Yamaha XP500 Service Manual
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Yamaha XP500 Service Manual

Yamaha XP500 Service Manual

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Table of Contents

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2005
XP500
XP500A
5VU5-AE1
SERVICE MANUAL

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Summary of Contents for Yamaha XP500

  • Page 1 2005 XP500 XP500A 5VU5-AE1 SERVICE MANUAL...
  • Page 3 EAS00000 XP500/XP500A 2005 SERVICE MANUAL ©2004 by Yamaha Motor Co., Ltd. First edition, September 2004 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. 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: How To Use This Manual

    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.

  • Page 6: General Information

    EAS00008 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system COOL 8 Electrical system...

  • Page 7: Table Of Contents

    EAS00012 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...

  • Page 9: Gen Info

    INFO...
  • Page 10 INFO CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION................1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF FI SYSTEM ................. 1-2 FI SYSTEM....................1-3 OUTLINE OF ANTI-LOCK BRAKE SYSTEM (XP500A) ......1-4 INSTRUMENT FUNCTION ..............1-15 IMPORTANT INFORMATION ............... 1-19 PREPARATION FOR REMOVAL AND DISASSEMBLY......
  • Page 11 INFO...

  • Page 12: General Information

    SCOOTER IDENTIFICATION INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame. EAS00018 MODEL LABEL The model label 2 is affixed to the storage box. This information will be needed to order spare parts.

  • Page 13: Features

    FEATURES INFO EAS00019 FEATURES EAS00896 OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions. In a conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber.

  • Page 14: Fi System

    FEATURES INFO EAS00897 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump) maintains the fuel pressure that is applied to the fuel injector at 240 ~ 260 kPa (2.40 ~ 2.60 kg/cm , 34.1 ~ 37.0 psi) higher than the intake manifold pressure.

  • Page 15: Outline Of Anti-Lock Brake System (Xp500A)

    EAS00872 The operation of the Yamaha ABS brakes is the same as conventional vehicle, with a right hand brake lever for operating the front wheel brake and a left hand brake lever for operating the rear wheel brake.
  • Page 16 FEATURES INFO ABS block diagram 1 Rear brake master cylinder 6 Hydraulic control valve A Rear wheel sensor 2 Hydraulic unit 7 Front brake master cylinder B Front wheel sensor 3 Hydraulic pump 8 Rear brake caliper C ABS warning light 4 ABS motor 9 Front brake caliper 5 Buffer chamber...
  • Page 17 FEATURES INFO EAS00873 Useful terms • Wheel speed: The rotation speed of the front and rear wheels. • Chassis speed: The speed of the chassis. When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced.
  • Page 18 FEATURES INFO EAS00874 È Brake force and vehicle stability Brake force When the brake pressure is increased, wheel speed is reduced. Slip occurs between the tire and the road surface and brake force is gener- ated. The limit of this brake force is determined Side force by the friction force between the tire and the road surface and is closely related to wheel...
  • Page 19 FEATURES INFO EAS00876 ABS operation and vehicle control If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the limit of control. To make the rider aware of this condition, the ABS has been designed to generate a reaction-force pulsat- ing action in the brake lever.
  • Page 20 FEATURES INFO EAS00878 ABS component functions • Wheel sensors and sensor rotors Wheel sensors 1 detect the wheel rotation speed and transmit the wheel rotation signal to the ECU (ABS). Each wheel sensor is composed of a perma- nent magnet and a coil. The wheel sensors are installed in the sensor housing for each wheel.
  • Page 21 FEATURES INFO • Electronic control unit (ECU) The ECU (ABS) 1 controls the ABS and is located on the right side of the vehicle near the top of the front fork. To protect the ECU (ABS) from water damage, it is protected by a cover. •...
  • Page 22 FEATURES INFO Composition and operation The fail-safe relay is composed of the solenoid relay 1 and ABS motor relay 2. The solenoid relay is activated (continuous) by signals transmitted from the ECU (ABS). As a result, the solenoid valve 3 can be operated. If a malfunction occurs in the circuit, the solenoid relay is deactivated and it becomes impossible for the solenoid valve to reduce the hydraulic pressure of the brake fluid and normal braking is resumed.
  • Page 23 FEATURES INFO ABS operation The ABS hydraulic circuit consists of two systems: the front wheel and rear wheel. The following describes the front system only. • Normal braking (ABS not activated) When the ABS is not activated port D A of the solenoid valve is closed because a control signal has not been transmitted from the ECU (ABS) and port A 7 and port B 9 of the flow control valve are open.
  • Page 24 FEATURES INFO • Emergency braking (ABS activated) 1) Depressurized state When the front wheel is about to lockup, port D A of the solenoid valve is opened by the “depres- surization” signal transmitted from the ECU (ABS). When this occurs, the spool of the flow control valve compresses the return spring to close port B 9.
  • Page 25 FEATURES INFO 2) Pressurized state Port D A is closed by the “pressurization” signal transmitted from the ECU (ABS). Before this occurs, the spool of the flow control valve has compressed the return spring to close port B 9. Brake fluid that has entered through port A 7 is further restricted by the orifice 0 and the brake fluid is sent to the brake calipers via port A 7 and port C C.

  • Page 26: Instrument Function

    FEATURES INFO INSTRUMENT FUNCTION Multi-function display WARNING Be sure to stop the vehicle before making any setting changes to the multi-function display. The multi-function display is equipped with the following: • a fuel meter 1 • a coolant temperature meter 2 •...
  • Page 27 FEATURES INFO When approximately 2.8 L (0.62 Imp gal, 0.74 US gal) of fuel remains in the fuel tank, the bottom segment of the fuel meter and fuel level warning symbol will start flashing, and the display will automatically change to the fuel reserve tripmeter mode “TRIP F”...
  • Page 28 FEATURES INFO Oil change indicator “OIL” This indicator flashes at the initial 1,000 km (600 mi), then at 5,000 km (3,000 mi) and every 5,000 km (3,000 mi) thereafter to indi- cate that the engine oil should be changed. After changing the engine oil, reset the oil change indicator.
  • Page 29 FEATURES INFO V-belt replacement indicator “V-BELT” This indicator flashes every 20,000 km (12,000 mi) when the V-belt needs to be replaced. The electrical circuit of the indicator can be checked according to the following pro- cedure. 1. Turn the key to “ON” and make sure that the engine stop switch is set to “...

  • Page 30: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 31: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu-...

  • Page 32: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...

  • Page 33: Special Tools

    SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 34 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Flywheel puller 90890-01362 YU-33270-B This tool is used to remove the A.C. mag- neto rotor. Fork seal driver weight Fork seal driver weight 90890-01367 Fork seal driver attachment (41 mm) YM-A5142-4 Fork seal driver These tools are used to install the oil attachment seal, dust seal, and the outer tube bush-...
  • Page 35 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Thickness gauge 90890-03079 YM-34483 This tool is used to measure the valve clearance. Compression gauge Compression gauge Extension 90890-03081 YU-33223 Extension These tools are used to measure engine 90890-04082 compression. Vacuum gauge Vacuum gauge 90890-03094 YU-44456...
  • Page 36 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Digital circuit tester 90890-03174 This tool is used to check electrical sys- tem. Fuel pressure adapter 90890-03181 This tool is used to measure fuel pres- sure. Valve spring compres- Valve spring compressor Valve spring compressor attachment 90890-04019 YM-04019...
  • Page 37 This tool is used to install the crankshaft journal bearings. Ignition checker 90890-06754 YM-34487 This tool is used to check the ignition sys- tem components. Yamaha bond No. 1215 ® Sealant (Quick Gasket Bond 90890-85505 Sealant ACC-11001-05-01 This bond is used to seal two mating sur- faces (e.g., crankcase mating surfaces).

  • Page 38: Spec

    SPEC...
  • Page 39 LUBRICATION POINTS AND LUBRICANT TYPES ........2-24 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ....2-24 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES ..... 2-26 OIL FLOW DIAGRAMS ................. 2-27 COOLANT FLOW DIAGRAMS ..............2-31 CABLE ROUTING ..................2-32 XP500...................... 2-39 XP500A ....................2-56...
  • Page 40 SPEC...

  • Page 41: Specifications

    Minimum turning radius 2,800 mm (110.2 in) ---- Weight Wet (with oil and a full fuel tank) 225 kg (496 lb) (XP500) ---- 230 kg (507 lb) (XP500A) ---- Maximum load (total of cargo, rider, 190 kg (419 lb) (XP500)

  • Page 42: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled 4-stroke, DOHC ---- Displacement 499 cm (30.45 cu.in) ---- Cylinder arrangement Forward inclined parallel 2-cylinder ---- Bore × stroke 66 × 73 mm (2.60 × 2.87 in) ---- Compression ratio 11.0 : 1 ----...
  • Page 43 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Cartridge (paper) ---- Bypass valve opening pressure 80 ~ 120 kPa ---- (0.8 ~ 1.2 kg/cm , 11.6 ~ 17.4 psi) Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clear- 0.04 ~ 0.12 mm (0.0016 ~ 0.0047 in) 0.20 mm ance...
  • Page 44 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (left) ---- Camshaft cap inside diameter 23.000 ~ 23.021 mm (0.9055 ~ 0.9063 in) ---- Camshaft journal diameter 22.967 ~ 22.980 mm (0.9042 ~ 0.9047 in) ---- Camshaft-journal-to-camshaft cap 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) 0.08 mm clearance...
  • Page 45 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valves, valve seats, valve guides Valve clearance (cold) Intake 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in) ---- Exhaust 0.25 ~ 0.30 mm (0.0098 ~ 0.0118 in) ---- Valve dimensions Head Diameter Face Width Seat Width Margin Thickness Valve head diameter A...
  • Page 46 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve stem runout ---- 0.04 mm (0.0016 in) Valve seat width Intake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.06 in) Exhaust 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.06 in) Valve springs Free length...
  • Page 47 SPEC ENGINE SPECIFICATIONS Item Standard Limit Winding direction (top view) Intake Clockwise ---- Exhaust Clockwise ---- Valve lifter Valve lifter outside diameter Intake 24.476 ~ 24.500 mm (0.9636 ~ 0.9646 in) 24.451 mm (0.9626 in) Exhaust 24.476 ~ 24.500 mm (0.9636 ~ 0.9646 in) 24.451 mm (0.9626 in) Cylinders Bore...
  • Page 48 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston rings Top ring Ring type Barrel ---- Dimensions (B × T) 0.80 × 2.45 mm (0.03 × 0.10 in) ---- End gap (installed) 0.15 ~ 0.25 mm (0.0059 ~ 0.0098 in) 0.50 mm (0.0197 in) Ring side clearance 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in)
  • Page 49 SPEC ENGINE SPECIFICATIONS Item Standard Limit Crankshaft Width A 50.00 ~ 50.60 mm (1.969 ~ 1.992 in) ---- Width B 118.55 ~ 118.60 mm (4.667 ~ 4.669 in) ---- Maximum runout C ---- 0.03 mm (0.0012 in) Big end side clearance D 0.160 ~ 0.262 mm (0.0063 ~ 0.0103 in) ---- Big end radial clearance E...
  • Page 50 SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch damper springs 1 Height 3.30 mm (0.13 in) 2.90 mm (0.11 in) Spring quantity ---- Clutch damper spring 2 Height 4.70 mm (0.19 in) 4.40 mm (0.17 in) Spring quantity ---- V-belt V-belt width 32.0 mm (1.26 in) 30.5 mm (1.20 in)

  • Page 51: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond ---- Caster angle 28° ---- Trail 95 mm (3.74 in) ---- Front wheel Wheel type Cast wheel ---- 14M/C × MT3.50 Size ---- Material Aluminum ---- Wheel travel 120 mm (4.72 in) ---- Wheel runout...
  • Page 52 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless ---- Size 160/60R15 M/C 67H ---- Model/manufacturer TH01R/BRIDGESTONE ---- D252/DUNLOP ---- Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lbs) 250 kPa (2.50 kgf/cm , 36 psi) ---- 90 kg (198 lbs) ~ maximum load 280 kPa (2.80 kgf/cm...
  • Page 53 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Type Telescopic fork ---- Front fork type Coil spring/oil damper ---- Front fork travel 120.0 mm (4.72 in) ---- Fork spring free length 405.0 mm (15.94 in) 400.0 mm (15.75 in) Installed length 400.0 mm (15.75 in) ---- Collar length...
  • Page 54 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Swingarm Free play (at the end of the swing- arm) Radial ---- 1.0 mm (0.04 in) Axial ---- 1.0 mm (0.04 in) Secondary drive chain Model/manufacturer 23RH303.5-82ASM/Borg warner ---- Link quantity ---- Primary drive chain Model/manufacturer 89HV302.5RCF-66/Borg warner ----...

  • Page 55: Electrical Specifications

    Advancer type Digital ---- 189 ~ 231 Ω at 20 °C (68 °F)/gray–black Crankshaft position sensor resis- ---- tance/color ECU (engine) Model/manufacturer TBDF07/DENSO (XP500) ---- TBDF13/DENSO (XP500A) ---- Ignition coils Model/manufacturer JO313/DENSO ---- Minimum ignition spark gap 6 mm (0.24 in) ---- 1.87 ~ 2.53 Ω...
  • Page 56 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Bulbs (voltage, wattage × quantity) Headlight 12 V, 60 W/55 W + 12 V, 55 W ---- 12 V, 5 W × 2 Auxiliary light ---- 12 V, 5 W/21 W × 2 Tail/brake light ---- 12 V, 21 W ×...
  • Page 57 0.140 ~ 0.144 kΩ ---- Fuses Main fuse 30 A ---- Headlight fuse 15 A ---- Signaling system fuse 20 A (XP500) ---- 15 A (XP500A) ---- Ignition fuse 10 A ---- Radiator fan motor fuse 15 A ---- Lighting system fuse...

  • Page 58: Conversion Table

    CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.

  • Page 59: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Part name Q’ty Remarks size Nm m · kg ft · lb Spark plug — Cylinder head cover Bolt Camshaft cap Bolt Cylinder head and cylinder body Cylinder head and cylinder body Cylinder head and cylinder body Bolt Cylinder head (exhaust pipe)
  • Page 60 SPEC TIGHTENING TORQUES Tightening torque Thread Item Part name Q’ty Remarks size Nm m · kg ft · lb Timing plug Plug A.C. magneto cover Bolt V-belt case Bolt V-belt case Bolt V-belt case cover 1 Bolt V-belt case cover 2 Bolt Plate and right crankcase cover Bolt...
  • Page 61 SPEC TIGHTENING TORQUES Crankcase tightening sequence: 1 ~ 8 M8 Bolt 9 ~ 21 M6 Bolt Cylinder head tightening sequence: 2 - 21...

  • Page 62: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Thread Item Remarks size Nm m · kg ft · lb Upper bracket pinch bolt Steering stem nut 11.0 Lower ring nut See NOTE. Front fork cap bolt Lower bracket pinch bolt Front fender Damper rod assembly bolt Upper handlebar holder...
  • Page 63 SPEC TIGHTENING TORQUES Tightening torque Thread Item Remarks size Nm m · kg ft · lb Headlight unit and front cowling Tail/brake light assembly and frame Footrest board and frame Upper side cover moulding and passenger foot- rest Rear side cover and frame Leg shield, footrest board and frame Footrest board and frame Seat damper...

  • Page 64: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Oil seal lips O-rings Bearing and bushes Crankshaft pins Piston surfaces Piston pins and connecting rod small end Balancer surface Connecting rod big end thrust surface Connecting rod bolts and nuts Crankshaft thrust surface...
  • Page 65 BEL-RAY Primary sheave ® assembly lube BEL-RAY Secondary sheave ® assembly lube Swingarm pivot shaft bearing Yamaha bond Crankcase mating surface No. 1215 Yamaha bond A.C. magneto lead No. 1215 Yamaha bond Cylinder head cover (gasket mating surface) No. 1215...

  • Page 66: Chassis Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point Symbol Front wheel oil seal lip Steering bearings and oil seal lip Throttle grip inner surface and throttle cables Brake lever pivoting point and metal-to-metal moving parts (left and right) Parking brake lock lever cable and parking brake lock lever (cable connec- tion area) Sidestand pivoting point, metal-to-metal moving parts...

  • Page 67: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Oil pump 9 Oil pipe 2 Oil tank 0 Oil delivery pipe 3 Oil strainer 4 Relief valve 5 Oil cooler 6 Oil filter cartridge 7 Exhaust camshaft 8 Intake camshaft 2 - 27...
  • Page 68 SPEC OIL FLOW DIAGRAMS 1 Oil strainer 2 Crankshaft 2 - 28...
  • Page 69 SPEC OIL FLOW DIAGRAMS 1 Clutch 2 Right main journal bearing 3 Main gallery plug 2 - 29...
  • Page 70 SPEC OIL FLOW DIAGRAMS Exhaust camshaft Intake camshaft Piston cooler Crankshaft Oil filter cartridge Oil tank Oil cooler Relief valve Check valve Strainer Flush oil pump Suction oil pump Oil pan Strainer 2 - 30...

  • Page 71: Coolant Flow Diagrams

    SPEC COOLANT FLOW DIAGRAMS EAS00035 COOLANT FLOW DIAGRAMS 1 Coolant reservoir 2 Thermostat 3 Radiator 4 Water pump 5 Radiator fan 6 Radiator cap 7 Fast idle plunger 2 - 31...

