OWNER’S MANUAL XP500 XP500A 15B-28199-E0
EAU26943 DECLARATION of CONFORMITY We Company: MORIC CO., LTD. Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Hereby declare that the product: Kind of equipment: IMMOBILIZER Type-designation: 5SL-00 is in compliance with following norm(s) or documents: R&TTE Directive(1999/5/EC) EN300 330-2 v1.1.1(2001-6), EN60950-1(2001) Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC) Place of issue: Shizuoka, Japan Date of issue: 1 Aug. 2002 Revolution record No.
INTRODUCTION EAU10110 Welcome to the Yamaha world of motorcycling! As the owner of the XP500/XP500A, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XP500/XP500A.
IMPORTANT MANUAL INFORMATION EAU34111 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the scooter operator, a bystander, or a person inspecting or repairing the scooter. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the scooter.
IMPORTANT MANUAL INFORMATION EAU10200 XP500/XP500A OWNER’S MANUAL ©2006 by Yamaha Motor Co., Ltd. 1st edition, September 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
TABLE OF CONTENTS SAFETY INFORMATION ...................1-1 Further safe-riding points .................1-4 DESCRIPTION ...................................2-1 Left view ...........................................2-1 Right view .........................................2-2 Controls and instruments..................2-3 INSTRUMENT AND CONTROL FUNCTIONS ........................................3-1 Immobilizer system ..........................3-1 Main switch/steering lock .................
TABLE OF CONTENTS Replacing an auxiliary light bulb ....6-35 Troubleshooting .............................6-35 Troubleshooting charts ..................6-36 SCOOTER CARE AND STORAGE ...........................................7-1 Matte color caution ..........................7-1 Care .................................................7-1 Storage ............................................7-3 SPECIFICATIONS ..............................8-1 CONSUMER INFORMATION..............9-1 Identification numbers .........
SAFETY INFORMATION EAU10261 1 SCOOTERS ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS SCOOTER. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF SCOOTER OPERATION. THE WARNINGS ● OBSERVE AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
SAFETY INFORMATION Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control. The operator should keep both hands on the handlebar and both feet on the footboard during operation to maintain control of the scooter. The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with both hands and keep both feet on the passenger footrests.
SAFETY INFORMATION 1 When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the scooter as possible. Make sure to distribute the weight as evenly as possible on both sides of the scooter to minimize imbalance or instability. ● Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the scooter before riding. Check accessory mounts and cargo restraints frequently.
SAFETY INFORMATION Take care not to spill any gasoline on the engine or exhaust system when refueling. Never refuel while smoking or in the vicinity of an open flame. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your scooter in an area that has adequate ventilation.
SAFETY INFORMATION ● 1 and ankle so they do not flap), and a bright colored jacket. Do not carry too much luggage on the scooter. An overloaded scooter is unstable.
SAFETY INFORMATION 1 1-6
DESCRIPTION EAU10410 Left view 2 3 10 9 8 7 6 5 1 4 1 2 3 4 5 6 7 8 9 1. Fuel tank cap (page 3-12) 2. Rear storage compartment (page 3-16) 3. Helmet holder (page 3-15) 4. Grab bar (page 5-2) 5. Chain drive oil filler cap (page 6-14) 6. Engine oil filler cap (page 6-11) 7. V-belt air filter element (left) 8. Engine oil drain bolt (page 6-11) 9. Engine oil level check window (page 6-11) 10.
DESCRIPTION EAU10420 Right view 1 2 3 4 5 2 3 4 5 6 7 9 8 7 1. Battery (page 6-29) 2. Fuses (page 6-30) 3. Owner’s tool kit (page 6-1) 4. Front storage compartment (page 3-16) 5. Air filter element (page 6-17) 6. Coolant level check window (page 6-15) 7. V-belt air filter element (right) 8. Centerstand (page 6-26) 6 9.
DESCRIPTION EAU10430 Controls and instruments 1 2 3 4 5 6 7 8 1 2 3 4 5 6 9 10 7 8 9 1. Rear brake lever (page 3-10) 2. Left handlebar switches (page 3-9) 3. Rear brake lock lever (page 3-11) 4. Speedometer (page 3-4) 5. Multi-function display (page 3-5) 6. Tachometer (page 3-5) 7. Right handlebar switches (page 3-9) 8. Front brake lever (page 3-10) 9. Throttle grip (page 6-19) 10.
