Yamaha 2007 XP500 Service Manual page 89

1. Main switch/immobilizer unit
2. ECU (ABS)
3. Throttle cable
4. Brake hose
5. Fail-safe relay
6. Meter assembly
7. Coolant system air bleed hose
8. Horn lead
9. Ignition coil
10. Radiator filer hose
11. Coolant reservoir hose
12. Throttle position sensor coupler
13. Radiator fan motor lead
14. Starter motor lead
15. Rectifier/regulator
16. Starting circuit cut-off relay 2
17. Starting circuit cut-off relay 1
18. Turn signal/hazard relay
19. O sensor
2
20. V-belt replacement indicator reset coupler
21. O sensor coupler
2
22. Fuel pump lead
23. Fuel tank breather hose
24. Rear brake lock lever cable
25. Main switch lead
26. Wire harness
27. Seat lock cable
28. Seat lock cable (left)
29. Negative battery lead
30. Rear wheel sensor lead
31. Frame
32. Storage box
33. V-belt replacement indicator reset coupler lead
34. O sensor lead
2
35. Fuel hose
36. Tail/brake light assembly
37. ECU lead
38. Stay
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. Connect the wire harness (wire taped area) to
the T stud of frame.
D. Fasten the cooling system air bleed hose and
rear brake lock lever cable together with the
plastic clip. The open ends of the clip should
face downward.
E. 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).
F. Fasten the wire harness, main switch lead, and
seat lock cable with the plastic band under the
stay 1. Be sure to fasten the seat lock cable on
the metal section of the outer cable.
G. Pass the main switch lead between stay 1 and
seat lock cable.
H. Fasten the wire harness and ECU (engine) lead
to the stay 1 with a holder.
I. 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.
J. Connect the wire harness to the headlight sub
wire harness (cowling side).
K. Fasten the headlight and turn signal sub-wire
harness to the stay 1 with a plastic holder.
L. Fasten the ECU (engine) lead, ABS test coupler
lead and headlight sub-wire harness to the stay
1 with a plastic holder. When fastening them
using a plastic holder, make sure not to cross
the branch leads.
M. Fasten the coolant reservoir hose to the stay 1
with a plastic holder.
N. Route the ignition coil lead through the inside of
the ignition coil bracket.
O. Route the ignition coil lead through the inside of
the ignition coil bracket.
P. Use the plastic holder on the back of the frame
to hold the radiator fan motor lead.
Q. Fasten the radiator fan motor lead and side-
stand switch lead to the frame with a plastic
holder.
R. Fasten the wire harness and positive battery
leads with a plastic band. Face the end of the
plastic band upward.
S. To the starter relay
T. Pass the wire harness, rectifier/regulator lead,
and rear wheel sensor lead through the guide,
making sure that the rectifier/regulator lead is
routed below the wire harness and rear wheel
sensor lead.
U. Make sure that the seat lock cable do not lean
over the storage box.
V. Fasten the starter motor lead, negative battery
lead and seat lock cable (left) to the frame with
a plastic holder.
W. Fasten the starter motor lead and negative bat-
tery lead to the frame with a plastic holder.
X. Insert the seat lock cable and the cylinder
mounting rubber into the frame stay.
Y. Pass the O
2
Z. Fasten the O
plastic band.
AA. 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.
AB. Make sure that the V-belt replacement indicator
reset coupler does not project out of the clam-
shell cover.
AC. Fasten the O
ment indicator reset coupler lead to the frame
with a plastic holder.
AD. Pass the wire harness and seat lock cable in
the frame holder.
AE. Pass the rear brake lock lever cable under the
coolant pipe.
AF. 40 – 50 mm (1.57 – 1.97 in)
AG. Fasten the wire harness to the frame with the
plastic band. The buckle of the plastic band
should be facing towards the storage box.
2-52
CABLE ROUTING
sensor lead to the lead guide.
sensor lead to the frame with a
2
sensor lead and V-belt replace-
2