  • Page 72: Cable Routing

    SPEC CABLE ROUTING EAS00035 CABLE ROUTING 1 Headlight sub-wire harness É Connect the headlight sub-wire harness to the 2 Horn wire harness on top of the stay (left and right). 3 Horn (H mark on the back of the horn) After making the connection, push the coupler between the front cowling and the air filter case.
  • Page 73 SPEC CABLE ROUTING Ë Fasten the headlight sub-wire harness using a Ñ Route the throttle cables through the hole of the lead holder. (left and right) lower handlebar cover. Ì Connect the turn signal light. (left and right) Ò Connect the brake light switch lead through the Í...
  • Page 74 SPEC CABLE ROUTING Õ Fasten the right handlebar switch leads to the handlebar with a plastic band. Ö Route the rear brake hose and left handlebar switch leads over the wire harness. 2 - 34...
  • Page 75 SPEC CABLE ROUTING 1 Rear brake hose Ê Fasten the grommets on the brake hoses with 2 Front brake hose the holder. 3 Rear brake lock lever cable Ë Install the rear brake lock lever cable after lubri- 4 Left handlebar switch cating the grease to the cable end.
  • Page 76 SPEC CABLE ROUTING 1 Grommet C Fuel tank breather hose 2 Fuel over flow hose D Hose holder 3 Fuel tank E Hose holder 4 Fuel overflow tray F Fuel hose 5 Fuel tank cap G Fuel pump lead 6 Upper side cover moulding (left) H Hose guide 7 Hose guide I Roll over valve assembly...
  • Page 77 SPEC CABLE ROUTING È Do not protrude from the upper side cover moul- Î 2 ~ 5 mm (0.08 ~ 0.20 in) Ï Install the grommet to the footrest board ding (left). É Fix the fuel overflow hose with the white paint securely.
  • Page 78 SPEC CABLE ROUTING Ô Align the projection on the fuel pump with the Ø After connecting the fuel hose connector to the projection on the fuel tank when installing the fuel tank, install the fuel hose connector cover fuel pump. completely onto the connector.

  • Page 79: Xp500

    SPEC CABLE ROUTING XP500 1 Main switch/immobilizer unit A Throttle position sensor coupler 2 Throttle cable B Starter motor lead 3 Brake hose C Rectifier/regulator 4 Meter assembly D Starting circuit cut-off relay 1 5 Cooling system air bleed hose...
  • Page 80 SPEC CABLE ROUTING K Rear brake lock lever cable È After adjusting the adjustment nut, attach the L Negative battery lead front and rear parts of the boot tightly. M Seat lock cable (left) É Pass the seat lock cable between wire harness N Frame and frame.
  • Page 81 SPEC CABLE ROUTING Í After connecting the wire harness and meter Ñ Fasten the ECU (engine) lead to the stay 1 with assembly lead, use a plastic holder to connect a plastic holder. When fastening them using a them to stay 1. plastic holder, make sure not to cross the branch Î...
  • Page 82 SPEC CABLE ROUTING Õ Insert the tail/brake light coupler between the Ú Fasten the starter motor lead, negative battery wire harness and the seat lock cable (left). lead and seat lock cable (right) to the frame with Ö To the tail/brake light a plastic holder.
  • Page 83 SPEC CABLE ROUTING Þ Fasten the starter motor lead and negative bat- Á Fasten the O sensor lead and V-belt replace- tery lead to the frame with a plastic band. Posi- ment indicator reset coupler lead to the frame tion the band clasp on the bottom of the frame with a plastic holder.
  • Page 84 SPEC CABLE ROUTING Pass the wire harness to the frame wire har- ness holder. After making the connections, push the cou- plers into the space inside the frame above the mudguard. Install the band’s fastened part between frame and storage box. Route the seat lock cable through the frame bracket side and under the wire harness.
  • Page 85 SPEC CABLE ROUTING 1 Rear brake lock lever cable A Crankcase breather hose 2 Throttle cable (decelerator cable, double lock- B Throttle cable (accelerator cable, single locknut) nut) 3 Fast idle inlet hose È Pass the rear brake lock lever cable to the cable 4 Rear brake hose guide.
  • Page 86 SPEC CABLE ROUTING Ê Pass the fuel tank breather hose by the outside Î Fasten the sidestand switch lead to the frame of the wire harness. with a plastic holder. Ë Pass the wire harness by the outside of the rear Ï...
  • Page 87 SPEC CABLE ROUTING 1 Rear brake lock lever cable B Battery M Frame 2 Coolant system air bleed hose C Positive battery lead 3 Thermostat outlet hose D Fuel pump lead 4 Fuel tank breather hose E Fuel overflow hose 5 Fuel hose F Intake air pressure sensor 6 Negative battery lead...
  • Page 88 SPEC CABLE ROUTING È Route the wire harness against the stay 1 wire Ì Fasten the rear brake lock lever cable to the guide. frame with a plastic holder. É Fasten the lean angle cut-off switch lead to the Í Be sure not to pinch the storage box light switch stay 1 with a plastic band.
  • Page 89 SPEC CABLE ROUTING Ï Pass the wire harness and seat lock cable Ô Route the negative battery lead and the fuse box through the guide. lead from the storage box opening to the bottom Ð Fasten the negative battery lead and the starter of the cross pipe.
  • Page 90 SPEC CABLE ROUTING Ø Fasten the wire harness and seat lock cable to Ý Fasten the wire harness to the frame with a plas- the frame with a plastic holder. tic holder. Ù Pass the wire harness, lead and cable the out- Þ...
  • Page 91 SPEC CABLE ROUTING To the storage box light switch on the seat 10 ~ 15 mm (0.39 ~ 0.59 in) hinge. Route the wire harness through the wire guide. Fasten the fuel injector lead (#1/#2), intake air Pass the speed sensor lead under the stay 1 pressure sensor lead to the frame with a plas- and cross pipe, and then over the brake hose tic holder.
  • Page 92 SPEC CABLE ROUTING 1 Cooling system air bleed hose È Pass the rear brake lock lever cable on the front 2 Storage box light switch lead side of throttle cable. 3 Coolant reservoir hose É Position of clamp. 4 Spark plug lead #2 Ê...
  • Page 93 SPEC CABLE ROUTING Î Fasten the sidestand switch lead to the frame with a plastic holder. Ï Fasten the rear brake hose to the stay 1 with a plastic holder. Ð Route the throttle cable through the cable holder. Ê É...
  • Page 94 SPEC CABLE ROUTING 1 Brake hose holder 1 È Fasten the speed sensor lead along the inside of 2 Front brake hose the brake hose. 3 Speed sensor É 50 ~ 60 mm (1.97 ~ 2.36 in) 4 Plastic holder Ê...
  • Page 95 SPEC CABLE ROUTING Î Make sure that brake pipe touches the projec- Ô Engage the hose holder rib more than 3 notch. tion. Face the hose holder projection to the back. Ï Make sure that the slot in the speed sensor fits Õ...

  • Page 96: Xp500A

    SPEC CABLE ROUTING XP500A 1 Main switch/immobilizer unit A Coolant reservoir hose 2 ECU (ABS) B Throttle position sensor coupler 3 Throttle cable C Radiator fan motor lead 4 Brake hose D Starter motor lead 5 Fail-safe relay E Rectifier/regulator 6 Meter assembly F Starting circuit cut-off relay 2 7 Coolant system air bleed hose...
  • Page 97 SPEC CABLE ROUTING V Storage box sensor coupler L Fuel pump lead W V-belt replacement indicator reset coupler lead M Fuel tank breather hose sensor lead N Rear brake lock lever cable Y Fuel hose O Main switch lead P Wire harness Q Seat lock cable R Seat lock cable (left) S Negative battery lead...
  • Page 98 SPEC CABLE ROUTING È After adjusting the adjustment nut, attach the Ì Route the main switch lead in front of the ignition front and rear parts of the boot tightly. coil bracket, then to the outside of the frame. É Pass the seat lock cable between wire harness Í...
  • Page 99 SPEC CABLE ROUTING Ð After connecting the left headlight sub-wire har- Ó Fasten the ECU (engine) lead, ABS test coupler ness and wire harness (by matching the coupler lead and headlight sub-wire harness to the stay colors), fold back the lead facing to the right and 1 with a plastic holder.
  • Page 100 SPEC CABLE ROUTING × Fasten the radiator fan motor lead and sidestand Û Make sure that the seat lock cable do not lean switch lead to the frame with a plastic holder. over the storage box. Ø Fasten the wire harness and positive battery Ü...
  • Page 101 SPEC CABLE ROUTING À Fasten the O sensor lead to the frame with a Fasten the O sensor lead and V-belt replace- plastic band. ment indicator reset coupler lead to the frame Á Fasten the starter motor lead and negative bat- with a plastic holder.
  • Page 102 SPEC CABLE ROUTING Fasten the rear wheel sensor lead to the swin- After making the connections, push the cou- garm with the plastics holders. The open end plers into the space inside the frame above the of each holder should be facing downward. mudguard.
  • Page 103 SPEC CABLE ROUTING T stud for position setting Route the seat lock cable through the frame bracket side and under the wire harness. Install the band’s fastened part between frame and storage box. Ï Ð Ñ Î Ì Í Ò Ë...
  • Page 104 SPEC CABLE ROUTING 1 Rear brake lock lever cable A Crankcase breather hose 2 Throttle cable (decelerator cable, double lock- B Throttle cable (accelerator cable, single locknut) nut) 3 Fast idle inlet hose È Pass the rear brake lock lever cable to the cable 4 Rear brake hose guide.
  • Page 105 SPEC CABLE ROUTING Ë Pass the wire harness by the outside of the rear Ï Pass the front wheel sensor lead to the lead footrest mounting boss. (When installing the rear holder (2 locations). footrest, do not catch or pinch the A.C. magneto lead in the bracket.) Ì...
  • Page 106 SPEC CABLE ROUTING 1 Rear brake lock lever cable B Battery M Fuel injector lead #2 2 Cooling system air bleed hose C Seat lock N Seat lock cable 3 Thermostat outlet hose D Positive battery lead O Wire harness 4 Fuel tank breather hose E Fuel pump lead P Storage box light connector...
  • Page 107 SPEC CABLE ROUTING È Route the wire harness against the stay 1 wire Í Fasten the rear brake lock lever cable to the guide. frame with a plastic holder. É Fasten the lean angle cut-off switch lead to the Î Be sure not to pinch the storage box light switch stay 1 with a plastic band.
  • Page 108 SPEC CABLE ROUTING Ñ Connect the seat lock cable (black) to the right Õ Place the rubber cover over the starter relay, seat lock. starter relay coupler, positive battery lead termi- Ò Pass the seat lock cable (black) between the nal, and starter motor lead terminal.
  • Page 109 SPEC CABLE ROUTING Ú Fasten the wire harness, positive battery lead ß Connect the ABS motor fuse box to the fuse box 2. À Install the storage box light switch to the storage and seat lock cable to the mad guard with a plastic holder.
  • Page 110 SPEC CABLE ROUTING Fasten the fuel injector lead (#1/#2), intake air Pass the front wheel sensor lead under the pressure sensor lead to the frame with a plas- stay 1 and cross pipe. tic holder. Place the front wheel sensor lead between the Pass the intake air pressure sensor lead over ribs of the air filter case.
  • Page 111 SPEC CABLE ROUTING 1 Throttle cable B Rear brake lock lever cable 2 Fail-safe relay C Stay 1 3 ECU (ABS) D Rear brake hose 4 ABS test coupler E Hydraulic unit 5 Cooling system air bleed hose F Hydraulic unit solenoid coupler 6 Storage box light switch lead G Front wheel sensor coupler 7 Coolant reservoir hose...
  • Page 112 SPEC CABLE ROUTING Ë Route the main switch lead over the tube of the Ð Fasten the sidestand switch lead to the frame stay 1. with a plastic holder. Ì Fasten the cooling system air bleed hose to the Ñ Fasten the storage box light switch lead to the stay 1 with a plastic holder.
  • Page 113 SPEC CABLE ROUTING 1 Front wheel sensor 0 Brake hose (hydraulic unit to rear brake caliper) 2 ABS motor coupler A Brake hose (hydraulic unit to front brake caliper) 3 Fail-safe relay 4 ECU (ABS) È Route the front wheel sensor lead in front of the 5 Hydraulic unit solenoid coupler brake hose (hydraulic unit to front brake cali- 6 Hydraulic unit overflow hose...
  • Page 114 SPEC CABLE ROUTING Ë Route the hydraulic unit overflow hose to the Ï Install the brake hose (hydraulic unit to front outside of the stay 1. brake caliper) onto the hydraulic unit. The brake Ì Fasten the hydraulic unit overflow hose with the hose and its union bolt hole are identified by lower hose holder first, and then fasten it with white paint marks.
  • Page 115 SPEC CABLE ROUTING Ñ Route the hydraulic unit solenoid lead and ABS Ó Fasten the grommets on the brake hose (front motor lead under the hydraulic unit when install- brake master cylinder to hydraulic unit) and the ing the unit, making sure not to pinch the leads brake hose (rear brake master cylinder to between the hydraulic unit and hydraulic unit hydraulic unit) with the brake hose holder.
  • Page 116 SPEC CABLE ROUTING 1 Plastic holder È Engage the hose holder rib more than 3 notch. 2 Brake hose holder 2 Face the hose holder projection to the back. 3 Brake hose holder 1 É Make sure that the white paint on the brake hose 4 Front brake hose faces to back (right side only).
  • Page 117 SPEC CABLE ROUTING Í Install the stopper to lower bracket projection. Ó Make sure that brake pipe touches the projec- Î Fasten the front wheel sensor lead to the center tion. Ô Make sure that the slot in the sensor housing fits of brake hose holder.
  • Page 120 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART ......3-1 SEAT ....................... 3-3 COVER AND PANEL ..................3-4 FRONT COWLING ..................3-4 SIDE COVER MOULDINGS AND LEG SHIELD........3-5 REAR COVERS AND TAIL/BRAKE LIGHT ASSEMBLY ......3-6 FUEL TANK.....................
  • Page 121 CHECKING THE BRAKE FLUID LEVEL..........3-47 CHECKING THE BRAKE PADS ............. 3-48 CHECKING THE BRAKE HOSES............3-48 BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500) .....3-49 BLEEDING THE BRAKE SYSTEM (XP500A).........3-50 CHECKING AND ADJUSTING THE STEERING HEAD ......3-53 CHECKING THE FRONT FORK ............. 3-56 CHECKING THE TIRES................3-57...

  • Page 122: Periodic Checks And Adjustments

    • From 50000 km, repeat the maintenance intervals starting from 10000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)
  • Page 123 PERIODIC MAINTENANCE AND LUBRICATION CHART ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ √ √ • Check bearing play and steering for roughness. Steering bearings 13 * (See page 4-86.) • Lubricate with lithium-soap-based grease. Every 20000 km Chassis fasteners •...

  • Page 124: Seat

    SEAT SEAT Order Job/Part Q’ty Remarks Removing the seat Removing the parts in the order listed. Fuel lid Seat For installation, reverse the removal pro- cedure. 3 - 3...

  • Page 125: Cover And Panel

    COVER AND PANEL COVER AND PANEL FRONT COWLING Order Job/Part Q’ty Remarks Removing the front cowling Removing the parts in the order listed. Footrest board mat (left and right) Front side cover moulding (left and right) Rearview mirror (left and right) Front cowling upper cover Windshield Front cowling inner panel...

  • Page 126: Side Cover Mouldings And Leg Shield

    COVER AND PANEL SIDE COVER MOULDINGS AND LEG SHIELD Order Job/Part Q’ty Remarks Removing the side cover mouldings Removing the parts in the order listed. and leg shield Upper side cover mole (left and right) Lower side cover mole (left and right) Center cover Hinge cover Side cover (left and right)

  • Page 127: Rear Covers And Tail/Brake Light Assembly

    COVER AND PANEL REAR COVERS AND TAIL/BRAKE LIGHT ASSEMBLY Order Job/Part Q’ty Remarks Removing the rear covers and tail/ Removing the parts in the order listed. brake light assembly Seat Open. Upper side cover mole (left and right) Refer to “SIDE COVER MOULDINGS AND LEG SHIELD”.

  • Page 128: Fuel Tank

    FUEL TANK FUEL TANK 10 Nm (1.0 m kg, 7.2 ft 4 Nm (0.4 m kg, 2.9 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 129 FUEL TANK 10 Nm (1.0 m kg, 7.2 ft 4 Nm (0.4 m kg, 2.9 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 130: Removing The Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose connector cover 1 3. Disconnect: • fuel hose 2 • fuel pump coupler 3 •...

  • Page 131: Installing The Fuel Pump

    FUEL TANK INSTALLING THE FUEL PUMP 1. Install: • fuel pump gasket • fuel pump • fuel pump bracket 4 Nm (0.4 m · kg, 2.9 ft · lb) NOTE: • Do not damage the installation surfaces of the fuel tank when installing the fuel pump. •...

  • Page 132: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 133 ADJUSTING THE VALVE CLEARANCE 7. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in) Exhaust valve 0.25 ~ 0.30 mm (0.0098 ~ 0.0118 in) M MMM M MMM M MMM M MMM M MMM...
  • Page 134 ADJUSTING THE VALVE CLEARANCE 8. Remove: • intake camshaft • exhaust camshaft CAUTION: Before removing the camshafts from the cylinder head, tilt up the engine at least 25°. NOTE: • Refer to “CAMSHAFTS” in chapter 5. • When removing the timing chain and cam- shafts, fasten a wire to the timing chain to retrieve it if it falls into the crankcase.
  • Page 135 ADJUSTING THE VALVE CLEARANCE c. Round off the original valve pad number according to the following table. Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm (0.058 in)) Rounded value = 150 d.
  • Page 136 ADJUSTING THE VALVE CLEARANCE f. Install the exhaust and intake camshafts, timing chain and camshaft caps. Camshaft cap bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • Refer to “CAMSHAFTS” in chapter 5. • Lubricate the camshaft bearings, camshaft lobes and camshaft journals.
  • Page 137 ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLE INTAKE ORIGINAL VALVE PAD NUMBER MEASURED VALVE CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 ~ 0.07...

  • Page 138: Synchronizing The Throttle Bodies

    ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE THROTTLE BODIES 10.Install: • all removed parts NOTE: For installation, reverse the removal proce- dure. SYNCHRONIZING THE THROTTLE BODIES NOTE: Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked.
  • Page 139 SYNCHRONIZING THE THROTTLE BODIES 6. Measure: • engine idling speed Out of specification → Adjust. Refer “ADJUSTING ENGINE IDLING SPEED”. Engine idling speed 1,100 ~ 1,300 r/min 7. Adjust: • throttle body synchronization M MMM M MMM M MMM M MMM M MMM a.