INSTRUMENT AND CONTROL FUNCTIONS EAU10972 Immobilizer system ● an immobilizer system indicator light (See page 3-3.) The key with the red bow is used to register codes in each standard key. Since re-registering is a difficult process, take the vehicle along with all three keys to a Yamaha dealer to have them re-registered. Do not use the key with the red bow for driving. It should only be used for re-registering the standard keys. Always use a standard key for driving. ● ● ● ● ECA11820 1.
INSTRUMENT AND CONTROL FUNCTIONS EAU10471 Main switch/steering lock come on, and the engine can be started. The key cannot be removed. NOTE: The headlights come on automatically when the engine is started and stay on until the key is turned to “OFF” or the sidestand is moved down. 1 2 3 4 5 6 7 8 9 EAU10660 The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. NOTE: Be sure to use the standard key (black bow) for regular use of the vehicle.
INSTRUMENT AND CONTROL FUNCTIONS wise the battery may discharge. EAU11003 Indicator and warning lights 1 2 3 4 5 1. Turn signal indicator lights “ ” and “ 2. High beam indicator light “ ” ” 3. Immobilizer system indicator light 4. Engine trouble warning light “ ” 5. Anti-lock Brake System (ABS) warning light “ ABS ” (for ABS models) EAU11030 Turn signal indicator lights “ ” and “ ” The corresponding indicator light flashes when the turn signal switch is pushed to the left or right.
INSTRUMENT AND CONTROL FUNCTIONS flashes while riding, the ABS may be defective. If this occurs, have a Yamaha dealer check the electrical circuit. 1 2 3 4 5 See page 3-11 for an explanation of the ABS. The electrical circuit of the warning light can be checked by setting the engine stop switch to “ ” and turning the key to “ON”. The warning light should come on for a few seconds, and then go off. If the warning light does not come on or remains on, have a Yamaha dealer check the electrical circuit.
INSTRUMENT AND CONTROL FUNCTIONS EAU11872 Tachometer EAU33519 1 Multi-function display 2 3 4 EWA12311 1 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function display. 2 2 1 2 3 1. Tachometer 2. Tachometer red zone The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 ● ● ● ● cator started flashing) a self-diagnosis device a clock an oil change indicator a V-belt replacement indicator NOTE: ● Be sure to turn the key to “ON” before using the “SELECT” and “RESET” buttons. ● When the key is turned to “ON”, all of the display segments of the multi-function display will appear one after the other and then disappear, in order to test the electrical circuit.
INSTRUMENT AND CONTROL FUNCTIONS page 6-36.) ECA10020 CAUTION: Do not operate the engine if it is overheated. Oil change indicator “OIL” This indicator flashes at the initial 1000 km (600 mi), then at 5000 km (3000 mi) and every 5000 km (3000 mi) thereafter to indicate that the engine oil should be changed. After changing the engine oil, reset the oil change indicator. (See page 6-11.) If the engine oil is changed before the oil change indicator comes on (i.e.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 If any of the immobilizer system circuits are defective, the immobilizer system indicator light will flash, and then the multi-function display will indicate a two-digit error code when the key is turned to “ON”. NOTE: If the multi-function display indicates error code 52, this could be caused by transponder interference. If this error appears, try the following. 1. Use the code re-registering key to start the engine.
INSTRUMENT AND CONTROL FUNCTIONS EAU12347 Handlebar switches Right leased, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has returned to the center position. 1 Left 1 2 EAU12500 Horn switch “ ” Press this switch to sound the horn. 3 2 3 EAU12660 1. Engine stop switch “ 4 1. Pass switch “ 2. Hazard switch “ 3. Start switch “ ” 2. Dimmer switch “ / 3. Turn signal switch “ 4.
INSTRUMENT AND CONTROL FUNCTIONS EAU41700 EAU12900 Front brake lever 1 2 3 4 5 6 7 8 The engine trouble warning light will come on when the key is turned to “ON” and the start switch is pushed, but this does not indicate a malfunction. EAU12950 Rear brake lever 1 1 EAU12733 Hazard switch “ ” With the key in the “ON” or “ ” position, use this switch to turn on the hazard lights (simultaneous flashing of all turn signal lights).
