage box 8. Starter motor lead 9. Rear brake lock cable 10.Brake hose 11.Wire harness A.
Page 86 CABLE ROUTING Frame (left side view) 2-39...
Page 87 1. Buzzer lead leads does not matter. 2. Intake air temperature sensor lead M. Route the ground lead between the frame 3. Yamaha diagnostic tool coupler and wire harness. 4. Negative battery lead N. Install the ground lead with the caulked sec- 5.
Page 88 CABLE ROUTING Rear frame (left side view) 2-41...
Page 89 CABLE ROUTING 1. Centerstand lock solenoid coupler 2. Centerstand lock solenoid lead 3. Sidestand switch 4. Sidestand switch lead 5. Starter motor lead 6. Plastic locking tie 7. Footboard 8. Joint coupler lead 9. Wire harness (seat/fuel lid lock solenoid lead) 10.Rear frame 11.Wire harness 12.Generator cover protector...
Page 90 CABLE ROUTING Frame (left side view) 2-43...
Page 91 CABLE ROUTING 1. Stator coil coupler 2. Sidestand relay 3. Turn signal/hazard relay 4. Radiator fan motor relay 5. Seat heater relay (power) (for XP530D-A) 6. Seat heater relay (control) (for XP530D-A) 7. Windshield drive unit relay (down) (for XP530D-A) 8.
Page 92 CABLE ROUTING Frame (top view) 2-45...
Page 93 CABLE ROUTING 1. Fuse box 4 (for XP530D-A) 2. Fuse box 5 (for XP530D-A) 3. Fuse box 2 4. Starter relay lead 5. Fuse box 1 6. Fuse box 3 7. ABS ECU coupler 8. Intake air pressure sensor 9. Lean angle sensor 10.Canister purge hose 11.Coolant temperature sensor 12.Coupler cover...
Page 94 CABLE ROUTING Frame (top view) 2-47...
Page 95 CABLE ROUTING 1. Fuel pump lead 2. Seat/fuel lid lock solenoid coupler 3. Seat lock cable 4. Tail/brake light lead (right) 5. Tail/brake light 6. Tail/brake light lead (left) 7. Storage box light 8. Windshield drive unit relay (up) (for XP530D- 9.
Page 96 CABLE ROUTING Handlebar (top and left side view) (for XP530E-A/XP530-A) 2-49...
Page 97 CABLE ROUTING 1. Rear brake lock cable 2. Handlebar cover 3. Throttle cable (decelerator cable) 4. Throttle cable (accelerator cable) 5. Front brake hose (front brake master cylinder to hydraulic unit) 6. Front brake master cylinder 7. Throttle grip 8. Handlebar switch (right) 9.
Page 98 CABLE ROUTING Handlebar (front view) (for XP530E-A/XP530-A) 2-51...
Page 99 CABLE ROUTING X. Clamp installing procedure 1. Brake master cylinder 1. Mark the reference point on the lead of 2. Front brake hose (front brake master cylinder each component. to hydraulic unit) 2. Align the marking of each lead and fasten 3.
Page 100 CABLE ROUTING Handlebar (top and left side view) (for XP530D-A) 2-53...
Page 101 CABLE ROUTING 1. Rear brake lock cable 2. Handlebar cover 3. Throttle cable (decelerator cable) 4. Throttle cable (accelerator cable) 5. Front brake hose (front brake master cylinder to hydraulic unit) 6. Front brake master cylinder 7. Throttle grip 8. Handlebar switch (right) 9.
Page 102 CABLE ROUTING Handlebar (front view) (for XP530D-A) 2-55...
Page 103 CABLE ROUTING Q. Install the rear brake hose with the yellow 1. Brake master cylinder paint mark on the metal part facing the front. 2. Front brake hose (front brake master cylinder R. Route the metal part of the rear brake hose to hydraulic unit) between the guides of the brake master cylin- 3.
Page 104 CABLE ROUTING Front brake (front, left side and right side view) 2-57...
Page 105 CABLE ROUTING 1. Headlight stay 2. Front brake hose (hydraulic unit to front brake caliper) 3. Front brake hose (left brake caliper to right brake caliper) 4. Clamp 5. Front wheel sensor lead 6. Front brake caliper (left) 7. Front wheel sensor 8.
Page 106 CABLE ROUTING Frame (right side view) 2-59...
Page 107 CABLE ROUTING 1. Rear frame 2. Rear brake hose (hydraulic unit to rear brake caliper) 3. Rear brake lock cable 4. Electrical components tray 5. Guide 6. Frame 7. Rear wheel sensor lead 8. Plastic locking tie 9. Clamp 10.Fuel tank bracket 11.Cable guide A.
Page 108 CABLE ROUTING Rear brake (right side view) 2-61...
Page 109 CABLE ROUTING 1. Rear brake lock caliper 2. Rear brake lock cable 3. Holder 4. Rear brake hose (hydraulic unit to rear brake caliper) 5. Swingarm (right) 6. Clamp 7. Rear brake caliper 8. Rear wheel sensor lead 9. Rear brake disc 10.Bracket 11.Rear frame 12.Stay...
Page 110 CABLE ROUTING Fuel tank (right side view) 2-63...
Page 111 CABLE ROUTING 1. Fuel tank breather hose (fuel tank to rollover valve) 2. Fuel tank 3. Clamp 4. Rear brake hose (hydraulic unit to rear brake caliper) 5. Fuel tank breather hose (rollover valve to canister) 6. Coolant pipe 7. Canister purge hose (hose joint to canister) 8.
Page 112 CABLE ROUTING Fuel tank (left side view) 2-65...
Page 113 CABLE ROUTING 1. Fuel tank overflow hose 2. Hose joint 3. Fuel tank cap 4. Filler cover 5. Fuel tank 6. Fuel pump 7. Fuel hose 8. Fuel pump lead A. Install the fuel tank overflow hose with the mark facing the outside. B.
Page 114 CABLE ROUTING Fuel tank (top view) 2-67...
Page 115 CABLE ROUTING 1. Canister holder 2. Canister 3. Fuel tank breather hose (fuel tank to rollover valve) 4. Rollover valve 5. Fuel tank 6. Fuel hose 7. Intake air pressure sensor 8. Thermostat cover 9. Clip 10.Canister purge hose (hose joint to canister) 11.Canister purge hose (throttle body to hose joint) A.
Page 116 CABLE ROUTING Air filter case and throttle body (left side view) 2-69...
Page 117 CABLE ROUTING 1. Air filter element 2. Intake manifold 3. Clamp 4. Cylinder head breather hose 5. Throttle body assembly 6. Air filter case 7. Fuel rail 8. Intake air pressure sensor hose 9. Intake air pressure sensor A. Place the clamp at a distance of 1–4 mm (0.04–0.16 in) from the hose end.
Page 118 CABLE ROUTING Radiator (right side view) 2-71...
Page 119 CABLE ROUTING S. Install the hose clamp with the screw head 1. Thermostat outlet hose facing the outside. 2. Thermostat T. Install the hose clamp with the screw head 3. Cooling system air bleed hose facing the front at an angle of 45 from the 4.
Page 120 CABLE ROUTING Radiator (left side view) 2-73...
Page 121 CABLE ROUTING 1. Thermostat 2. Thermostat outlet hose 3. Coolant hose 4. Oil cooler inlet hose 5. Radiator outlet hose 6. Radiator 7. Coolant reservoir 8. Coolant reservoir breather hose 9. Hose clamp 10.Clamp 11.Oil cooler 12.Clip A. Install the clamp with its end facing the top. B.
Page 122 CABLE ROUTING Radiator (top view) 2-75...
Page 123 CABLE ROUTING 1. Radiator cap 2. Radiator filler hose 3. Coolant reservoir hose 4. Rear brake hose (hydraulic unit to rear brake caliper) 5. Radiator bracket 6. Frame 7. Thermostat outlet hose 8. Thermostat 9. Coolant hose 10.Oil cooler inlet hose 11.Radiator outlet hose 12.Coolant reservoir 13.Canister purge hose (hose joint to canister)
Page 124 CABLE ROUTING Hydraulic unit assembly (top and front view) 2-77...
Page 125 CABLE ROUTING 1. Rear brake hose (hydraulic unit to rear brake caliper) 2. Rear brake hose (rear brake master cylinder to hydraulic unit) 3. Front brake hose (front brake master cylinder to hydraulic unit) 4. Front brake hose (hydraulic unit to front brake caliper) 5.
Page 126 CABLE ROUTING 2-79...
Page 127 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL ......................3-4 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ..............3-5 ADJUSTING THE VALVE CLEARANCE ...........3-5 CHECKING THE ENGINE IDLING SPEED ..........3-9...
Page 128 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY (for XP530D-A) ..................3-26 CHECKING THE CONNECTING ARM AND RELAY ARM......3-27 CHECKING THE ENGINE OIL LEVEL.............3-27 CHANGING THE ENGINE OIL ..............3-27 MEASURING THE ENGINE OIL PRESSURE .........3-29 CHECKING THE COOLANT LEVEL............3-30 CHECKING THE COOLING SYSTEM .............3-30 CHANGING THE COOLANT..............3-31 REPLACING THE V-BELT ...............3-33 CHECKING THE BRAKE LIGHT SWITCHES..........3-33...
Page 129 • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 130 PERIODIC MAINTENANCE ODOMETER READINGS CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check operation, fluid level, and for fluid leakage.  ...
Page 131 PERIODIC MAINTENANCE ODOMETER READINGS CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check coolant level and vehi-     ...
Page 132 CHECKING THE VEHICLE USING THE CHECKING THE FUEL LINE YAMAHA DIAGNOSTIC TOOL The following procedure applies to all of the fuel, Use the Yamaha diagnostic tool and check the breather and overflow hoses. vehicle according to the following procedure. 1. Remove: 1.
Page 133 PERIODIC MAINTENANCE Damage/wear  Replace the spark plug. • Insulator “2” Abnormal color  Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • Spark plug (with a spark plug cleaner or wire brush) 7. Measure: • Spark plug gap “a” (with a wire thickness gauge) Out of specification ...
Page 134 PERIODIC MAINTENANCE 1. Remove: • Windshield • Front cover • Windshield inner panel • Meter assembly • Rearview mirror • Bottom side cowling • Side panel • Radiator cover • Bottom center cowling • Front cowling assembly 6. Measure: • Leg shield assembly •...
Page 135 PERIODIC MAINTENANCE d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at TDC, turn the crankshaft clockwise as specified in the following table. 0˚ 360˚ 720˚ A. Degrees that the crankshaft is turned clock- wise B.
Page 136 PERIODIC MAINTENANCE Example: 1.55 mm (0.061 in) + 0.03 mm (0.001 in) = 1.58 mm (0.062 in) The valve pad number is 158. e. Round off the valve pad number according to the following table, and then select the suit- able valve pad.
Page 137 3. Check: • ISC (Idle Speed Control) learning value “00” or “01”  Check the intake system. “02”  Clean the throttle bodies. Refer to “CHECKING AND CLEANING THE THROTTLE BODIES” on page 7-9. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the Yamaha diagnostic tool.
Page 138 PERIODIC MAINTENANCE If out of specification  Adjust the throttle 4. Install: • Hose “1” body synchronization. (Parts No.: 5JW-24311-00) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • 3-way joint “2” Adjusting the throttle body synchronization (Parts No.: 68V-24376-00) 1. Adjust: • Intake air pressure sensor hose “3” •...
Page 139 PERIODIC MAINTENANCE 3. Install: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Center cover 2. Stop the engine and remove the measuring Refer to “GENERAL CHASSIS (2)” on page equipment. 4-11. 3. Install: • Intake air pressure sensor hose EAS30625 • Cap CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- 4.
Page 140 PERIODIC MAINTENANCE 4. Install: 3. Install: • Footboard (right) • All removed parts • Side cover (right) EAS30626 • Fuel tank cover assembly CHECKING THE CANISTER • Center cover 1. Remove: Refer to “GENERAL CHASSIS (2)” on page • Bottom side cowling 4-11.
Page 141 Yamaha diagnostic tool. For more information, refer to the opera- tion manual of the Yamaha diagnostic tool. 1. Connect the Yamaha diagnostic tool to the coupler. For information about connecting the Yamaha diagnostic tool, refer to “YAMAHA DIAGNOSTIC TOOL”...
Page 142 PERIODIC MAINTENANCE 5. Check: 3. Remove: • V-belt case air filter elements • V-belt case air filter case cover “1” Damage  Replace. • V-belt case air filter case “2” ECA13441 • V-belt case air filter element (right) “3” NOTICE Since the V-belt case air filter element is a dry type, do not let grease or water contact it.
Page 143 PERIODIC MAINTENANCE • When refilling, be careful that water does “REAR BRAKE” on page 4-53. not enter the brake master cylinder reser- voir. Water will significantly lower the boil- Drive on the road, operate the front and rear ing point of the brake fluid and could cause brakes separately and check to see if the brakes vapor lock.
Page 144 PERIODIC MAINTENANCE air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce in loss of control and possi- bly an accident. Therefore, check and if necessary, bleed the brake system. ECA13490 NOTICE After adjusting the brake lever position, make sure there is no brake drag.
Page 145 PERIODIC MAINTENANCE brake hoses and brake hose holders. the brake master cylinder reservoir to overflow. 1. Check: • When bleeding the ABS, make sure that there • Brake hose is always enough brake fluid before applying Cracks/damage/wear  Replace. the brake. Ignoring this precaution could allow 2.
Page 146 PERIODIC MAINTENANCE throttle grip or handlebar grip. 2. Adjust: • Rear brake lock cable length h. Tighten the bleed screw and then release the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ brake lever. a. Turn the rear brake lock cable adjusting nut i. Repeat steps (e) to (h) until all of the air bub- “1”...
Page 147 PERIODIC MAINTENANCE EAS31427 Rear brake lock adjusting nut CHECKING THE REAR BRAKE LOCK PADS 15 N·m (1.5 kgf·m, 11 lb·ft) The following procedure applies to all of the brake pads. e. Make sure that the tire can be turned by hand 1.
Page 148 No guarantee con- NEVER OVERLOAD THE VEHICLE. cerning handling characteristics can be giv- en if a tire combination other than one Tire air pressure (measured on approved by Yamaha is used on this vehicle. cold tires) 1 person Front tire Front Size 225 kPa (2.25 kgf/cm², 33 psi)
Page 149 PERIODIC MAINTENANCE EAS30641 CHECKING THE WHEEL BEARINGS The following procedure applies to all of the wheel bearings. 1. Check: • Wheel bearings Refer to “FRONT WHEEL” on page 4-22 and “REAR WHEEL” on page 4-31. EAS30802 CHECKING THE SWINGARM OPERATION 1.
Page 150 PERIODIC MAINTENANCE part, and calculate the average of the read ECA25750 NOTICE values. A drive belt that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident.
Page 151 • Drive pulley assembly inner part “a” 1. Remove: Recommended lubricant • Drive belt upper guard and lower guard YAMAHA GREASE “J” (Shell Al- Refer to “REAR WHEEL” on page 4-31. vania EP Grease R0®) 2. Remove: • Drive belt Refer to “BELT DRIVE”...
Page 152 PERIODIC MAINTENANCE EAS30645 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. Place the vehicle on a maintenance stand so that the front wheel is elevated.
Page 153 PERIODIC MAINTENANCE EAS30856 CHECKING THE CENTERSTAND 1. Check: • Centerstand operation Check that the centerstand moves smoothly. Rough movement  Repair or replace. EAS30857 LUBRICATING THE CENTERSTAND Lubricate the pivoting point, metal-to-metal mov- ing parts and spring contact point of the center- stand.
Page 154 PERIODIC MAINTENANCE EAS30808 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • Rear shock absorber assembly operation Push down hard on the seat several times and check if the rear shock absorber rebound smoothly. Rough movement  Replace. Refer to “REAR SHOCK ABSORBER AS- SEMBLY”...
Page 155 PERIODIC MAINTENANCE Recommended brand YAMALUBE SAE viscosity grades 10W-40 Recommended engine oil grade API service SG type or higher, JASO standard MA ECA13361 NOTICE • Engine oil also lubricates the clutch and the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ wrong oil types or additives could cause clutch slippage.
Page 156 PERIODIC MAINTENANCE cation with an oil filter wrench. Oil filter cartridge 17 N·m (1.7 kgf·m, 13 lb·ft) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • Gasket • Engine oil drain bolt (along with the O-ring) 4. Drain: Lubricate the O-ring of the engine oil drain bolt •...
Page 157 PERIODIC MAINTENANCE c. Start the engine and keep it idling until engine 4. Install: • Oil pressure gauge “1” oil starts to seep from the oil check bolt. If no • Adapter “2” engine oil comes out after one minute, turn the engine off so that it will not seize.
Page 158 PERIODIC MAINTENANCE essary, correct the antifreeze concentra- 6. Install: • Engine oil pressure check point plug tion of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may Lubricate the O-ring of the engine oil pressure be used.
Page 159 PERIODIC MAINTENANCE 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. Scalding hot fluid and steam may 3.
Page 160 PERIODIC MAINTENANCE ECA13481 NOTICE • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.
Page 161 PERIODIC MAINTENANCE EAS31188 EAS31147 REPLACING THE V-BELT CHECKING AND LUBRICATING THE 1. Remove: CABLES • Bottom side cowling The following procedure applies to all of the in- • Side panel ner and outer cables. • Bottom center cowling EWA13270 WARNING Refer to “GENERAL CHASSIS (1)”...