  • Page 140: Adjusting The Exhaust Gas Volume

    SYNCHRONIZING THE THROTTLE BODIES/ ADJUSTING THE EXHAUST GAS VOLUME 9. Stop the engine and remove the measuring equipment. 10.Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0.12 ~ 0.20 in) 11.Remove: •...

  • Page 141: Checking The Exhaust Gas At Idle

    ADJUSTING THE EXHAUST GAS VOLUME/ CHECKING THE EXHAUST GAS AT IDLE 5. Press the “SELECT” 1 and “RESET” 2 buttons to select a cylinder. NOTE: The selected cylinder number appears on the tripmeter LCD. • Both the “SELECT” button and “RESET” but- ton can be used to change the selected cylin- der number.
  • Page 142 CHECKING THE EXHAUST GAS AT IDLE 2. Remove: • center cover • side cover (left and right) Refer to “SIDE COVER MOULDINGS AND LEG SHIELD”. 3. Install: • pocket tester 1 (onto the engine oil drain bolt) Pocket tester 90890-03112, YU-03112-C 4.

  • Page 143: Adjusting The Engine Idling Speed

    CHECKING THE EXHAUST GAS AT IDLE/ ADJUSTING THE ENGINE IDLING SPEED 7. Measure: • carbon monoxide density • hydrocarbon density Out of specification → Replace the muffler assembly. Carbon monoxide density (when catalytic converter is operating) 0.2 ~ 1.2% (Reference value) 8.

  • Page 144: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 5. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0.12 ~ 0.20 in) 6.
  • Page 145 ADJUSTING THE THROTTLE CABLE FREE PLAY 3. Adjust: • throttle cable free play M MMM M MMM M MMM M MMM M MMM NOTE: When the scooter is accelerating, the acceler- ator cable 1 is pulled. Throttle body side a. Loosen the locknut 1 on the decelerator cable.

  • Page 146: Checking The Spark Plugs

    ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS e. Slide the rubber cover to its original posi- tion. WARNING After adjusting the throttle cable free play, turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.

  • Page 147: Checking The Ignition Timing

    CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING 5. Check: • electrode 1 Damage/wear → Replace the spark plug. • insulator 2 Abnormal color → Replace the spark plug. Normal color is a medium-to-light tan color. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7.

  • Page 148: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 3. Install: • timing light 1 (onto the spark plug lead of cylinder #1) Timing light 90890-03141, YM-33277-B 4. Check: • ignition timing M MMM M MMM M MMM M MMM M MMM a.
  • Page 149 MEASURING THE COMPRESSION PRESSURE 1. Remove: • footrest board (left and right) • inner fender Refer to “SIDE COVER MOULDINGS AND LEG SHIELD”. 2. Measure: • valve clearance Out of specification → Adjust. Refer “ADJUSTING VALVE CLEARANCE”. 3. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 150 MEASURING THE COMPRESSION PRESSURE M MMM M MMM M MMM M MMM M MMM a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING To prevent sparking, ground all spark plug leads before cranking the engine.

  • Page 151: Checking The Engine Oil Level

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CHECKING THE ENGINE OIL LEVEL 1. Stand the scooter on a level surface. NOTE: • Place the scooter on a suitable stand. • Make sure that the scooter is upright. 2. Start the engine when the engine is cool, let it idle for two minutes, and then stop it.
  • Page 152 CHANGING THE ENGINE OIL 3. Remove: • engine oil filler cap 1 • engine oil drain bolt 2 (along with the gasket) 4. Drain: • engine oil (completely from the crankcase) 5. If the oil filter cartridge is also to be replaced, perform the following procedure.
  • Page 153 CHANGING THE ENGINE OIL 8. Fill: • crankcase (with the specified amount of the recom- mended engine oil) Quantity Total amount 3.6 L (3.17 Imp qt, 3.81 US qt) Without oil filter cartridge replacement 2.8 L (2.46 Imp qt, 2.96 US qt) With oil filter cartridge replace- ment 2.9 L (2.55 Imp qt, 3.07 US qt)

  • Page 154: Measuring The Engine Oil Pressure

    MEASURING THE ENGINE OIL PRESSURE EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: • engine oil level Below the minimum level mark → Add the recommended engine oil to the proper level. 2. Remove: • left lower side cover mole Refer to “SIDE COVER MOULDINGS AND LEG SHIELD”.

  • Page 155: Cleaning The Air Filter Element

    MEASURING THE ENGINE OIL PRESSURE/ CLEANING THE AIR FILTER ELEMENT 6. Measure: • engine oil pressure (at the following conditions) Out of specification → Replace. Engine oil pressure 150 kPa (1.50 kg/cm , 21.8 psi) at 1,200 r/min Engine oil temperature 70 °C (158 °F) Engine oil pressure Possible causes Faulty oil pump...

  • Page 156: Cleaning The V-Belt Case Air Filter Element

    CLEANING THE AIR FILTER ELEMENT/ CLEANING THE V-BELT CASE AIR FILTER ELEMENT 5. Install: • air filter element • air filter case cover CAUTION: Never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine.
  • Page 157 CLEANING THE V-BELT CASE AIR FILTER ELEMENT 3. Remove: • V-belt case air filter element (left) 1 • V-belt case air filter element (right) 2 4. Clean: • V-belt case air filter element Apply compressed air to the inner surface of V-belt case air filter element.

  • Page 158: Checking The Throttle Body Joints And Intake Manifolds

    CHECKING THE THROTTLE BODY JOINTS AND INTAKE MANIFOLDS/ CHECKING THE FUEL HOSES AND FUEL TANK BREATHER HOSE/ CHECKING THE CRANKCASE BREATHER HOSE CHECKING THE THROTTLE BODY JOINTS AND INTAKE MANIFOLDS The following procedure applies to all of the throttle body joints and intake manifolds. 1.

  • Page 159: Checking The Crankcase Breather Hose

    CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM 2. Check: • crankcase breather hose 1 Cracks/damage → Replace. Loose connection → Connect properly. CAUTION: Make sure that the crankcase breather hose is routed correctly. 3. Install: • leg shield Refer to “SIDE COVER MOULDINGS AND LEG SHIELD”.

  • Page 160: Checking The Coolant Level

    CHECKING THE EXHAUST SYSTEM/ CHECKING THE COOLANT LEVEL 4. Install: • inner fender Refer to “SIDE COVER MOULDINGS AND LEG SHIELD”. • right rear side cover Refer to “REAR COVERS AND TAIL/ BRAKE LIGHT ASSEMBLY”. EAS00103 CHECKING THE COOLANT LEVEL 1.

  • Page 161: Checking The Cooling System

    CHECKING THE COOLING SYSTEM CHECKING THE COOLING SYSTEM 1. Remove: • footrest board (left and right) • leg shield • inner fender Refer to “SIDE COVER MOULDINGS AND LEG SHIELD”. 2. Check: • radiator 1 • radiator inlet hose 2 •...

  • Page 162: Changing The Coolant

    CHANGING THE COOLANT CHANGING THE COOLANT 1. Remove: • left footrest board mat • front side cover mole (left and right) Refer to “FRONT COWLING”. • coolant reservoir cap access panel • lower side cover mole (left and right) • inner fender Refer to “SIDE COVER MOULDINGS AND LEG SHIELD”.
  • Page 163 CHANGING THE COOLANT 7. Check: • rubber washer 1 • drain bolt 2 8. Install: • drain bolt 1.6 Nm (0.16 m · kg, 1.2 ft · lb) 9. Connect: • coolant reservoir hose 10.Fill: • cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol...

  • Page 164: Checking The Chain Drive Oil Level

    CHANGING THE COOLANT/ CHECKING THE CHAIN DRIVE OIL LEVEL • Use only distilled water. Soft water may be used if distilled water is not available. • If coolant comes into contact with painted surfaces, immediately wash them with water. • Do not mix different types of antifreeze. 11.Install: •...

  • Page 165: Changing The Chain Drive Oil

    CHECKING THE CHAIN DRIVE OIL LEVEL/ CHANGING THE CHAIN DRIVE OIL 3. Remove: • chain drive oil filler cap 1 4. Check: • chain drive oil level Wipe the dipstick clean, insert it into the oil filler hole (without screw it in), and then remove it to check the oil level.
  • Page 166 CHECKING THE CHAIN DRIVE OIL LEVEL 5. Fill: • chain drive oil (with the specified amount of the recom- mended chain drive oil) Quantity 0.70 L (0.62 Imp qt, 0.74 US qt) 6. Check: • chain drive oil level Refer to “CHECKING THE CHAIN DRIVE OIL LEVEL”.

  • Page 167: Chassis

    ADJUSTING THE REAR BRAKE LOCK LEVER CABLE CHASSIS ADJUSTING THE REAR BRAKE LOCK LEVER CABLE WARNING Do not use the rear brake lock lever while driving. NOTE: • Place the scooter on the centerstand. • Before adjusting the rear brake lock lever, check the rear brake fluid level.

  • Page 168: Checking The Brake Fluid Level

    CHECKING THE BRAKE FLUID LEVEL EAS00116 CHECKING THE BRAKE FLUID LEVEL 1. Stand the scooter on a level surface. NOTE: • Place the scooter on a suitable stand. • Make sure that the scooter is upright. 2. Check: È • brake fluid level Below the minimum level mark a →...

  • Page 169: Checking The Brake Pads

    CHECKING THE BRAKE PADS/ CHECKING THE BRAKE HOSES CHECKING THE BRAKE PADS È The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pad Wear indicator groove 1 almost disap- peared → Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES”...

  • Page 170: Bleeding The Hydraulic Brake System (Xp500)

    BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500) EAS00135 BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500) WARNING Bleed the hydraulic brake system when- ever: • the system was disassembled. • a brake hose was loosened, disconnected or replaced. • the brake fluid level is very low.

  • Page 171: Bleeding The Brake System (Xp500A)

    BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)/ BLEEDING THE BRAKE SYSTEM (XP500A) g. Loosen the bleed screw. NOTE: Loosening the bleed screw will release the pressure and cause the brake levers to contact the handlebar. h. Tighten the bleed screw and then release the brake lever.
  • Page 172 BLEEDING THE BRAKE SYSTEM (XP500A) WARNING Bleed the ABS whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. NOTE: • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to over- flow.
  • Page 173 BLEEDING THE BRAKE SYSTEM (XP500A) g. Loosen the bleed screw. NOTE: Loosening the bleed screw will release the pressure and cause the brake levers to contact the handlebar. h. Tighten the bleed screw, and then release the brake lever. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.

  • Page 174: Checking And Adjusting The Steering Head

    CHECKING AND ADJUSTING THE STEERING HEAD EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
  • Page 175 CHECKING AND ADJUSTING THE STEERING HEAD 6. Adjust: • steering head M MMM M MMM M MMM M MMM M MMM a. Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3. b. Loosen the lower ring nut 4 and then tighten it to specification with a steering nut wrench 5.
  • Page 176 CHECKING AND ADJUSTING THE STEERING HEAD 7. Install: • upper bracket 1 • steering stem nut 2 8. Tighten: • upper bracket pinch bolt 30 Nm (3.0 m · kg, 22 ft · lb) • steering stem nut 110 Nm (11.0 m · kg, 80 ft · lb) 9.

  • Page 177: Checking The Front Fork

    CHECKING THE FRONT FORK EAS00149 CHECKING THE FRONT FORK 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Check: • inner tube Damage/scratches → Replace. •...

  • Page 178: Checking The Tires

    • Operation of an overloaded scooter could cause tire damage, an accident or an injury. NEVER OVERLOAD THE SCOOTER. Basic weight 225 kg (496 lb) (XP500) (with oil and a 230 kg (507 lb) (XP500A) full fuel tank) Maximum 190 kg (419 lb) (XP500)
  • Page 179 Tubeless wheel Tube or tubeless • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.

  • Page 180: Checking The Wheels

    CHECKING THE TIRES/ CHECKING THE WHEELS Front tire Manufacturer Size Model 120/70R14 BRIDGESTONE TH01F M/C 55H 120/70R14 DUNLOP D252F M/C 55H Rear tire Manufacturer Size Model 160/60R-15 BRIDGESTONE TH01R M/C 67H 160/60R-15 DUNLOP D252 M/C 67H WARNING After mounting a new tire, ride conserva- tively for a while to become accustomed to the “feel”...

  • Page 181: Checking And Lubricating The Cables

    CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS/ LUBRICATING THE CENTERSTAND EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables. WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its movement.

  • Page 182: Lubricating The Sidestand

    LUBRICATING THE SIDESTAND EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of sidestand. Recommended lubricant Lithium-soap-based grease 3 - 61...

  • Page 183: Chk Adj

    CHECKING AND CHARGING THE BATTERY EAS00179 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 184 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 185 CHECKING AND CHARGING THE BATTERY 5. Charge: Charging Ambient temperature 20 °C (68 °F) • battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. • Never remove the MF battery sealing caps.
  • Page 186 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charger NOTE: Ammeter Leave the battery unused for more than 30 minutes before Measure the open-circuit measuring its open-circuit voltage. voltage prior to charging. NOTE: Set the charging voltage to Connect a charger and 16 ~ 17 V.
  • Page 187 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.

  • Page 188: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: • battery terminals Dirt →...
  • Page 189 Set the main switch to “ON” and verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit. L LLL L LLL L LLL L LLL L LLL È XP500 É É XP500A 3 - 68...
  • Page 190 CHECKING THE FUSES Item Amperage Q’ty Main fuse 30 A Headlight fuse 15 A Signaling system 20 A (XP500) fuse 15 A (XP500A) Ignition fuse 10 A Radiator fan motor 15 A fuse Lighting system 10 A fuse Fuel injection sys-...

  • Page 191: Replacing The Headlight Bulbs

    REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Remove: • front cowling Refer to “FRONT COWLING”. 2. Disconnect: • headlight coupler 1 3. Remove: • headlight bulb holder cover 2 4.

  • Page 192: Adjusting The Headlight Beam

    REPLACING THE HEADLIGHT BULBS/ ADJUSTING THE HEADLIGHT BEAM 8. Install: • headlight bulb holder cover 9. Connect: • headlight coupler 10.Install: • front cowling Refer to “FRONT COWLING”. EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • headlight beam (vertically) M MMM M MMM M MMM M MMM...

  • Page 194: Chas

    CHAS...
  • Page 195 CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC............... 4-1 REMOVING THE FRONT WHEEL (XP500) ..........4-6 REMOVING THE FRONT WHEEL AND FRONT WHEEL SENSOR (XP500A) ....................4-6 CHECKING THE FRONT WHEEL ............4-8 CHECKING THE BRAKE DISC..............4-9 CHECKING THE FRONT WHEEL SENSOR AND SENSOR ROTOR (XP500A) ....................4-11...
  • Page 196 CHAS FRONT AND REAR BRAKES............... 4-24 FRONT BRAKE PADS ................4-24 REAR BRAKE PADS................4-25 REPLACING THE FRONT BRAKE PADS ..........4-26 REPLACING THE REAR BRAKE PADS..........4-28 FRONT BRAKE MASTER CYLINDER............4-32 REAR BRAKE MASTER CYLINDER ............4-35 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ..... 4-38 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER....
  • Page 197 CHAS REAR SHOCK ABSORBER .................4-89 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER..4-90 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER ................4-90 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-91 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER ................4-91 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ....
  • Page 198 CHAS...

  • Page 199: Front Wheel And Brake Disc

    Front brake caliper (left and right) Refer to “REMOVING Front wheel axle pinch bolt Loosen. THE FRONT WHEEL Front wheel axle (XP500)” and “INSTALL- ING THE FRONT WHEEL Front wheel (XP500)”. Speed sensor Collar Dust cover...
  • Page 200 CHAS FRONT WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. (XP500) Oil seal Bearing Collar For assembly, reverse the disassembly procedure. 4 - 2...
  • Page 201 CHAS FRONT WHEEL AND BRAKE DISC EAS00889 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • 23 Nm (2.3 m kg, 17 ft • • 40 Nm (4.0 m kg, 29 ft •...
  • Page 202 CHAS FRONT WHEEL AND BRAKE DISC 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • 23 Nm (2.3 m kg, 17 ft • • 40 Nm (4.0 m kg, 29 ft •...
  • Page 203 CHAS FRONT WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. (XP500A) Oil seal Bearing Collar For assembly, reverse the disassembly procedure. 4 - 5...

  • Page 204: Removing The Front Wheel (Xp500)

    CHAS FRONT WHEEL AND BRAKE DISC EAS00520 REMOVING THE FRONT WHEEL (XP500) 1. Stand the scooter on a level surface. WARNING Securely support the so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
  • Page 205 CHAS FRONT WHEEL AND BRAKE DISC 1. Stand the scooter on a level surface. WARNING Securely support the so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2.

  • Page 206: Checking The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EAS00525 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent wheel axle. 2. Check: • tire •...

  • Page 207: Checking The Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC 5. Replace: • wheel bearings • oil seals M MMM M MMM M MMM M MMM M MMM a. Clean the outside of the front wheel hub. b. Remove the oil seals 1 with a flat-head screwdriver.
  • Page 208 CHAS FRONT WHEEL AND BRAKE DISC b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is sta- tionary. c. Remove the brake caliper. d. Hold the dial gauge at a right angle against the brake disc surface.

  • Page 209: Checking The Front Wheel Sensor And Sensor Rotor (Xp500A)

    CHAS FRONT WHEEL AND BRAKE DISC CHECKING THE FRONT WHEEL SENSOR AND SENSOR ROTOR (XP500A) 1. Check: • front wheel sensor 1 Cracks/bends/distortion → Replace. Iron powder/dust → Clean. 2. Measure: • front wheel sensor resistance Connect the pocket tester (Ω × 1k) to the terminals of the front wheel sensor coupler.
  • Page 210 CHAS FRONT WHEEL AND BRAKE DISC 2. Find: • front wheel’s heavy spot M MMM M MMM M MMM M MMM M MMM a. Place the front wheel on a suitable balanc- ing stand. b. Spin the front wheel. c. When the front wheel stops, put an “X ”...

