2007 XP500 XP500A SERVICE MANUAL 15B-28197-E0
EAS20040 XP500/XP500A 2007 SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. First edition, November 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one 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.
EAS20090 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. ● The manual is divided into chapters and each chapter is divided into sections. The current section title is shown at the top of each page “1”. ● Sub-section titles appear in smaller print than the section title “2”.
EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 2 3 4 5 6 7 8 T. 1 R. 9 10 E 12 11 13 B 15 M G 14 M LS 16 LT New 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6. Wear limit, clearance 7. Engine speed 8. Electrical data 9. Engine oil 10. Gear oil 11. Molybdenum-disulfide oil 12. Wheel-bearing grease 13.
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9
GENERAL INFORMATION IDENTIFICATION .......................................................................................... 1-1 VEHICLE IDENTIFICATION NUMBER ................................................... 1-1 MODEL LABEL........................................................................................ 1-1 FEATURES.................................................................................................... 1-2 OUTLINE OF FI SYSTEM ..........................................................
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the frame. 1 EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
FEATURES EAS20170 FEATURES EAS15B1002 OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum 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.
FEATURES EAS15B1003 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/cm2, 34.1–37.0 psi) higher than the intake manifold pressure.
FEATURES EAS15B1004 OUTLINE OF ANTI-LOCK BRAKE SYSTEM (XP500A) Yamaha ABS features 1. The Yamaha ABS (Anti-Lock Brake System) features a dual electronic control system, which acts on the front and rear brakes independently. 2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of the vehicle. 3. The hydraulic unit, which is the main component of the ABS, is centrally located on the vehicle to increase mass centralization.
FEATURES ABS block diagram 1. 2. 3. 4. 5. 6. 7. 8. Rear brake caliper 9. Front brake caliper 10. ECU (ABS) 11. Rear wheel sensor 12. Front wheel sensor 13. ABS warning light Rear brake master cylinder Hydraulic unit Hydraulic pump ABS motor Buffer chamber Hydraulic control valve Front brake master cylinder EAS15B1005 Useful terms ● Wheel speed: The rotation speed of the front and rear wheels. ● Chassis speed: The speed of the chassis.
FEATURES 0%: There is no slip between the wheel and the road surface. The chassis speed is equal to the wheel speed. 100%: The wheel speed is “0”, but the chassis is moving (i.e., wheel lock). EAS15B1006 Brake force and vehicle stability When the brake pressure is increased, wheel speed is reduced. Slip occurs between the tire and the road surface and brake force is generated.
FEATURES EAS15B1008 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 pulsating action in the brake lever. NOTE: When the ABS is activated, a pulsating action may be felt at the brake lever, but this does not indicate a malfunction.
FEATURES sure. But, if there is a tendency of the wheel to lock on a slippery road surface, due to engine braking, the ABS may not be able to prevent the wheel from locking. EWA15B1004 WARNING The ABS controls only the tendency of the wheel to lock caused by applying the brakes. The ABS cannot prevent wheel lock on slippery surfaces, such as ice, when it is caused by engine braking, even if the ABS is operating.
FEATURES ● 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. 1 ● ABS control operation The ABS control operation performed in the ECU (ABS) is divided into the following two parts. ● Hydraulic control ● Self-diagnosis These operations are performed once every 8/1,000 of a second.
FEATURES 1. 2. 3. 4. 5. 6. Receive signals 7. Control operation 8. Depressurize/pressurize Software operation flow Set the main switch to “ON”. Initialize Self-diagnosis (when static) Self-diagnosis (when riding) A. 8/1,000 of a second ● Fail-safe relay The fail-safe relay controls the power supply of the hydraulic unit and is located upper the ECU (ABS). 1 1.
FEATURES Composition and operation The fail-safe relay is composed of the solenoid relay “1” and fail-safe 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.
FEATURES 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 “11” 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.
FEATURES ● Emergency braking (ABS activated) 1.Depressurized state When the front wheel is about to lockup, port D “11” of the solenoid valve is opened by the “depressurization” 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”. Brake fluid that has entered through port A “7” is restricted by the orifice “10” and the brake fluid is sent to the brake caliper via port C “13” and port D “11”, and the buffer chamber.
FEATURES 2.Pressurized state Port D “11” 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 “10” and the brake fluid is sent to the brake calipers via port A “7” and port C “13”.