Page 162 PERIODIC MAINTENANCE EAS30816 Throttle grip free play CHECKING AND CHARGING THE BATTERY 1.0–3.0 mm (0.04–0.12 in) Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-230. EAS30662 CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-229. EAS30664 ADJUSTING THE HEADLIGHT BEAMS 1.
Page 163 PERIODIC MAINTENANCE Right headlight Direction “a” Headlight beam moves to the left. Direction “b” Headlight beam moves to the right. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-35...
Page 164 PERIODIC MAINTENANCE 3-36...
Page 165 CHASSIS GENERAL CHASSIS (1) ..................4-1 ADJUSTING THE WINDSHIELD HEIGHT (for XP530E-A/XP530-A) ..4-7 REMOVING THE FRONT COVER.............4-7 REMOVING THE SIDE PANEL..............4-8 INSTALLING THE SIDE PANEL ..............4-8 REMOVING THE INNER PANEL...............4-9 REMOVING THE BATTERY COVER ............4-10 GENERAL CHASSIS (2) ................4-11 REMOVING THE SIDE COVER...............4-15 REMOVING THE FOOTBOARD ..............4-15 REMOVING THE REAR COVER .............4-15 REMOVING THE REAR COWLING............4-16...
Page 166 INSTALLING THE FRONT BRAKE CALIPERS ........4-49 REMOVING THE FRONT BRAKE MASTER CYLINDER ......4-50 CHECKING THE FRONT BRAKE MASTER CYLINDER......4-50 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ....4-50 INSTALLING THE FRONT BRAKE MASTER CYLINDER.......4-50 REAR BRAKE ....................4-53 INTRODUCTION ..................4-61 CHECKING THE REAR BRAKE DISC.............4-61 REPLACING THE REAR BRAKE PADS..........4-61 REMOVING THE REAR BRAKE CALIPER ..........4-62 DISASSEMBLING THE REAR BRAKE CALIPER ........4-63...
Page 167 INSTALLING THE STEERING HEAD ............4-99 BELT DRIVE ....................4-100 CHECKING THE DRIVE BELT ..............4-101 INSTALLING THE DRIVE PULLEY ASSEMBLY ........4-101 INSTALLING THE DRIVE BELT ............4-101 REAR SHOCK ABSORBER ASSEMBLY............4-102 HANDLING THE REAR SHOCK ABSORBER ........4-103 DISPOSING OF A REAR SHOCK ABSORBER ........4-103 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-103 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....4-104 CHECKING THE CONNECTING ARM AND RELAY ARM....4-104...
Page 168 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the windshield and meter assembly (for XP530E-A/XP530-A) 1.6 N ・ m (0.16 kgf ・ m, 1.2 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・...
Page 169 GENERAL CHASSIS (1) Removing the windshield and meter assembly (for XP530D-A) 1.6 N ・ m (0.16 kgf ・ m, 1.2 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・...
Page 170 GENERAL CHASSIS (1) Removing the front turn signal light and front cowling assembly 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 2.8 N ・...
Page 171 GENERAL CHASSIS (1) Removing the bottom cowling 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...
Page 172 GENERAL CHASSIS (1) Removing the battery and leg shield assembly 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) 4.3 N ・ m (0.43 kgf ・ m, 3.2 lb ・ ft) 4.0 N ・...
Page 173 GENERAL CHASSIS (1) Removing the battery and leg shield assembly 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) 4.3 N ・ m (0.43 kgf ・ m, 3.2 lb ・ ft) 4.0 N ・...
Page 174 GENERAL CHASSIS (1) EAS31397 ADJUSTING THE WINDSHIELD HEIGHT (for XP530E-A/XP530-A) 1. Adjust: • Windshield height ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the windshield covers “1” by remov- ing the quick fasteners “2”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS31398 REMOVING THE FRONT COVER 1. Remove: • Front cover “1” b.
Page 175 GENERAL CHASSIS (1) Remove projections “a” on the front cover from grommets “b”. c. Remove the side panel “1”. Remove the side panel by removing the lower part “a” and upper part “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30821 REMOVING THE SIDE PANEL The following procedure applies to both of the side panels.
Page 176 GENERAL CHASSIS (1) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the side panel “1”. Install the side panel by installing the lower part “a” and upper part “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: • Bottom side cowling EAS30819 REMOVING THE INNER PANEL The following procedure applies to both of the in- ner panels.
Page 177 GENERAL CHASSIS (1) b. Remove the inner panel “1” by moving it in ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the arrow direction. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS31677 REMOVING THE BATTERY COVER 1. Remove: • Battery cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the battery cover screw “2”. b. Remove the part “a” of the battery cover. c.
Page 178 GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the footboard 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 4.0 N ・...
Page 179 GENERAL CHASSIS (2) Removing the rear cowling and mudguard assembly 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・...
Page 180 GENERAL CHASSIS (2) Removing the rear cowling assembly and seat assembly 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.5 N ・...
Page 181 GENERAL CHASSIS (2) Removing the storage box 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 0.7 N ・ m (0.07 kgf ・ m, 0.52 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) 16 N ・...
Page 182 GENERAL CHASSIS (2) Refer to “GENERAL CHASSIS (1)” on page EAS31519 REMOVING THE SIDE COVER 4-1. The following procedure applies to both of the • Center cover side covers. • Side cover 1. Remove: 2. Remove: • Side cover “1” •...
Page 183 GENERAL CHASSIS (2) b. Remove the rear cowling “1” by sliding it rear- ward. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the quick fasteners “2”. b. Remove the rear cover “1” by sliding it rear- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ward. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS31841 REMOVING THE REAR COWLING The following procedure applies to both of the rear cowlings.
Page 184 GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the battery box and ECU (Engine Control Unit) 36 N ・ m (3.6 kgf ・ m, 27 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 43 N ・...
Page 185 GENERAL CHASSIS (3) Removing the electrical components tray (for XP530E-A/XP530-A) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) 7 N ・...
Page 186 GENERAL CHASSIS (3) Removing the electrical components tray (for XP530D-A) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 7 N ・...
Page 187 GENERAL CHASSIS (3) Removing the headlight stay 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 18 N ・...
Page 188 GENERAL CHASSIS (3) EAS31850 INSTALLING THE WINDSHIELD DRIVE UNIT (for XP530D-A) 1. Check: • Windshield drive unit operation After installing the windshield drive unit to the headlight stay, check the operation of the drive unit. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the windshield drive unit “1”, and then connect the windshield drive unit coupler to the wire harness.
Page 189 FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 35 N ・...
Page 190 FRONT WHEEL Disassembling the front wheel 2.0 N ・ m (0.20 kgf ・ m, 1.5 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 191 FRONT WHEEL ject it to shocks. EAS30145 REMOVING THE FRONT WHEEL • If any solvent gets on the wheel sensor ro- ECA21380 tor, wipe it off immediately. NOTICE 1. Remove: Keep magnets (including magnetic pick-up • Oil seals tools, magnetic screwdrivers, etc.) away •...
Page 192 FRONT WHEEL EAS30151 ASSEMBLING THE FRONT WHEEL ECA21340 NOTICE • Do not drop the wheel sensor rotor or sub- ject it to shocks. • If any solvent gets on the wheel sensor ro- tor, wipe it off immediately. 1. Install: •...
Page 193 FRONT WHEEL d. Install the new oil seals. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: • Front wheel sensor rotor Wheel sensor rotor bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) LOCTITE® ECA17200 NOTICE Replace the wheel sensor rotor bolts with new ones. Install the wheel sensor rotor with the stamped mark “1”...
Page 194 FRONT WHEEL • Do not drop or shock the wheel sensor or the wheel sensor rotor. 1. Check: • Front wheel sensor “1” Cracks/bends/distortion  Replace. Iron powder/dust  Clean. 2. Check: • Front wheel sensor rotor “1” Cracks/damage/scratches  Replace the front wheel sensor rotor.
Page 195 FRONT WHEEL b. Turn the front wheel 90 so that the heavy ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ spot is positioned as shown. a. Spin the front wheel. b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. c.
Page 196 FRONT WHEEL “3”  pinch bolt “2”  pinch bolt “3”. c. Temporarily install the pinch bolts “4” and “5”, and then tighten the pinch bolts to 21 N·m (2.1 kgf·m, 15 lb·ft) in the order of pinch bolt “5”  pinch bolt “4”  pinch bolt “5”. 2.
Page 197 FRONT WHEEL Distance “a” (between the front wheel sensor rotor and front wheel sensor) 0.3–1.1 mm (0.01–0.04 in) Measure the distance between the front wheel sensor rotor and front wheel sensor in several places in one rotation of the front wheel. Do not turn the front wheel while the thickness gauge is installed.
Page 198 REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 160 N ・ m (16 kgf ・ m, 118 lb ・ ft) 16 N ・...
Page 199 REAR WHEEL Removing the rear brake disc and rear wheel pulley 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 64 N ・...
Page 200 REAR WHEEL Disassembling the rear wheel assembly Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing (left) Collar Wheel bearing (right) 4-33...
Page 201 REAR WHEEL (left side and right side) EAS30910 REMOVING THE REAR WHEEL ECA21390 NOTICE Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel sensor “1”, otherwise the wheel sensor may be damaged, resulting in improper performance of the ABS. 4.
Page 202 REAR WHEEL c. Clean the rear wheel drive hub with a clean EAS30159 CHECKING THE REAR WHEEL cloth, especially the surfaces that contact the 1. Check: pulley. • Wheel axle d. Install the new rear wheel pulley and drive • Wheel bearings belt guide.
Page 203 REAR WHEEL Refer to “ASSEMBLING THE FRONT EAS30165 INSTALLING THE REAR WHEEL (DISC WHEEL” on page 4-25. BRAKE) 1. Install: EAS30167 MAINTENANCE OF THE REAR WHEEL • Rear wheel sensor rotor SENSOR AND SENSOR ROTOR • Rear brake disc ECA21060 NOTICE Rear wheel sensor bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Page 204 REAR WHEEL • Fit the brake torque stop pin “a” on the swing- Rear wheel pulley bolt arm into the slot “b” on the rear brake caliper 64 N·m (6.4 kgf·m, 47 lb·ft) bracket. LOCTITE® • When installing the rear brake caliper bracket Drive belt guide bolt and the rear wheel sensor housing, align the 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Page 205 REAR WHEEL Rear wheel sensor bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) ECA21080 NOTICE Make sure there are no foreign materials in the rear wheel sensor rotor and rear wheel sensor. Foreign materials cause damage to the rear wheel sensor rotor and rear wheel sensor.
Page 206 REAR WHEEL sor rotor and the rear wheel sensor. Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 11.Adjust: • Rear brake lock cable length Refer to “ADJUSTING THE REAR BRAKE LOCK CABLE” on page 3-18. 4-39...
Page 207 FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 35 N ・...
Page 208 FRONT BRAKE Removing the front brake master cylinder 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.0 N ・ m (0.10 kgf ・ m, 0.73 lb ・ ft) 6 N ・...
Page 209 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-42...
Page 210 FRONT BRAKE Removing the front brake calipers 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 211 FRONT BRAKE Disassembling the front brake calipers 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 212 FRONT BRAKE d. Hold the dial gauge at a right angle against EAS30168 INTRODUCTION the brake disc surface. EWA14101 e. Measure the runout 1.5 mm (0.06 in) below WARNING the edge of the brake disc. Disc brake components rarely require disas- sembly.
Page 213 FRONT BRAKE d. Measure the brake disc runout. 3. Measure: e. If out of specification, repeat the adjustment • Brake pad wear limit “a” steps until the brake disc runout is within Out of specification  Replace the brake specification. pads as a set.
Page 214 FRONT BRAKE LOWER c. Tighten the bleed screw. 8. Check: • Brake lever operation Brake caliper bleed screw Soft or spongy feeling  Bleed the brake sys- 5 N·m (0.5 kgf·m, 3.7 lb·ft) tem. Refer to “BLEEDING THE HYDRAULIC d. Install the brake pads and brake pad spring. BRAKE SYSTEM”...
Page 215 FRONT BRAKE EAS30172 DISASSEMBLING THE FRONT BRAKE Recommended brake component replacement schedule CALIPERS The following procedure applies to both of the Brake pads If necessary brake calipers. Piston seals Every two years 1. Remove: • Brake caliper pistons “1” Piston dust seals Every two years •...
Page 216 FRONT BRAKE replace the brake caliper piston dust seals 2. Remove: and brake caliper piston seals. • Front brake caliper 3. Install: Specified brake fluid • Brake pads DOT 4 • Brake pad spring • Brake pad pin • Brake pad clips EAS30175 INSTALLING THE FRONT BRAKE CALIPERS •...
Page 217 FRONT BRAKE (brake master cylinder body) Obstruction  Blow out with compressed air. 2. Check: • Brake master cylinder kit LOWER Damage/scratches/wear  Replace. 3. Check: • Brake master cylinder reservoir cap “1” • Brake master cylinder reservoir “2” • Brake master cylinder reservoir diaphragm holder “3”...
Page 218 FRONT BRAKE sure the brake hose does not touch other parts • Install the front brake master cylinder holder (e.g., wire harness, cables, leads). Correct if with the “ ” mark “a” facing up. necessary. • Make sure that brake master cylinder assem- bly touches the end of handlebar bracket “b”.
Page 219 FRONT BRAKE LOWER 6. Check: • Brake lever operation Soft or spongy feeling  Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-17. 4-52...
Page 220 REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Rear brake caliper Rear brake pad...
Page 221 REAR BRAKE Removing the rear brake master cylinder 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.0 N ・ m (0.10 kgf ・ m, 0.73 lb ・ ft) 6 N ・...
Page 222 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-55...
Page 223 REAR BRAKE Removing the rear brake caliper 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
Page 224 REAR BRAKE Disassembling the rear brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw Brake caliper body 4-57...
Page 225 REAR BRAKE Removing the rear brake lock pads 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear brake lock cable adjusting nut Rear brake lock spring Rear brake lock caliper Rear brake lock pad 4-58...
Page 226 REAR BRAKE Removing the rear brake lock caliper 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear brake lock cable adjusting nut Rear brake lock spring Rear brake lock caliper 4-59...
Page 227 REAR BRAKE Disassembling the rear brake lock caliper 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 17 N ・...
Page 228 REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit 4.5 mm (0.18 in) EWA14101 WARNING 5. Adjust: Disc brake components rarely require disas- • Brake disc deflection sembly. Therefore, always follow these pre- Refer to “CHECKING THE FRONT BRAKE ventive measures: DISCS”...
Page 229 REAR BRAKE ECA14150 Brake pad lining thickness NOTICE 8.0 mm (0.31 in) • Do not allow grease to contact the brake Limit pads. 0.8 mm (0.03 in) • Remove any excess grease. 6. Install: • Rear brake caliper • Rear brake caliper bolts Rear brake caliper bolt 27 N·m (2.7 kgf·m, 20 lb·ft) 7.
Page 230 REAR BRAKE EAS30188 CHECKING THE REAR BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seal Every two years Piston dust seal Every two years Brake hoses Every four years Every two years and EAS30187 Brake fluid whenever the brake is DISASSEMBLING THE REAR BRAKE disassembled...
Page 231 REAR BRAKE EAS30189 2. Remove: ASSEMBLING THE REAR BRAKE CALIPER • Rear brake caliper EWA17080 3. Install: WARNING • Brake pad supports • Before installation, all internal brake com- • Rear brake pads ponents should be cleaned and lubricated • Rear brake caliper with clean or new brake fluid.
Page 232 REAR BRAKE Refer to “BLEEDING THE HYDRAULIC EAS30194 CHECKING THE REAR BRAKE MASTER BRAKE SYSTEM” on page 3-17. CYLINDER 6. Check: 1. Check: • Brake fluid level • Brake master cylinder Below the minimum level mark “a” Add the Damage/scratches/wear  Replace. specified brake fluid to the proper level.
Page 233 REAR BRAKE • First, tighten the upper bolt, then the lower bolt. Angle “b” (brake master cylinder and handlebar bracket) 120.1–122.7 3. Fill: • Brake master cylinder reservoir (with the specified amount of the specified brake fluid) Specified brake fluid DOT 4 EWA13540 WARNING...
Page 234 REAR BRAKE LOWER 6. Check: • Brake lever operation Push on the back of the pad using a rod with a Soft or spongy feeling  Bleed the brake sys- round end. tem. 4. Remove: Refer to “BLEEDING THE HYDRAULIC •...
Page 235 REAR BRAKE Rear brake lock caliper bolt 23 N·m (2.3 kgf·m, 17 lb·ft) 10.Adjust: • Rear brake lock cable length Refer to “ADJUSTING THE REAR BRAKE LOCK CABLE” on page 3-18. EAS31418 REPLACING THE REAR BRAKE LOCK CABLE 1. Remove: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 236 REAR BRAKE • Rear brake lock spring “3” • Rear brake lock caliper bolts “4” • Rear brake lock caliper “5” 2. Install: • Rear brake lock caliper bracket Rear brake lock caliper bracket bolt EAS31420 CHECKING THE REAR BRAKE LOCK 22 N·m (2.2 kgf·m, 16 lb·ft) CALIPER LOCTITE®...