  • Page 211: Installing The Front Wheel (Xp500)

    CHAS FRONT WHEEL AND BRAKE DISC EAS00542 INSTALLING THE FRONT WHEEL (XP500) 1. Lubricate: • oil seal lips • speedometer drive gear • speedometer driven gear Recommended lubricant Lithium-soap-based grease 2. Install: • speed sensor (to front wheel) NOTE: Make sure that the speed sensor unit and the wheel hub are installed with the two projec- tions meshed into the two slots respectively.

  • Page 212: Installing The Front Wheel And Front Wheel Sensor (Xp500A)

    CHAS FRONT WHEEL AND BRAKE DISC 5. Install: • front brake calipers WARNING Make sure that the brake hoses are routed properly. 6. Tighten: • front brake caliper bracket bolt 1 40 Nm (4.0 m · kg, 29 ft · lb) EAS00542 INSTALLING THE FRONT WHEEL AND FRONT WHEEL SENSOR (XP500A)
  • Page 213 CHAS FRONT WHEEL AND BRAKE DISC 3. Tighten: • front wheel axle 1 59 Nm (5.9 m · kg, 43 ft · lb) Use the damper rod holder 2. • front wheel axle pinch bolt 3 23 Nm (2.3 m · kg, 17 ft · lb) Damper rod holder (14 mm) 90890-04085 CAUTION:...

  • Page 214: Rear Wheel And Brake Disc

    REAR WHEEL AND BRAKE DISC REAR WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Removing the rear wheel (XP500) Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated. Rear brake caliper...
  • Page 215 CHAS REAR WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Removing the rear wheel (XP500A) Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated. Tail/brake light assembly Refer to “COVER AND PANEL”...
  • Page 216 CHAS REAR WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Rear wheel axle pinch bolt Loosen. Refer to “INSTALLING THE REAR WHEEL SEN- Rear wheel axle nut/washer SOR (XP500A)”. Rear wheel axle Collar Sensor housing Refer to “INSTALLING THE REAR WHEEL SENSOR (XP500A)”.
  • Page 217 CHAS REAR WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Brake disc Rear wheel drive hub O-ring Oil seal Bearing For assembly, reverse the disassembly procedure. 4 - 19...

  • Page 218: Removing The Rear Wheel (Xp500)

    CHAS REAR WHEEL AND BRAKE DISC EAS00561 REMOVING THE REAR WHEEL (XP500) 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.

  • Page 219: Checking The Rear Wheel Sensor And Sensor Rotor (Xp500A)

    CHAS REAR WHEEL AND BRAKE DISC 3. Remove: • brake caliper NOTE: Do not squeeze the brake lever when remov- ing the brake caliper. CHECKING THE REAR WHEEL SENSOR AND SENSOR ROTOR (XP500A) Refer to “CHECKING THE FRONT WHEEL SENSOR AND SENSOR ROTOR (XP500A)”. EAS00565 CHECKING THE REAR WHEEL 1.

  • Page 220: Adjusting The Rear Wheel Static Balance

    CHAS REAR WHEEL AND BRAKE DISC EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed.
  • Page 221 CHAS REAR WHEEL AND BRAKE DISC 2. Install: • rear wheel sensor 1 30 Nm (3.0 m · kg, 22 ft · lb) NOTE: When installing the rear wheel sensor, check the rear wheel sensor lead for twists and the sensor electrode for foreign materials.

  • Page 222: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES FRONT BRAKE PADS 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Front brake caliper retaining bolt (lower) Front brake caliper retaining bolt (upper)

  • Page 223: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES REAR BRAKE PADS Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Rear brake caliper retaining bolt Rear brake caliper bracket bolt Brake caliper Brake pad Refer to “REPLACING THE REAR BRAKE PADS”.

  • Page 224: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 225 CHAS FRONT AND REAR BRAKES 3. Measure: • brake pad thickness a Out of specification → Replace the brake pads as a set. Minimum brake pad thickness 0.8 mm (0.03 in) 4. Install: • brake pad spring 1 • brake pad springs 2 •...

  • Page 226: Replacing The Rear Brake Pads

    8. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” and “BLEED- ING THE BRAKE SYSTEM (XP500A)” in chapter 3. EAS00583 REPLACING THE REAR BRAKE PADS NOTE:...
  • Page 227 CHAS FRONT AND REAR BRAKES 2. Remove: • brake pads 1 • brake pad springs 2 3. Measure: • brake pad thickness a Out of specification → Replace the brake pads as a set. Minimum brake pad thickness 0.8 mm (0.03 in) 4.
  • Page 228 CHAS FRONT AND REAR BRAKES M MMM M MMM M MMM M MMM M MMM a. Connect a suitable hose 1 tightly to the brake caliper bleed screw 2. Put the other end of this hose into an open container. b.
  • Page 229 LEVEL” in chapter 3. 9. Check: • brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” and “BLEED- ING THE BRAKE SYSTEM (XP500A)” in chapter 3. 4 - 31...

  • Page 230: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Upper handlebar cover Refer to “HANDLEBAR”. Brake fluid Drain. Brake master cylinder reservoir cap Brake master cylinder reservoir dia- phragm holder Brake master cylinder reservoir dia-...
  • Page 231 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Union bolt Refer to “DISASSEMBLING THE Brake hose FRONT BRAKE MASTER CYLINDER” Copper washer and “ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLIN- Brake master cylinder holder DER”. Brake master cylinder Front brake light switch For installation, reverse the removal pro- cedure.
  • Page 232 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly procedure. 4 - 34...

  • Page 233: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order listed. inder Upper handlebar cover Refer to “HANDLEBAR”. Brake fluid Drain. Brake master cylinder reservoir cap Brake master cylinder reservoir dia- phragm holder Brake master cylinder reservoir dia-...
  • Page 234 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Union bolt Refer to “DISASSEMBLING THE REAR Brake hose BRAKE MASTER CYLINDER” and Copper washer “ASSEMBLING AND INSTALLING THE Brake master cylinder holder REAR BRAKE MASTER CYLINDER”. Brake master cylinder Rear brake light switch For installation, reverse the removal pro- cedure.

  • Page 235: Disassembling The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly procedure. 4 - 37...
  • Page 236 CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hoses 3 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the...

  • Page 237: Checking The Front And Rear Brake Master Cylinders

    CHAS FRONT AND REAR BRAKES EAS00592 È CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: • brake master cylinder 1 Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction →...

  • Page 238: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00596 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components.
  • Page 239 CHAS FRONT AND REAR BRAKES 3. Install: • copper washers 1 • brake hose 2 • union bolt 3 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Proper brake hose routing is essential to insure safe scooter operation. Refer to “CABLE ROUTING”...

  • Page 240: Assembling And Installing The Rear Brake Master Cylinder

    Therefore, always clean up any spilt brake fluid immediately. 6. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” and “BLEED- ING THE BRAKE SYSTEM (XP500A)” in chapter 3. 7. Check: • brake fluid level Below the minimum level mark a →...
  • Page 241 CHAS FRONT AND REAR BRAKES 2. Install: • brake master cylinder 1 • brake master cylinder holder 2 • holder bolts 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • Install the brake master cylinder holder with the “UP”...
  • Page 242 Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” and “BLEED- ING THE BRAKE SYSTEM (XP500A)” in chapter 3. 6. Check: • brake fluid level Below the minimum level mark a →...

  • Page 243: Front Brake Caliper

    CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPER 27 Nm (2.7 m kg, 19 ft • • 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty Remarks Removing the front brake caliper Remove the parts in the order listed.
  • Page 244 CHAS FRONT AND REAR BRAKES 27 Nm (2.7 m kg, 19 ft • • 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty Remarks Front brake caliper bracket bolt 2 Refer to “ASSEMBLING AND INSTALL- ING THE FRONT BRAKE CALIPER”.
  • Page 245 CHAS FRONT AND REAR BRAKES EAS00614 Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. Bleed screw Dust seal Refer to “DISASSEMBLING THE FRONT BRAKE CALIPER” and Brake caliper piston seal “ASSEMBLING AND INSTALLING THE Brake caliper piston FRONT BRAKE CALIPER”.

  • Page 246: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES REAR BRAKE CALIPER Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. Rear brake lock lever cable Refer to “DISASSEMBLING THE REAR BRAKE CALIPER”. Spring Union bolt Refer to “DISASSEMBLING THE REAR BRAKE CALIPER”...
  • Page 247 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Brake pad spring Refer to “ASSEMBLING AND INSTALL- Rear brake caliper bracket bolt ING THE REAR BRAKE CALIPER”. Brake caliper bracket For installation, reverse the removal pro- cedure. 4 - 49...

  • Page 248: Disassembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order listed. Brake caliper piston Refer to “DISASSEMBLING THE REAR BRAKE CALIPER” and “ASSEMBLING Dust seal AND INSTALLING THE REAR BRAKE Piston seal...
  • Page 249 CHAS FRONT AND REAR BRAKES EAS00619 DISASSEMBLING THE FRONT BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers • brake hose 2 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.

  • Page 250: Checking The Front And Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES 1. Remove: • nut 1 • rear brake lock lever cable 2 • pin 3 • spring 4 • union bolt 5 • copper washers 6 • brake hose 7 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.
  • Page 251 CHAS FRONT AND REAR BRAKES 1. Check: È • brake caliper pistons 1 Rust/scratches/wear → Replace the brake caliper. • brake caliper cylinders 2 Scratches/wear → Replace the brake cali- per. • brake caliper body 3 Cracks/damage → Replace the brake cali- per.

  • Page 252: Assembling And Installing The Front Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00635 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort.
  • Page 253 Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 7. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” and “BLEED- ING THE BRAKE SYSTEM (XP500A)” in chapter 3. 4 - 55...

  • Page 254: Assembling And Installing The Rear Brake Caliper

    9. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” and “BLEED- ING THE BRAKE SYSTEM (XP500A)” in chapter 3. ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING •...
  • Page 255 CHAS FRONT AND REAR BRAKES 2. Install: • brake caliper piston 1 Turn the brake caliper piston clockwise until section a of the brake caliper piston is level with the surface of the brake caliper body. NOTE: Align the recesses b in the brake caliper pis- ton with the brake caliper body as shown in the illustration.
  • Page 256 Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 8. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” and “BLEED- ING THE BRAKE SYSTEM (XP500A)” in chapter 3. 4 - 58...
  • Page 257 LEVEL” in chapter 3. 10.Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” and “BLEED- ING THE BRAKE SYSTEM (XP500A)” in chapter 3. 11.Install: • spring • pin •...

  • Page 258: Ecu (Abs) And Fail-Safe Relay (Xp500A)

    CHAS FRONT AND REAR BRAKES EAS00888 ECU (ABS) AND FAIL-SAFE RELAY (XP500A) 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the ECU (ABS) and fail- Remove the parts in the order listed. safe relay (XP500A) Front cowling Refer to “COVER AND PANEL”...

  • Page 259: Hydraulic Unit (Xp500A)

    CHAS FRONT AND REAR BRAKES EAS00891 HYDRAULIC UNIT (XP500A) 16 Nm (1.6 m kg, 11 ft • • 30 Nm (3.0 m kg, 22 ft • • 30 Nm (3.0 m kg, 22 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 260 CHAS FRONT AND REAR BRAKES 16 Nm (1.6 m kg, 11 ft • • 30 Nm (3.0 m kg, 22 ft • • 30 Nm (3.0 m kg, 22 ft • • 16 Nm (1.6 m kg, 11 ft • •...
  • Page 261 CHAS FRONT AND REAR BRAKES CAUTION: Do not remove the hydraulic unit to check the resistance of the solenoid valves and the ABS motor for continuity. WARNING Refill with the same type of brake fluid that is already in the system. Mixing fluids may result in a harmful chemical reaction, lead- ing to poor braking performance.

  • Page 262: Removing The Hydraulic Unit

    CHAS FRONT AND REAR BRAKES REMOVING THE HYDRAULIC UNIT 1. Remove: • brake hose 1 (from the front brake master cylinder) • brake hose 2 (to the front brake caliper) • brake hose 3 (from the rear brake master cylinder) •...

  • Page 263: Installing The Hydraulic Unit

    CHAS FRONT AND REAR BRAKES INSTALLING THE HYDRAULIC UNIT Proceed in the reverse order of disassembly. Pay attention to the following items. 1. Install: • hydraulic unit 16 Nm (1.6 m · kg, 11 ft · lb) NOTE: • When tightening the hydraulic unit nuts, first temporarily tighten the front nuts, and then tighten the rear nut and the front nuts to specification in the order given.
  • Page 264 CHAS FRONT AND REAR BRAKES 4. Fill: • brake master cylinder reservoirs Recommended brake fluid DOT 4 5. Bleed the brake system. 6. Check the operation of the hydraulic unit according to the brake levers response. (Refer to “[D-6-3-1] Hydraulic unit operation test 1”.) CAUTION: Always check the operation of the hydrau-...

  • Page 265: Handlebar

    CHAS HANDLEBAR HANDLEBAR Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Upper handlebar cover Band Grip end Front brake light switch connector Disconnect. Right handlebar switch Throttle cable Disconnect. Throttle grip Refer to “INSTALLING THE HANDLEBAR”.
  • Page 266 CHAS HANDLEBAR Order Job/Part Q’ty Remarks Parking brake lever/holder Rear brake lock lever cable Disconnect. Refer to “INSTALLING Left handlebar switch THE HANDLEBAR”. Rear brake master cylinder holder Rear brake master cylinder Handlebar grip Refer to “REMOVING THE HANDLE- BAR” and “INSTALLING THE HANDLE- BAR”.

  • Page 267: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Remove: • handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
  • Page 268 CHAS HANDLEBAR 2. Install: • handlebar 1 • handlebar upper holders 2 23 Nm (2.3 m · kg, 17 ft · lb) WARNING First, tighten the bolts on the front side of the handlebar holder, then on the rear side. NOTE: •...
  • Page 269 CHAS HANDLEBAR 5. Connect: • rear brake lock lever cable NOTE: Lubricate the inside of the rear brake lock lever cable and parking brake lever with a thin coat of lithium-soap-based grease. 6. Install: • left handlebar switch 1 NOTE: Align the projection a on the right handlebar switch with the hole b in the handlebar.
  • Page 270 CHAS HANDLEBAR 9. Install: • right handlebar switch 1 WARNING Make sure the throttle grip operates smoothly. NOTE: Align the projection a on the right handlebar switch with the hole b in the handlebar. 10.Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”...

  • Page 271: Front Fork

    CHAS FRONT FORK FRONT FORK Order Job/Part Q’ty Remarks Removing the front fork Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Front cowling/leg shield Refer to “COVER AND PANEL” in chap- ter 3.
  • Page 272 CHAS FRONT FORK Order Job/Part Q’ty Remarks Upper bracket pinch bolt Loosen. Refer to “REMOVING THE FRONT FORK Cap bolt Loosen. LEGS” and “INSTALLING Lower bracket pinch bolt Loosen. THE FRONT FORK Front fork leg LEGS”. For installation, reverse the removal pro- cedure.
  • Page 273 CHAS FRONT FORK Order Job/Part Q’ty Remarks Disassembling the front fork leg Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Fork spring seat Fork spring Refer to “DISASSEMBLING THE Damper rod assembly bolt FRONT FORK LEGS”...
  • Page 274 CHAS FRONT FORK Order Job/Part Q’ty Remarks Inner tube bushing Dust seal Refer to “DISASSEMBLING THE Oil seal clip FRONT FORK LEGS” and “ASSEM- Oil seal BLING THE FRONT FORK LEGS”. Washer Outer tube bushing For assembly, reverse the disassembly procedure.

  • Page 275: Removing The Front Fork Legs

    CHAS FRONT FORK EAS00651 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
  • Page 276 CHAS FRONT FORK 2. Drain: • fork oil NOTE: Stroke the outer tube several times while draining the fork oil. 3. Remove: • damper rod assembly bolt NOTE: While holding the cartridge cylinder with the damper rod holder 1 and T-handle 2, loosen the damper rod assembly bolt.

  • Page 277: Checking The Front Fork Legs

    CHAS FRONT FORK EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 Bends/damage/scratches → Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.

  • Page 278: Assembling The Front Fork Legs

    CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Make sure that 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 279 CHAS FRONT FORK 5. Tighten: • damper rod assembly bolt 1 Damper rod assembly bolt 23 Nm (2.3 m · kg, 17 ft · lb) ® LOCTITE NOTE: ® • Apply the locking agent (LOCTITE ) to the threads of the damper rod assembly bolt. •...
  • Page 280 CHAS FRONT FORK NOTE: • Before installing the oil seal, apply lithium- soap-based grease onto its lips. • Apply fork oil onto the outer surface of the inner tube. • Before installing the oil seal, cover the top of the front fork leg with a plastic bag 4 to pro- tect the oil seal during installation.

  • Page 281: Installing The Front Fork Legs

    CHAS FRONT FORK 11.Install: • fork spring • fork spring seat • spacer • cap bolt NOTE: • Install the spring with the smaller pitch facing • Before installing the cap bolt, lubricate its O- ring with grease. • Temporarily tighten the cap bolt. EAS00663 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the...

  • Page 282: Steering Head

    CHAS STEERING HEAD STEERING HEAD LOWER BRACKET Order Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Front cowling Refer to “COVER AND PANEL” in chap- ter 3. Front wheel Refer to “FRONT WHEEL AND BRAKE DISC”.
  • Page 283 CHAS STEERING HEAD Order Job/Part Q’ty Remarks Bearing cover Bearing outer race Upper bearing Bearing inner race Refer to “INSTALLING THE STEERING HEAD”. Bearing outer race Lower bearing Bearing inner race Oil seal Lower bracket For installation, reverse the removal pro- cedure.

  • Page 284: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00678 REMOVING THE LOWER BRACKET 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Remove: • upper bracket 3. Remove: • lock washer 1 •...