FEATURES EAS15B1001 NOTE: MULTI-FUNCTION DISPLAY ● 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. EWA12311 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function display.
FEATURES To reset a tripmeter, select it by pushing the “SELECT” button until “TRIP” or “TRIP F” begins flashing (“TRIP” or “TRIP F” will only flash for five seconds). While “TRIP” or “TRIP F” is flashing, push the “RESET” button for at least one second. If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km (3 mi).
FEATURES engine stop switch is set to “ON”. 2. Disconnect the V-belt replacement reset coupler “1” for two to ten seconds. 3. And then, connect the V-belt replacement reset coupler, the V-belt replacement indicator will come on for 1.4 seconds. And the V-belt replacement indicator will go off. NOTE: If the V-belt is replaced before the V-belt replacement indicator comes on (i.e.
IMPORTANT INFORMATION EAS20180 IMPORTANT INFORMATION EAS20190 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. EAS20210 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease. 2.
IMPORTANT INFORMATION ECA13300 CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfaces. EAS20240 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip “1”, make sure the sharp-edged corner “2” is positioned opposite the thrust “3” that the circlip receives. a.
CHECKING THE CONNECTIONS EAS20250 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 → Connect and disconnect several times. Pocket tester 90890-03112 Analog pocket tester YU-03112-C NOTE: ● If there is no continuity, clean the terminals. checking the wire harness, perform steps (1) to (3).
SPECIAL TOOLS EAS20260 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 inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. NOTE: For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
SPECIAL TOOLS Tool name/Tool No.
SPECIAL TOOLS Tool name/Tool No. Illustration Oil filter wrench 90890-01469 Oil filter wrench YM-01469 Reference pages 3-13 66.
SPECIAL TOOLS Tool name/Tool No.
SPECIAL TOOLS Tool name/Tool No. Illustration Reference pages Valve spring compressor 90890-04019 YM-04019 5-18, 5-23 Valve spring compressor attachment 90890-04114 Valve spring compressor adapter 19.
SPECIAL TOOLS Tool name/Tool No. Illustration Reference pages Valve guide reamer (ø4) 90890-04113 Valve guide reamer (4.0 mm) YM-04113 5-19 Sheave spring compressor 90890-04134 YM-04134 5-55, 5-57 Sheave fixed block 90890-04135 Sheave fixed bracket YM-04135 5-55, 5-57 Plane bearing installer 90890-04139 5-62 Ignition checker 90890-06754 Opama pet-4000 spark checker YM-34487 8-113 Digital tachometer 90890-06760 YU-39951-B 3-8 Yamaha bond No. 1215 (Three Bond No.
SPECIAL TOOLS 1-27
SPECIFICATIONS GENERAL SPECIFICATIONS ...................................................................... 2-1 ENGINE SPECIFICATIONS .......................................................................... 2-2 CHASSIS SPECIFICATIONS ........................................................................ 2-9 1 ELECTRICAL SPECIFICATIONS ................................................................. 2-12 TIGHTENING TORQUES ..............................................................................
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model XP500 15B1 (EUR) XP500 15B4 (EUR) XP500A 15B2 (EUR) XP500A 15B5 (EUR) XP500W 15B3 (AUS) XP500W 15B6 (AUS) Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius 2235 mm (88.0 in) 775 mm (30.5 in) 1410 mm (55.5 in) 795 mm (31.3 in) 1575 mm (62.0 in) 130 mm (5.12 in) 2800 mm (110.2 in) Weight With oil and fuel XP500 227.0 kg (500 lb) XP500A 232.0 kg (511 lb) XP500W 225.
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Displacement Cylinder arrangement Bore × stroke Compression ratio Standard compression pressure (at sea level) Liquid cooled 4-stroke, DOHC 499.0 cm3 Forward-inclined parallel 2-cylinder 66.0 × 73.0 mm (2.60 × 2.87 in) 11.00 :1 1400 kPa/360 r/min (199.1 psi/360 r/min) (14.