Page 237 REAR BRAKE Rear brake lock caliper piston locknut 22 N·m (2.2 kgf·m, 16 lb·ft) Left-hand thread 8. Install: • Rear brake lock adjusting nut • Cap Rear brake lock adjusting nut 15 N·m (1.5 kgf·m, 11 lb·ft) 6. Adjust: • Piston adjusting bolt 9.
Page 238 ABS (Anti-lock Brake System) EAS20032 ABS (Anti-lock Brake System) Removing the hydraulic unit assembly 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 239 ABS (Anti-lock Brake System) EAS30728 ABS COMPONENTS CHART 1. Yamaha diagnostic tool coupler 2. ABS warning light 3. ABS ECU fuse/ABS solenoid fuse/ABS motor fuse 4. Hydraulic unit assembly 5. Front wheel sensor rotor 6. Front wheel sensor 7. Front brake caliper 8.
Page 240 ABS (Anti-lock Brake System) EAS30197 REMOVING THE HYDRAULIC UNIT ASSEMBLY ECA18230 NOTICE Unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. EWA13930 WARNING Refill with the same type of brake fluid that is 2. Remove: already in the system.
Page 241 ABS (Anti-lock Brake System) EAS30200 INSTALLING THE HYDRAULIC UNIT Connect the ABS ECU coupler, and then push ASSEMBLY the lock lever of the coupler in the direction of the 1. Install: arrow shown. • Hydraulic unit assembly ECA21371 NOTICE Do not remove the rubber plugs or bolts (M10 ...
Page 242 • For the brake line routing confirmation, use the diagnosis of function of the Yamaha diagnostic tool. 6. Start the Yamaha diagnostic tool and display • Before performing the brake line routing confir- the diagnosis of function screen. mation, make sure that no malfunctions have 7.
Page 243 Securely support the vehicle so that there is no danger of it falling over. • For the ABS reaction-force confirmation, use the diagnosis of function of the Yamaha diag- nostic tool. For more information, refer to the operation manual of the Yamaha diagnostic tool.
Page 244 • The reaction-force pulsating action consists of quick pulses. 6. Start the Yamaha diagnostic tool and display • Be sure to continue operating the front brake the diagnosis of function screen. lever and rear brake lever even after the pul- 7.
Page 245 12.Push the OFF/LOCK switch. 13.Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler, and then in- stall the protective cap. 14.Push the ON/start switch.
Page 246 HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar cover 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...
Page 247 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) * YAMAHA GREASE “F” Order Job/Parts to remove Q’ty...
Page 248 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) * YAMAHA GREASE “F” Order Job/Parts to remove Q’ty...
Page 249 HANDLEBAR Removing the handlebar 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 7 N ・...
Page 250 HANDLEBAR EAS30203 REMOVING THE HANDLEBAR 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: • Handlebar grip “1” Blow compressed air between the handlebar and the handlebar grip, and gradually push the EAS30205 INSTALLING THE HANDLEBAR...
Page 251 (for XP530D-A) 6. Lubricate: • Rear brake lock cable (to cable end) Recommended lubricant YAMAHA GREASE “F” 7. Connect: • Rear brake lock cable (to rear brake lock lever) Rotate the lever to the position “a”, and then in- stall the rear brake lock cable.
Page 252 Remove the protective cap “1”, and then con- nect the Yamaha diagnostic tool to coupler. There should be 1–3 mm (0.04–0.12 in) of clear- ance “a” between the handlebar grip and the grip For information about using the Yamaha diag- end.
Page 253 If the Yamaha diagnostic tool screen value is not 93–109, adjust the accelerator position sensor angle. q. Repeat steps (f) to (p) until the Yamaha diag- nostic tool screen values are within the spec- ified ranges. r. If the Yamaha diagnostic tool screen values...
Page 254 FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 10 N ・...
Page 255 FRONT FORK Disassembling the front fork legs 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 256 FRONT FORK 1. Remove: EAS30206 REMOVING THE FRONT FORK LEGS • Cap bolt “1” The following procedure applies to both of the • Spacer “2” front fork legs. • Damper rod locknut “3” 1. Stand the vehicle on a level surface. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 257 FRONT FORK 3. Remove: • Damper rod assembly bolt • Damper rod assembly ECA17401 NOTICE For the damper rod assembly, the right side is used for the rebound operation and left side for the compression. Pay attention not to mistake the right and left. 5.
Page 258 FRONT FORK EAS30209 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. EWA13660 WARNING • Make sure the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor han- dling and a loss of stability.
Page 259 FRONT FORK 6. Install: • Oil seal clip “1” Adjust the oil seal clip so that it fits into the outer tube groove. 3. Install: • Outer tube (to the inner tube) 4. Install: • Outer tube bushing “1” • Washer “2” 7.
Page 260 (with the specified amount of the recom- • Damper rod assembly bolt “1” mended fork oil) Damper rod assembly bolt Recommended oil 23 N·m (2.3 kgf·m, 17 lb·ft) Yamaha Suspension Oil 01 LOCTITE® Quantity (left) 447.0 cm³ (15.11 US oz, 15.77 Imp.oz) Quantity (right) While holding the damper rod assembly with the 437.0 cm³...
Page 261 FRONT FORK • When disassembling and assembling the (along with the O-ring front fork leg, do not allow any foreign ma- EWA12850 WARNING terial to enter the front fork. Always use a new O-ring. 12.After filling the front fork leg, slowly stroke the damper rod assembly “1”...
Page 262 FRONT FORK bracket pinch bolts. Make sure the outer tube is flush with the top of the upper bracket. 2. Tighten: • Lower bracket pinch bolts “1” • Cap bolt “2” • Upper bracket pinch bolt “3” Lower bracket pinch bolt 23 N·m (2.3 kgf·m, 17 lb·ft) f.
Page 263 STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 130 N ・ m (13 kgf ・ m, 96 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 7 N ・...
Page 264 STEERING HEAD Removing the lower bracket 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 130 N ・ m (13 kgf ・ m, 96 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 7 N ・...
Page 265 STEERING HEAD EAS30213 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 ring nut • Rubber washer •...
Page 266 STEERING HEAD 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage  Replace. EAS30216 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” •...
Page 267 48 N ・ m (4.8 kgf ・ m, 35 lb ・ ft) 48 N ・ m (4.8 kgf ・ m, 35 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) * Filling the YAMAHA GREASE “J” (Shell Alvania EP Grease R0®). Order Job/Parts to remove Q’ty...
Page 268 BELT DRIVE EAS30236 CHECKING THE DRIVE BELT 1. Clean: • Drive belt ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wipe the drive belt with a clean cloth. b. Put the drive belt in a mixture of mild deter- gent and water. Then, remove any dirt from the drive belt.
Page 269 REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 50 N ・ m (5.0 kgf ・ m, 37 lb ・ ft) 75 N ・ m (7.5 kgf ・ m, 55 lb ・ ft) 9 10 50 N ・...
Page 270 REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER 50 mm (1.97 in) EWA13740 WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsi- ble for property damage or personal injury that may result from improper handling of...
Page 271 REAR SHOCK ABSORBER ASSEMBLY EAS30220 CHECKING THE REAR SHOCK ABSORBER • When installing the oil seals “2” to the connect- ASSEMBLY ing arms “3”, face the character stamp of the oil 1. Check: seals outside. • Rear shock absorber rod •...
Page 272 REAR SHOCK ABSORBER ASSEMBLY Installed depth “a” 6.5 mm (0.26 in) Installed depth “b” 6 mm (0.24 in) Installed depth “c” 1.0–2.0 mm (0.04–0.08 in) • When installing the oil seals “2” to the relay arm, face the character stamp of the oil seals outside.
Page 273 SWINGARM EAS20037 SWINGARM Removing the swingarm 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 6 N ・...
Page 274 SWINGARM Removing the swingarm 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 6 N ・...
Page 275 SWINGARM EAS30226 EAS30227 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: • Swingarm (left) “1” EWA13120 WARNING • Swingarm (right) “2” Securely support the vehicle so that there is Bends/cracks/damage  Replace. no danger of it falling over.
Page 276 SWINGARM 3. Install: • Dowel pins • Swingarm • Swingarm bolts • Drive pulley assembly • Drive pulley assembly bolt Swingarm bolt 40 N·m (4.0 kgf·m, 30 lb·ft) Drive pulley assembly bolt 48 N·m (4.8 kgf·m, 35 lb·ft) 4. Tighten: •...
Page 277 ENGINE ENGINE INSPECTION ..................5-1 MEASURE THE COMPRESSION PRESSURE.........5-1 ENGINE REMOVAL..................5-2 INSTALLING THE ENGINE................5-6 CAMSHAFTS....................5-7 REMOVING THE CAMSHAFTS..............5-9 CHECKING THE CAMSHAFTS ...............5-10 CHECKING THE CAMSHAFT SPROCKETS ..........5-11 CHECKING THE TIMING CHAIN GUIDES..........5-11 CHECKING THE TIMING CHAIN TENSIONER........5-11 INSTALLING THE CAMSHAFTS .............5-12 CYLINDER HEAD...................5-15 REMOVING THE CYLINDER HEAD............5-16 CHECKING THE CYLINDER HEAD ............5-16...
Page 278 CHECKING THE SLIDERS ..............5-39 CHECKING THE SECONDARY SHEAVE ..........5-39 ASSEMBLING THE PRIMARY SHEAVE ..........5-40 ASSEMBLING THE SECONDARY SHEAVE...........5-40 INSTALLING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY SHEAVE ASSEMBLY AND V-BELT ............5-41 INSTALLING THE V-BELT CASE ............5-43 GENERATOR AND STARTER CLUTCH ............5-44 REMOVING THE GENERATOR ..............5-47 REMOVING THE STARTER CLUTCH ............5-47 CHECKING THE STARTER CLUTCH .............5-47 CHECKING THE OIL STRAINER ............5-48...
Page 279 INSTALLING THE CONNECTING RODS..........5-73 INSTALLING THE CRANKSHAFT ASSEMBLY........5-75 TRANSMISSION.....................5-77 CHECKING THE TRANSMISSION ............5-78...
Page 280 ENGINE INSPECTION Out of specification  Refer to steps (c) and EAS20041 ENGINE INSPECTION (d). Compression pressure EAS30249 MEASURE THE COMPRESSION PRESSURE 1696–2184 kPa/470 r/min (17.0– The following procedure applies to all of the cyl- 21.8 kgf/cm²/470 r/min, 241.3– inders. 310.6 psi/470 r/min) Insufficient compression pressure will result in a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 281 ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the exhaust assembly 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 31 N ・...
Page 282 ENGINE REMOVAL Disconnecting the leads 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Windshield/Front cover/Windshield inner panel/Meter assembly/Rearview mirror/Bottom Refer to “GENERAL CHASSIS (1)”...
Page 283 ENGINE REMOVAL Disconnecting the leads 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Swingarm Refer to “SWINGARM” on page 4-106. Air filter case/Throttle body assembly/Intake Refer to “THROTTLE BODY”...
Page 284 ENGINE REMOVAL Removing the engine 83 N ・ m (8.3 kgf ・ m, 61 lb ・ ft) 105 N ・ m (10.5 kgf ・ m, 77 lb ・ ft) 70 N ・ m (7.0 kgf ・ m, 52 lb ・ ft) 77 N ・...
Page 285 ENGINE REMOVAL EAS30251 INSTALLING THE ENGINE 1. Install: • All removed parts • Apply locking agent (LOCTITE®) to engine mounting bolt (front upper side) “1”, engine mounting bolt (front right lower side) “2”, en- gine mounting bolts (front left lower side) “3”, and rear frame bolts “5”.
Page 286 CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”...
Page 287 CAMSHAFTS Removing the camshafts 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 8 N ・...
Page 288 CAMSHAFTS 2. Remove: EAS30256 REMOVING THE CAMSHAFTS • Timing chain tensioner “1” 1. Align: • Timing chain tensioner gasket • “I” mark “a” on the generator rotor (with the stationary pointer “b” on the genera- tor cover) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. 3.
Page 289 CAMSHAFTS 4. Measure: EAS30257 • Camshaft-journal-to-camshaft-cap clearance CHECKING THE CAMSHAFTS Out of specification  Measure the camshaft 1. Check: journal diameter. • Camshaft lobes Blue discoloration/pitting/scratches  Re- Camshaft-journal-to-camshaft- place the camshaft. cap clearance 2. Measure: 0.028–0.062 mm (0.0011–0.0024 • Camshaft lobe dimensions “a” Out of specification ...
Page 290 CAMSHAFTS with the Plastigauge®. Camshaft cap bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) d. Remove the camshaft caps and then mea- sure the width of the Plastigauge® “1”. a. 1/4 tooth b. Correct 1. Timing chain 2. Camshaft sprocket EAS30265 CHECKING THE TIMING CHAIN GUIDES 1.
Page 291 CAMSHAFTS b. Lock the timing chain tensioner rod by setting ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ the circlip “3” to groove “4” while pushing the a. Turn the crankshaft clockwise. timing chain tensioner rod. b. When piston #1 is at TDC on the compres- c. Push the timing chain tensioner rod “c”. sion stroke, align the “I”...
Page 292 CAMSHAFTS • When tightening the camshaft cap, tighten the surface, as shown in the illustration. four bolts on the both ends of the cap tempo- ECA13740 rarily to lower the entire cap, while paying at- NOTICE tention not to twist the dowel pins and camshaft Do not turn the crankshaft when installing journal.
Page 293 ANCE” on page 3-5. 8. Install: • Timing chain guide (upper side) • Gaskets (to the cylinder head cover) Apply Yamaha bond No. 1215 “1” onto the mat- ing surfaces of the cylinder head cover and gas- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ kets. 5. Turn: •...
Page 294 CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 20 N ・...
Page 295 CYLINDER HEAD EAS30276 REMOVING THE CYLINDER HEAD 1. Remove: • Cylinder head bolts • Cylinder head nuts • Loosen the bolts and nuts in the proper se- quence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
Page 296 CYLINDER HEAD • Lubricate the cylinder head nuts and washers with engine oil. 3. Tighten: • Cylinder head nuts “1”–“6” • Cylinder head bolts “7”, “8” • Cylinder bolt “9” Cylinder head nut 1st: 10 N·m (1.0 kgf·m, 7.4 lb·ft) 2nd: 20 N·m (2.0 kgf·m, 15 lb·ft) 3rd: 120...
Page 297 VALVES AND VALVE SPRINGS EAS20045 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 5-15. Valve lifter Valve pad Valve cotter Valve spring retainer Valve spring Intake valve Exhaust valve Valve stem seal...
Page 298 VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.
Page 299 VALVES AND VALVE SPRINGS 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 (intake) 0.010–0.037 mm (0.0004–0.0015 Limit b. Install the new valve guide with the valve 0.080 mm (0.0032 in) guide installer “2”...
Page 300 VALVES AND VALVE SPRINGS 2. Check: Valve guide remover (ø4) • Valve seat 90890-04111 Pitting/wear  Replace the cylinder head. Valve guide remover (4.0 mm) 3. Measure: YM-04111 • Valve seat width “a” Valve guide installer (ø4) Out of specification  Replace the cylinder 90890-04112 head.
Page 301 VALVES AND VALVE SPRINGS e. Apply a fine lapping compound to the valve face and repeat the above steps. After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve f. After every lapping procedure, be sure to clean off all of the lapping compound from the face should be lapped.
Page 302 VALVES AND VALVE SPRINGS (with an oil stone) 2. Measure: • Valve spring tilt “a” 2. Lubricate: Out of specification  Replace the valve • Valve stem “1” • Valve stem seal “2” spring. (with the recommended lubricant) Spring tilt (intake) 1.6 mm (0.06 in) Recommended lubricant Spring tilt (exhaust)
Page 303 VALVES AND VALVE SPRINGS 6. Lubricate: b. Smaller pitch • Valve pad 4. Install: (with the recommended lubricant) • Valve cotters Recommended lubricant Molybdenum disulfide oil Install the valve cotters by compressing the valve spring with the valve spring compressor 7.
Page 304 CYLINDER AND PISTONS EAS20046 CYLINDER AND PISTONS Removing the cylinder and pistons 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-15. Coolant hose Disconnect.
Page 305 CYLINDER AND PISTONS • Oil ring EAS30289 REMOVING THE PISTON The following procedure applies to all of the pis- When removing a piston ring, open the end gap ton. with your fingers and lift the other side of the ring 1.
Page 306 CYLINDER AND PISTONS c. Measure piston skirt diameter “a” with the mi- Piston ring crometer. Top ring Ring side clearance 0.030–0.065 mm (0.0012–0.0026 Side clearance limit 0.115 mm (0.0045 in) 2nd ring Ring side clearance 0.020–0.055 mm (0.0008–0.0022 Side clearance limit 0.115 mm (0.0045 in) b.
Page 307 CYLINDER AND PISTONS 4. Calculate: a. Bottom of cylinder • Piston-pin-to-piston-pin-bore clearance b. Upper of cylinder Out of specification  Replace the piston pin EAS30293 and piston as a set. CHECKING THE PISTON PINS The following procedure applies to both of the Piston-pin-to-piston-pin-bore clearance = Piston pin bore inside diameter - piston pins.