  • Page 285: Installing The Steering Head

    CHAS STEERING HEAD 3. Replace: • bearings • bearing races M MMM M MMM M MMM M MMM M MMM a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer.
  • Page 286 CHAS STEERING HEAD 3. Install: • upper bracket 1 • steering stem nut 2 4. Install: • front fork legs Refer to “FRONT FORK”. NOTE: Temporarily tighten the lower bracket pinch bolts. 5. Tighten: • steering stem nut 2 110 Nm (11.0 m · kg, 80 ft · lb) 4 - 88...

  • Page 287: Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER REAR SHOCK ABSORBER Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. Muffler Refer to “MUFFLER ASSEMBLY” in chapter 5. Bolt Lock washer Collar Bolt/nut Rear shock absorber Collar Washer Spacer Bearing...

  • Page 288: Handling The Rear Shock Absorber And Gas Cylinder

    CHAS REAR SHOCK ABSORBER EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information.

  • Page 289: Removing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER EAS00693 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.

  • Page 290: Installing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: • spacer • bearings Recommended lubricant Lithium-soap-based grease 2. Install: • rear shock absorber assembly 1 • bolt (rear side) 2 • nut 3 53 Nm (5.3 m · kg, 38 ft · lb) 3.

  • Page 291: Anti-Lock Brake System (Xp500A)

    CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) ANTI-LOCK BRAKE SYSTEM (XP500A) EAS00882 ABS COMPONENTS 1 ABS warning light 8 Front brake caliper 2 Fail-safe relay 9 Front wheel sensor 3 Electronic control unit (ECU) 0 Front disc rotor 4 Hydraulic unit 5 Rear disc rotor 6 Rear brake caliper 7 Rear wheel sensor 4 - 93...
  • Page 292 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) 4 - 94...

  • Page 293: Circuit Diagram

    CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) EAS00884 CIRCUIT DIAGRAM 4 - 95...
  • Page 294 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) 4 Main switch 9 ABS control unit fuse B Signaling system fuse G Battery H ABS motor fuse I Main fuse M Starting circuit cut-off relay 2 N Starting circuit cut-off relay 1 R Start switch S Engine stop switch U Front brake light switch W ECU (engine)

  • Page 295: Cautions For Operation

    CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) CAUTIONS FOR OPERATION ABS warning light: • When the main switch is set to “ON”, the ABS warning light comes on for 2 seconds, then goes off. • If the ABS warning light comes on while riding, stop the vehicle, and then set the main switch to “OFF”, then set the main switch to “ON”.

  • Page 296: Troubleshooting

    CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) TROUBLESHOOTING EAS00881 ABS troubleshooting outline Use this section to troubleshoot the ABS. Read this service manual carefully and make sure you understand the information provided before repairing any malfunctions or performing service. The electronic control unit (ECU) has an ABS self-diagnostic function. When failures occur in the ABS, the ABS warning light on the meter assembly indicates a malfunction.
  • Page 297 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) ABS self-diagnosis by the ECU (ABS) The ECU (ABS) performs a static check on the ABS when the main switch is set to “ON”. The ECU (ABS) also monitors the ABS while riding the vehicle and checks for malfunctions. If malfunctions occur, the malfunction codes are stored in the memory of the ECU (ABS).
  • Page 298 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) EAS00886 Basic troubleshooting process Does not come on. Comes on for 2 seconds, then goes off. Check the ABS warning light. Flashing Remains on. [B-1] [B-3] [B-2] [B-5] [B-4] Warning light does Warning light Warning light Present Past not come on.
  • Page 299 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) EAS00887 ABS troubleshooting • [A] ABS malfunction check using the ABS warning light Set the main switch to “ON”. (Do not start the engine.) → [B-1] 1) Warning light does not come on. → [B-2] 2) Warning light remains on.
  • Page 300 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [B-4] ABS malfunction check using the ABS self-diagnosis (past malfunction) To access the test coupler 1. Remove the protective cap and connect the test coupler adaptor 2 to the test coupler. The T/C terminal (sky blue) is now grounded. 1) Indicate the malfunction code (Example: malfunction code 11) Multifunction display →...
  • Page 301 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [B-5] ABS malfunction check using the ABS self-diagnosis (present malfunction) NOTE: Before proceeding, read [B-3], “Function of the test coupler terminals”. To access the test coupler. Remove the protective cap and connect the test coupler adaptor to the test coupler.
  • Page 302 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [C] Determining the cause and location of the malfunction • [C-1] Only the ABS warning light does not come on when the main switch is set to “ON” NOTE: Check following the steps in sequence. 1.
  • Page 303 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [C-3] ABS warning light flashes With the engine off, check the front and rear brake switches. Check if the brake light comes on when the front or rear brake is applied. 1) The light does not come on for only one brake. →...
  • Page 304 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [C-5] Diagnosis by the malfunction code Malfunction codes are used to determine the malfunctions that have occurred. (Refer to “[B-4] ABS malfunction check using the ABS self-diagnosis (past malfunction)” and “[B-5] ABS malfunction check using the ABS self-diagnosis (present malfunction)”.) The malfunction codes are explained in the following table.
  • Page 305 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) Malfunction Problem Check point Reference code Defective operation of the ABS motor is • Fail-safe relay [C-5-9] Mal- detected. (ABS motor keeps running and will • Wire harness (ABS system’s circuit) function code not stop.) •...
  • Page 306 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [C-5-1] Malfunction code 11 (Front wheel sensor signal is not received correctly.) Set the main switch to “OFF”, then back to “ON” after removing the test coupler adaptor. 1) ABS warning light remains on. →...
  • Page 307 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [C-5-3] Malfunction codes 13 (front wheel) and 14 (rear wheel) (Incorrect signal is detected from either the front or rear wheel.) 1) The wheel sensors or sensor rotors are not properly installed. 1 Installation of the front or rear wheel sensor →...
  • Page 308 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [C-5-6] Malfunction code 31 (Disconnection is detected between the fail-safe relay and the hydraulic unit solenoid.) Check the following: 1) ABS motor fuse • Check if the ABS motor fuse beside the battery is blown. 2) Hydraulic unit solenoid coupler •...
  • Page 309 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [C-5-8] Malfunction code 33 (ABS motor operation malfunction is detected. [ABS motor stops and does not rotate.]) Check the following: 1) ABS motor fuse • Check if the ABS motor fuse beside the battery is blown. 2) Fail-safe relay →...
  • Page 310 • Check the brake hose lines for kinks and deterioration. WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. • Check that the connections of the brake hose lines from the brake master cylinder to the hydrau- lic unit and to the front brake caliper from the hydraulic unit are correct.
  • Page 311 • Check the brake hose lines for kinks and deterioration (particularly between the hydraulic unit and the rear brake caliper). WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. 4 - 113...
  • Page 312 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • Check that the connections of the brake hose lines from the brake master cylinder to the hydrau- lic unit and to the rear brake caliper from the hydraulic unit are correct. WARNING The rear brake will not function properly if the connections are reversed. •...
  • Page 313 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [C-5-12] Malfunction code 51 (Front wheel does not recover from the locking tendency even though the signal is continuously transmitted from the ECU (ABS) to release the hydraulic pressure [when the battery voltage is low].) Check the following: 1) Rotation of the front wheel Refer to “[C-5-10] Malfunction code 41”.
  • Page 314 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [D-1] Maintenance of the ECU (ABS) CHECKING THE ECU (ABS) 1. Remove: • ECU (ABS) 2. Check: • ECU (ABS) terminals 1 → Replace the ECU Cracks/damage (ABS). • ECU (ABS) coupler terminals 2 Defective connections/contamination/dis- connections →...
  • Page 315 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [D-2] Maintenance of the ABS fail-safe relay CHECKING THE FAIL-SAFE RELAY 1. Check: • solenoid relay for continuity Connect the pocket tester (Ω × 1) to the ter- minals. Check for continuity between terminals 3 and 4 of the solenoid relay.
  • Page 316 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) 2. Check: • ABS motor relay for continuity Connect the pocket tester (Ω × 1) to the ter- minals of the ABS motor relay. Check for continuity between terminals 1 and 6 of the ABS motor relay. Positive tester probe →...
  • Page 317 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [D-4] Maintenance of the rear wheel sen- sor and sensor rotor CHECKING THE REAR WHEEL SENSOR AND SENSOR ROTOR Refer to “CHECKING THE FRONT WHEEL SENSOR AND SENSOR ROTOR (XP500A)”. • [D-5] Maintenance of the hydraulic unit CAUTION: Do not remove the hydraulic unit to check the resistance of the solenoid valves and...
  • Page 318 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) 3. Check: • ABS motor for continuity Connect the pocket tester (Ω × 1) to the ter- minals of the ABS motor coupler. Positive tester probe → Terminal 1 Negative tester probe → Terminal 2 There is continuity.
  • Page 319 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) 2. Check: • installation of the wheel sensors to the sen- sor housings (Refer to “[D-3] Maintenance of the front wheel sensor and sensor rotor” and “[D-4] Maintenance of the rear wheel sensor and sensor rotor”.) Wheel sensor 30 Nm (3.0 m ·...
  • Page 320 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) 4. Check: • battery voltage Battery voltage Higher than 12.8 V Lower than 12.8 V → Charge or replace the battery. NOTE: • If the battery voltage is lower than 12.8 V, charge the battery and perform hydraulic unit operation test 1.
  • Page 321 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) 9. After releasing the start switch, operate the brake levers simultaneously. NOTE: • A reaction-force pulsating action is gener- ated in the front brake lever 1 0.5 second after the rear brake lever and front brake lever are operated simultaneously and con- tinues for approximately 1 second.
  • Page 322 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) 12.Set the main switch to “OFF”. 13.Remove the test coupler adaptor from the test coupler. 14.Set the main switch to “ON”. 15.Set the engine stop switch to “ ”. • [D-6-3-2] Hydraulic unit operation test 2 WARNING Securely support the vehicle so that there is no danger of it falling over.
  • Page 323 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) 6. Set the main switch to “ON” while operating the brake levers simultaneously. CAUTION: When the main switch is set to “ON”, be sure to operate both the brake levers simul- taneously. If only the brake levers are oper- ated, set the main switch to “OFF”...
  • Page 324 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) 3. Set the engine stop switch 1 to “ ”. CAUTION: Be sure to set the engine stop switch to “ ”. If the start switch is pushed without setting the engine stop switch to “ ”, the starter motor gears or other parts may be damaged.
  • Page 325 CHAS ANTI-LOCK BRAKE SYSTEM (XP500A) • [D-6-6] Delete function test 1. Place the vehicle on the centerstand. 2. Set the main switch to “OFF”. 3. Connect the test coupler adapter to the test coupler. 4. Set the main switch to “ON”. 5.
  • Page 328 CHAPTER 5 ENGINE ENGINE REMOVAL ..................5-1 MUFFLER ASSEMBLY ................5-1 LEADS AND HOSES................. 5-2 ENGINE..................... 5-5 INSTALLING THE ENGINE............... 5-6 CAMSHAFTS....................5-7 CYLINDER HEAD COVER................ 5-7 CAMSHAFTS .................... 5-8 REMOVING THE CAMSHAFTS..............5-9 CHECKING THE CAMSHAFTS ..............5-10 CHECKING THE CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES ...............5-12 CHECKING THE TIMING CHAIN TENSIONER........
  • Page 329 OIL PUMP...................... 5-42 CHECKING THE OIL PUMP ..............5-45 CHECKING THE RELIEF VALVE ............5-46 CHECKING THE OIL DELIVERY PIPES ..........5-46 CHECKING THE OIL STRAINER ............5-46 CHECKING THE OIL PUMP DRIVE CHAIN ...........5-46 ASSEMBLING THE OIL PUMP...............5-46 CLUTCH ......................5-48 REMOVING THE CLUTCH ..............
  • Page 330 TRANSMISSION.................... 5-84 REMOVING THE TRANSMISSION ............5-85 CHECKING THE TRANSMISSION ............5-85 ASSEMBLING THE CRANKCASE............5-86 CHAIN DRIVE....................5-87 CHECKING THE SWINGARM ..............5-91 CHECKING THE CHAIN DRIVE ASSEMBLY.........5-91 ASSEMBLING THE CHAIN DRIVE ASSEMBLY ........5-91 INSTALLING THE CHAIN DRIVE ............5-92...

  • Page 332: Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL MUFFLER ASSEMBLY Order Job/Part Q’ty Remarks Removing the muffler assembly Remove the parts in the order listed. Right rear side cover/inner fender Refer to “COVER AND PANEL” in chap- ter 3. sensor coupler Disconnect. Protector 1 sensor Protector 2 Muffler assembly...

  • Page 333: Leads And Hoses

    ENGINE REMOVAL LEADS AND HOSES 5 Nm (0.5 m kg, 3.6 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed.
  • Page 334 ENGINE REMOVAL 5 Nm (0.5 m kg, 3.6 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks V-belt case air filter element (left)/water Refer to “WATER PUMP” in chapter 6. pump inlet pipe/water pump outlet pipe Throttle body/injector Refer to “THROTTLE BODY”...
  • Page 335 ENGINE REMOVAL 5 Nm (0.5 m kg, 3.6 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Intake air pressure sensor hose Disconnect. Right passenger footrest For installation, reverse the removal pro- cedure.

  • Page 336: Engine

    ENGINE REMOVAL ENGINE 87 Nm (8.7 m kg, 63 ft • • 48 Nm (4.8 m kg, 35 ft • • 48 Nm (4.8 m kg, 35 ft • • Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. Front lower mounting bolt/washer Spacer Refer to “INSTALLING THE ENGINE”.

  • Page 337: Installing The Engine

    ENGINE REMOVAL INSTALLING THE ENGINE 1. Install: • rear mounting bolt/nut 1 • front upper mounting bolt/nut 2 • washers • spacer 3 • front lower mounting bolts 4 NOTE: Do not fully tighten the bolts. 2. Tighten: • rear mounting nut 1 87 Nm (8.7 m ·...

  • Page 338: Camshafts

    CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Engine Refer to “ENGINE REMOVAL”. Intake manifold Refer to “THROTTLE BODY” in chapter Spark plug Cylinder head cover Cylinder head cover gasket Dowel pin For installation, reverse the removal pro- cedure.
  • Page 339 CAMSHAFTS CAMSHAFTS 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Timing chain tensioner Timing chain tensioner gasket Camshaft cap...

  • Page 340: Removing The Camshafts

    CAMSHAFTS REMOVING THE CAMSHAFTS 1. Remove: • timing plug 1 2. Align: • “I” mark a on the A.C. magneto rotor (with the stationary pointer b on the A.C. magneto cover) M MMM M MMM M MMM M MMM M MMM a.

  • Page 341: Checking The Camshafts

    CAMSHAFTS 5. Remove: CAUTION: Before removing the camshafts from the cylinder head, tilt up the engine at least 25°. • intake camshaft cap 1 • exhaust camshaft cap 2 • dowel pins CAUTION: To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in.
  • Page 342 CAMSHAFTS 2. Measure: • camshaft lobe dimensions a and b Out of specification → Replace the cam- shaft. Camshaft lobe dimension Intake a 33.252 ~ 33.352 mm (1.3091 ~ 1.3131 in) <Limit>: 33.152 mm (1.3052 in) b 24.956 ~ 25.056 mm (0.9825 ~ 0.9865 in) <Limit>: 24.856 mm (0.9786 in)

  • Page 343: Checking The Camshaft Sprockets

    CAMSHAFTS c. Install the dowel pins and camshaft caps. NOTE: • Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • Do not turn the camshaft when measuring the camshaft-journal-to-camshaft cap clear- ®...

  • Page 344: Checking The Timing Chain Tensioner

    CAMSHAFTS 2. Check: • timing chain guide (intake side) 1 • timing chain guide (exhaust side) 2 • timing chain guide (top side) 3 Damage/wear → Replace the defective part(-s). CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage/rough movement →...
  • Page 345 CAMSHAFTS M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “I” mark a on the A.C. magneto rotor with the stationary pointer b on the A.C.
  • Page 346 CAMSHAFTS 3. Install: • timing chain tensioner gasket • timing chain tensioner M MMM M MMM M MMM M MMM M MMM a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. b. While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until if stops.
  • Page 347 CAMSHAFTS 6. Measure: • valve clearance Out of specification → Adjust. Refer “ADJUSTING VALVE CLEARANCE” in chapter 3. 7. Install: • cylinder head cover gasket • cylinder head cover 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Tighten the cylinder head cover bolts in stages and in a crisscross pattern.

  • Page 348: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Intake and exhaust camshafts Refer to “CAMSHAFTS”. Cylinder head Refer to “REMOVING THE CYLINDER HEAD” and “INSTALLING THE CYLIN- DER HEAD”. Cylinder head gasket Dowel pin For installation, reverse the removal pro-...

  • Page 349: Removing The Cylinder Head

    CYLINDER HEAD REMOVING THE CYLINDER HEAD 1. Remove: • cylinder head bolts • cylinder head nuts NOTE: • Loosen the nuts and bolts in the proper sequence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.

  • Page 350: Installing The Cylinder Head

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD 1. Install: • dowel pins • cylinder head gasket 2. Install: • cylinder head NOTE: Pass the timing chain through the timing chain cavity. 3. Tighten: • cylinder head nuts 1 35 Nm (3.5 m · kg, 25 ft · lb) •...

  • Page 351: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Valve lifter Valve pad Valve cotter Valve retainer Valve spring Refer to “REMOVING THE VALVES”...

  • Page 352: Removing The Valves

    VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal.

  • Page 353: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 4. Remove: • valve retainer 1 • valve spring 2 • valve stem seal 3 • valve spring seat 4 • valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES...
  • Page 354 VALVES AND VALVE SPRINGS M MMM M MMM M MMM M MMM M MMM a. Remove the valve guide with a valve guide remover 1. b. Install the new valve guide with a valve guide installer 2 and valve guide remover c.

  • Page 355: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the oil seal. Valve stem runout 0.04 mm (0.0016 in) EAS00240...
  • Page 356 VALVES AND VALVE SPRINGS b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. d. Measure the valve seat width. NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed.