ENGINE SPECIFICATIONS Thermostat Model/manufacturer Valve opening temperature Valve full open temperature Valve lift (full open) Radiator core Width Height Depth Water pump Water pump type Reduction ratio 4JH/NIPPON THERMOSTAT 69.0–73.0 °C (156.20–163.40 °F) 85.0 °C (185.00 °F) 8.0 mm (0.31 in) 330.0 mm (12.99 in) 138.0 mm (5.43 in) 24.0 mm (0.94 in) Single suction centrifugal pump 23/19 (1.210) Spark plug (s) Manufacturer/model Spark plug gap NGK/CR7E 0.7–0.8 mm (0.028–0.
ENGINE SPECIFICATIONS Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Model/number of links Tensioning system SCR-0409 SV/132 Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake Exhaust Valve dimensions Valve head diameter A (intake) Valve head diameter A (exhaust) 0.15–0.20 mm (0.0059–0.0079 in) 0.25–0.30 mm (0.0098–0.0118 in) 24.90–25.10 mm (0.9803–0.9882 in) 21.90–22.10 mm (0.8622–0.8701 in) A Valve face width B (intake) Valve face width B (exhaust) 1.140–1.980 mm (0.
ENGINE SPECIFICATIONS Valve-stem-to-valve-guide clearance (intake) Limit Valve-stem-to-valve-guide clearance (exhaust) Limit Valve stem runout 0.010–0.037 mm (0.0004–0.0015 in) 0.080 mm (0.0032 in) 0.025–0.052 mm (0.0010–0.0020 in) 0.100 mm (0.0039 in) 0.040 mm (0.0016 in) Cylinder head valve seat width (intake) Limit Cylinder head valve seat width (exhaust) Limit 0.90–1.10 mm (0.0354–0.0433 in) 1.6 mm (0.06 in) 0.90–1.10 mm (0.0354–0.0433 in) 1.6 mm (0.
ENGINE SPECIFICATIONS Wear limit Taper limit Out of round limit 66.100 mm (2.6024 in) 0.050 mm (0.0020 in) 0.050 mm (0.0020 in) Piston Piston-to-cylinder clearance Limit Diameter D Height H 0.020–0.045 mm (0.0008–0.0018 in) 0.15 mm (0.0059 in) 65.965–65.980 mm (2.5970–2.5976 in) 9.0 mm (0.35 in) H D Offset Offset direction Piston pin bore inside diameter Limit Piston pin outside diameter Limit 0.50 mm (0.0197 in) Intake side 15.002–15.013 mm (0.5906–0.5911 in) 15.043 mm (0.5922 in) 14.991–15.000 mm (0.
ENGINE SPECIFICATIONS B T End gap (installed) Ring side clearance 0.10–0.35 mm (0.0039–0.0138 in) 0.040–0.160 mm (0.0016–0.0063 in) Connecting rod Oil clearance (using plastigauge®) Bearing color code Small end inside diameter 0.026–0.050 mm (0.0010–0.0020 in) 1.Blue 2.Black 3.Brown 4.Green 15.005–15.018 mm (0.5907–0.5913 in) Crankshaft Width A Width B Runout limit C Big end side clearance D Big end radial clearance E 50.00–50.60 mm (1.969–1.992 in) 118.55–118.60 mm (4.67–4.67 in) 0.030 mm (0.
ENGINE SPECIFICATIONS V-belt V-belt width Limit 32.0 mm (1.26 in) 30.5 mm (1.20 in) Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation V-belt automatic Spur gear/helical gear 52/32 × 36/22 (2.659) Chain drive 41/25 × 40/29 (2.262) Centrifugal automatic type Air filter Air filter element Dry element Fuel pump Pump type Model/manufacturer Maximum consumption amperage Output pressure Electrical 5VU/AISAN 1.
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Caster angle Trail Diamond 28.00 ° 95.0 mm (3.74 in) Front wheel Wheel type Rim size Rim material Wheel travel Radial wheel runout limit Lateral wheel runout limit Wheel axle bending limit Cast wheel 14M/C x MT3.50 Aluminum 120.0 mm (4.72 in) 1.0 mm (0.04 in) 0.5 mm (0.02 in) 0.25 mm (0.
CHASSIS SPECIFICATIONS Brake pad lining thickness (inner) Limit Brake pad lining thickness (outer) Limit Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Recommended fluid 6.2 mm (0.24 in) 0.8 mm (0.03 in) 6.2 mm (0.24 in) 0.8 mm (0.03 in) 14.00 mm (0.55 in) 30.16 mm (1.19 in) 25.40 mm (1.