Page 308 CYLINDER AND PISTONS • Make sure the mark “a” on the piston points to- wards the exhaust side of the cylinder. • Reinstall each piston into its original cylinder. • Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crank- case.
Page 309 ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Bottom side cowling/Side panel/Bottom center Refer to “GENERAL CHASSIS (1)”...
Page 310 ELECTRIC STARTER Disassembling the starter motor 11 N ・ m (1.1 kgf ・ m, 8.1 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) * When replacing any of the starter motor front cover, armature assembly, starter motor yoke, insulator, and starter motor rear cover, replace the starter motor assembly.
Page 311 ELECTRIC STARTER EAS30325 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt  Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification  Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut (depth) 1.
Page 312 ELECTRIC STARTER 6. Check: • Gear teeth Connect the starter motor lead to the starter mo- Damage/wear  Replace the starter motor tor in the direction shown in the illustration. assembly. 7. Check: • Bearing Damage/pitting  Replace the starter motor assembly.
Page 313 V-BELT AUTOMATIC TRANSMISSION EAS20050 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 11 N ・ m (1.1 kgf ・ m, 8.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 24 N ・...
Page 314 90 N ・ m (9.0 kgf ・ m, 66 lb ・ ft) 160 N ・ m (16 kgf ・ m, 118 lb ・ ft) *1 Apply YAMAHA GREASE “G” (Shell Sunlight Grease 3®). *2 Apply YAMAHA GREASE “H” (Polyurea Grease®).
Page 315 V-BELT AUTOMATIC TRANSMISSION Disassembling the primary sheave *1 Apply YAMAHA GREASE “H” (Polyurea Grease®). *2 When replacing the primary sliding sheave or collar, replace them as a set. Order Job/Parts to remove Q’ty Remarks Slider Primary sheave weight Primary sliding sheave...
Page 316 V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave 90 N ・ m (9.0 kgf ・ m, 66 lb ・ ft) * Apply YAMAHA GREASE “H” (Polyurea Grease®). Order Job/Parts to remove Q’ty Remarks Secondary sheave spring seat nut Upper spring seat...
Page 317 V-BELT AUTOMATIC TRANSMISSION EAS31435 EAS30312 REMOVING THE PRIMARY SHEAVE AND DISASSEMBLY THE SECONDARY SHEAVE SECONDARY SHEAVE 1. Loosen: • Secondary sheave spring seat nut “1” 1. Remove: • Primary sheave nut “1” • Secondary sheave nut “2” • While holding the secondary fixed sheave “2” with the sheave holder “3”, loosen the second- While holding the primary and secondary ary sheave spring seat nut with the locknut...
Page 318 V-BELT AUTOMATIC TRANSMISSION Cracks/damage  Replace. EAS30317 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: • Primary sheave weight Cracks/damage/wear  Replace. 2. Measure: • Primary sheave weight outside diameter EAS30315 CHECKING THE V-BELT Out of specification ...
Page 319 • Secondary sliding sheave inner surface “2” • Oil seals 3. Lubricate: (with the recommended lubricant) • Guide pin groove “1” • O-rings “2” Recommended lubricant (with the recommended lubricant) YAMAHA GREASE “H” (Poly- urea Grease®) Recommended lubricant YAMAHA GREASE “H” (Poly- urea Grease®) 5-40...
Page 320 INSTALLING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY SHEAVE ASSEMBLY AND V-BELT 1. Apply: • Sealant (onto the inner V-belt case seal) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 2. Install: 5. Tighten: • V-belt case air duct joint clamp “1”...
Page 321 45 mm (1.77 in)) bolts “4” to spread apart the secondary sheave and then install the V-belt. Recommended lubricant Make sure to install the V-belt with the arrow YAMAHA GREASE “G” (Shell facing in the direction shown. Sunlight Grease 3®) • Install the V-belt and secondary sheave as- sembly then pass the V-belt the primary sheave side.
Page 322 V-BELT AUTOMATIC TRANSMISSION EAS31235 INSTALLING THE V-BELT CASE 1. Install: • Oil seal “1” (into outer V-belt case) Installed depth of oil seal “a” 4.0–4.3 mm (0.16–0.17 in) 2. Fill the space “b” shown in the illustration with 10 g (0.35 oz) or more of lithium-soap-based grease.
Page 323 GENERATOR AND STARTER CLUTCH EAS20140 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch (17) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 65 N ・ m (6.5 kgf ・ m, 48 lb ・ ft) Specified angle 120˚...
Page 324 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch (17) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 65 N ・ m (6.5 kgf ・ m, 48 lb ・ ft) Specified angle 120˚ 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 325 GENERATOR AND STARTER CLUTCH Removing the stator coil and oil tank 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) * When replacing the crankshaft position sensor or stator coil, replace them as a set.
Page 326 GENERATOR AND STARTER CLUTCH EAS30867 REMOVING THE GENERATOR Flywheel puller 90890-01362 1. Remove: Heavy duty puller • Generator cover YU-33270-B 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 327 GENERATOR AND STARTER CLUTCH EAS31439 CHECKING THE OIL STRAINER 1. Check: • Oil strainer Damage  Replace. Contaminants  Clean with solvent. EAS31440 ASSEMBLING THE OIL TANK 1. Install: • Bearing 2. Check: Seal “a” is adhered only on one side of the bear- •...
Page 328 • Lubricate the generator rotor nut seats and threads with engine oil. 3. Apply: • Sealant (onto the crankshaft position sensor/stator lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 2. Tighten: • Generator rotor nut “1” Generator rotor nut (1st) 65 N·m (6.5 kgf·m, 48 lb·ft)
Page 329 GENERATOR AND STARTER CLUTCH Tighten the generator cover bolts in stages and in a crisscross pattern. 5-50...
Page 330 CLUTCH EAS20055 CLUTCH Removing the clutch 65 N ・ m (6.5 kgf ・ m, 48 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Bottom side cowling/Side panel/Bottom center Refer to “GENERAL CHASSIS (1)” on page cowling 4-1. Center cover/Fuel tank cover assembly/Side Refer to “GENERAL CHASSIS (2)”...
Page 331 CLUTCH Disassembling the clutch 130 N ・ m (13 kgf ・ m, 96 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Clip Spring stopper plate Clutch spring plate Pressure plate Clutch plate 2 Clutch damper spring Friction plate Clutch plate 1 Clutch spring Thrust plate Clutch boss nut...
Page 332 CLUTCH Disassembling the clutch 130 N ・ m (13 kgf ・ m, 96 lb ・ ft) (12) Order Job/Parts to remove Q’ty Remarks Thrust plate Clutch weight Clutch housing 5-53...
Page 333 CLUTCH EAS30346 REMOVING THE CLUTCH 1. Remove: • Clutch assembly nut “1” • Clutch assembly “2” • Before removal, put alignment marks “a” and “b” as shown. • While holding the clutch assembly with the ro- tor holding tool “3”, loosen the clutch assembly nut.
Page 334 CLUTCH EAS30348 CHECKING THE FRICTION PLATES Clutch plate 1 thickness 1.30–1.50 mm (0.051–0.059 in) The following procedure applies to all of the fric- Warpage limit tion plates. 0.10 mm (0.004 in) 1. Check: Clutch plate 2 thickness • Friction plate 1.80–2.00 mm (0.071–0.079 in) Damage/wear ...
Page 335 CLUTCH Out of specification  Replace the clutch ratic clutch operation. spring plate. Clutch spring plate height 4.70 mm (0.19 in) Minimum height 4.40 mm (0.17 in) EAS30353 CHECKING THE CLUTCH BOSS 1. Check: • Clutch boss splines Damage/pitting/wear  Replace the clutch boss.
Page 336 CLUTCH • Clutch boss nut 2. Tighten: • Clutch boss nut “1” Clutch boss nut 130 N·m (13 kgf·m, 96 lb·ft) While holding the clutch boss “2” with the univer- sal clutch holder “3”, tighten the clutch boss nut. Universal clutch holder 90890-04086 Universal clutch holder YM-91042...
Page 337 CLUTCH EAS30363 INSTALLING THE CLUTCH 1. Install: • Clutch assembly “1” • Clutch assembly nut “2” Clutch assembly nut 65 N·m (6.5 kgf·m, 48 lb·ft) • Align the “a” and “b” during reassembly. • While holding the clutch assembly with the ro- tor holding tool “3”, tighten the clutch assembly nut.
Page 338 OIL PUMP EAS20054 OIL PUMP Removing the oil pump assembly 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Bottom side cowling/Side panel/Bottom center Refer to “GENERAL CHASSIS (1)”...
Page 339 OIL PUMP Disassembling the oil pump assembly 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) * When replacing any of the part, replace the oil pump assembly. Order Job/Parts to remove Q’ty...
Page 340 OIL PUMP EAS30337 CHECKING THE OIL PUMP 1. Check: • Oil pump driven gear “1” • Oil pump housing 2 “2” • Oil pump housing 1 “3” Cracks/damage/wear  Replace the oil pump assembly. EAS30342 ASSEMBLING THE OIL PUMP 1. Lubricate: •...
Page 341 CRANKCASE EAS20059 CRANKCASE Separating the crankcase 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 24 N ・ m (2.4 kgf ・ m, 18 lb ・ ft) 7 N ・...
Page 342 CRANKCASE Separating the crankcase 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 24 N ・ m (2.4 kgf ・ m, 18 lb ・ ft) 7 N ・...
Page 343 CRANKCASE Removing the oil seals and bearings Order Job/Parts to remove Q’ty Remarks Crankshaft assembly Refer to “CRANKSHAFT” on page 5-67. Transmission Refer to “TRANSMISSION” on page 5-77. Bearing retainer Oil seal Bearing 5-64...
Page 344 • Sealant face hammer. Tap only on reinforced por- (onto the crankcase mating surfaces) tions of the crankcase, not on the crankcase Yamaha bond No. 1215 mating surfaces. Work slowly and carefully 90890-85505 and make sure the crankcase halves sepa- (Three bond No.1215®)
Page 345 CRANKCASE 5. Install: • Crankcase bolts (M8) • Crankcase bolts (M6) Crankcase bolt (M8) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Crankcase bolt (M6) 24 N·m (2.4 kgf·m, 18 lb·ft) Tighten each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern.
Page 346 CRANKSHAFT EAS20061 CRANKSHAFT Removing the crankshaft assembly 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 58 N ・ m (5.8 kgf ・ m, 43 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-62. Dowel pin Balancer cylinder Crankshaft assembly...
Page 347 CRANKSHAFT Removing the connecting rods 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) Specified angle 90˚ 60 N ・ m (6.0 kgf ・ m, 44 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) Specified angle 90˚...
Page 348 CRANKSHAFT EAS30415 REMOVING THE CONNECTING RODS The following procedure applies to all of the con- necting rods. 1. Remove: • Connecting rod cap “1” • Connecting rod “2” • Big end bearings Identify the position of each big end bearing so that it can be reinstalled in its original place.
Page 349 CRANKSHAFT Out of specification  Replace the big end bearings. Connecting rod Oil clearance 0.036–0.060 mm (0.0014–0.0024 Balancer Oil clearance 0.036–0.060 mm (0.0014–0.0024 d. Assemble the connecting rod halves. The following procedure applies to all of the connecting rods and balancer connecting •...
Page 350 CRANKSHAFT spectively, then the bearing size for P (connecting rod) - P (crankshaft) = 5 - 1 = 4 (green) Bearing color code Code 1 Blue Code 2 Black Code 3 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Brown 4. Select: Code 4 • Big end bearings (P –P Green •...
Page 351 CRANKSHAFT Crankshaft journal diameter 54.984-55.000 mm (2.1647- 2.1654 in) d. Measure the crankshaft journal bearing in- side diameter “b” of each crankshaft journal bearing at two places. e. If crankshaft journal bearing inside diameter is “55.03” and crankshaft journal diameter is “54.98”, then the journal oil clearance is: Journal oil clearance: Crankshaft journal bearing inside diameter -...
Page 352 CRANKSHAFT Bearing color code Code 0 White Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green Code 5 Yellow EAS31446 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS The following procedure applies to both of the crankshaft journal bearings. 1. Attach: •...
Page 353 CRANKSHAFT • Make sure the characters “d” on both the con- c. Tighten the connecting rod nuts further to necting rod and connecting rod cap are reach the specified angle 90. aligned. Connecting rod nut (2nd) Specified angle 90 EWA13400 WARNING If the connecting rod nut is tightened more than the specified angle, do not loosen the...
Page 354 CRANKSHAFT EAS30428 INSTALLING THE CRANKSHAFT ASSEMBLY 1. Install: • Crankshaft assembly “1” • Balancer cylinder “2” • Balancer cylinder bolt ECA13970 NOTICE To avoid scratching the crankshaft and to 6. Tighten: ease the installation procedure, lubricate the • Balancer connecting rod nuts oil seal lips with lithium-soap-based grease and each bearing with engine oil.
Page 355 CRANKSHAFT 5-76...
Page 356 TRANSMISSION EAS20062 TRANSMISSION Removing the transmission Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-62. Secondary shaft Collar Primary driven gear Main axle 1st pinion gear Drive axle 1st wheel gear Circlip 5-77...
Page 357 TRANSMISSION EAS30433 CHECKING THE TRANSMISSION 1. Check: • Transmission gears Blue discoloration/pitting/wear  Replace. 2. Check: • Transmission gear movement Rough movement  Replace the defective part(s). 3. Check: • Main axle Cracks/damage/wear  Replace the main axle. 4. Measure: •...
Page 358 TRANSMISSION 5-79...
Page 359 COOLING SYSTEM RADIATOR......................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 OIL COOLER....................6-5 CHECKING THE OIL COOLER ..............6-6 INSTALLING THE OIL COOLER ...............6-6 THERMOSTAT....................6-7 CHECKING THE THERMOSTAT...............6-8 INSTALLING THE THERMOSTAT ASSEMBLY ........6-8 WATER PUMP ....................6-9 DISASSEMBLING THE WATER PUMP...........6-11 CHECKING THE WATER PUMP .............6-11 ASSEMBLING THE WATER PUMP............6-11 INSTALLING THE WATER PUMP ............6-12...
Page 360 RADIATOR EAS20063 RADIATOR Removing the radiator 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 13 N ・...
Page 361 RADIATOR Removing the radiator 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 13 N ・...
Page 362 RADIATOR EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction  Clean. Apply compressed air to the rear of the radia- tor. Damage  Repair or replace. Straighten any flattened fins with a thin, flathead screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
Page 363 RADIATOR pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 364 OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Bottom side cowling/Side panel/Radiator Refer to “GENERAL CHASSIS (1)”...
Page 365 OIL COOLER (with the specified amount of the recom- EAS30441 CHECKING THE OIL COOLER mended coolant) 1. Check: Refer to “CHANGING THE COOLANT” on • Oil cooler page 3-31. Cracks/damage  Replace. • Crankcase 2. Check: (with the specified amount of the recom- •...
Page 366 THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Bottom side cowling/Side panel/Bottom center Refer to “GENERAL CHASSIS (1)”...
Page 367 THERMOSTAT 2. Check: EAS30443 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage  Replace. • Thermostat Does not open at 71–85 C (159.8–185.0 F) EAS30445 INSTALLING THE THERMOSTAT  Replace. ASSEMBLY 1. Install: • Thermostat Install the thermostat with its breather hole “a” facing forward.
Page 368 WATER PUMP EAS20066 WATER PUMP Removing the water pump 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・...
Page 369 WATER PUMP Disassembling the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Water pump housing cover Circlip Impeller shaft Mechanical seal Bearing Oil seal Water pump housing 6-10...
Page 370 WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (impeller side) “1” • Water pump housing cover “1” • Water pump housing “2” (from the impeller, with a thin, flathead screw- driver) •...
Page 371 WATER PUMP ECA20330 ECA20340 NOTICE NOTICE Never lubricate the mechanical seal (hous- Make sure the mechanical seal (impeller ing side) surface with oil or grease. side) is flush with the impeller. Use the special tool and a press to press the me- If the surface “a”...
Page 372 WATER PUMP Refer to “CHANGING THE COOLANT” on page 3-31. 3. Check: • Cooling system Leaks  Repair or replace any faulty part. Refer to “INSTALLING THE RADIATOR” on page 6-3. 4. Measure: • Radiator cap valve opening pressure Below the specified pressure  Replace the radiator cap.
Page 373 FUEL SYSTEM FUEL TANK ......................7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 CHECKING THE FUEL PUMP OPERATION..........7-3 CHECKING THE ROLLOVER VALVE ............7-3 INSTALLING THE FUEL PUMP..............7-4 INSTALLING THE FUEL TANK..............7-4 THROTTLE BODY ....................7-5 CHECKING THE INJECTORS (BEFORE REMOVING) ......7-9 REMOVING THE FUEL HOSE (FUEL RAIL SIDE) ........7-9 REMOVING THE INJECTORS ..............7-9...
Page 374 FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) 4.0 N ・...
Page 375 FUEL TANK Removing the rollover valve and canister 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Bottom side cowling/Side panel/Bottom center Refer to “GENERAL CHASSIS (1)” on page cowling 4-1. Center cover/Fuel tank cover assembly/Side Refer to “GENERAL CHASSIS (2)”...
Page 376 FUEL TANK 4. Remove: EAS30450 REMOVING THE FUEL TANK • Fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. Do not set the fuel tank down so that the instal- 2. Remove: lation surface of the fuel pump is directly under •...