INSTRUMENT AND CONTROL FUNCTIONS EAU12962 Rear brake lock lever ● 1 rear brake lock lever is applied. To provide secure locking of the rear wheel, apply the rear brake lever first before moving the rear brake lock lever to the left. EWA12361 1. Rear brake lock lever This vehicle is equipped with a rear brake lock lever to prevent the rear wheel from moving while stopped at traffic signals, railroad crossings, etc.
INSTRUMENT AND CONTROL FUNCTIONS EAU13174 1 2 3 4 5 6 7 8 NOTE: ● When the ABS is activated, the brakes are operated in the usual way. A pulsating action may be felt at the brake levers, but this does not indicate a malfunction. ● This ABS has a test mode which allows the owner to experience the pulsating at the brake levers when the ABS is operating. However, special tools are required, so please consult your Yamaha dealer when performing this test. Fuel tank cap To remove the fuel tank cap 1.
INSTRUMENT AND CONTROL FUNCTIONS move it. 3. Close the lid. EAU13211 Fuel fuel may deteriorate painted surfaces or plastic parts. EWA11260 WARNING Make sure that the fuel tank cap is properly installed and locked in place before riding the scooter. EAU33520 1 Recommended fuel: REGULAR UNLEADED GASOLINE ONLY Fuel tank capacity: 14.0 L (3.70 US gal) (3.08 Imp.gal) 2 ECA11400 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank.
INSTRUMENT AND CONTROL FUNCTIONS EAU13431 Catalytic converter This model is equipped with a catalytic converter in the exhaust system. 1 2 3 EAU13932 Seat EWA10860 WARNING The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. To open the seat 1. Place the scooter on the centerstand. 2. Insert the key into the main switch, and then turn it counterclockwise to “OPEN”.
INSTRUMENT AND CONTROL FUNCTIONS EAU14270 EAU14340 Adjusting the rider backrest Helmet holder The rider backrest can be adjusted to the three different positions shown. 1 1 1 2 2 3 1. Rider backrest 2. Bolt 1. Rider backrest Adjust the backrest as follows. 1. Open the seat. (See page 3-14.) 2. Remove the backrest bolts. 3. Slide the backrest forward or backward to the desired position. 4. Install and securely tighten the backrest bolts. 5. Close the seat. 3-15 1.
INSTRUMENT AND CONTROL FUNCTIONS EAU14503 EWA10160 1 WARNING Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident. 2 3 4 Storage compartments Front storage compartment To open the front storage compartment, slide the lever up, and then pull on the lever. To release the helmet from the helmet holder Open the seat, remove the helmet holding cable from the helmet holder and the helmet, and then close the seat.
INSTRUMENT AND CONTROL FUNCTIONS when using the storage compartment. ● Since the storage compartment accumulates heat when exposed to the sun, do not store anything susceptible to heat inside it. ● To avoid humidity from spreading through the storage compartment, wrap wet articles in a plastic bag before storing them in the compartment. ● Since the storage compartment may get wet while the scooter is being washed, wrap any articles stored in the compartment in a plastic bag.
INSTRUMENT AND CONTROL FUNCTIONS EAU15301 Sidestand 1 2 3 4 pair it if it does not function properly. The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright. The ignition circuit cut-off system (comprising the sidestand switch and brake light switches) has the following functions. ● It prevents starting when the sidestand is up, but neither brake is applied.
INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Keep the front or rear brake applied. 5. Push the start switch. Does the engine start? NO NOTE: This check is most reliable if performed with a warmed-up engine. 2 The sidestand switch may be defective. The scooter should not be ridden until checked by a Yamaha dealer. YES With the engine still off: 6. Move the sidestand up. 7.
PRE-OPERATION CHECKS EAU15592 1 2 3 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
PRE-OPERATION CHECKS EAU15605 Pre-operation check list ITEM CHECKS ● Fuel ● ● ● Engine oil ● ● Chain drive oil ● ● Coolant ● ● ● ● ● Front brake ● ● ● ● ● ● ● Rear brake ● ● ● ● ● Throttle grip ● ● Check fuel level in fuel tank. Refuel if necessary. Check fuel line for leakage. Check oil level in engine. If necessary, add recommended oil to specified level. Check vehicle for oil leakage. Check vehicle for oil leakage. Check coolant level in reservoir.