CHASSIS SPECIFICATIONS Spring rate K2 Spring stroke K1 Spring stroke K2 Optional spring available Enclosed gas/air pressure (STD) 294.00 N/mm (1678.74 lb/in) (29.98 kgf/mm) 0.0–28.8 mm (0.00–1.13 in) 28.8–43.0 mm (1.13–1.69 in) No 4900 kPa (696.9 psi) (49.0 kgf/cm2) Swingarm Swingarm end free play limit (radial) Swingarm end free play limit (axial) 1.0 mm (0.04 in) 1.0 mm (0.
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Ignition timing (B.T.D.C.) Crankshaft position sensor resistance Transistorized coil ignition (digital) Digital 10.0 °/1200 r/min 189–231 Ω (Gy-B) Engine control unit Model/manufacturer XP500 TBDF48/DENSO XP500A TBDF49/DENSO XP500W TBDF07/DENSO Ignition coil Model/manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance JO313/DENSO 6.
ELECTRICAL SPECIFICATIONS 12 V, 5.0 W × 1 14 V, 2.0 W × 3 License plate light Meter lighting Indicator light Turn signal indicator light High beam indicator light Engine trouble warning light ABS warning light Immobilizer system indicator light 14 V, 1.4 W × 2 14 V, 1.4 W × 1 14 V, 1.4 W × 1 XP500A 14 V, 1.
ELECTRICAL SPECIFICATIONS Parking lighting fuse Fuel injection system fuse ABS motor fuse ABS control unit fuse Backup fuse Reserve fuse Reserve fuse 10.0 A 10.0 A XP500A 30.0 A XP500A 5.0 A 10.0 A 30.0 A XP500 20.0 A XP500A 15.0 A XP500W 20.0 A XP500 15.0 A XP500A 10.0 A XP500W 15.0 A XP500 10.0 A XP500A 5.0 A XP500W 10.
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
TIGHTENING TORQUES Thread size Q’ty Tightening torque Chain guide (intake side) M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Water pump housing cover M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Water pump assembly M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Coolant pipe M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Radiator filler neck M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb) Radiator drain bolt M12 1 1.6 Nm (0.16 m•kg, 1.2 ft•lb) Water pump inlet pipe M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Water pump outlet pipe M6 1 10 Nm (1.
TIGHTENING TORQUES Thread size Q’ty Tightening torque Right crankcase cover M8 2 24 Nm (2.4 m•kg, 17 ft•lb) V-belt case air filter cover and V-belt case air filter element (right) M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb) V-belt case air filter element (left) M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Generator cover protector M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb) Generator cover protector cover M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Starter clutch M8 3 30 Nm (3.0 m•kg, 22 ft•lb) Clutch boss nut M36 1 90 Nm (9.
TIGHTENING TORQUES Crankcase tightening sequence: Cylinder head tightening sequence: 2-18
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread size Q’ty Tightening torque Upper bracket pinch bolt M8 2 30 Nm (3.0 m•kg, 22 ft•lb) Steering stem nut M22 1 110 Nm (11.0 m•kg, 80 ft•lb) Lower ring nut M25 1 20 Nm (2.0 m•kg, 14 ft•lb) Front fork cap bolt M38 1 24 Nm (2.4 m•kg, 17 ft•lb) Lower bracket pinch bolt M8 4 23 Nm (2.3 m•kg, 17 ft•lb) Front fender M6 4 7 Nm (0.7 m•kg, 5.1 ft•lb) Damper rod assembly bolt M10 2 23 Nm (2.
TIGHTENING TORQUES Thread size Q’ty Tightening torque ECU (ABS) bracket (XP500A) M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Hydraulic unit (XP500A) M8 3 16 Nm (1.6 m•kg, 11 ft•lb) Brake lever M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb) Swingarm and pivot shaft M22 1 7 Nm (0.7 m•kg, 5.1 ft•lb) Pivot shaft and lock nut M22 1 100 Nm (10.0 m•kg, 72 ft•lb) Chain drive case and swingarm M10 3 40 Nm (4.0 m•kg, 29 ft•lb) Rear shock absorber (front side) M16 1 68 Nm (6.
LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips LS O-rings LS Bearing and bushes E Crankshaft pins E Piston surfaces E Piston pins and connecting rod small end E Balancer surface E Connecting rod big end thrust surface E Connecting rod bolts and nuts M Crankshaft thrust surface E Crankshaft journals E Camshaft lobs M Camshaft journals M Camshaft cap M Valve stems (intake and exhau
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Main and drive axle serration E or LS Drive axle spline E or LS Chain drive case and taper bearing LS Bearing (chain drive case) Chain drive oil Primary sheave spacer Shell BT grease 3® Primary sheave nut Shell BT grease 3® Secondary sheave nut BEL-RAY assembly lube® Primary sheave BEL-RAY assembly lube® Secondary sheave BEL-RAY assembly lube® Swingarm pivot shaft bearing LS Crankcase mating surface Yamaha bond No.
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Rear shock absorber bearing and collar inner surface LS Swingarm, oil seal lip and collar inner surface LS Rear shock absorber bolt (front side) LS 2-23
LUBRICATION POINTS AND LUBRICANT TYPES 2-24
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-25
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Piston cooler 4. Crankshaft 5. Oil tank 6. Oil pan 7. Strainer 8. Suction oil pump 9. Flush oil pump 10. Check valve 11. Relief valve 12. Oil cooler 13.
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Oil tank 3. Oil strainer 4. Relief valve 5. Oil cooler 6. Oil filter cartridge 7. Exhaust camshaft 8. Intake camshaft 9. Oil pipe 10.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Clutch 2. Right main journal bearing 3.
COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-33
COOLING SYSTEM DIAGRAMS 1. 2. 3. 4. 5. 6. 7.
CABLE ROUTING EAS20430 CABLE ROUTING 2-35
CABLE ROUTING 1. Headlight sub-wire harness 2. Horn 3. Horn (H mark on the back of the horn) A. Securely fasten the wire strap to the front cowling hook to prevent it from being pulled out by the headlight assembly. (left and right) B. Connect the headlight sub-wire harness to the wire harness on top of the stay (left and right). After making the connection, push the coupler between the front cowling and the air filter case. C.
CABLE ROUTING 2-37
CABLE ROUTING 1. 2. 3. 4. Rear brake hose Front brake hose Rear brake lock lever cable Left handlebar switch A. Route the rear brake lock lever cable in front of the handlebar, then down through the space between the handlebar and the upper bracket. B. Fasten the wire harness by sliding the plastic holder on the wire harness onto the stud on the handlebar. C. Fasten the grommets on the brake hoses with the holder. D. Install the rear brake lock lever cable after lubricating the grease to the cable end. E.
CABLE ROUTING 2-39
CABLE ROUTING 1. Grommet 2. Fuel over flow hose 3. Fuel tank 4. Fuel overflow tray 5. Fuel tank cap 6. Upper side cover moulding (left) 7. Hose guide 8. Grommet 9. Footrest board 10. Hose clamp 11. Fuel tank breather hose 12. Rear footrest assembly 13. Fuel tank breather hose 14. Hose holder 15. Hose holder 16. Fuel hose 17. Fuel pump lead 18. Hose guide 19. Roll over valve assembly 20. Holder 21. Fuel pump 22. Fuel pump bracket 23. Fuel hose connector cover A.
CABLE ROUTING 2-41
CABLE ROUTING L. Route the ignition coil lead through the inside of the ignition coil bracket. M. Fasten the radiator fan motor lead and sidestand switch lead to the frame with a plastic holder. N. Insert the tail/brake light coupler between the wire harness and the seat lock cable (left). O. To the tail/brake light. P. To the starter relay. Q. Route the wire harness and rectifier/regulator lead through the frame wire holder. Place the rectifier/regulator lead under the wire harness. R.
CABLE ROUTING 2-43
CABLE ROUTING 1. Rear brake lock lever cable 2. Throttle cable (decelerator cable, double locknut) 3. Fast idle inlet hose 4. Rear brake hose 5. A.C. magneto lead 6. Fuel tank breather hose 7. Coolant hose 8. Sidestand switch 9. Fast idle outlet hose 10. Radiator outlet hose 11. Crankcase breather hose 12. Throttle cable (accelerator cable, single locknut) A. Pass the rear brake lock lever cable to the cable guide. B. Route the wire harness through the frame guide.