Page 377 FUEL TANK • Install the fuel hose securely onto the fuel pump until a distinct “click” is heard. • To install the fuel hose onto the fuel pump, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown.
Page 378 THROTTLE BODY EAS20070 THROTTLE BODY Removing the air filter case 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 3.0 N ・...
Page 379 THROTTLE BODY Removing the throttle body 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 2.0 N ・ m (0.20 kgf ・ m, 1.5 lb ・ ft) 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) 3.0 N ・...
Page 380 THROTTLE BODY Removing the throttle body 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 2.0 N ・ m (0.20 kgf ・ m, 1.5 lb ・ ft) 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) 3.0 N ・...
Page 381 THROTTLE BODY Disassembling the throttle body assembly 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Throttle position sensor Canister purge hose Hose joint...
Page 382 THROTTLE BODY hose. Any remaining pressure in the fuel EAS30475 CHECKING THE INJECTORS (BEFORE hose may cause the fuel to spray out. Place REMOVING) a container or rag under the hose to catch 1. Check: any fuel that spills. Always clean up any •...
Page 383 • Do not turn the bypass air screws “a”; oth- erwise, the throttle body synchronization will be affected. Recommended cleaning solvent Yamaha Oil & Brake Cleaner d. Apply the recommended cleaning solvent to the throttle valves and the inside of the throt- tle bodies to remove any carbon deposits.
Page 384 THROTTLE BODY aged. TLE BODIES” on page 3-9. • Do not allow carbon deposits or other for- 5. Place the vehicle on a maintenance stand so eign materials to enter any of the passages that the rear wheel is elevated. in each throttle body or in the space be- 6.
Page 385 THROTTLE BODY EAS30482 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ CHECKING THE FUEL PRESSURE a. Connect the fuel injector pressure adapter “1” 1. Check: to the fuel rail joint “2”, and then connect an • Fuel pressure air compressor “3” to the adapter. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b. Connect the pressure gauge “4” to the fuel in- a.
Page 386 Remove the protective cap “1”, and then con- When installing the fuel hose, make sure that nect the Yamaha diagnostic tool to coupler. it is securely connected, and that the fuel hose connector cover on the fuel hose is in...
Page 387 THROTTLE BODY ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7-14...
Page 388 THROTTLE BODY 7-15...
Page 389 CIRCUIT DIAGRAM .................8-47 TROUBLESHOOTING ................8-53 FUEL INJECTION SYSTEM................8-55 CIRCUIT DIAGRAM .................8-55 ECU SELF-DIAGNOSTIC FUNCTION.............8-61 TROUBLESHOOTING METHOD.............8-61 YAMAHA DIAGNOSTIC TOOL ..............8-62 TROUBLESHOOTING DETAILS (FAULT CODE) ........8-63 CRUISE CONTROL SYSTEM (for XP530D-A)..........8-117 CIRCUIT DIAGRAM ................8-117 CRUISE CONTROL CIRCUIT OPERATION..........8-119 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-121 BASIC PROCESS FOR TROUBLESHOOTING ........8-122...
Page 390 FUEL PUMP SYSTEM..................8-135 CIRCUIT DIAGRAM ................8-135 TROUBLESHOOTING ................8-141 WINDSHIELD DRIVE SYSTEM (for XP530D-A) .........8-143 CIRCUIT DIAGRAM ................8-143 TROUBLESHOOTING ................8-145 GRIP WARMER SYSTEM (for XP530D-A)..........8-147 CIRCUIT DIAGRAM ................8-147 TROUBLESHOOTING ................8-149 SEAT HEATER SYSTEM (for XP530D-A) ...........8-151 CIRCUIT DIAGRAM ................8-151 TROUBLESHOOTING ................8-153 ABS (Anti-lock Brake System) ..............8-157 CIRCUIT DIAGRAM ................8-157 ABS COMPONENTS CHART ..............8-163...
Page 391 ELECTRICAL COMPONENTS..............8-215 CHECKING THE SWITCHES ..............8-221 CHECKING THE BULBS AND BULB SOCKETS ........8-228 CHECKING THE FUSES ...............8-229 REPLACING THE ECU (Engine Control Unit) ........8-230 CHECKING AND CHARGING THE BATTERY........8-230 CHECKING THE RELAYS ..............8-233 CHECKING THE DIODES..............8-239 CHECKING THE SPARK PLUG CAPS..........8-240 CHECKING THE IGNITION COIL ............8-241 CHECKING THE IGNITION SPARK GAP..........8-241 CHECKING THE CRANKSHAFT POSITION SENSOR......8-242...
Page 392 IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM XP530E-A...
Page 393 IGNITION SYSTEM 4. Joint coupler 5. Remote control unit 11.Crankshaft position sensor 14.Ignition system relay 15.Battery 17.Main fuse 19.Engine ground 21.Ignition fuse 45.Diode 1 46.Sidestand relay 47.Diode 2 49.Starting circuit cut-off relay 50.Sidestand switch 51.Handlebar switch (right) 52.Engine stop switch 89.ECU (Engine Control Unit) 90.Ignition coil 91.Spark plug...
Page 394 IGNITION SYSTEM XP530-A...
Page 395 IGNITION SYSTEM 4. Joint coupler 5. Remote control unit 11.Crankshaft position sensor 14.Ignition system relay 15.Battery 17.Main fuse 19.Engine ground 21.Ignition fuse 45.Diode 1 46.Sidestand relay 47.Diode 2 49.Starting circuit cut-off relay 50.Sidestand switch 51.Handlebar switch (right) 52.Engine stop switch 94.ECU (Engine Control Unit) 95.Ignition coil 96.Spark plug...
Page 396 IGNITION SYSTEM XP530D-A...
Page 397 IGNITION SYSTEM 4. Joint coupler 5. Remote control unit 11.Crankshaft position sensor 14.Ignition system relay 15.Battery 17.Main fuse 19.Engine ground 20.Signaling system fuse 21.Ignition fuse 26.Diode (fuse box) 40.Headlight relay (dimmer) 46.Diode 1 47.Sidestand relay 48.Diode 2 50.Starting circuit cut-off relay 51.Sidestand switch 52.Handlebar switch (right) 53.Engine stop switch...
Page 398 IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Front cowling assembly/Side panels 2. Center cover 3. Footboards/Side covers 4. Rear cowling (right) 1. Check the fuses. (Main and ignition) Replace the fuse(s).
Page 399 IGNITION SYSTEM 9. Check the starting circuit cut-off re- lay. Replace the starting circuit cut-off relay. Refer to “CHECKING THE RE- NG LAYS” on page 8-233. OK 10.Check the sidestand relay. Refer to “CHECKING THE RE- Replace the sidestand relay. NG...
Page 400 ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM XP530E-A...
Page 401 ELECTRIC STARTING SYSTEM 4. Joint coupler 5. Remote control unit 14.Ignition system relay 15.Battery 16.Starter relay 17.Main fuse 18.Starter motor 19.Engine ground 20.Signaling system fuse 21.Ignition fuse 26.Diode (fuse box) 40.Headlight relay (dimmer) 46.Sidestand relay 47.Diode 2 49.Starting circuit cut-off relay 50.Sidestand switch 51.Handlebar switch (right) 52.Engine stop switch...
Page 402 ELECTRIC STARTING SYSTEM XP530-A 8-11...
Page 403 ELECTRIC STARTING SYSTEM 4. Joint coupler 5. Remote control unit 14.Ignition system relay 15.Battery 16.Starter relay 17.Main fuse 18.Starter motor 19.Engine ground 20.Signaling system fuse 21.Ignition fuse 26.Diode (fuse box) 40.Headlight relay (dimmer) 46.Sidestand relay 47.Diode 2 49.Starting circuit cut-off relay 50.Sidestand switch 51.Handlebar switch (right) 52.Engine stop switch...
Page 404 ELECTRIC STARTING SYSTEM XP530D-A 8-13...
Page 405 ELECTRIC STARTING SYSTEM 4. Joint coupler 5. Remote control unit 14.Ignition system relay 15.Battery 16.Starter relay 17.Main fuse 18.Starter motor 19.Engine ground 20.Signaling system fuse 21.Ignition fuse 26.Diode (fuse box) 40.Headlight relay (dimmer) 47.Sidestand relay 48.Diode 2 50.Starting circuit cut-off relay 51.Sidestand switch 52.Handlebar switch (right) 53.Engine stop switch...
Page 406 ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and pressing the ON/start switch for one second, the starter motor can only operate if at least one of the following conditions is met: •...
Page 407 ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Ignition system relay 4. Remote control unit 5. Signaling system fuse 6. Ignition fuse 7. Front brake light switch 8. Rear brake light switch 9. Diode (fuse box) 10.Starting circuit cut-off relay 11.ON/start switch 12.ECU (Engine Control Unit) 13.Fuel injection system relay...
Page 408 ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank 4. Rear cover (right) 1. Check the fuses. (Main, ignition and signaling sys- tem) Replace the fuse(s).
Page 409 ELECTRIC STARTING SYSTEM 9. Check the starter relay. Refer to “CHECKING THE RE- Replace the starter relay. NG LAYS” on page 8-233. OK 10.Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the handlebar switch (right). NG...
Page 410 CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM XP530E-A 8-19...
Page 411 CHARGING SYSTEM 4. Joint coupler 12.AC magneto 13.Rectifier/regulator 15.Battery 17.Main fuse 19.Engine ground A. Wire harness B. Negative battery sub-wire harness 8-20...
Page 412 CHARGING SYSTEM XP530-A 8-21...
Page 413 CHARGING SYSTEM 4. Joint coupler 12.AC magneto 13.Rectifier/regulator 15.Battery 17.Main fuse 19.Engine ground A. Wire harness B. Negative battery sub-wire harness 8-22...
Page 414 CHARGING SYSTEM XP530D-A 8-23...
Page 415 CHARGING SYSTEM 4. Joint coupler 12.AC magneto 13.Rectifier/regulator 15.Battery 17.Main fuse 19.Engine ground A. Wire harness B. Negative battery sub-wire harness 8-24...
Page 416 CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank 4. Rear cover (right) 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUSES” NG...
Page 417 CHARGING SYSTEM 8-26...
Page 418 LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM XP530E-A 8-27...
Page 419 68.Tail/brake light (left) 69.Tail/brake light (right) 72.Smart key system relay (unlock) 75.Meter assembly 77.Meter light 84.High beam indicator light 86.Yamaha diagnostic tool coupler 89.ECU (Engine Control Unit) A. Wire harness B. Negative battery sub-wire harness C. Headlight sub-wire harness (headlight har- ness) D.
Page 420 LIGHTING SYSTEM XP530-A 8-29...
Page 421 69.Tail/brake light (left) 70.Tail/brake light (right) 73.Smart key system relay (unlock) 77.Meter assembly 79.Meter light 86.High beam indicator light 91.Yamaha diagnostic tool coupler 94.ECU (Engine Control Unit) A. Wire harness B. Negative battery sub-wire harness C. Headlight sub-wire harness (headlight har- ness) D.
Page 422 LIGHTING SYSTEM XP530D-A 8-31...
Page 423 71.Tail/brake light (left) 72.Tail/brake light (right) 79.Smart key system relay (unlock) 87.Meter assembly 89.Meter light 98.High beam indicator light 103.Yamaha diagnostic tool coupler 106.ECU (Engine Control Unit) A. Wire harness B. Negative battery sub-wire harness C. Headlight sub-wire harness (headlight har- ness) D.
Page 424 LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, auxiliary light, high beam indicator light, tail/brake light, li- cense plate light, meter light or storage box light. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2.
Page 425 LIGHTING SYSTEM 9. Check the storage box light switch. Refer to “CHECKING THE Replace the storage box light switch. NG SWITCHES” on page 8-221. OK 10.Check the entire lighting system’s wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness.
Page 426 SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM XP530E-A 8-35...
Page 427 79.Engine trouble warning light 80.Traction control system indicator light 81.Turn signal indicator light (left) 82.Turn signal indicator light (right) 85.Multi-function display 86.Yamaha diagnostic tool coupler 89.ECU (Engine Control Unit) 95.Coolant temperature sensor 96.Intake air temperature sensor 105.Fuel sender 107.ABS ECU (Electronic Control Unit) 109.Rear wheel sensor...
Page 428 SIGNALING SYSTEM XP530-A 8-37...
Page 429 81.Engine trouble warning light 82.Traction control system indicator light 83.Turn signal indicator light (left) 84.Turn signal indicator light (right) 87.Multi-function display 91.Yamaha diagnostic tool coupler 94.ECU (Engine Control Unit) 100.Coolant temperature sensor 101.Intake air temperature sensor 110.Fuel sender 112.ABS ECU (Electronic Control Unit) 114.Rear wheel sensor...
Page 430 SIGNALING SYSTEM XP530D-A 8-39...
Page 431 91.Engine trouble warning light 92.Traction control system indicator light 93.Turn signal indicator light (left) 94.Turn signal indicator light (right) 99.Multi-function display 103.Yamaha diagnostic tool coupler 106.ECU (Engine Control Unit) 112.Coolant temperature sensor 113.Intake air temperature sensor 122.Fuel sender 124.ABS ECU (Electronic Control Unit) 126.Rear wheel sensor...
Page 432 SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to operate. • The speedometer fails to operate. •...
Page 433 SIGNALING SYSTEM Checking the signaling system The horn fails to sound. 1. Check the horn switch. The horn switch is faulty. Replace the han- Refer to “CHECKING THE dlebar switch (left). NG SWITCHES” on page 8-221. OK 2. Check the entire signaling system’s wiring.
Page 434 SIGNALING SYSTEM 4. Check the entire signaling system’s wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. NG page 8-35. OK Replace the meter assembly or re- mote control unit. The fuel meter fails to operate. 1.
Page 435 SIGNALING SYSTEM Replace if there is an open or short circuit. • Between rear wheel sensor coupler and ABS ECU coupler. (Black–Black) (White–White) • Between ABS ECU coupler and ECU (engine control unit) coupler. (White/Yellow–White/Yellow) • Between ECU coupler and meter assembly coupler. (Light green/Blue–Light green/Blue) (Light green/White–Light green/White) The tachometer fails to operate.
Page 436 SIGNALING SYSTEM The oil change indicator fails to come on. 1. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. NG page 8-35. OK Replace the meter assembly. The buzzer does not sound. 1.
Page 437 SIGNALING SYSTEM 8-46...
Page 438 COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM XP530E-A 8-47...
Page 439 19.Engine ground 21.Ignition fuse 23.Radiator fan motor fuse 25.Backup fuse 75.Meter assembly 85.Multi-function display 86.Yamaha diagnostic tool coupler 87.Radiator fan motor 88.Radiator fan motor relay 89.ECU (Engine Control Unit) 95.Coolant temperature sensor A. Wire harness B. Negative battery sub-wire harness...
Page 440 COOLING SYSTEM XP530-A 8-49...
Page 441 19.Engine ground 21.Ignition fuse 23.Radiator fan motor fuse 25.Backup fuse 77.Meter assembly 87.Multi-function display 91.Yamaha diagnostic tool coupler 92.Radiator fan motor 93.Radiator fan motor relay 94.ECU (Engine Control Unit) 100.Coolant temperature sensor A. Wire harness B. Negative battery sub-wire harness...
Page 442 COOLING SYSTEM XP530D-A 8-51...
Page 443 19.Engine ground 21.Ignition fuse 23.Radiator fan motor fuse 25.Backup fuse 87.Meter assembly 99.Multi-function display 103.Yamaha diagnostic tool coupler 104.Radiator fan motor 105.Radiator fan motor relay 106.ECU (Engine Control Unit) 112.Coolant temperature sensor A. Wire harness B. Negative battery sub-wire harness...
Page 444 COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank 4. Footboard (right) 5. Rear cowling (right) 1. Check the fuses. (Main, ignition, radiator fan motor and backup) Replace the fuse(s). NG...
Page 445 COOLING SYSTEM 8-54...
Page 446 FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM XP530E-A 8-55...
Page 447 51.Handlebar switch (right) 52.Engine stop switch 75.Meter assembly 79.Engine trouble warning light 84.High beam indicator light 85.Multi-function display 86.Yamaha diagnostic tool coupler 87.Radiator fan motor 88.Radiator fan motor relay 89.ECU (Engine Control Unit) 90.Ignition coil 91.Spark plug 92.Grip warmer connector 93.Grip warmer (left) (OPTION)
Page 448 FUEL INJECTION SYSTEM XP530-A 8-57...
Page 449 51.Handlebar switch (right) 52.Engine stop switch 77.Meter assembly 81.Engine trouble warning light 86.High beam indicator light 87.Multi-function display 91.Yamaha diagnostic tool coupler 92.Radiator fan motor 93.Radiator fan motor relay 94.ECU (Engine Control Unit) 95.Ignition coil 96.Spark plug 97.Grip warmer connector 98.Grip warmer (left) (OPTION)
Page 450 FUEL INJECTION SYSTEM XP530D-A 8-59...
Page 451 76.Front brake light switch 77.Rear brake light switch 87.Meter assembly 91.Engine trouble warning light 98.High beam indicator light 99.Multi-function display 103.Yamaha diagnostic tool coupler 104.Radiator fan motor 105.Radiator fan motor relay 106.ECU (Engine Control Unit) 107.Ignition coil 108.Spark plug 109.Grip warmer connector 110.Grip warmer (left)
Page 452 • Fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the fault code numbers that have a condition of “Detected” using the Yamaha diagnostic tool. b. Identify the faulty system with the fault code number. c. Identify the probable cause of the malfunction.
