Yamaha 2007 XP500 Service Manual page 79

1. Main switch/immobilizer unit
2. Throttle cable
3. Brake hose
4. Meter assembly
5. Cooling system air bleed hose
6. Horn lead
7. Radiator filer hose
8. Ignition coil
9. Coolant reservoir hose
10. Radiator fan motor lead
11. Throttle position sensor coupler
12. Starter motor lead
13. Rectifier/regulator
14. Starting circuit cut-off relay 1
15. Turn signal/hazard relay
16. O sensor
2
17. V-belt replacement indicator reset coupler
18. O sensor coupler
2
19. Fuel pump lead
20. Fuel tank breather hose
21. Rear brake lock lever cable
22. Negative battery lead
23. Seat lock cable (left)
24. Frame
25. Wire harness
26. Storage box
27. V-belt replacement indicator reset coupler lead
28. O sensor lead
2
29. Fuel hose
30. Tail/brake light assembly
31. Main switch lead
A. After adjusting the adjustment nut, attach the
front and rear parts of the boot tightly. Apply the
silicone grease to the inside of the boot and sur-
face of the adjusting nut possible, when install-
ing the boot.
B. Pass the seat lock cable between wire harness
and frame.
C. Use the plastic holder on the back of the frame
to hold the radiator fan motor lead.
D. Connect the wire harness (wire taped area) to
the T stud of frame.
E. Pass the main switch lead between stay 1 and
seat lock cable.
F. After connecting the wire harness and meter
assembly lead, use a plastic holder to connect
them to stay 1.
G. After connecting the left headlight sub-wire har-
ness and wire harness (by matching the cou-
pler colors), fold back the lead facing to the right
and insert it into the air filter case rib.
H. Connect the wire harness to the headlight sub
wire harness (cowling side).
I. Fasten the headlight and turn signal sub-wire
harness to the stay 1 with a plastic holder.
J. Fasten the ECU (engine) lead to the stay 1 with
a plastic holder. When fastening them using a
plastic holder, make sure not to cross the
branch leads.
K. Fasten the coolant reservoir hose to the stay 1
with a plastic holder.
L. Route the ignition coil lead through the inside of
the ignition coil bracket.
M. Fasten the radiator fan motor lead and side-
stand switch lead to the frame with a plastic
holder.
N. Insert the tail/brake light coupler between the
wire harness and the seat lock cable (left).
O. To the tail/brake light.
P. To the starter relay.
Q. Route the wire harness and rectifier/regulator
lead through the frame wire holder. Place the
rectifier/regulator lead under the wire harness.
R. Make sure that the seat lock cable do not lean
over the storage box.
S. Fasten the starter motor lead, negative battery
lead and seat lock cable (left) to the frame with
a plastic holder.
T. Fasten the starter motor lead and negative bat-
tery lead to the frame with a plastic holder.
U. Fasten the wire harness to the frame with the
plastic band. The buckle of the plastic band
should be facing towards the storage box.
V. Insert the seat lock cable and the cylinder
mounting rubber into the frame stay.
W. Fasten the starter motor lead and negative bat-
tery lead to the frame with a plastic band. Posi-
tion the band clasp on the bottom of the frame
and face the band end to the outside.
X. Install the clamshell cover around the V-belt
replacement indicator reset coupler and O
sensor coupler.
Y. Make sure that the V-belt replacement indicator
reset coupler does not project out of the clam-
shell cover.
Z. Fasten the O
ment indicator reset coupler lead to the frame
with a plastic holder.
AA. Pass the wire harness and seat lock cable in
the frame holder.
AB. Pass the rear brake lock lever cable under the
coolant pipe.
AC. 40 – 50 mm (1.57 – 1.97 in)
AD. Fasten the O
plastic band.
AE. Pass the O
2
AF. Pass the wire harness to the frame wire har-
ness holder.
AG. After making the connections, push the cou-
plers into the space inside the frame above the
mudguard.
AH. Install the band fastened part between frame
and storage box.
AI. Route the seat lock cable through the frame
bracket side and under the wire harness.
AJ. T stud for position setting
AK. Fasten the wire harness, main switch lead and
seat lock cable with a clamp to under the cowl-
ing stay (Fasten the seat lock cables metal pipe
section).
AL. Route the taillight lead onto the seat lock cable,
wire harness and positive battery lead.
AM. Install the turn signal light lead, make sure
does not hide the turn signal light lead under
the tail light assembly as shown area.
2-42
CABLE ROUTING
sensor lead and V-belt replace-
2
sensor lead to the frame with a
2
sensor lead to the lead guide.
2