CABLE ROUTING 2-45
CABLE ROUTING Q. Fasten the wire harness and seat lock cable to the frame with a plastic holder. R. Pass the wire harness, lead and cable the outside of the frame bracket. S. Install the starter relay to the mad guard. T. Fasten the wire harness, positive battery lead and seat lock cable to the mad guard with a plastic holder. U. Route the positive battery lead through the under the seat lock cable. V. Fasten the wire harness to the frame with a plastic holder. W.
CABLE ROUTING XP500 2-47
CABLE ROUTING 1. Cooling system air bleed hose 2. Storage box light switch lead 3. Coolant reservoir hose 4. Spark plug lead #2 5. Radiator fan motor lead 6. Sidestand switch lead 7. Spark plug lead #1 8. Rear brake lock lever cable 9. Rear brake hose 10. Speed sensor lead A. Pass the rear brake lock lever cable on the front side of throttle cable. B. Position of clamp. C. Position the relay straighten. D. Fasten the cooling system air bleed hose to the stay 1 with a plastic holder. E.
CABLE ROUTING 2-49
CABLE ROUTING 1. 2. 3. 4. 5. 6. 7. 8. 9. Brake hose holder 1 Front brake hose Speed sensor Plastic holder Brake hose holder 2 Speed sensor lead Stay 1 Brake hose holder 3 Rear brake hose 1 A. Fasten the speed sensor lead along the inside of the brake hose. B. 50 – 60 mm (1.97 – 2.36 in) C. Turn the handlebar completely to the right, and then fasten the brake hose and speed sensor lead together with the plastic holder. D. Install the stopper to lower bracket projection. E.
CABLE ROUTING 2-51
CABLE ROUTING H. Fasten the wire harness and ECU (engine) lead to the stay 1 with a holder. I. After connecting the left headlight sub-wire harness and wire harness (by matching the coupler colors), fold back the lead facing to the right and insert it into the air filter case rib. J. Connect the wire harness to the headlight sub wire harness (cowling side). K. Fasten the headlight and turn signal sub-wire harness to the stay 1 with a plastic holder. L.
CABLE ROUTING 2-53
CABLE ROUTING AH. Fasten the rear wheel sensor lead to the swingarm with the plastics holders. The open end of each holder should be facing downward. AI. Route the rear wheel sensor lead behind the relay leads. AJ. 10 – 20 mm (0.39 – 0.79 in) AK. Fasten the rear wheel sensor lead and wire harness to the frame with the plastic band. AL. Pass the wire harness and rear wheel sensor lead to the frame wire harness holder. AM.
CABLE ROUTING 2-55
CABLE ROUTING 1. Rear brake lock lever cable 2. Throttle cable (decelerator cable, double locknut) 3. Fast idle inlet hose 4. Rear brake hose 5. A.C. magneto lead 6. Fuel tank breather hose 7. Coolant hose 8. Sidestand switch 9. Fast idle outlet hose 10. Radiator outlet hose 11. Crankcase breather hose 12. Throttle cable (accelerator cable, single locknut) A. Pass the rear brake lock lever cable to the cable guide. B. Route the wire harness through the frame guide. C.
CABLE ROUTING 2-57
CABLE ROUTING P. Fasten the wire harness and seat lock cable to the frame with a plastic holder. Q. Pass the wire harness, lead and cable the outside of the frame bracket. R. Install the starter relay to the mad guard. S. Fasten the wire harness, positive battery lead and seat lock cable to the mad guard with a plastic holder. T. Route the positive battery lead through the under the seat lock cable. U. Fasten the wire harness to the frame with a plastic holder. V.
CABLE ROUTING 2-59
CABLE ROUTING 1. Throttle cable 2. Fail-safe relay 3. ECU (ABS) 4. ABS test coupler 5. Cooling system air bleed hose 6. Storage box light switch lead 7. Coolant reservoir hose 8. Spark plug lead #2 9. Radiator fan motor lead 10. Sidestand switch lead 11. Spark plug lead #1 12. Rear brake lock lever cable 13. Stay 1 14. Rear brake hose 15. Hydraulic unit 16. Hydraulic unit solenoid coupler 17. Front wheel sensor coupler A. Pass the rear brake lock lever cable on the front side of throttle cable. B.