Page 453 EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool USB 90890-03256 Yamaha diagnostic tool (A/I) 90890-03254 A generic scan tool can also be used to identify malfunctions.
Page 454 Write the VIN/frame number in the ECU. View logs: Displays the logging data. However, the Yamaha diagnostic tool cannot be used to freely change the basic vehicle functions, such as adjusting the ignition timing. Connecting the Yamaha diagnostic tool Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.
Page 455 Check the locking condition of mode of the Yamaha diagnostic the coupler. tool. Disconnect the coupler and Condition is “Recovered”  Go check the pins (bent or broken to item 6 and finish the service.
Page 456 Check the locking condition of replace the wire harness. fault code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 6 and finish the service.
Page 457 Check the locking condition of replace the wire harness. fault code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
Page 458 FUEL INJECTION SYSTEM Fault code No. P0107, P0108 [P0107] Intake air pressure sensor: ground short circuit detected. Item [P0108] Intake air pressure sensor: open or power short circuit detected. 1. Intake air pressure sensor 2. ECU 3. Sensor input lead 4.
Page 459 FUEL INJECTION SYSTEM Fault code No. P0107, P0108 [P0107] Intake air pressure sensor: ground short circuit detected. Item [P0108] Intake air pressure sensor: open or power short circuit detected. [For P0108] Open circuit Between intake air pressure sensor coupler and ECU coupler: pink/white–pink/white If there is no continuity, replace the wire harness.
Page 460 Improperly installed sensor  fault code using the malfunction Reinstall or replace the sensor. mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 5.
Page 461 (Code No. 03) check the condition of the fault When engine is stopped: code using the malfunction Atmospheric pressure at the mode of the Yamaha diagnostic current altitude and weather tool. Condition is “Recovered”  Go conditions is indicated. At sea level: Approx. 101 kPa to item 7 and finish the service.
Page 462 Check the locking condition of replace the wire harness. fault code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
Page 463 FUEL INJECTION SYSTEM Fault code No. P0112, P0113 [P0112] Intake air temperature sensor: ground short circuit detected. Item [P0113] Intake air temperature sensor: open or power short circuit detected. Br/W Br/W 1. Intake air temperature sensor 2. ECU 3. Sensor output lead 4.
Page 464 Improperly installed sensor  fault code using the malfunction Reinstall or replace the sensor. mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 5.
Page 465 (Code No. 05) then check the condition of the When engine is cold: fault code using the malfunction Displayed temperature is close mode of the Yamaha diagnostic to the ambient temperature. tool. Condition is “Recovered”  Go The displayed temperature is not close to the ambient temper- to item 7 and finish the service.
Page 466 Disconnect the coupler and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
Page 467 FUEL INJECTION SYSTEM Fault code No. P0117, P0118 [P0117] Coolant temperature sensor: ground short circuit detected. Item [P0118] Coolant temperature sensor: open or power short circuit detected. [For P0118] Open circuit Between wire harness coupler (ECU side) and ECU coupler: green/red–green/red If there is no continuity, replace the wire harness.
Page 468 Improperly installed sensor  fault code using the malfunction Reinstall or replace the sensor. mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 5.
Page 469 Check the locking condition of replace the wire harness. fault code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 8 and finish the service.
Page 470 FUEL INJECTION SYSTEM Fault code No. P0122, P0123, P0222, P0223, P2135 [P0122] Throttle position sensor: ground short circuit detected. [P0123] Throttle position sensor: open or power short circuit detected. Item [P0222] Throttle position sensor: ground short circuit detected. [P0223] Throttle position sensor: open or power short circuit detected.
Page 471 FUEL INJECTION SYSTEM Fault code No. P0122, P0123, P0222, P0223, P2135 [P0122] Throttle position sensor: ground short circuit detected. [P0123] Throttle position sensor: open or power short circuit detected. Item [P0222] Throttle position sensor: ground short circuit detected. [P0223] Throttle position sensor: open or power short circuit detected.
Page 472 FUEL INJECTION SYSTEM Fault code No. P0122, P0123, P0222, P0223, P2135 [P0122] Throttle position sensor: ground short circuit detected. [P0123] Throttle position sensor: open or power short circuit detected. Item [P0222] Throttle position sensor: ground short circuit detected. [P0223] Throttle position sensor: open or power short circuit detected.
Page 473 Improperly installed sensor  fault code using the malfunction Reinstall or adjust the sensor. mode of the Yamaha diagnostic Refer to “ADJUSTING THE tool. Condition is “Recovered”  Go THROTTLE POSITION SEN- SOR” on page 7-13.
Page 474 Refer to “CHECKING THE fault code using the malfunction THROTTLE POSITION SEN- mode of the Yamaha diagnostic SOR” on page 8-246. tool. Condition is “Recovered”  Go to item 8 and finish the service.
Page 475 Improperly installed sensor  fault code using the malfunction Reinstall or replace the sensor. mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 2.
Page 476 Actuates fuel injector #1 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #1 is actuated Procedure five times by listening for the operating sound.
Page 477 Actuates fuel injector #2 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #2 is actuated Procedure five times by listening for the operating sound.
Page 478 5 seconds. light goes off. Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P0335 Fault code No. P0335 Crankshaft position sensor: no normal signals are received from Item the crankshaft position sensor.
Page 479 Check the locking condition of replace the wire harness. code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
Page 480 Diagnostic code No. Actuates the ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times. Procedure •...
Page 481 Check the condition of the fault Refer to “CHECKING THE code using the malfunction IGNITION COIL” on page 8-241. mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 6.
Page 482 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
Page 483 Refer to “THROTTLE BODY” on Check the condition of the fault page 7-5. code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 4 and finish the service. Condition is “Detected”  Go to item 2.
Page 484 8-19. Check the condition of the fault Defective rectifier/regulator or code using the malfunction AC magneto  Replace. mode of the Yamaha diagnostic Defective connection in the tool. charging system circuit  Prop- Condition is “Recovered”  Go erly connect or replace the wire to item 2 and finish the service.
Page 485 EEPROM data error for adjust- EEPROM. fault code using the malfunction ment of CO concentration of cyl- Refer to “ADJUSTING THE mode of the Yamaha diagnostic inder #1. EXHAUST GAS VOLUME” on tool. Condition is “Recovered”  Go page 3-12.
Page 486 (Code No. 60) then check the condition of the EEPROM data error for ISC fault code using the malfunction (idle speed control) learning val- mode of the Yamaha diagnostic ues. tool. Condition is “Recovered”  Go “12” is indicated in the diagnos- tic mode.
Page 487 Yamaha diagnostic tool. Condition is “Recovered”  Go to item 8 and finish the service. Condition is “Detected”  Go to item 4.
Page 488 Actuates the starting circuit cut-off relay five times at one-second inter- vals. Actuation The “check” indicator on the Yamaha diagnostic tool screen come on each time the relay is actuated. Check that the starting circuit cut-off relay is actuated five times by listen- Procedure ing for the operating sound.
Page 489 Between starter relay and igni- Check the condition of the fault tion system relay coupler. code using the malfunction red–red mode of the Yamaha diagnostic Between ignition system relay tool. Condition is “Recovered”  Go coupler and remote control unit coupler.
Page 490 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered”  Go of the pins).
Page 491 Sidestand extended: “OFF” Check the condition of the fault Replace if defective. code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 6.
Page 492 Blown fuse  Replace the fuse. Push the ON/start switch, and Check the main fuse. then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
Page 493 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered”  Go of the pins).
Page 494 FUEL INJECTION SYSTEM Fault code No. P1604, P1605 [P1604] Lean angle sensor: ground short circuit detected. Item [P1605] Lean angle sensor: open or power short circuit. [For P1604] Ground short circuit Between lean angle sensor coupler and ground: yellow/green–ground If there is continuity, replace the wire harness. [For P1605] Open circuit Between lean angle sensor coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness.
Page 495 “OFF”, and then back to page 8-242. “ON”. Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service. Condition is “Detected”  Go to item 5.
Page 496 Check the locking condition of replace the wire harness. fault code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
Page 497 Push the ON/start switch, and the wire harness. then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 4.
Page 498 FUEL INJECTION SYSTEM Fault code No. P2122, P2123, P2127, P2128, P2138 [P2122] Accelerator position sensor: open or ground short circuit detected. [P2123] Accelerator position sensor: power short circuit detected. Item [P2127] Accelerator position sensor: ground short circuit detected. [P2128] Accelerator position sensor: open or power short circuit detected.
Page 499 FUEL INJECTION SYSTEM Fault code No. P2122, P2123, P2127, P2128, P2138 [P2122] Accelerator position sensor: open or ground short circuit detected. [P2123] Accelerator position sensor: power short circuit detected. Item [P2127] Accelerator position sensor: ground short circuit detected. [P2128] Accelerator position sensor: open or power short circuit detected.
Page 500 FUEL INJECTION SYSTEM Fault code No. P2122, P2123, P2127, P2128, P2138 [P2122] Accelerator position sensor: open or ground short circuit detected. [P2123] Accelerator position sensor: power short circuit detected. Item [P2127] Accelerator position sensor: ground short circuit detected. [P2128] Accelerator position sensor: open or power short circuit detected.
Page 501 Improperly installed sensor  fault code using the malfunction Reinstall or adjust the sensor. mode of the Yamaha diagnostic Refer to “ADJUSTING THE tool. Condition is “Recovered”  Go THROTTLE POSITION SEN- SOR” on page 7-13.
Page 502 Delete the fault code and check Confirm that the fault code has that the engine trouble warning a condition of “Recovered” light goes off. using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P2158 Fault code No.
Page 503 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
Page 504 Improperly installed sensor  Check the condition of the fault Reinstall or replace the sensor. code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 8 and finish the service. Condition is “Detected”  Go to item 2.
Page 505 10 seconds. Between O sensor coupler and Check the condition of the fault code using the malfunction ECU coupler. mode of the Yamaha diagnostic gray/green–gray/green tool. pink/black–pink/black Condition is “Recovered”  Go Between O sensor coupler and to item 8 and finish the service.
Page 506 Check the locking condition of replace the wire harness. fault code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 6 and finish the service.
Page 507 FUEL INJECTION SYSTEM 8-116...
Page 508 CRUISE CONTROL SYSTEM (for XP530D-A) EAS20087 CRUISE CONTROL SYSTEM (for XP530D-A) EAS30544 CIRCUIT DIAGRAM 8-117...
Page 509 77.Rear brake light switch 78.Grip cancel switch 85.Tracking system control unit 87.Meter assembly 95.Cruise control system indicator light 96.Cruise control setting indicator light 99.Multi-function display 103.Yamaha diagnostic tool coupler 106.ECU (Engine Control Unit) A. Wire harness B. Negative battery sub-wire harness 8-118...
Page 510 CRUISE CONTROL SYSTEM (for XP530D-A) EAS30666 CRUISE CONTROL CIRCUIT OPERATION 8-119...
Page 511 CRUISE CONTROL SYSTEM (for XP530D-A) 1. Battery 2. Main fuse 3. Ignition system relay 4. Backup fuse 5. Fuel injection system fuse 6. Signaling system fuse 7. Brake light fuse 8. Ignition fuse 9. Cruise control system fuse 10.Cruise control power switch 11.Cruise control setting switch 12.Front brake light switch 13.Rear brake light switch...
Page 512 • Use sufficiently charged regular batteries only. [A] Malfunction check using the cruise control system indicator light [B] Use the Yamaha diagnostic tool to determine the cause of the malfunction for the stored fault code from the condition and place where the malfunction occurred.
Page 513 Delete the fault codes. Return to [A]. DETAILS (FAULT CODE)” codes. Comes on [B-2] Check the malfunction history using the malfunction mode of the Yamaha diagnostic tool. Is there any malfunction history? Is there automatic Explain the conditions for [B-3] automatically deactivating the...
Page 514 CRUISE CONTROL SYSTEM (for XP530D-A) EWA17441 WARNING When maintenance or checks have been performed on components related to the cruise control system, be sure to perform a final check before delivering the vehicle to the customer. Refer to “[C-2] FINAL CHECK” on page 8-133. EAS30669 [A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT Push the ON/start switch, and then push the cruise control power switch.
Page 515 Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
Page 516 Operate the front brake lever, brake light fuse) and then check the condition of the fault code using the mal- function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item A-10 and finish the ser- vice.
Page 517 Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
Page 518 Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
Page 519 B-10 Delete the fault code and check Confirm that the fault code has that the engine trouble warning a condition of “Recovered” light goes off. using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P0564 Fault code No.
Page 520 (bent or broken malfunction mode of the terminals and locking condition Yamaha diagnostic tool. Condition is “Recovered”  Go of the pins). to item A-9 and finish the ser- vice.
Page 521 “SET–” side of the cruise control setting switch, and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item A-9 and finish the ser- vice. Condition is “Detected”  Go to item A-8.
Page 522 Disconnect the coupler and the fault code using the mal- check the pins (bent or broken function mode of the Yamaha terminals and locking condition diagnostic tool. Condition is “Recovered”  Go of the pins).
Page 523 Between fuse box and handle- function mode of the Yamaha bar switch coupler (left). diagnostic tool. Condition is “Recovered”  Go red/white–yellow/black Between handlebar switch cou- to item B-9 and finish the ser- pler (left) and ECU coupler.
Page 524 EAS30674 [C-1] DELETING THE FAULT CODES 1. Delete the fault code using the malfunction of the Yamaha diagnostic tool, and check that the engine trouble warning light goes off. EAS30675 [C-2] FINAL CHECK 1.
Page 525 CRUISE CONTROL SYSTEM (for XP530D-A) 8-134...
Page 526 FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM XP530E-A 8-135...
Page 527 FUEL PUMP SYSTEM 4. Joint coupler 5. Remote control unit 14.Ignition system relay 15.Battery 17.Main fuse 19.Engine ground 21.Ignition fuse 24.Fuel injection system fuse 25.Backup fuse 48.Fuel injection system relay 51.Handlebar switch (right) 52.Engine stop switch 89.ECU (Engine Control Unit) 106.Fuel pump A.
Page 528 FUEL PUMP SYSTEM XP530-A 8-137...
Page 529 FUEL PUMP SYSTEM 4. Joint coupler 5. Remote control unit 14.Ignition system relay 15.Battery 17.Main fuse 19.Engine ground 21.Ignition fuse 24.Fuel injection system fuse 25.Backup fuse 48.Fuel injection system relay 51.Handlebar switch (right) 52.Engine stop switch 94.ECU (Engine Control Unit) 111.Fuel pump A.
Page 530 FUEL PUMP SYSTEM XP530D-A 8-139...
Page 531 17.Main fuse 19.Engine ground 21.Ignition fuse 24.Fuel injection system fuse 25.Backup fuse 49.Fuel injection system relay 52.Handlebar switch (right) 53.Engine stop switch 103.Yamaha diagnostic tool coupler 106.ECU (Engine Control Unit) 123.Fuel pump A. Wire harness B. Negative battery sub-wire harness 8-140...
Page 532 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank 1. Check the fuses. (Main, ignition, backup and fuel in- jection system) Replace the fuse(s).
Page 533 FUEL PUMP SYSTEM 8-142...
Page 534 WINDSHIELD DRIVE SYSTEM (for XP530D-A) EAS20083 WINDSHIELD DRIVE SYSTEM (for XP530D-A) EAS30517 CIRCUIT DIAGRAM 8-143...
Page 535 WINDSHIELD DRIVE SYSTEM (for XP530D-A) 3. Windshield motor fuse 4. Joint coupler 5. Remote control unit 14.Ignition system relay 15.Battery 17.Main fuse 19.Engine ground 21.Ignition fuse 25.Backup fuse 58.Handlebar switch (left) 63.Menu switch 64.Select switch 82.Windshield drive unit 83.Windshield drive unit relay (down) 84.Windshield drive unit relay (up) 87.Meter assembly 99.Multi-function display...
Page 536 WINDSHIELD DRIVE SYSTEM (for XP530D-A) EAS30518 TROUBLESHOOTING The windshield fails to move. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Leg shield 3. Rear cowling (right) 1. Check that there are no rocks or other foreign material in the wind- Remove the foreign material.
Page 537 WINDSHIELD DRIVE SYSTEM (for XP530D-A) 9. Check the windshield drive unit re- lay (down). Replace the windshield drive unit relay Refer to “CHECKING THE RE- (down). NG LAYS” on page 8-233. OK 10.Check the windshield drive motor. Refer to “CHECKING THE WIND- Replace the windshield drive unit.
Page 538 GRIP WARMER SYSTEM (for XP530D-A) EAS20167 GRIP WARMER SYSTEM (for XP530D-A) EAS31007 CIRCUIT DIAGRAM 8-147...
Page 539 21.Ignition fuse 25.Backup fuse 58.Handlebar switch (left) 63.Menu switch 64.Select switch 87.Meter assembly 99.Multi-function display 103.Yamaha diagnostic tool coupler 106.ECU (Engine Control Unit) 109.Grip warmer connector 110.Grip warmer (left) 111.Grip warmer (right) A. Wire harness B. Negative battery sub-wire harness...