  • Page 357: Checking The Valve Springs

    VALVES AND VALVE SPRINGS e. Apply a fine lapping compound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g.

  • Page 358: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 3. Measure: • valve spring tilt a Out of specification → Replace the valve spring. Maximum spring tilt Intake valve spring 1.6 mm (0.06 in) Exhaust valve spring 1.6 mm (0.06 in) EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters.
  • Page 359 VALVES AND VALVE SPRINGS 3. Install: • valve 1 • valve spring seat 2 • valve stem seal 3 • valve spring 4 • valve retainer 5 (into the cylinder head) NOTE: • Make sure that each valve is installed in its original place.
  • Page 360 VALVES AND VALVE SPRINGS 6. Lubricate: • valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 7. Install: • valve pad • valve lifter CAUTION: CAUTION: After making sure that the valve pads are fully inserted, install the valve lifter taking care so that the pads do not fall.

  • Page 361: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON Order Job/Part Q’ty Remarks Removing the cylinder and piston Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”. Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin Piston pin clip Refer to “REMOVING THE CYLINDERS Piston pin AND PISTONS”...

  • Page 362: Removing The Cylinders And Pistons

    CYLINDER AND PISTON REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the pistons. 1. Remove: • piston pin clip 1 • piston pin 2 • piston 3 CAUTION: Do not use a hammer to drive the piston pin out.

  • Page 363: Checking The Cylinders And Pistons

    CYLINDER AND PISTON EAS00256 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Check: • piston wall • cylinder wall Vertical scratches → Rebore or replace the cylinder, and replace the piston and piston rings as a set.

  • Page 364: Checking The Piston Rings

    CYLINDER AND PISTON c. Measure piston skirt diameter “P” with the micrometer. Micrometers (50 ~ 75 mm) 90890-03008, YU-03008 a 9.0 mm (0.35 in) from the bottom edge of the piston Piston size “P” 65.965 ~ 65.980 mm Standard (2.5970 ~ 2.5976 in) d.

  • Page 365: Checking The Piston Pins

    CYLINDER AND PISTON 2. Install: • piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the piston crown as shown. a 10 mm (0.39 in) 3. Measure: • piston ring end gap Out of specification → Replace the piston ring.

  • Page 366: Installing The Pistons And Cylinders

    CYLINDER AND PISTON 2. Measure: • piston pin outside diameter a Out of specification → Replace the piston pin. Piston pin outside diameter 14.991 ~ 15.000 mm (0.5902 ~ 0.5906 in) <Limit>: 14.971 mm (0.5894 in) 3. Measure: • piston pin bore diameter b (in the piston) Out of specification →...
  • Page 367 CYLINDER AND PISTON 2. Install: • piston • piston pin • piston pin clip NOTE: • Apply engine oil onto the piston pin. • Make sure that the punch mark a on the pis- ton points towards the exhaust side of the cylinder.

  • Page 368: Starter Clutch And A.c. Magneto Rotor

    STARTER CLUTCH AND A.C. MAGNETO ROTOR STARTER CLUTCH AND A.C. MAGNETO ROTOR Order Job/Part Q’ty Remarks Removing the starter clutch and Remove the parts in the order listed. A.C. magneto rotor Left side panel/lower side cover mould- Refer to “COVER AND PANEL” in chap- ing/footrest board ter 3.
  • Page 369 STARTER CLUTCH AND A.C. MAGNETO ROTOR Order Job/Part Q’ty Remarks Oil tank Gasket Dowel pin Oil strainer Starter coil assembly A.C. magneto rotor nut Refer to “REMOVING THE A.C. MAG- Spacer NETO ROTOR” and “INSTALLING THE A.C. MAGNETO ROTOR”. A.C. magneto rotor Starter clutch Woodruff key Starter clutch idler gear shaft...

  • Page 370: Removing The A.c. Magneto Rotor

    STARTER CLUTCH AND A.C. MAGNETO ROTOR REMOVING THE A.C. MAGNETO ROTOR 1. Remove: • A.C. magneto rotor cover NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 371: Checking The Starter Clutch

    STARTER CLUTCH AND A.C. MAGNETO ROTOR CHECKING THE STARTER CLUTCH 1. Check: • starter clutch Damage/wear → Replace. 2. Check: • starter clutch idle gear • starter clutch idle gear shaft • starter clutch gear Pitting/burrs/chips/roughness/wear → Replace the defective parts. 3.
  • Page 372 A.C. magneto rotor nut another + 120°. 3. Apply: • sealant (onto the stator coil assembly lead grom- met) Yamaha bond No. 1215 90890-85505 ® Sealant (Quick Gasket ACC-11001-05-01 4. Install: • A.C. magneto rotor cover 10 Nm (1.0 m ·...

  • Page 373: Oil Pump

    OIL PUMP OIL PUMP Order Job/Part Q’ty Remarks Removing the oil pump Removing the parts in the order listed. Left side panel/lower side cover mould- Refer to “COVER AND PANEL” in chap- ing/footrest board ter 3. Coolant Drain. Refer to “CHANGING THE COOLANT” in chapter 3.
  • Page 374 OIL PUMP Order Job/Part Q’ty Remarks Oil delivery pipe Relief valve assembly For installation, reverse the removal pro- cedure. 5 - 43...
  • Page 375 OIL PUMP Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. Oil pump housing Oil pump outer rotor Oil pump inner rotor Refer to “ASSEMBLING THE OIL PUMP”. Dowel pin Oil pump housing center Washer Oil pump cover Oil pump driven gear...

  • Page 376: Checking The Oil Pump

    OIL PUMP CHECKING THE OIL PUMP 1. Check: • oil pump driven gear 1 • oil pump housing 2 • oil pump cover 3 Cracks/damage/wear → Replace the defec- tive part(s). 2. Measure: The following procedure applies to all of the inner rotor and outer rotor.

  • Page 377: Checking The Relief Valve

    OIL PUMP EAS00365 CHECKING THE RELIEF VALVE 1. Check: • relief valve body 1 • relief valve 2 • spring 3 • O-ring 4 Damage/wear → Replace the defective part(s). EAS00367 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes.
  • Page 378 OIL PUMP 2. Install: • pins • inner rotors NOTE: When installing the inner rotor, align the pin 1 in the oil pump shaft with the groove a on the inner rotor. 3. Check: • oil pump operation Refer to “CHECKING THE OIL PUMP”. 5 - 47...

  • Page 379: Clutch

    CLUTCH CLUTCH Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. A.C. magneto cover Refer to “STARTER CLUTCH AND A.C. MAGNETO ROTOR”. Clutch assembly nut Refer to “REMOVING THE CLUTCH” Clutch assembly and “INSTALLING THE CLUTCH”. For installation, reverse the removal pro- cedure.
  • Page 380 CLUTCH Order Job/Part Q’ty Remarks Disassembling the clutch Remove the parts in the order listed. Circlip Spring stopper plate Clutch damper spring 2 Pressure plate Clutch plate 2 Refer to “DISASSEMBLING THE Clutch damper spring 1 CLUTCH” and “ASSEMBLING THE CLUTCH”.
  • Page 381 CLUTCH Order Job/Part Q’ty Remarks Circlip Bearing Clutch boss Collar Weight Clutch housing For assembly, reverse the disassembly procedure. 5 - 50...
  • Page 382 CLUTCH REMOVING THE CLUTCH 1. Remove: • clutch assembly nut 1 • clutch assembly 2 NOTE: • Before removal, apply a and b alignment marks. • While holding the clutch assembly with the rotor holding tool 3, loosen the clutch assembly nut.

  • Page 383: Checking The Friction Plates

    CLUTCH 3. Remove: • clutch boss nut 1 NOTE: While holding the clutch boss 2 with the clutch holding tool 3, loosen the clutch boss nut. Clutch holding tool 90890-04086, YM-91042 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates.

  • Page 384: Checking The Clutch Springs And Clutch Damper Springs

    CLUTCH CHECKING THE CLUTCH SPRINGS AND CLUTCH DAMPER SPRINGS The following procedure applies to all of the clutch springs. 1. Check: • clutch spring Damage → Replace the clutch springs as a set. 2. Measure: • clutch spring free length a Out of specification →...

  • Page 385: Checking The Clutch Boss

    CLUTCH EAS00285 CHECKING THE CLUTCH BOSS 1. Check: • clutch boss splines Damage/pitting/wear → Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. EAS00286 CHECKING THE PRESSURE PLATE AND THRUST PLATE 1. Check: •...
  • Page 386 CLUTCH 2. Install: • clutch boss • primary drive gear • clutch boss nut 1 3. Tighten: • clutch boss nut 90 Nm (9.0 m · kg, 65 ft · lb) NOTE: While holding the clutch boss 2 with the clutch holding tool 3, tighten the clutch boss nut.

  • Page 387: Installing The Clutch

    CLUTCH INSTALLING THE CLUTCH 1. Install: • clutch assembly 1 • clutch assembly nut 2 65 Nm (6.5 m · kg, 47 ft · lb) NOTE: • Align the a and b during reassembly. • While holding the clutch assembly with the rotor holding tool 3, tighten the clutch assembly nut.
  • Page 388 V-BELT AUTOMATIC TRANSMISSION V-BELT AUTOMATIC TRANSMISSION V-BELT CASE Order Job/Part Q’ty Remarks Removing the V-belt case Remove the parts in the order listed. Muffler Refer to “ENGINE REMOVAL”. V-belt case cover 1 V-belt case cover 2 V-belt case air filter cover V-belt case air filter element Lead holder V-belt case...

  • Page 389: V-Belt Automatic Transmission

    V-BELT AUTOMATIC TRANSMISSION V-BELT AND PRIMARY/SECONDARY SHEAVE ® 1 Shell BT grease 3 ® 2 BEL-RAY assembly lube Order Job/Part Q’ty Remarks Removing the V-belt and primary/ Remove the parts in the order listed. secondary sheave V-belt case air filter element (left) Refer to “WATER PUMP”...
  • Page 390 V-BELT AUTOMATIC TRANSMISSION ® 1 Shell BT grease 3 ® 2 BEL-RAY assembly lube Order Job/Part Q’ty Remarks V-belt case air duct joint clamp Loosen. Refer to “INSTALLING THE PRIMARY SHEAVE V-belt case air duct ASSEMBLY, SECOND- ARY SHEAVE ASSEM- BLY AND V-BELT”.
  • Page 391 V-BELT AUTOMATIC TRANSMISSION ® BEL-RAY assembly lube Order Job/Part Q’ty Remarks Disassembling the primary sheave Remove the parts in the order listed. Refer to “DISASSEMBLING THE PRI- Slider MARY SHEAVE” and “ASSEMBLING THE PRIMARY SHEAVE”. Weight Primary sliding sheave Collar For assembly, reverse the disassembly procedure.
  • Page 392 V-BELT AUTOMATIC TRANSMISSION ® BEL-RAY assembly lube Order Job/Part Q’ty Remarks Disassembly the secondary sheave Remove the parts in the order listed. Secondary sheave spring seat nut Refer to “DISASSEMBLING THE SEC- ONDARY SHEAVE” and “ASSEMBLING THE SECONDARY SHEAVE”. Upper spring seat Compression spring Spring seat Secondary sliding sheave...

  • Page 393: Removing The Primary Sheave Assembly

    V-BELT AUTOMATIC TRANSMISSION REMOVING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY SHEAVE ASSEMBLY AND V-BELT 1. Remove: • primary sheave nut 1 • secondary sheave nut 2 NOTE: While holding the primary and secondary sheave with the sheave holder, loosen the nut. Sheave holder 90890-01481 2.

  • Page 394: Disassembling The Secondary Sheave

    V-BELT AUTOMATIC TRANSMISSION DISASSEMBLING THE PRIMARY SHEAVE 1. Remove: • cam 1 • slider 2 • weight 3 DISASSEMBLING THE SECONDARY SHEAVE 1. Remove: • secondary sheave spring seat nut 1 NOTE: Install the sheave spring compressor 2 onto the secondary sheave as shown. Then, com- press the spring, and remove the secondary sheave spring seat nut 1 with locknut wrench Sheave spring compressor 2...

  • Page 395: Checking The V-Belt Case Air Duct

    V-BELT AUTOMATIC TRANSMISSION CHECKING THE V-BELT CASE AIR DUCT 1. Check • V-belt case air duct Cracks/damage → Replace. CHECKING THE PRIMARY SHEAVE 1. Check: • primary sliding sheave 1 • primary fixed sheave 2 Cracks/damage/wear → Replace the pri- mary sliding sheave and primary fixed sheave as a set.

  • Page 396: Checking The Secondary Sheave

    V-BELT AUTOMATIC TRANSMISSION EAS00322 CHECKING THE SECONDARY SHEAVE 1. Check: • secondary fixed sheave • secondary sliding sheave Cracks/damage/wear → Replace the sec- ondary fixed and sliding sheaves as a set. 2. Check: • torque cam groove 1 Damage/wear → Replace the secondary fixed and sliding sheaves as a set.

  • Page 397: Assembling The Secondary Sheave

    V-BELT AUTOMATIC TRANSMISSION EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: • secondary fixed sheave shaft’s outer and inner surfaces 1 • secondary sliding sheave’s outer and inner surfaces 2 • grease nipple groove • oil seals (with the recommended lubricant) Recommended lubricant ®...

  • Page 398: Installing The Primary Sheave Assembly

    V-BELT AUTOMATIC TRANSMISSION 6. Tighten: • secondary sheave spring seat nut 90 Nm (9.0 m · kg, 65 ft · lb) NOTE: Attach the sheave spring compressor 2 onto the secondary sheave as shown. Then compress the spring, and tighten the secondary sheave spring seat nut 1 with lock- nut wrench 3.
  • Page 399 V-BELT AUTOMATIC TRANSMISSION 2. Install: • primary fixed sheave 1 • V-belt 2 • secondary sheave assembly 3 CAUTION: Do not allow grease to contact the V-belt, primary and secondary pulleys. NOTE: • When installing the belt, screw M6 (more than 45 mm (1.77 in)) bolts 4 to spread apart the secondary sheave and then install the belt.
  • Page 400 V-BELT AUTOMATIC TRANSMISSION 5. Tighten: • primary sheave nut 1 160 Nm (16.0 m · kg, 115 ft · lb) CAUTION: • Before tightening the nut to remount the primary sheave, make sure that the serra- tions of the cam are fitted firmly into the serrations of the crankshaft.

  • Page 401: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT CRANKSHAFT ASSEMBLY Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Engine Refer to “ENGINE REMOVAL”. Cylinder head Refer to “CYLINDER HEAD”. Cylinder/piston Refer to “CYLINDER AND PISTON”. Starter clutch/A.C.
  • Page 402 CRANKCASE AND CRANKSHAFT Order Job/Part Q’ty Remarks Dowel pin Crankshaft assembly Refer to “INSTALLING THE CRANK- SHAFT”. Balancer cylinder Right crankcase Oil strainer Dowel pin Crankshaft main journal bearing Refer to “REMOVING THE CRANK- SHAFT MAIN JOURNAL BEARINGS” and “INSTALLING THE CRANKSHAFT MAIN JOURNAL BEARINGS”...

  • Page 403: Connecting Rod

    CRANKCASE AND CRANKSHAFT CONNECTING ROD Order Job/Part Q’ty Remarks Removing the connecting rod Remove the parts in the order listed. Connecting rod Refer to “REMOVING THE CONNECT- Connecting rod (balancer) ING RODS” and “INSTALLING THE Connecting rod cap CONNECTING RODS”. Big end bearing Circlip Piston pin...

  • Page 404: Disassembling The Crankcase

    CRANKCASE AND CRANKSHAFT EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: • crankcase bolts NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.

  • Page 405: Removing The Connecting Rods

    CRANKCASE AND CRANKSHAFT EAS00391 REMOVING THE CONNECTING RODS The following procedure applies to all of the connecting rods. 1. Remove: • connecting rod 1 • big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place. EAS00399 CHECKING THE CRANKCASE 1.
  • Page 406 CRANKCASE AND CRANKSHAFT 2. Check: • crankshaft journal surfaces • crankshaft pin surfaces • bearing surfaces Scratches/wear → Replace the crankshaft. 3. Measure: • crankshaft-pin-to-big-end-bearing clear- ance Out of specification → Replace the big end bearings. Crankshaft-pin-to-big-end-bear- ing clearance 0.026 ~ 0.050 mm (0.0010 ~ 0.0020 in) M MMM M MMM...
  • Page 407 CRANKCASE AND CRANKSHAFT d. Assemble the connecting rod halves. NOTE: • Do not move the connecting rod or crank- shaft until the clearance measurement has been completed. • Apply molybdenum disulfide grease onto the bolts, threads, and nut seats. • Make sure that the “Y” mark c on the con- necting rod faces towards the left side of the crankshaft.
  • Page 408 CRANKCASE AND CRANKSHAFT 4. Select: • big end bearings (P NOTE: • The numbers È stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. • “P ”...
  • Page 409 CRANKCASE AND CRANKSHAFT a. Clean the surface of main journal and jour- nal bearings. b. Check the bearing surface. If the bearing surface is worn or scratched, the bearings should be replace. NOTE: If either of the right or left journal bearing is worn or scratched, both bearings should be replaced as a set.
  • Page 410 CRANKCASE AND CRANKSHAFT 6. Select: • crankshaft journal bearings (J NOTE: • The numbers È stamped into the crankshaft web and the numbers 1 on the crankcase are used to determine the replacement crankshaft journal bearing size. • “J ” refer to the bearings shown in the crankshaft illustration.