PRE-OPERATION CHECKS ITEM CHECKS ● Wheels and tires 1 ● ● Brake levers 2 ● Centerstand, sidestand 3 Chassis fasteners 4 Instruments, lights, signals and switches Sidestand switch ● ● ● ● ● ● ● ● ● ● Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. Make sure that operation is smooth. Lubricate lever pivoting points if necessary. Make sure that operation is smooth. Lubricate pivots if necessary.
OPERATION AND IMPORTANT RIDING POINTS EAU15970 EAU36510 Starting the engine ● ● ● ● EWA11250 ECA10250 WARNING Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time.
OPERATION AND IMPORTANT RIDING POINTS cold! 1 2 3 EAU16760 Starting off NOTE: Before starting off, allow the engine to warm up. 1. While pulling the rear brake lever with your left hand and holding the grab bar with your right hand, push the scooter off the centerstand. (a) The speed can be adjusted by opening and closing the throttle. To increase the speed, turn the throttle grip in direction (a). To reduce the speed, turn the throttle grip in direction (b). 5 6 7 1.
OPERATION AND IMPORTANT RIDING POINTS EAU16792 Braking Rear cult. 1. Close the throttle completely. 2. Apply both front and rear brakes simultaneously while gradually increasing the pressure. 2 Front 3 EWA10300 ● ● ● ● WARNING Avoid braking hard or suddenly (especially when leaning over to one side), otherwise the scooter may skid or overturn. Railroad crossings, streetcar rails, iron plates on road construction sites, and manhole covers become extremely slippery when wet.
OPERATION AND IMPORTANT RIDING POINTS EAU16820 Tips for reducing fuel consumption 1 2 3 4 5 Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: ● Avoid high engine speeds during acceleration. ● Avoid high engine speeds with no load on the engine. ● Turn the engine off instead of letting it idle for an extended length of time (e.g., in traffic jams, at traffic lights or at railroad crossings).
OPERATION AND IMPORTANT RIDING POINTS EAU17212 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10310 ● ● WARNING Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn. 2 3 4 5 ECA10380 6 CAUTION: Never park in an area where there are fire hazards such as grass or other flammable materials.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17280 1 2 3 4 5 6 7 8 9 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages. The intervals given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions.
PERIODIC MAINTENANCE AND MINOR REPAIR a Yamaha dealer perform it for you. EWA10350 WARNING Modifications not approved by Yamaha may cause loss of performance and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17706 Periodic maintenance and lubrication chart 1 2 NOTE: ● The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. ● 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. 3 NO.
PERIODIC MAINTENANCE AND MINOR REPAIR NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING (× 1000 km) 1 9 * Brake hoses ● Check for cracks or damage. Replace. Check runout and for damage. Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. Check bearing for looseness or damage. Check bearing play and steering for roughness. Lubricate with lithium-soap-based grease. Make sure that all nuts, bolts and screws are properly tightened. Check operation. Lubricate.
PERIODIC MAINTENANCE AND MINOR REPAIR NO. ITEM Front and rear brake switches Moving parts and cables 25 * 1 2 3 26 Throttle grip housing and cable 27 * Lights, signals and switches 28 * CHECK OR MAINTENANCE JOB ● Check operation. ● Lubricate. Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable. Check operation. Adjust headlight beam.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18712 2 Removing and installing cowlings and panels 4 2 The cowlings and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed. 1 2 1 2 3 1. Panel A 2. Panel B 3. Panel C 4. Cowling A 4 1. Screw 2. Nut 4 2. Remove the cowling screws. 5 3 2 EAU33422 5 1 1. Panel D 2. Cowling B 3. Panel E 4. Cowling C 5.
PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the cowling bolts, and then pull the cowling off. 1 To install the cowling 1. Place the cowling in the original position, and then install the bolts. 2. Install the battery cover by installing the screws. 1 2 2 3 4 5 6 7 8 9 EAU33431 1. Bolt 2. Screw 2. Remove the cowling screws and bolts. 3. Unhook the cowling from the holder at the bottom. 4. Unhook the front of the cowling by pushing it up, and then pull the cowling out. To install the cowling 1.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Pull outward on the front of the panel. 1 1 To install the panel Place the panel in the original position, and then install the screws. 1 2 3 1. Screw 1. Screw To install the panel Place the panel in the original position, and then install the screws. To install the panel Place the panel in the original position, install the screws, and then place the floorboard mat back.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU19593 Checking the spark plugs 1 2 1 3 1. Screw 4 5 6 To install the panel Place the panel in the original position, and then install the screws. 3. Remove the spark plug cap. The spark plugs are important engine components, which are easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR To check the spark plugs 1. Check that the porcelain insulator around the center electrode on each spark plug is a medium-to-light tan (the ideal color when the vehicle is ridden normally). 2. Check that all spark plugs installed in the engine have the same color. NOTE: If any spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. 3.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU19854 Engine oil and oil filter cartridge 1 2 3 4 The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the vehicle on the centerstand. tles, and then check the oil level through the check window located at the bottom-left side of the crankcase.
PERIODIC MAINTENANCE AND MINOR REPAIR 2 1 1 2 1 3 1. Engine oil drain bolt NOTE: Skip steps 4–6 if the oil filter cartridge is not being replaced. 4. Remove the oil filter cartridge with an oil filter wrench. 1. Oil filter wrench 2. Oil filter cartridge 1. Torque wrench NOTE: An oil filter wrench is available at a Yamaha dealer. 5. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure that the O-ring is properly seated. 6.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 2.80 L (2.96 US qt) (2.46 Imp.qt) With oil filter cartridge replacement: 2.90 L (3.07 US qt) (2.55 Imp.qt) ECA11620 3 4 5 6 7 8 9 CAUTION: ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU19994 Chain drive oil The chain drive oil should be changed as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Remove panel F. (See page 6-6.) 2. Place an oil pan under the chain drive case to collect the used oil. 3. Remove the oil filler cap and drain bolt to drain the oil from the chain drive case. 1 Tightening torque: Chain drive oil drain bolt: 20 Nm (2.0 m·kgf, 14.5 ft·lbf) 5.
PERIODIC MAINTENANCE AND MINOR REPAIR 10. Install the panel. 1 2 EAU20070 Coolant The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. 1 2 3 EAU42831 3 4 5 6 7 8 9 To check the coolant level 1. Place the vehicle on a level surface and hold it in an upright position. NOTE: ● The coolant level must be checked on a cold engine since the level varies with engine temperature.
PERIODIC MAINTENANCE AND MINOR REPAIR coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. er by removing the screw. 1 EWA10380 2 WARNING Never attempt to remove the radiator cap when the engine is hot. 1 1. Coolant reservoir cap 1. Coolant reservoir cover 2. Screw 5. Open the reservoir cap, add coolant to the maximum level mark, and then close the reservoir cap.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU21121 Cleaning the air filter element 1 2 3 4 The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. 1. Remove cowling A. (See page 6-6.) 2. Remove the windshield by removing the screws. 1. Screw 2. Panel 1. Air filter element 1 7 1 8 1. Screw 9 1 1 1 4.
PERIODIC MAINTENANCE AND MINOR REPAIR air filter case. EAU33481 ECA10480 CAUTION: ● Make sure that the air filter element is properly seated in the air filter case. ● The engine should never be operated without the air filter element installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn. 7. Install the air filter case cover by installing the screws. 8. Place the panel in the original position, and then install the screws. 9. Install the windshield and the cowling.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU21382 Checking the throttle cable free play 1 2 1 EAU21401 EAU33600 Valve clearance Tires The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR Tire air pressure (measured on cold tires): 0–90 kg (0–198 lb): Front: 225 kPa (33 psi) (2.25 kgf/cm2) Rear: 250 kPa (36 psi) (2.50 kgf/cm2) XP500 90–188 kg (198–414 lb) XP500A 90–183 kg (198–403 lb): Front: 225 kPa (33 psi) (2.25 kgf/cm2) Rear: 280 kPa (41 psi) (2.