Page 540 GRIP WARMER SYSTEM (for XP530D-A) EAS31008 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Front cowlings 2. Leg shield 3. Footboards The grip warmers do not become warm at all. 1. Check that the engine trouble warn- Perform the troubleshooting for fault code ing light is on and that “Err”...
Page 541 2. Check that the engine trouble warn- Perform the troubleshooting for fault code ing light is on and that fault code No. No. P0500. Refer to “TROUBLESHOOT- P0500 is displayed in the Yamaha ING DETAILS (FAULT CODE)” on page NG diagnostic tool display.
Page 542 SEAT HEATER SYSTEM (for XP530D-A) EAS20312 SEAT HEATER SYSTEM (for XP530D-A) EAS32438 CIRCUIT DIAGRAM 8-151...
Page 543 SEAT HEATER SYSTEM (for XP530D-A) 4. Joint coupler 5. Remote control unit 14.Ignition system relay 15.Battery 17.Main fuse 19.Engine ground 20.Signaling system fuse 25.Backup fuse 58.Handlebar switch (left) 63.Menu switch 64.Select switch 87.Meter assembly 99.Multi-function display 100.Seat heater relay (power) 101.Seat heater relay (control) 102.Seat heater 106.ECU (Engine Control Unit)
Page 544 SEAT HEATER SYSTEM (for XP530D-A) EAS32439 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Front cowlings 2. Footboards 3. Rear cowling (right) The seat heater do not become warm at all. 1. Check that the seat heater is not Adjust the temperature levels of the seat turned off.
Page 545 SEAT HEATER SYSTEM (for XP530D-A) 9. Check the entire seat heater system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. NG page 8-151. OK Replace the meter assembly. The seat heater is abnormally hot while the engine is idling. 1.
Page 546 SEAT HEATER SYSTEM (for XP530D-A) The temperature levels of the seat heater settings cannot be changed. 1. Check the menu switch. • The menu switch is faulty. Refer to “CHECKING THE • Replace the handlebar switch (left). NG SWITCHES” on page 8-221. OK...
Page 547 SEAT HEATER SYSTEM (for XP530D-A) 8-156...
Page 548 ABS (Anti-lock Brake System) EAS20085 ABS (Anti-lock Brake System) EAS30843 CIRCUIT DIAGRAM XP530E-A 8-157...
Page 549 62.Rear brake light switch 68.Tail/brake light (left) 69.Tail/brake light (right) 75.Meter assembly 83.ABS warning light 85.Multi-function display 86.Yamaha diagnostic tool coupler 89.ECU (Engine Control Unit) 107.ABS ECU (Electronic Control Unit) 108.Front wheel sensor 109.Rear wheel sensor A. Wire harness B. Negative battery sub-wire harness...
Page 550 ABS (Anti-lock Brake System) XP530-A 8-159...
Page 551 63.Rear brake light switch 69.Tail/brake light (left) 70.Tail/brake light (right) 77.Meter assembly 85.ABS warning light 87.Multi-function display 91.Yamaha diagnostic tool coupler 94.ECU (Engine Control Unit) 112.ABS ECU (Electronic Control Unit) 113.Front wheel sensor 114.Rear wheel sensor A. Wire harness B. Negative battery sub-wire harness...
Page 552 ABS (Anti-lock Brake System) XP530D-A 8-161...
Page 553 75.Brake light fuse 76.Front brake light switch 77.Rear brake light switch 87.Meter assembly 97.ABS warning light 99.Multi-function display 103.Yamaha diagnostic tool coupler 106.ECU (Engine Control Unit) 124.ABS ECU (Electronic Control Unit) 125.Front wheel sensor 126.Rear wheel sensor A. Wire harness B.
Page 554 ABS (Anti-lock Brake System) EAS30525 ABS COMPONENTS CHART 8-163...
Page 555 ABS (Anti-lock Brake System) 1. Yamaha diagnostic tool coupler 2. ABS warning light 3. Fuse box (ABS motor fuse, ABS solenoid fuse, and ABS ECU fuse) 4. ABS ECU 5. Front wheel sensor rotor 6. Front wheel sensor 7. Front brake caliper 8.
Page 556 ABS (Anti-lock Brake System) EAS30844 ABS COUPLER LOCATION CHART Br/Y Ch Dg R/G R/W P/W P/B Dg Ch G/R G/L G W/G W/R W/L Y B/W Lg/W Lg/L B/W R/G R/G (Gy) Br/Y Ch Dg R/G R/W P/W P/B B/W Br/Y Dg Ch G/R G/L G W/G W/R W/L Y B/W Lg/W Lg/L B/W R/G R/G (Gy)
Page 557 ABS (Anti-lock Brake System) 1. Rear wheel sensor coupler 2. Meter assembly coupler (for XP530E-A) 3. Meter assembly coupler (for XP530-A) 4. Meter assembly coupler (for XP530D-A) 5. Yamaha diagnostic tool coupler 6. Front wheel sensor coupler 7. ABS ECU coupler 8-166...
Page 558 The following troubleshooting describes the problem identification and service method using the Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG- NOSIS USING THE FAULT CODES” on page 8-171. For troubleshooting items other than the following items, follow the normal service method.
Page 559 Previous malfunctions can be checked since the ABS ECU also stores the mal- function history. The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in- formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES”...
Page 560 • Can the tool communicate with is defective. the ABS ECU? Can communicate [A-5] ABS ECU and FI ECU The connection with the Yamaha • Return to [A]. fail to communicate. diagnostic tool is defective. • The wire harness is defective.
Page 561 EAS31162 [A-3] THE ABS WARNING LIGHT COMES ON Connect the Yamaha diagnostic tool to the Yamaha diagnostic tool coupler and execute functional di- agnosis. (For information about how to execute functional diagnosis, refer to the operation manual that is included with the tool.) Check that communication with the ABS ECU is possible.
Page 562 ABS ECU coupler and ground. If there is no continuity, the wire harness is defective. Replace the wire harness. • Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou- pler.
Page 563 Removing the battery cover. Refer to “REMOVING THE BATTERY COVER” on page 4-10. Removing the protective cap, and then connect the Yamaha diagnostic tool to the coupler “1”. Details about the displayed fault codes are shown in the following chart. Refer to this chart and check the vehicle.
Page 564 ABS (Anti-lock Brake System) Fault code Item Symptom Check point Rear wheel sensor (abnor- Rear wheel sensor signal is • Foreign material adhered mal pulse period) not received properly. (The around the rear wheel sen- pulse period is abnormal • Incorrect installation of the while the vehicle is traveling.) rear wheel •...
Page 565 ABS (Anti-lock Brake System) Fault code Item Symptom Check point Brake light switch or Brake light signal is not • Defective signaling system tail/brake light received properly while the (tail/brake light or brake vehicle is traveling. (Brake light switch) • Defective coupler between light circuit, or front or rear brake light switch circuit.) the signaling system...
Page 566 ABS (Anti-lock Brake System) Fault code Item Symptom Check point Rear wheel ABS (intermit- • Pulses from the rear wheel • Incorrect installation of the tent wheel speed pulses or sensor are received inter- rear wheel sensor (for fault incorrect depressurization) mittently while the vehicle code No.
Page 567 ABS (Anti-lock Brake System) Fault code Item Symptom Check point Hydraulic unit assembly Abnormal data is detected in • Defective hydraulic unit (defective ABS ECU) the hydraulic unit assembly. assembly Hydraulic unit assembly Abnormality is detected in • Defective hydraulic unit (abnormal internal power the power supply circuit in assembly...
Page 568 ABS (Anti-lock Brake System) Fault code No. 12 Fault code No. Item Rear wheel sensor (intermittent pulses or no pulses) Rear wheel sensor signal is not received properly. (Pulses are not Symptom received or are received intermittently while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the rear...
Page 569 ABS (Anti-lock Brake System) Fault code No. Item Front wheel sensor (abnormal pulse period) Front wheel sensor signal is not received properly. (The pulse period Symptom is abnormal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed installation of the sensor...
Page 570 ABS (Anti-lock Brake System) Fault code No. 15 Push the OFF/LOCK switch before disconnecting or connecting a coupler. Fault code No. Item Front wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the front wheel sensor. Order Item/components and probable cause Check or maintenance job Defective coupler between the front wheel...
Page 571 ABS (Anti-lock Brake System) Fault code No. 16 Push the OFF/LOCK switch before disconnecting or connecting a coupler. Fault code No. Item Rear wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the rear wheel sensor. Order Item/components and probable cause Check or maintenance job Defective coupler between the rear wheel...
Page 572 ABS (Anti-lock Brake System) Fault code No. 17, 45 If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault code No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code No.
Page 573 ABS (Anti-lock Brake System) Fault code No. Item Rear wheel sensor (missing pulses) Rear wheel sensor signal is not received properly. (Missing pulses Symptom are detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
Page 574 ABS (Anti-lock Brake System) Fault code No. 31 Push the OFF/LOCK switch before disconnecting or connecting a coupler. Fault code No. Item Hydraulic unit assembly (abnormal ABS solenoid power supply) Power is not supplied to the solenoid circuit in the hydraulic unit Symptom assembly.
Page 575 ABS (Anti-lock Brake System) Fault code No. Item Hydraulic unit assembly (abnormal ABS motor power supply) Power is not supplied to the motor circuit in the hydraulic unit Symptom assembly. Order Item/components and probable cause Check or maintenance job Defective coupler between the battery •...
Page 576 ABS (Anti-lock Brake System) Fault code No. Front wheel ABS (intermittent wheel speed pulses or incorrect Item depressurization) • Pulses from the front wheel sensor are received intermittently while the vehicle is traveling. Symptom • Front wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure.
Page 577 ABS (Anti-lock Brake System) Fault code No. 43 Fault code No. Item Front wheel sensor (missing pulses) Front wheel sensor signal is not received properly. (Missing pulses Symptom are detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor...
Page 578 ABS (Anti-lock Brake System) Fault code No. 51, 52 Fault code No. • Vehicle system power supply (voltage of ABS ECU power supply is high) (for fault code No. 51) Item • Vehicle system power supply (voltage of wheel sensor power sup- ply is high) (for fault code No.
Page 579 ABS (Anti-lock Brake System) Fault code No. 54 Push the OFF/LOCK switch before disconnecting or connecting a coupler. Fault code No. Hydraulic unit assembly (defective ABS solenoid and ABS motor Item power supply circuits) Abnormality is detected in the solenoid or motor power supply cir- Symptom cuit in the hydraulic unit assembly.
Page 580 ABS (Anti-lock Brake System) Fault code No. 63 Fault code No. Item Front wheel sensor power supply (voltage of power supply is low) Power voltage supplied from the ABS ECU to the front wheel sensor Symptom is too low. Order Item/components and probable cause Check or maintenance job Short circuit in the wire harness between •...
Page 581 ABS (Anti-lock Brake System) Fault code No. 64 Fault code No. Item Rear wheel sensor power supply (voltage of power supply is low) Power voltage supplied from the ABS ECU to the rear wheel sensor Symptom is too low. Order Item/components and probable cause Check or maintenance job Short circuit in the wire harness between •...
Page 582 EAS31167 [B-3] DELETING THE FAULT CODES To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault codes, refer to the operation manual of the Yamaha diagnostic tool. Check that all the displayed fault codes are deleted.
Page 583 ABS (Anti-lock Brake System) 8-192...
Page 584 SMART KEY SYSTEM EAS20201 SMART KEY SYSTEM EAS31452 CIRCUIT DIAGRAM XP530E-A 8-193...
Page 585 75.Meter assembly 76.Smart key system indicator light 81.Turn signal indicator light (left) 82.Turn signal indicator light (right) 85.Multi-function display 86.Yamaha diagnostic tool coupler 89.ECU (Engine Control Unit) A. Wire harness B. Negative battery sub-wire harness D. Headlight sub-wire harness (headlight har-...
Page 586 SMART KEY SYSTEM XP530-A 8-195...
Page 587 77.Meter assembly 78.Smart key system indicator light 83.Turn signal indicator light (left) 84.Turn signal indicator light (right) 87.Multi-function display 91.Yamaha diagnostic tool coupler 94.ECU (Engine Control Unit) A. Wire harness B. Negative battery sub-wire harness D. Headlight sub-wire harness (headlight har-...
Page 588 SMART KEY SYSTEM XP530D-A 8-197...
Page 589 87.Meter assembly 88.Smart key system indicator light 93.Turn signal indicator light (left) 94.Turn signal indicator light (right) 99.Multi-function display 103.Yamaha diagnostic tool coupler 106.ECU (Engine Control Unit) A. Wire harness B. Negative battery sub-wire harness D. Headlight sub-wire harness (headlight har-...
Page 590 SMART KEY SYSTEM EAS31453 TROUBLESHOOTING Vehicle power does not turn on. (Meter light and tail/brake light do not come on.) Engine does not start even though vehicle power is turned on. Seat/fuel lid or storage compartment lid (for XP530-A/XP530D-A) does not open. (Vehicle power is turned on.) Before troubleshooting, remove the following part(s): 1.
Page 591 SMART KEY SYSTEM Checking the smart key system Before checking the smart key system, make sure that the smart key is located within the operating range of the smart key system and that the key is turned on. Vehicle power does not turn on. (Meter light and tail/brake light do not come on.) •...
Page 592 SMART KEY SYSTEM 5. The smart key system indicator light “ ” flashes. (The indicator light repeatedly flash- Steering lock unit data error or malfunction es 3 times, and then goes off after  Replace the steering lock unit. YES approximately 20 seconds.) Refer to “SMART KEY SYSTEM SELF-DIAGNOSIS”...
Page 593 SMART KEY SYSTEM 2. Check the OFF/LOCK switch and Parking/Unlock switch. Replace the OFF/LOCK switch and/or Refer to “CHECKING THE Parking/Unlock switch. NG SWITCHES” on page 8-221. OK 3. Check that the smart key system in- dicator light “ ” flashes when the Communication between the remote con- Parking/Unlock switch on the vehi- trol unit and meter is not possible.
Page 594 SMART KEY SYSTEM 3. Check that the smart key system in- Communication between the remote con- dicator light “ ” flashes when the trol unit and meter is not possible.  Parking/Unlock switch on the vehi- Check the wire harness (Light cle is operated.
Page 595 SMART KEY SYSTEM 3. Check that the smart key system in- Communication between the remote con- dicator light “ ” flashes when the trol unit and centerstand lock unit is not ON/start switch on the vehicle is op- possible.  Check the wire harness (Light erated.
Page 596 SMART KEY SYSTEM EAS31534 SMART KEY SYSTEM SELF-DIAGNOSIS The smart key system is equipped with a self-diagnostic function. If a malfunction is detected in the sys- tem, the malfunction will be indicated by the flash pattern of the smart key system indicator light “ ”. The smart key system indicator light “...
Page 597 SMART KEY SYSTEM Flashing time/number Malfunction and Item Flash pattern of flashes check point • ECU communication error 0.3 (s) Flashes continuously • Data error Check the wire harness. until the error is • ECU malfunction Check the ECU. resolved/flashes 4 Check the remote con- 0.3 (s) 1.0 (s)
Page 598 SMART KEY SYSTEM EAS31535 SMART KEY SYSTEM EMERGENCY MODE When the smart key is lost, damaged, or its battery has discharged, the vehicle can still be turned on and the engine started. You will need a mechanical key and the smart key system identification number. To operate the vehicle in emergency mode, carry out the following steps.
Page 599 SMART KEY SYSTEM 7. Inputting the identification number is done by counting the number of flashes of the smart key system indicator light “ ”. For example, if the identification number is 123456: Push and hold the Parking/Unlock switch.  The smart key system indicator light “...
Page 600 SMART KEY SYSTEM EAS31536 REGISTERING A SMART KEY The following procedure can be used to register additional smart keys or a new smart key in case the original smart key is lost. • A maximum of 6 smart keys can be registered to the remote control unit. •...
Page 601 SMART KEY SYSTEM 6. If the smart key is registered successfully, the smart key system indicator light “ ” will come on for 3 seconds, and then the smart key system will turn off. If the smart key was not registered successfully, the smart key system indicator light “ ” will flash for 3 seconds, and then the smart key system will turn off.
Page 602 SMART KEY SYSTEM 7. Push the OFF/LOCK switch and Parking/Unlock switch simultaneously for 2 seconds. The use of only the verified smart keys will be enabled. The use of all other smart keys will be disabled. If the procedure was not completed successfully, repeat the procedure from step (1). EAS32446 REPLACING THE REMOTE CONTROL UNIT, STEERING LOCK, AND ECU The remote control unit, steering lock, and ECU cannot be replaced at the same time.
Page 603 SMART KEY SYSTEM EAS31719 REPLACEMENT PARTS LIST When replacing the parts, refer to the following sections. • Refer to “SMART KEY SYSTEM EMERGENCY MODE” on page 8-207. • Refer to “REGISTERING A SMART KEY” on page 8-209. • Refer to “REPLACING THE REMOTE CONTROL UNIT, STEERING LOCK, AND ECU” on page 8-211.
Page 604 SMART KEY SYSTEM Required item when Replacement parts (when an item is required replacing parts in order to replace parts)   Required. Replace. Smart key identi-  fication number : Do not replace. or smart key is Faulty part Remarks required.