  • Page 411: Installing The Crankshaft Main Journal Bearings

    CRANKCASE AND CRANKSHAFT INSTALLING THE CRANKSHAFT MAIN JOURNAL BEARINGS 1. Attach: • crankshaft main journal bearings NOTE: Attach the crankshaft main journal bearing to the plane bearing installer 1. Plane bearing installer 90890-04139 2. Install: • crankshaft main journal bearings 2 NOTE: •...
  • Page 412 CRANKCASE AND CRANKSHAFT 3. Install: • connecting rod cap NOTE: Be sure that the characters a on the side of the cap and connecting rod are aligned. 4. Tighten: • nuts (connecting rod cap) 16 Nm (1.6 m · kg, 11 ft · lb) + 90° NOTE: Apply molybdenum disulfide grease to the rod cap bolt threads and nut surfaces.

  • Page 413: Installing The Crankshaft

    CRANKCASE AND CRANKSHAFT 5. Install: • balancer connecting rod • connecting rod cap 60 Nm (6.0 m · kg, 43 ft · lb) CAUTION: • When tightening the nuts be sure to use an F-type torque wrench. • Without pausing, tighten to full torque specification.
  • Page 414 CRANKCASE AND CRANKSHAFT 2. Apply: • sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 ® Sealant (Quick Gasket ACC-11001-05-01 NOTE: Do not allow any sealant to come into contact with the oil gallery. 3. Install: • dowel pins •...

  • Page 415: Transmission

    TRANSMISSION TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Left crankcase Refer to “CRANKCASE AND CRANK- SHAFT”. Secondary shaft Main axle Primary driven gear First pinion gear Washer Drive axle First wheel gear Circlip Bearing Oil seal...

  • Page 416: Removing The Transmission

    TRANSMISSION REMOVING THE TRANSMISSION 1. Remove: • left crankcase Refer to “CRANKCASE AND CRANK- SHAFT”. 2. Remove: • secondary shaft 1 • main axle 2 • drive axle 3 • primary driven gear 4 • first wheel gear 5 • first pinion gear EAS00425 CHECKING THE TRANSMISSION 1.

  • Page 417: Assembling The Crankcase

    TRANSMISSION 4. Check: • transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). 5. Check: • transmission gear movement Rough movement → Replace the defective part(s). 6. Check: • circlips Damage/bends/looseness → Replace. EAS00418 ASSEMBLING THE CRANKCASE Refer to “CRANKCASE AND CRANKSHAFT”. 5 - 86...

  • Page 418: Chain Drive

    CHAIN DRIVE CHAIN DRIVE Order Job/Part Q’ty Remarks Removing the chain drive assembly Remove the parts in the order listed. Chain drive oil Drain. Refer to “CHANGING THE CHAIN DRIVE OIL” in chapter 3. Rear shock absorber Refer to “REAR SHOCK ABSORBER” in chapter 4.
  • Page 419 CHAIN DRIVE Order Job/Part Q’ty Remarks Collar Oil seal Bearing Left rear footrest Chain drive assembly Chain drive holder assembly O-ring For installation, reverse the removal pro- cedure. 5 - 88...
  • Page 420 CHAIN DRIVE Order Job/Part Q’ty Remarks Disassembling the chain drive Remove the parts in the order listed. assembly Chain drive case (outer) Secondary drive chain Secondary drive gear Secondary driven gear Middle shaft Primary drive chain Primary drive gear Primary driven gear Bearing Oil seal Collar...
  • Page 421 CHAIN DRIVE Order Job/Part Q’ty Remarks Retainer For assembly, reverse the disassembly procedure. 5 - 90...

  • Page 422: Checking The Swingarm

    CHAIN DRIVE CHECKING THE SWINGARM 1. Check: • swingarm 1 Damage/wear → Replace. 2. Check: • pivot shaft 1 • collar • bearing • oil seal Damage/wear → Replace. CHECKING THE CHAIN DRIVE ASSEMBLY 1. Check: • primary drive chain 1 •...

  • Page 423: Installing The Chain Drive

    CHAIN DRIVE INSTALLING THE CHAIN DRIVE 1. Install: • chain drive assembly • swingarm • pivot shaft • washer • nut 2. Tighten: • swingarm bolt 40 Nm (4.0 m · kg, 29 ft · lb) 3. Tighten: • pivot shaft 7 Nm (0.7 m ·...

  • Page 424: Cool

    COOL...
  • Page 425 COOL CHAPTER 6 COOLING SYSTEM RADIATOR AND OIL COOLER ..............6-1 CHECKING THE RADIATOR..............6-3 CHECKING THE OIL COOLER ..............6-4 INSTALLING THE OIL COOLER AND RADIATOR ........6-4 THERMOSTAT ....................6-6 CHECKING THE THERMOSTAT.............. 6-7 INSTALLING THE THERMOSTAT............6-7 WATER PUMP....................6-9 DISASSEMBLING THE WATER PUMP..........6-12 CHECKING THE WATER PUMP ............
  • Page 426 COOL...

  • Page 427: Cooling System

    COOL RADIATOR AND OIL COOLER COOLING SYSTEM RADIATOR AND OIL COOLER Order Job/Part Q’ty Remarks Removing the radiator and oil cooler Remove the parts in the order listed. Footrest board/leg shield/inner fender Refer to “COVER AND PANEL” in chap- ter 3. Engine oil Drain.
  • Page 428 COOL RADIATOR AND OIL COOLER Order Job/Part Q’ty Remarks Coolant pipe Fast idle outlet hose Disconnect. Radiator outlet hose Disconnect. Radiator fan motor coupler Disconnect. Radiator filler neck Radiator filler hose Stay Radiator Radiator fan Oil filter cartridge Oil cooler inlet hose Disconnect.

  • Page 429: Checking The Radiator

    COOL RADIATOR AND OIL COOLER EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: NOTE: Straighten any flattened fins with a thin, flat- head screwdriver.

  • Page 430: Checking The Oil Cooler

    COOL RADIATOR AND OIL COOLER EAS00458 CHECKING THE OIL COOLER 1. Check: • oil cooler Cracks/damage → Replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose Cracks/damage/wear → Replace. EAS00459 INSTALLING THE OIL COOLER AND RADIATOR 1.
  • Page 431 COOL RADIATOR AND OIL COOLER 4. Check: • cooling system Leaks → Repair or replace any faulty part. M MMM M MMM M MMM M MMM M MMM a. Attach the radiator cap tester 1 to the radi- ator. Radiator cap tester 90890-01325, YU-24460-01 Radiator cap tester adapter 90890-01352, YU-33984...

  • Page 432: Thermostat

    COOL THERMOSTAT THERMOSTAT 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Center cover/side cover Refer to “COVER AND PANEL” in chap- ter 3.

  • Page 433: Checking The Thermostat

    COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat Does not open at 69 ~ 73 °C (156.2 ~ 163.4 °F) → Replace. M MMM M MMM M MMM M MMM M MMM a. Suspend the thermostat in a container filled with water.
  • Page 434 COOL THERMOSTAT 3. Fill: • cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 4. Check: • cooling system Leaks → Repair or replace any faulty part. 5. Measure: • radiator cap opening pressure Below the specified pressure →...

  • Page 435: Water Pump

    COOL WATER PUMP WATER PUMP Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. Left upper side cover moulding/left Refer to “COVER AND PANEL” in chap- footrest board ter 3. Coolant Drain. Refer to “CHANGING THE COOLANT” in chapter 3.
  • Page 436 COOL WATER PUMP Order Job/Part Q’ty Remarks Water pump assembly Refer to “INSTALLING THE WATER PUMP”. For installation, reverse the removal pro- cedure. 6 - 10...
  • Page 437 COOL WATER PUMP Order Job/Part Q’ty Remarks Disassembling the water pump Remove the parts in the order listed. NOTE: NOTE: It is not necessary to remove the impeller shaft, unless the coolant level is extremely low or coolant contains engine oil. Water pump housing cover O-ring Circlip...

  • Page 438: Disassembling The Water Pump

    COOL WATER PUMP EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: • water pump seal 1 NOTE: NOTE: Remove the water pump seal from the outside of the water pump housing. 2 Water pump housing 2. Remove: • oil seal 1 (with a thin, flat-head screwdriver) NOTE: NOTE:...

  • Page 439: Checking The Water Pump

    COOL WATER PUMP EAS00474 CHECKING THE WATER PUMP 1. Check: • water pump housing cover 1 • water pump housing 2 • impeller shaft 3 • water pump seal 4 • oil seal 5 • rubber damper • rubber damper holder Cracks/damage/wear →...
  • Page 440 NOTE: NOTE: • Install the water pump seal with the special tools. • Before installing the water pump seal, apply Yamaha bond No.1215 or Sealant (Quick ® ) 2 to the water pump housing 3. Gasket Mechanical seal installer 90890-04078, YM-33221-A 4...

  • Page 441: Installing The Water Pump

    COOL WATER PUMP 5. Measure: • tilt Out of specification → Repeat steps (3) and (4). CAUTION: CAUTION: Make sure that the rubber damper and rub- ber damper holder are flush with the impel- ler. Maximum impeller shaft tilt 0.15 mm (0.006 in) 1 Straightedge 2 Impeller INSTALLING THE WATER PUMP...
  • Page 444 CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM................7-1 WIRING DIAGRAM ................... 7-2 ECU (engine) SELF-DIAGNOSTIC FUNCTION........7-3 ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION) ................7-4 FAIL-SAFE ACTION TABLE ..............7-4 TROUBLESHOOTING CHART ..............7-6 DIAGNOSTIC MODE ................7-7 TROUBLESHOOTING DETAILS ............7-12 THROTTLE BODY..................

  • Page 446: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Ignition coil 9 Throttle position sensor G Crankshaft position sensor 2 Air filter case 0 Fuel injector H Coolant temperature sensor 3 Intake air temperature sensor A Fuel tank I Spark plug 4 Fuel injection system relay B Fuel delivery hose 5 Lean angle cut-off switch...

  • Page 447: Wiring Diagram

    FUEL INJECTION SYSTEM WIRING DIAGRAM 7 - 2...

  • Page 448: Ecu (Engine) Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS00899 ECU (engine) SELF-DIAGNOSTIC FUNCTION The ECU (engine) is equipped with a self-diagnostic function in order to ensure that the fuel injec- tion system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 449: Alternate Instructions Operation Control

    FUEL INJECTION SYSTEM EAS00901 Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned to “ON” and when the start switch is being pushed. If the warning light does not come on under these conditions, the warning light bulb may be defective.
  • Page 450 FUEL INJECTION SYSTEM Fault Engine start- Vehicle drive- Item Symptom Fail-safe action code No. ability ability Faulty the FID valve Stuck FID valve. (when fully Able Able open) Lean angle cut-off The scooter has over turned. switch (latch up Lean angle cut-off switch-open Unable Unable detected) (open or...

  • Page 451: Troubleshooting Chart

    FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. * Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on. The engine trouble warning light does not come on.

  • Page 452: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press hold “SELECT”...
  • Page 453 FUEL INJECTION SYSTEM 8. Verify the operation of the sensor or actua- tor. • Sensor operation The data representing the operating condi- tions of the sensor appears on the trip LCD. • Actuator operation Set the engine stop switch to “ ”...
  • Page 454 FUEL INJECTION SYSTEM EAS00906 Fault code table Fault Symptom Probable cause of malfunction Diagnostic code code No. No normal signals are received from • Open or short circuit in wiring harness. the crankshaft position sensor. • Defective crankshaft position sensor. •...
  • Page 455 FUEL INJECTION SYSTEM Fault Symptom Probable cause of malfunction Diagnostic code code No. Power supply to the fuel injection sys- • Open circuit in wiring harness. (blue/yellow – red/black tem relay is not normal. line) — • Malfunction in “CHARGING SYSTEM” in chapter 8. Faulty ECU (engine) memory.
  • Page 456 FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) Fuel system voltage (bat- Displays the fuel system voltage (battery voltage). 0 ~ 18.7 V tery voltage) Engine stop switch is “ ”. Normally, approximately 12.0 V Sidestand switch Displays that the switch is ON or OFF.

  • Page 457: Troubleshooting Details

    FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) Malfunction history code • Displays the codes of the history of the self-diag- 12 ~ 50 display nosis malfunctions (i.e., a code of a malfunction (00) Displays when there is no mal- that occurred once and which has been corrected).
  • Page 458 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft position sensor. Used diagnostic code No. – – Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Installed condition of sensor Check the installed area for looseness or pinching.
  • Page 459 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor - open or short circuit detected. Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Defective intake air pressure sen- Replace if defective.
  • Page 460 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor - hose system malfunction (clogged or detached hose). Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Intake air pressure sensor hose is Repair or replace the sensor hose.
  • Page 461 FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit is detected in the input line from the sidestand switch to the ECU (engine). Used diagnostic code No. 20 (sidestand switch) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Defective sidestand switch...
  • Page 462 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit detected from the intake air temperature sensor. Used diagnostic code No. 05 (intake air temperature sensor) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Installed condition of sensor Check the installed area for looseness or pinching.
  • Page 463 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Used diagnostic code No. -- Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Installed state of O sensor Check the installed area for looseness or pinching. As the returning method start Connected state of connector...
  • Page 464 FUEL INJECTION SYSTEM Fault code No. Symptom The scooter has overturned. Used diagnostic code No. 08 (lean angle cut-off switch) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Defective lean angle cut-off switch Replace if defective. Reinstated by turn- 1.
  • Page 465 FUEL INJECTION SYSTEM Fault code No. Symptom Engine idling speed is too high. Used diagnostic code No. 01 (throttle position sensor) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Stuck FID valve detected. Inspect the throttle body. Reinstated by Replace if defective.
  • Page 466 FUEL INJECTION SYSTEM Fault code No. Symptom The ECU (engine) is unable to monitor the battery voltage. Used diagnostic code No. 09 (fuel system voltage) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Malfunction in ECU (engine) Fuel injection system relay is on.
  • Page 467 FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading or writing on EEPROM (CO adjustment value). Used diagnostic No. 60 (EEPROM improper cylinder indication) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Malfunction in ECU (engine) Execute diagnostic code 60 Reinstated by turn-...

  • Page 468: Throttle Body

    THROTTLE BODY THROTTLE BODY 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Part Q’ty...
  • Page 469 THROTTLE BODY 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Part Q’ty Remarks Intake air pressure sensor coupler...
  • Page 470 THROTTLE BODY 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Part Q’ty Remarks Intake manifold...
  • Page 471 THROTTLE BODY Order Job/Part Q’ty Remarks Disassembling the throttle body Remove the parts in the order listed. NOTE: Before disassembling the throttle body, make sure to note the number of times the air screw is turned out from the seated position to its set position. Throttle position sensor Fast idle plunger Idle adjust screw...

  • Page 472: Checking The Fuel Injectors

    THROTTLE BODY EAS00911 CAUTION: The throttle body should not be disassem- bled. EAS00912 CHECKING THE FUEL INJECTORS 1. Check: • fuel injectors Damage → Replace. EAS00913 CHECKING THE THROTTLE BODY 1. Check: • throttle body Cracks/damage → Replace the throttle body.
  • Page 473 THROTTLE BODY b. Disconnect the fuel hose 1 from the fuel pump. CAUTION: Although the fuel has been removed from the fuel tank, be careful when removing the fuel hoses, since there may be fuel remain- ing in it. NOTE: Before removing the hoses, place a few rags in the area under where it will be removed.

  • Page 474: Checking And Adjusting The Throttle Position Sensor

    THROTTLE BODY EAS00916 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: • throttle position sensor M MMM M MMM M MMM M MMM M MMM a.
  • Page 475 THROTTLE BODY NOTE: Check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide-open throttle) may differ slightly from those specified. Throttle position sensor resis- tance (0.52 ~ 0.9) ~ (4.0 ~ 6.0) kΩ at 20 °C (68 °F) (yellow –...

  • Page 476: Elec

    – ELEC...
  • Page 477 CIRCUIT DIAGRAM .................. 8-9 TROUBLESHOOTING ................8-10 ELECTRIC STARTING SYSTEM ..............8-15 CIRCUIT DIAGRAM (XP500) ..............8-15 CIRCUIT DIAGRAM (XP500A)..............8-16 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (XP500)..8-17 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (XP500A) ..8-18 TROUBLESHOOTING ................8-19 STARTER MOTOR..................8-23 CHECKING THE STARTER MOTOR .............8-25 ASSEMBLING THE STARTER MOTOR..........
  • Page 478 – ELEC IMMOBILIZER SYSTEM................8-54 SYSTEM DIAGRAM ................8-54 CIRCUIT DIAGRAM ................8-55 GENERAL INFORMATION ..............8-56 KEY CODE REGISTRATION ..............8-57 SELF-DIAGNOSIS MALFUNCTION CODES..........8-59 TROUBLESHOOTING ................8-61 CHECKING THE IMMOBILIZER SYSTEM ..........8-62 PART REPLACEMENT KEY REGISTRATION REQUIREMENTS..8-65...

  • Page 479: Electrical System

    – ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Front brake light switch 8 Starter relay 2 Rear brake light switch 9 Main fuse 3 Turn signal/hazard relay 0 Rectifier/regulator 4 Starting circuit cut-off relay 1 A Sidestand switch 5 Starting circuit cut-off relay 2 (XP500A) B Crankshaft position sensor 6 Battery...
  • Page 480 – ELEC ELECTRICAL COMPONENTS E Speed sensor (XP500) F Throttle position sensor G Ignition coil H Horn I Lean angle cut-off switch J Fuel injection system relay K Headlight relay L Radiator fan motor relay 8 - 2...
  • Page 481 – ELEC ELECTRICAL COMPONENTS 1 ECU (ABS) (XP500A) B Intake air temperature sensor 2 Fail-safe relay (XP500A) C ECU (engine) 3 Main switch/immobilizer unit 4 Intake air pressure sensor 5 Coolant temperature sensor 6 ABS motor fuse 7 Fuel pump 8 Rear wheel sensor (XP500A) sensor 0 Hydraulic unit (XP500A)

  • Page 482: Checking Switch Continuity

    – ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1.

  • Page 483: Checking The Switches

    – ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading →...

  • Page 484: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.

  • Page 485: Checking The Condition Of The Bulbs

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 486: Checking The Condition Of The Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester 90890-03112, YU-03112-C NOTE:...

  • Page 487: Ignition System

    – ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM 8 - 9...