PERIODIC MAINTENANCE AND MINOR REPAIR Tire information This model is equipped with tubeless tires. 1 2 3 4 5 edge and experience. To maximize the performance, durability, and safe operation of your vehicle, note the following points regarding the specified wheels. ● The wheel rims should be checked for cracks, bends or warpage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU33453 Front and rear brake lever free play Front brake system. EAU33473 EWA14211 WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the vehicle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident.
PERIODIC MAINTENANCE AND MINOR REPAIR To decrease the rear brake lock lever cable length, turn the adjusting nut in direction (b). EWA10650 1 2 WARNING If proper adjustment cannot be obtained as described, have a Yamaha dealer make this adjustment. EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR stalling the bolts, then tightening them to the specified torque. Tightening torque: Brake caliper bolt: 40 Nm (4.0 m·kgf, 28.9 ft·lbf) EAU22710 Checking the brake fluid level Front brake 1 ECA12822 CAUTION: Do not apply the rear brake or rear brake lock after the brake caliper has been removed, otherwise the brake caliper piston will be forced out. 1. Minimum level mark Rear brake 1 enter the brake system, possibly causing it to become ineffective.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 ● 2 3 4 5 ● when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock, and dirt may clog the ABS hydraulic unit valves. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23171 Lubricating the front and rear brake levers Front brake lever tenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) EAU23211 Checking and lubricating the centerstand and sidestand 2 3 4 5 Rear brake lever 6 7 8 The operation of the centerstand and sidestand should be checked before each ride, and the pivots and metal-to-metal contact surfaces should be lubricated if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23271 EWA10740 1 WARNING If the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. 2 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 EAU23290 Checking the steering Checking the wheel bearings Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground. The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR EWA10760 lowing FIRST AID. EXTERNAL: Flush with plenty of water. INTERNAL: Drink large quantities of water or milk and immediately call a physician. EYES: Flush with water for 15 minutes and seek prompt medical attention. Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space. KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN.
PERIODIC MAINTENANCE AND MINOR REPAIR necessary. 3. Fully charge the battery before installation. 4. After installation, make sure that the battery leads are properly connected to the battery terminals. ECA10630 CAUTION: keep the battery ● Always charged. Storing a discharged battery can cause permanent battery damage. ● To charge a sealed-type (MF) battery, a special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery.
PERIODIC MAINTENANCE AND MINOR REPAIR For non-ABS models amperage. 1 NOTE: To access the main fuse, remove the main fuse box cover as shown. 2 For ABS models 1 2 3 4 5 6 7 3 7 1 2 3 4 5 6 3 2 4 1 5 6 1. Main fuse 2. Spare main fuse 3. Main fuse box cover 1. Signaling system fuse 2. Headlight fuse 3. Ignition fuse 4. Radiator fan fuse 5. Fuel injection system fuse 6. Backup fuse (for odometer and clock) 7. Spare fuse 7 8 9 6-31 1. Signaling system fuse 2. Headlight fuse 3. Ignition fuse 4.
PERIODIC MAINTENANCE AND MINOR REPAIR the electrical circuit in question to check if the device operates. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: XP500 20.0 A XP500A 15.0 A Ignition fuse: 10.0 A Parking lighting fuse: 10.0 A Radiator fan fuse: 15.0 A Fuel injection system fuse: 10.0 A ABS control unit fuse: XP500A 5.0 A ABS motor fuse: XP500A 30.0 A Backup fuse: 10.
PERIODIC MAINTENANCE AND MINOR REPAIR and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. 1 2 1 2 1 3 4 1. Headlight bulb holder 2. Unhook. EWA10790 5 6 7 8 9 WARNING Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. 3.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU43050 Replacing a front turn signal light bulb 1. Place the scooter on the centerstand. 2. Remove the socket (together with the bulb) by turning it counterclockwise. EAU24270 Replacing a rear turn signal light bulb 1. Place the scooter on the centerstand. 2. Remove cowling C. (See page 6-6.) 3. Remove the socket (together with the turn signal light bulb) by turning it counterclockwise. bulb) by turning it clockwise. 7. Install the cowling. 2 3 4 1 5 1 6 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24330 License plate light 1 2 If the license plate light does not come on, have a Yamaha dealer check the electrical circuit or replace the bulb. EAU43230 Replacing an auxiliary light bulb This model is equipped with two auxiliary lights. If an auxiliary light bulb burns out, replace it as follows. 1. Remove the socket (together with the bulb) by pulling it out. 3 4 5 1 6 7 8 9 1. Auxiliary light bulb socket 2. Remove the defective bulb by pulling it out. 3.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU42500 Troubleshooting charts Starting problems or poor engine performance EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 2 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. 3 The engine does not start.
PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWAT1040 ● 1 ● 2 WARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled. Place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape.
SCOOTER CARE AND STORAGE EAU37833 Matte color caution EAU26100 Care ECA15192 CAUTION: Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle. Using a brush, harsh chemical products or cleaning compounds when cleaning these parts will scratch or damage their surface. Wax also should not be applied to any matte colored finished parts.
SCOOTER CARE AND STORAGE ● 1 2 3 4 5 6 7 8 9 ● thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte. Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents.
SCOOTER CARE AND STORAGE EWA10940 ● ● what products to use. WARNING Make sure that there is no oil or wax on the brakes or tires. If necessary, clean the brake discs and brake linings with a regular brake disc cleaner or acetone, and wash the tires with warm water and a mild detergent. Before operating the scooter test its braking performance and cornering behavior.
SCOOTER CARE AND STORAGE 1 2 3 4 5 6 7 8 9 fuel from deteriorating. 3. Perform the following steps to protect the cylinders, piston rings, etc. from corrosion. a. Remove the spark plug caps and the spark plugs. b. Pour a teaspoonful of engine oil into the spark plug bores. c. Install the spark plug caps onto the spark plugs, and then place the spark plugs on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d.
SPECIFICATIONS EAU2633J Dimensions: Overall length: 2235 mm (88.0 in) Overall width: 775 mm (30.5 in) Overall height: 1410 mm (55.5 in) Seat height: 795 mm (31.3 in) Wheelbase: 1575 mm (62.0 in) Ground clearance: 130 mm (5.12 in) Minimum turning radius: 2800 mm (110.2 in) Weight: With oil and fuel: XP500 227.0 kg (500 lb) XP500A 232.0 kg (511 lb) Engine: Engine type: Liquid cooled 4-stroke, DOHC Cylinder arrangement: Forward-inclined parallel 2-cylinder Displacement: 499.0 cm3 Bore × stroke: 66.0 × 73.
SPECIFICATIONS Trail: 95.0 mm (3.
SPECIFICATIONS Tail/brake light: 12 V, 5.0 W/21.0 W × 2 Front turn signal/position light: 12 V, 21 W/5.0 W × 2 Rear turn signal light: 12 V, 21.0 W × 2 Auxiliary light: 12 V, 5.0 W × 2 License plate light: 12 V, 5.0 W × 1 Meter lighting: 14 V, 2.0 W × 3 High beam indicator light: 14 V, 1.4 W × 1 Turn signal indicator light: 14 V, 1.4 W × 2 Engine trouble warning light: 14 V, 1.4 W × 1 ABS warning light: XP500A 14 V, 1.4 W × 1 Immobilizer system indicator light: LED Radiator fan fuse: 15.
CONSUMER INFORMATION EAU26351 Identification numbers 1 2 3 Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. KEY IDENTIFICATION NUMBER: 4 VEHICLE IDENTIFICATION NUMBER: 7 8 EAU26410 Vehicle identification number 1 1. Key identification number 2. Code re-registering key (red bow) 3.
CONSUMER INFORMATION EAU26500 Model label 2 1 3 4 1. Model label The model label is affixed to the inside of the rear storage compartment. (See page 3-16.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
INDEX A ABS (for ABS models) ............................ 3-11 ABS warning light (for ABS models) ......... 3-3 Acceleration and deceleration................... 5-2 Air filter element, cleaning....................... 6-17 Anti-theft alarm (optional).......................... 3-8 Auxiliary light bulb, replacing .................. 6-35 Front and rear brake pads, checking .......6-23 Front fork, checking .................................6-27 Fuel..........................................................
INDEX V Valve clearance .......................................6-19 Vehicle identification number.....................9-1 W Wheel bearings, checking .......................6-28 Wheels.....................................................
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.10–0.