Page 605 SMART KEY SYSTEM 8-214...
Page 606 ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-215...
Page 607 ELECTRICAL COMPONENTS 1. ECU (Engine Control Unit) 2. Hydraulic unit assembly 3. Buzzer 4. Intake air temperature sensor 5. Accelerator position sensor 6. Battery 7. Steering lock unit 8. Diode 3 9. Diode 5 10.Injector 11.Coolant temperature sensor 12.Spark plug 13.Spark plug cap 14.Radiator fan motor 15.Throttle servo motor...
Page 608 ELECTRICAL COMPONENTS 8-217...
Page 609 ELECTRICAL COMPONENTS 1. Fuel pump 2. Seat/fuel lid lock solenoid 3. Seat heater (for XP530D-A) 4. Storage box light switch 5. Sidestand relay/Turn signal/hazard relay/Radiator fan motor relay/Seat heater relay (power) (for XP530D-A)/Seat heater relay (control) (for XP530D-A)/Windshield drive unit relay (down) (for XP530D-A)/Wind- shield drive unit relay (up) (for XP530D-A) 6.
Page 610 ELECTRICAL COMPONENTS 8-219...
Page 611 ELECTRICAL COMPONENTS 1. Front brake light switch (for XP530E- A/XP530-A) 2. Front brake light switch (for XP530D-A) 3. Grip warmer (for XP530D-A) 4. Parking/Unlock switch 5. OFF/LOCK switch 6. Rear brake light switch (for XP530E- A/XP530-A) 7. Rear brake light switch (for XP530D-A) 8.
Page 612 ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES XP530E-A B L/B Br P R/B R/W L/W B PASS Br/W Br/Y W/L B/W W/R B/W W/G FREE PUSH (Neutral) DOWN Br/W Dg Br/Y L/W B Br/W Br/W 8-221...
Page 613 ELECTRICAL COMPONENTS 1. Dimmer/pass switch 2. Horn switch 3. Menu switch 4. Select switch 5. Turn signal switch 6. Rear brake light switch 7. Sidestand switch 8. Engine stop switch 9. ON/start switch 10.Hazard switch 11.Front brake light switch 12.OFF/LOCK switch 13.Parking/Unlock switch 14.Storage box light switch 8-222...
Page 614 ELECTRICAL COMPONENTS XP530-A B L/B Br P R/B R/W L/W B PASS Br/W Br/Y B/W W/G W/L B/W W/R B/W W/G FREE FREE PUSH PUSH (Neutral) DOWN Br/W Dg Br/Y W/G B/W Br/W Br/W 8-223...
Page 615 ELECTRICAL COMPONENTS 1. Dimmer/pass switch 2. Horn switch 3. Menu switch 4. Select switch 5. Turn signal switch 6. Rear brake light switch 7. Sidestand switch 8. Engine stop switch 9. ON/start switch 10.Hazard switch 11.Mode switch 12.Front brake light switch 13.OFF/LOCK switch 14.Parking/Unlock switch 15.Storage box light switch...
Page 616 ELECTRICAL COMPONENTS XP530D-A Y/B O/W R/G Y/B G/L G/W G/Y Y/B Y/W G/W G/Y Y/W Y/W R/B R/W L/W B PUSH FREE FREE Y/W G/Y Br/W Br/Y B/W W/G B L/B Br P FREE PUSH PASS W/L B/W W/R B/W W/G Br/Y FREE W/G B/W...
Page 617 ELECTRICAL COMPONENTS 1. Cruise control power switch 2. Cruise control setting switch 3. Dimmer/pass switch 4. Horn switch 5. Menu switch 6. Select switch 7. Turn signal switch 8. Sidestand switch 9. Front brake light switch 10.Rear brake light switch 11.Engine stop switch 12.ON/start switch 13.Hazard switch...
Page 618 ELECTRICAL COMPONENTS Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA18520 NOTICE 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 619 ELECTRICAL COMPONENTS ly affected. If the headlight bulb gets soiled, EAS30550 CHECKING THE BULBS AND BULB thoroughly clean it with a cloth moistened SOCKETS with alcohol or lacquer thinner. 2. Check: Do not check any of the lights that use LEDs. •...
Page 620 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Amperage Fuses Q’ty a. Install a good bulb into the bulb socket. rating b. Connect the digital circuit tester probes to the Headlight 7.5 A respective leads of the bulb socket. c. Check the bulb socket for continuity. If any of Taillight 7.5 A the readings indicate no continuity, replace...
Page 621 ELECTRICAL COMPONENTS deteriorate. EAS31006 REPLACING THE ECU (Engine Control Unit) • Charging time, charging amperage and 1. Push the ON/start switch (to OFF). charging voltage for a VRLA (Valve Regu- 2. Replace the ECU (Engine Control Unit). lated Lead Acid) battery are different from 3.
Page 622 ELECTRICAL COMPONENTS (refer to the appropriate charging method) • Positive tester probe  EWA13300 positive battery terminal WARNING • Negative tester probe  negative battery terminal Do not quick charge a battery. ECA13671 NOTICE • The charge state of a VRLA (Valve Regulated •...
Page 623 ELECTRICAL COMPONENTS g. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 624 ELECTRICAL COMPONENTS 8. Check: 1. Positive battery terminal • Battery terminals 2. Negative battery terminal Dirt  Clean with a wire brush. 3. Positive tester probe Loose connection  Connect properly. 4. Negative tester probe 9. Lubricate: A. XP530E-A/XP530-A • Battery terminals B.
Page 625 ELECTRICAL COMPONENTS Headlight relay (dimmer) Radiator fan motor relay First step: Y/B Br Br/R 1. Positive battery terminal 1. Positive tester probe 2. Negative battery terminal 2. Negative tester probe 3. Positive tester probe 3. Negative tester probe 4. Negative tester probe Result Result Continuity...
Page 626 ELECTRICAL COMPONENTS Sidestand relay Steering lock relay 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe Result Result Continuity Continuity...
Page 627 ELECTRICAL COMPONENTS Brake light relay (for XP530D-A) Second step: P/W Br/R G/Y Lg/B 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4.
Page 628 ELECTRICAL COMPONENTS Seat heater relay (control) (for XP530D-A) Second step: First step: P/B Br/R Y/B Br 1. Positive battery terminal 2. Negative battery terminal 1. Positive tester probe 3. Positive tester probe 2. Negative tester probe 4. Negative tester probe Result 5.
Page 629 ELECTRICAL COMPONENTS Br/R Br/R Br/R,R Br/R,R Br/R R/G Br/R R/G 1. Positive tester probe 1. Positive battery terminal 2. Negative tester probe 2. Negative battery terminal 3. Negative tester probe 3. Positive tester probe 4. Negative tester probe A. XP530E-A 5.
Page 630 ELECTRICAL COMPONENTS Result Diode 1 Continuity Continuity Positive tester probe  (between “1” and “2”) No continuity Green/Red, Blue/White “1” (between “1” and “3”) Negative tester probe  Red/Green “2” No continuity Second step: Positive tester probe  Red/Green “2” Negative tester probe ...
Page 631 ELECTRICAL COMPONENTS A. Diode 1 B. Diode 2 C. Diode 3 D. Diode 5 E. Diode (fuse box) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the diode from the wire harness. b. Connect the digital circuit tester () to the di- ode terminals as shown. c.
Page 632 ELECTRICAL COMPONENTS Secondary coil resistance 12.00–18.00 k ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the igni- tion coil. b. Connect the digital circuit tester () to the ig- nition coil as shown. Digital circuit tester (CD732) 90890-03243 c. Measure the spark plug cap resistance. Model 88 Multimeter with tachom- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 633 ELECTRICAL COMPONENTS Ignition checker 90890-06754 Oppama pet–4000 spark checker YM-34487 c. Push the ON/start switch and the engine stop switch to “ ”. d. Measure the ignition spark gap “a”. b. Measure the crankshaft position sensor re- sistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30561 CHECKING THE LEAN ANGLE SENSOR 1.
Page 634 ELECTRICAL COMPONENTS EAS30566 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification  Replace the stator coil. Stator coil resistance 0.224–0.336  c. Push the ON/start switch. d.
Page 635 ELECTRICAL COMPONENTS Refer to “CHECKING THE STATOR COIL” Digital circuit tester (CD732) on page 8-243. 90890-03243 Model 88 Multimeter with tachom- Battery charging voltage eter above 14 V at 5000 r/min YU-A1927 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester (AC V) to the •...
Page 636 ELECTRICAL COMPONENTS ature sensor is dropped, replace it. Fuel meter/fuel level warning indicator flash- es eight times, then goes off for 3 seconds in 2. Check: a repeated cycle (malfunction detected in fuel • Coolant temperature sensor resistance sender)  Replace the fuel pump assembly. Out of specification ...
Page 637 ELECTRICAL COMPONENTS 7-13. EAS30581 CHECKING THE THROTTLE POSITION SENSOR EAS30582 1. Remove: CHECKING THE ACCELERATOR POSITION • Throttle position sensor SENSOR (from the throttle bodies) 1. Remove: EWA16690 • Accelerator position sensor WARNING (from the throttle bodies) • Handle the throttle position sensor with EWA16700 special care.
Page 638 ELECTRICAL COMPONENTS from the wire harness. EAS30592 CHECKING THE THROTTLE SERVO MOTOR b. Connect the battery (DC V) to the windshield 1. Remove: drive unit terminals “1” as shown. • Air filter case Refer to “GENERAL CHASSIS (3)” on page 4-17.
Page 639 ELECTRICAL COMPONENTS EAS31016 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ CHECKING THE GRIP WARMERS (for a. Disconnect the seat heater coupler from the XP530D-A) wire harness. The following procedure applies to both of the b. Connect the digital circuit tester () to the grip warmers. seat heater coupler as shown. 1.
Page 640 ELECTRICAL COMPONENTS Digital circuit tester (CD732) Intake air temperature sensor re- 90890-03243 sistance 5400–6600  at 0 C (5400–6600 Model 88 Multimeter with tachom-  at 32 F) eter YU-A1927 Intake air temperature sensor re- Test harness S– pressure sensor sistance 289–391 ...
Page 641 ELECTRICAL COMPONENTS • Positive tester probe  Resistance positive battery terminal “1” 12.0  • Negative tester probe  negative battery terminal “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the fuel injector coupler from wire harness. b. Connect the digital circuit tester () to the fuel injector coupler.
Page 642 ELECTRICAL COMPONENTS from the wire harness. b. Connect the battery (DC 12 V) as shown. • Positive battery terminal  Brown “1” • Negative battery terminal  Red “2” c. Check the seat/fuel lid lock solenoid move- ment. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS32450 CHECKING THE STORAGE COMPARTMENT LID LOCK SOLENOID (for XP530-A/XP530D- 1.
Page 643 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 ................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM .........9-3 TROUBLESHOOTING AT THE ABS WARNING LIGHT ......9-4 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) .......................9-5 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION...
Page 644 TROUBLESHOOTING Electrical system EAS20090 TROUBLESHOOTING 1. Battery • Discharged battery EAS30599 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.
Page 645 TROUBLESHOOTING Electrical system 2. Engine oil 1. Battery • Incorrect oil level • Discharged battery • Incorrect oil viscosity (low) • Faulty battery • Deteriorated oil 2. Spark plug(s) 3. Primary sliding sheave • Incorrect spark plug gap • Seized primary sliding sheave •...
Page 646 TROUBLESHOOTING • Improperly connected hose • Incorrect oil viscosity • Damaged pipe • Incorrect oil level • Improperly connected pipe EAS30611 Fuel system UNSTABLE HANDLING 1. Throttle body (-ies) 1. Handlebar • Damaged or loose throttle body joint • Bent or improperly installed handlebar 2.
Page 647 TROUBLESHOOTING Tail/brake light does not come on • Faulty brake light switch • Too many electrical accessories • Incorrect connection • Faulty tail/brake light • Faulty ignition system relay • Faulty remote control unit Turn signal does not come on •...
Page 648 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) EAS20162 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) EAS31794 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM) For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-61. Fault Probable cause of Fail-safe system Item Vehicle symptom...
Page 649 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to The radiator fan motor P0118 perature sensor of the coolant temper- start.
Page 650 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0132 sensor (short cir- [P0132] High voltage Increased exhaust feedback is not of the O sensor cir- emissions. cuit detected (power carried out.
Page 651 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0500 Rear wheel sensor • Open or short cir- Vehicle speed is not Vehicle speed dis- (no normal signals are cuit in wire harness displayed on the played on the meter =...
Page 652 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P056C Cruise control cancel • Open or short cir- Cruise control system Cruise control system switch (open or short cuit in wire harness. cannot be operated.
Page 653 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0657 Fuel system voltage • Open or short cir- Engine is difficult to Monitor voltage = 12 (incorrect voltage sup- cuit in wire harness start.
Page 654 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P2122 [P2122] Accelerator [P2122, P2127] Low Engine response is No change in acceler- P2123 position sensor (open voltage of the acceler- poor.
Page 655 Vehicle symptom code No. malfunction operation U0155 CAN communication Communication Defective meter dis- Grip warmer output: (Yamaha error (with the meter) between the ECU and play. OFF is fixed. diagnostic the meter is not possi- Traction control does MAP changeover: tool) not work.
Page 656 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Meter display Procedure code No. Fuel system voltage Fuel system voltage Set the engine stop switch to (battery voltage) Approximately 12.0 “ ”, and then compare the actually measured battery voltage with the tool display value.
Page 657 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Meter display Procedure code No. EEPROM fault code display — • No history • No malfunctions detected (If the self-diagnosis fault code P062F is indicated, the ECU is defective.) • History exists 01–02 (CO adjustment value) •...
Page 658 • Connect an ignition vals. The “check” indicator on the checker. Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Injector #1 Actuates the injector #1 five Disconnect the fuel pump times at one-second inter- coupler.
Page 659 Check that injector #2 is The “check” indicator on the actuated five times by listen- Yamaha diagnostic tool ing for the operating sound. screen come on each time the fuel injector is actuated. Fuel injection system relay Actuates the fuel injection...
Page 660 EVENT CODE TABLE EAS20164 EVENT CODE TABLE The event code numbers listed below cannot be displayed on the meter. To display the event code numbers, use the Yamaha diagnostic tool. Item Symptom Possible causes Note Intake air pres- Brief abnormality...
Page 661 EVENT CODE TABLE Item Symptom Possible causes Note During idling, the Idling engine speed is • Implement diagnostic (Stuck at the adjustment is main- slow code 67, and check the • Clogged throttle body upper limit for tained at the upper ISC maintenance request.
Page 662 EVENT CODE TABLE EAS32023 TROUBLESHOOTING DETAILS (EVENT CODE) Event code No. 30 Event code No. Item Latch up detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Lean angle sensor output voltage Tool display • 0.4–1.4 (upright) •...
Page 663 EVENT CODE TABLE Event code No. 70 If another error code is displayed at the same time, check the other error code first and repair it. Event code No. Engine forcibly stops when the vehicle is left idling for a long period Item of time.
Page 664 EVENT CODE TABLE 9-21...
Page 665 26. Diode (fuse box) 84. High beam indicator light 27. ABS motor fuse 85. Multi-function display 28. ABS solenoid fuse 86. Yamaha diagnostic tool cou- 29. ABS ECU fuse pler 30. Headlight fuse 87. Radiator fan motor 31. Auxiliary DC jack fuse 88.
Page 666 89. Seat heater relay (control) (OP- 35. Storage box light switch TION) 36. Steering lock unit 90. Seat heater (OPTION) 37. Anti-theft alarm (OPTION) 91. Yamaha diagnostic tool cou- 38. Auxiliary DC jack pler 39. Diode 3 92. Radiator fan motor 40. Headlight relay (dimmer) 93.
Page 667 100.Seat heater relay (power) 48. Diode 2 101.Seat heater relay (control) 49. Fuel injection system relay 102.Seat heater 50. Starting circuit cut-off relay 103.Yamaha diagnostic tool cou- 51. Sidestand switch pler 52. Handlebar switch (right) 104.Radiator fan motor 53. Engine stop switch 105.Radiator fan motor relay...
Page 668 EAS30613 COLOR CODE Black Brown Chocolate Dark green Green Gray Blue Light green Orange Pink Sky blue White Yellow Black/Green Black/Blue Black/White Black/Yellow Br/B Brown/Black Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White Br/Y Brown/Yellow Green/Black Green/Blue Green/Red Green/White Green/Yellow Gy/G Gray/Green Blue/Black Blue/Green Blue/Red...
Page 671 XP530E-A 2017 XP530E-A 2017 XP530E-A 2017 XP530E-A 2017 XP530E-A 2017 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...
Page 672 XP530E-A 2017 XP530E-A 2017 XP530E-A 2017 XP530E-A 2017 XP530E-A 2017 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...
Page 673 XP530-A 2017 XP530-A 2017 XP530-A 2017 XP530-A 2017 XP530-A 2017 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...
Page 674 XP530-A 2017 XP530-A 2017 XP530-A 2017 XP530-A 2017 XP530-A 2017 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...
Page 675 XP530D-A 2017 XP530D-A 2017 XP530D-A 2017 XP530D-A 2017 XP530D-A 2017 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...
Page 676 XP530D-A 2017 XP530D-A 2017 XP530D-A 2017 XP530D-A 2017 XP530D-A 2017 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...

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