  • Page 488: Troubleshooting

    – ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no • Check the condition of the battery. spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses Minimum open-circuit voltage 2.
  • Page 489 – ELEC IGNITION SYSTEM EAS00743 EAS00745 4. Ignition spark gap 5. Spark plug cap resistance The following procedure applies to all of the The following procedure applies to all of the spark plugs. spark plug caps. • Disconnect the spark plug cap 1 from the •...
  • Page 490 – ELEC IGNITION SYSTEM EAS00746 EAS00748 6. Ignition coil resistance 7. Crankshaft position sensor resistance • Disconnect the ignition coil connectors • Disconnect the crankshaft position sensor from the ignition coil terminals. coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the •...
  • Page 491 1 Refer to “CHECKING THE SWITCHES”. • Is the sidestand switch OK? Replace side- stand switch. XP500 XP500A NOTE: When you switch the positive and negative tester probes, the readings in the above chart will be reversed. • Are the tester readings correct? Replace the starting circuit cut-off relay 1.
  • Page 492 – ELEC IGNITION SYSTEM EAS00754 12.Lean angle cut-off switch 13.Wiring • Remove the lean angle cut-off switch. • Connect the pocket tester (Ω × 1) to the • Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. lean angle cut-off switch terminals as •...

  • Page 493: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM (XP500) 8 - 15...

  • Page 494: Circuit Diagram (Xp500A)

    – ELEC ELECTRIC STARTING SYSTEM EAS00755 CIRCUIT DIAGRAM (XP500A) 8 - 16...

  • Page 495: Starting Circuit Cut-Off System Operation (Xp500)

    ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (XP500) If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if the following conditions are met: •...

  • Page 496: Starting Circuit Cut-Off System Operation (Xp500A)

    – ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (XP500A) If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if the following conditions are met: •...

  • Page 497: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition and signaling system fuses 2.
  • Page 498 Positive battery terminal → red/black 1 Negative battery terminal → light green 2 Positive battery terminal → green/yellow 1 XP500 Negative battery terminal → black 2 Positive tester probe → green/yellow 3 Negative tester probe → green/yellow 4 Positive tester probe → white/red 3 Negative tester probe →...
  • Page 499 • Connect the pocket tester (Ω × 1) and bat- ity. tery (12 V) to the starter relay terminals as Refer to “CHECKING THE SWITCHES”. shown. • Is the engine stop switch OK? XP500 Positive battery terminal → black 1 Negative battery terminal → blue/white 2 Replace right handlebar switch.
  • Page 500 Replace right handlebar switch. EAS00766 12.Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM (XP500)” or “CIRCUIT DIAGRAM (XP500A)”. • Is the starting system’s wiring properly connected and without defects? The starting system Properly connect or circuit is OK.

  • Page 501: Starter Motor

    – ELEC STARTER MOTOR EAS00767 STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Fuel tank Refer to “FUEL TANK” in chapter 3. Negative battery lead Disconnect. Starter motor lead Disconnect. Starter motor For installation, reverse the removal pro- cedure.
  • Page 502 – ELEC STARTER MOTOR Order Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed. Front bracket O-ring Shims Lock washer Oil seal Bearing Rear bracket Shims Brush holder set Armature assembly Starter motor yoke For assembly reverse the disassembly procedure.

  • Page 503: Checking The Starter Motor

    – ELEC STARTER MOTOR EAS00770 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3.
  • Page 504 – ELEC STARTER MOTOR Pocket tester 90890-03112, YU-03112-C Armature coil Commutator resistance 1 0.0015 ~ 0.0025 Ω at 20 °C (68 °F) Insulation resistance 2 Above 1 MΩ at 20 °C (68 °F) b. If any resistance is out of specification, replace the starter motor.

  • Page 505: Assembling The Starter Motor

    – ELEC STARTER MOTOR EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: • starter motor yoke 1 • front bracket 2 • rear bracket 3 NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and rear bracket.

  • Page 506: Charging System

    – ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM 8 - 28...

  • Page 507: Troubleshooting

    – ELEC CHARGING SYSTEM EAS00774 EAS00738 TROUBLESHOOTING 1. Main fuse The battery is not being charged. • Check the main fuse for continuity. Refer to “CHECKING THE FUSES” in Check: chapter 3. 1. main fuse • Is the main fuse OK? 2.
  • Page 508 – ELEC CHARGING SYSTEM EAS00775 EAS00776 3. Charging voltage 4. Stator coil resistance • Connect the pocket tester (DC 20 V) to the • Remove the generator cover. • Connect the pocket tester (Ω × 1) to the battery as shown. stator coils as shown.

  • Page 509: Lighting System

    – ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 8 - 31...
  • Page 510 – ELEC LIGHTING SYSTEM 4 Main switch 6 Storage box light switch 7 Storage box light 0 Backup fuse (storage box light, immobilizer unit and meter assembly) A Signaling system fuse B Headlight fuse E Lighting system fuse F Battery G Main fuse T ECU (engine) k Headlight relay...

  • Page 511: Troubleshooting

    – ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery Any of the following fail to light: head- • Check the condition of the battery. light, high beam indicator light, taillight, Refer to “CHECKING AND CHARGING licence plate light, storage box light, aux- THE BATTERY”...
  • Page 512 – ELEC LIGHTING SYSTEM EAS00786 7. Headlight relay 5. Pass switch • Remove the headlight relay. • Connect the pocket tester (Ω × 1) and bat- • Check the pass switch for continuity. Refer to “CHECKING THE SWITCHES”. tery (12 V) to the headlight relay terminals •...

  • Page 513: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EAS00788 Headlight coupler (wire harness side) CHECKING THE LIGHTING SYSTEM È high beam 1. The headlight and the high beam indicator light fail to come on. 1. Headlight bulb and socket • Check the headlight bulb and socket for continuity.
  • Page 514 – ELEC LIGHTING SYSTEM EAS00789 EAS00790 2. The meter light fails to come on. 3. The tail/brake light fails to come on. 1. Meter light bulb and socket 1. Tail/brake light bulb and socket • Check the meter light bulb and socket for •...
  • Page 515 – ELEC LIGHTING SYSTEM EAS00791 EAS00792 4. The auxiliary light fails to come on. 5. The license plate light fails to come on. 1. Auxiliary light bulb and socket 1. License plate light bulb and socket • Check the auxiliary light bulb and socket •...
  • Page 516 – ELEC LIGHTING SYSTEM EAS00792 6. The storage box light fails to come on. 1. Storage box light bulb and socket • Check the storage box light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. •...

  • Page 517: Signaling System

    – ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 8 - 39...
  • Page 518 – ELEC SIGNALING SYSTEM 4 Main switch 0 Backup fuse (storage box light, immobilizer unit and meter assembly) A Signaling system fuse E Lighting system fuse F Battery G Main fuse M Fuel pump Q Hazard switch R Front brake light switch T ECU (engine) a Speed sensor i Turn signal/hazard relay...

  • Page 519: Troubleshooting

    – ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to light: turn • Check the condition of the battery. signal light, brake light or an indicator Refer to “CHECKING AND CHARGING light. THE BATTERY” in chapter 3. •...

  • Page 520: Checking The Signaling System

    – ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the horn coupler at the horn. • Connect a jumper lead 1 to the brown ter- 1. Horn switch minal in the horn coupler and the horn ter- •...
  • Page 521 – ELEC SIGNALING SYSTEM EAS00798 3. Voltage 2. The tail/brake light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket tail/brake light assembly coupler (wire har- • Check the tail/brake light bulb and socket ness side) as shown.
  • Page 522 – ELEC SIGNALING SYSTEM EAS00799 4. Hazard switch 3. The turn signal light, turn signal indicator light or both fail to blink. • Check the hazard switch for continuity. Refer to “CHECKING THE SWITCHES”. 1. Turn signal light bulb and socket •...
  • Page 523 – ELEC SIGNALING SYSTEM È É 6. Voltage • Connect the pocket tester (DC 20 V) to the turn signal/hazard relay coupler (wire har- ness side) as shown. Positive tester probe → brown/white 1 Negative tester probe → ground Ê •...
  • Page 524 – ELEC SIGNALING SYSTEM 4. The V-belt replacement indicator fails to 3. Voltage come on. • Connect the pocket tester (DC 20 V) to the 1. V-belt replacement indicator bulb and meter assembly coupler (wire harness socket side) as shown. Positive tester probe →...
  • Page 525 – ELEC SIGNALING SYSTEM EAS00803 EAS00804 5. The engine oil change indicator fails to 7. The fuel meter fails to come on. come on. 1. Fuel sender 1. Engine oil change indicator bulb and • Drain the fuel from the fuel tank and then socket remove the fuel pump (fuel sender) from •...
  • Page 526 – ELEC SIGNALING SYSTEM 2. Voltage 3. Fuel meter • Connect the pocket tester (DC 20 V) to the • Set the main switch to “ON”. • Move the float up 1 or down 2. meter assembly coupler (wire harness side) as shown.
  • Page 527 – ELEC SIGNALING SYSTEM EAS00806 2. Voltage 8. The speedometer fails to operate. • Connect the pocket tester (DC 20 V) to the 1. Speed sensor meter assembly coupler (wire harness • Connect the pocket tester (DC 20 V) to the side) as shown.

  • Page 528: Cooling System

    – ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM 8 - 50...

  • Page 529: Troubleshooting

    – ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery • The radiator fan motor fails to turn. • Check the condition of the battery. • The coolant temperature meter (meter Refer to “CHECKING AND CHARGING assembly) fails to indicate. THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1.
  • Page 530 – ELEC COOLING SYSTEM EAS00809 5. Radiator fan motor relay 4. Radiator fan motor • Remove the radiator fan motor relay from • Disconnect the radiator fan motor coupler the wire harness. • Connect the pocket tester (Ω × 1) and bat- from the wire harness.
  • Page 531 – ELEC COOLING SYSTEM EAS00812 6. Coolant temperature sensor • Remove the coolant temperature sensor from the cylinder head. • Connect the pocket tester (Ω × 10) to the coolant temperature sensor 1 as shown. • Immerse the coolant temperature sensor in a container filled with coolant 2.

  • Page 532: Immobilizer System

    – ELEC IMMOBILIZER SYSTEM IMMOBILIZER SYSTEM SYSTEM DIAGRAM 1 Main switch and immobilizer unit 2 ECU (engine) 3 Immobilizer system indicator light Main switch R.... Red Br/L..Brown/Blue G/L..Green/Blue R/G ..Red/Green Ignition fuse R/W ..Red/White Immobilizer unit Backup Y/L ..
  • Page 533 – ELEC IMMOBILIZER SYSTEM CIRCUIT DIAGRAM 8 - 55...
  • Page 534 – ELEC IMMOBILIZER SYSTEM GENERAL INFORMATION This scooter is equipped with an immobilizer system to help prevent theft by registering codes in standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with black bows) that can be re-registered with new codes •...
  • Page 535 – ELEC IMMOBILIZER SYSTEM KEY CODE REGISTRATION Code registration of the code re-registering key or standard keys may be required when parts are replaced or a standard key is lost. NOTE: Each standard key is registered during production, therefore, registering the keys at purchase is not necessary.
  • Page 536 – ELEC IMMOBILIZER SYSTEM 3. Insert the standard key to be registered into the main switch, and then turn the main switch to “ON” within 5 seconds to activate the key registration mode. NOTE: All existing standard key codes will be erased from the memory when the key registration mode is activated.
  • Page 537 – ELEC IMMOBILIZER SYSTEM SELF-DIAGNOSIS MALFUNCTION CODES When a system malfunction occurs, the malfunction code number is displayed on the LCD display of the meter assembly and is indicated by the immobilizer system indicator light flash patterns. Malfunction Part Symptom Cause Action code...
  • Page 538 – ELEC IMMOBILIZER SYSTEM Immobilizer system indicator light malfunction code indication Units of 10: on for 1 second and off for 1.5 seconds. Units of 1: on for 0.5 second and off for 0.5 second. <Example> malfunction code 52 Light on Light off 0.5 0.5 0.5 8 - 60...
  • Page 539 – ELEC IMMOBILIZER SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery When the main switch is turned “ON”, • Check the condition of the battery. the immobilizer system indicator light Refer to “CHECKING AND CHARGING does not come on or flash. THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1.
  • Page 540 – ELEC IMMOBILIZER SYSTEM CHECKING THE IMMOBILIZER SYSTEM 2. Wiring 1. The immobilizer system indicator light does • Disconnect the meter assembly coupler not come on. and immobilizer unit coupler. 1. Voltage • Check the immobilizer system indicator light lead (green/blue) continuity. •...
  • Page 541 – ELEC IMMOBILIZER SYSTEM 2. No malfunction code is displayed on the LCD display of the meter assembly. 1. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. LCD display Positive tester probe → red/white 1 or red/green 2 Negative tester probe →...
  • Page 542 – ELEC IMMOBILIZER SYSTEM 3. When the main switch is turned to “ON”, the immobilizer system indicator light flashes. • Check if a metal object or other immobilizer system keys are placed near the immobilizer unit. If so, remove the object or keys, and then check the condition again. Turn the main switch to “ON”...
  • Page 543 – ELEC IMMOBILIZER SYSTEM PART REPLACEMENT KEY REGISTRATION REQUIREMENTS Parts to be replaced Required key Accessory Main Standard registration lock Immobilizer switch (engine) unit Standard key is lost New standard key All keys have been lost Code re-registering (including code re-reg- key and standard keys istering key) ECU (engine) is defec-...

  • Page 545: Trbl Shtg

    TRBL SHTG...

  • Page 546: Troubleshooting Trbl

    TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING FAILURE/HARD STARTING ............9-1 ENGINE..................... 9-1 FUEL SYSTEM..................9-1 ELECTRICAL SYSTEMS ................9-1 INCORRECT ENGINE IDLING SPEED............9-2 ENGINE..................... 9-2 FUEL SYSTEM..................9-2 ELECTRICAL SYSTEMS ................9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE .........9-2 ENGINE..................... 9-2 FUEL SYSTEM..................9-2 FAULTY CLUTCH ................... 9-2 ENGINE OPERATES BUT SCOOTER WILL NOT MOVE......9-2 CLUTCH SLIPS..................
  • Page 547 TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM..........9-5 HEADLIGHT DOES NOT COME ON ............9-5 HEADLIGHT BULB BURNT OUT.............. 9-5 TAIL/BRAKE LIGHT DOES NOT COME ON ..........9-5 TAIL/BRAKE LIGHT BULB BURNT OUT..........9-5 TURN SIGNAL DOES NOT COME ON ............ 9-5 TURN SIGNAL BLINKS SLOWLY............. 9-5 TURN SIGNAL REMAINS LIT..............9-5 TURN SIGNAL BLINKS QUICKLY............
  • Page 548 TRBL STARTING FAILURE/HARD STARTING SHTG EAS00845 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man- ual for checks, adjustments, and replacement of parts.

  • Page 549: Engine

    INCORRECT ENGINE IDLING SPEED/POOR MEDIUM- TRBL AND-HIGH-SPEED PERFORMANCE/FAULTY CLUTCH SHTG EAS00847 INCORRECT ENGINE IDLING SPEED ENGINE ELECTRICAL SYSTEMS Cylinder(s) and cylinder head Battery • Incorrect valve clearance • Discharged battery • Damaged valve train components • Faulty battery Air filter Spark plug(s) •...

  • Page 550: Poor Speed Performance

    TRBL FAULTY CLUTCH/OVERHEATING/OVERCOOLING SHTG POOR SPEED PERFORMANCE V-belt Primary sliding sheave • Oil or grease on the V-belt • Worn primary sliding sheave Primary pulley weight(s) Secondary fixed sheave • Faulty operation • Worn secondary fixed sheave • Worn primary pulley weight Secondary sliding sheave Primary fixed sheave •...

  • Page 551: Poor Braking Performance

    POOR BRAKING PERFORMANCE/ TRBL FAULTY FRONT FORK LEGS/UNSTABLE HANDLING SHTG EAS00857 POOR BRAKING PERFORMANCE • Worn brake pad • Worn brake disc • Air in hydraulic brake system • Leaking brake fluid • Faulty brake caliper kit • Faulty brake caliper seal •...

  • Page 552: Faulty Lighting Or Signaling System

    TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON TURN SIGNAL DOES NOT COME ON • Wrong headlight bulb • Faulty turn signal switch • Too many electrical accessories • Faulty turn signal/hazard relay •...
  • Page 554 XP500 2005 WIRING DIAGRAM 1 Crankshaft position sensor o Horn switch COLOR CODE 2 A.C. magneto p Turn signal switch B.... Black 3 Rectifier/regulator q Rear brake light switch Br ..Brown 4 Main switch r Tail/brake light assembly Ch ..Chocolate...
  • Page 555 XP500A 2005 WIRING DIAGRAM 1 Crankshaft position sensor o Radiator fan motor relay COLOR CODE 2 A.C. magneto p Radiator fan motor B.... Black 3 Rectifier/regulator q Turn signal/hazard relay Br ..Brown 4 Main switch r Horn Ch ..Chocolate 5 Immobilizer unit s Headlight relay Dg ..
  • Page 557 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 558 XP500 2005 WIRING DIAGRAM Y/L Y/G Gy/G W B/Y Br/W Y B/L W/Y R/L G/B B GRIP WARMER WIRE HARNESS SUB-WIRE HARNESS (GREEN) Br/L Br/L B/W B R/G R/G B (BLUE) Y/L G/L R/W R/W Lg Y/L Br/R DC TERMINAL...
  • Page 559 XP500A 2005 WIRING DIAGRAM Y/L Y/G Gy/G W/Y B/Y Br/W Y B/L W/B R/L G/B B GRIP WARMER WIRE HARNESS SUB-WIRE HARNESS Br/L Br/L (GREEN) DC TERMINAL R/G B WIRE HARNESS B/W B R/G SUB-WIRE HARNESS Y/L G/L R/W R/W Lg Y/L Br/R Br/W Br/W B/L...

This manual is also suitable for:

Xp500a

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