CABLE ROUTING 2-61
CABLE ROUTING 1. 2. 3. 4. 5. 6. 7. Front wheel sensor ABS motor coupler Fail-safe relay ECU (ABS) Hydraulic unit solenoid coupler Hydraulic unit overflow hose Brake hose (front brake master cylinder to hydraulic unit) 8. Brake hose (rear brake master cylinder to hydraulic unit) 9. Hydraulic unit 10. Brake hose (hydraulic unit to rear brake caliper) 11. Brake hose (hydraulic unit to front brake caliper) A.
CABLE ROUTING 2-63
CABLE ROUTING 1. 2. 3. 4. 5. 6. 7. Plastic holder Brake hose holder 2 Brake hose holder 1 Front brake hose Front wheel sensor lead Front wheel sensor Front housing A. Engage the hose holder rib more than 3 notch.Face the hose holder projection to the back. B. Make sure that the white paint on the brake hose faces to back (right side only). C. Install the hose holder to the innermost securely. D.
CABLE ROUTING 2-65
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .......................................................................... 3-1 INTRODUCTION ..................................................................................... 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ..................... 3-1 ENGINE ......................................................................................................... 3-3 ADJUSTING THE VALVE CLEARANCE ................................................
REPLACING THE HEADLIGHT BULBS ................................................. 3-32 ADJUSTING THE HEADLIGHT BEAMS.................................................
PERIODIC MAINTENANCE EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
PERIODIC MAINTENANCE ODOMETER READING (× 1000 km) NO. ITEM CHECK OR MAINTENANCE JOB ● Check bearing play and steer- ing for roughness. 13 * Steering bearings 1 10 20 30 40 √ √ √ √ √ ● Lubricate with lith- Every 20000 km ium-soap-based grease. ● Make sure that all nuts, bolts 14 * Chassis fasteners 15 Sidestand, centerstand ● Check operation. ● Lubricate. 16 * Sidestand switch ● Check operation.
ENGINE 6. Remove: ● V-belt case cover “1” EAS20470 ENGINE EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. 1 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. 1. Remove: ● Front cowling Refer to “GENERAL CHASSIS” on page 4-1.
ENGINE ● In order to be sure that the piston is at TDC, the alignment mark “c” on the intake camshaft sprocket and the alignment mark “d” on the exhaust camshaft sprocket must align with the cylinder head mating surface as shown in the illustration. ● Exhaust camshaft ECA15B1015 CAUTION: Before removing the camshafts from the cylinder head, tilt up the engine at least 25°. NOTE: ● Refer to “CAMSHAFTS” on page 5-6.
ENGINE Valve pad thickness 1.20–2.40 mm (0.0472–0.0945 in) Available valve pads 25 thicknesses in 0.05 mm (0.002 in) increments 2 1 NOTE: ● The thickness “a” of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. ● Since valve pads of various sizes are originally installed, the valve pad number must be rounded in order to reach the closest equivalent to the original. NOTE: ● Lubricate the valve pad with molybdenum disulfide grease.
ENGINE should be properly adjusted and the ignition timing should be checked. Engine idling speed 1100–1300 r/min 1. Stand the vehicle on a level surface. 7. Adjust: ● Throttle body synchronization NOTE: Place the vehicle on a suitable stand. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Remove: ● Seat Refer to “GENERAL CHASSIS” on page 4-1. ● Center cover ● Side cover (left and right) Refer to “GENERAL CHASSIS” on page 4-1. 3. Remove: ● Synchronizing pipe caps “1” a.
ENGINE Out of specification → Adjust. Make sure that the vacuum pressure is within specification. 9. Stop the engine and remove the measuring equipment. 10.Adjust: ● Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-8. tion. 1 2 Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 5. Press the “SELECT” “1” and “RESET” “2” buttons to select a cylinder. 11.Remove: ● Vacuum gauge 12.
ENGINE Direction “a” Engine idling speed is increased. Direction “b” Engine idling speed is decreased. 1 2 a 8. Release the switch to execute the selection. 9. Simultaneously press the “SELECT” and “RESET” buttons to return to the cylinder selection (step 5). 10.Turn the main switch to “OFF” to cancel the mode. 1 b ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS20610 ADJUSTING THE ENGINE IDLING SPEED 6. Adjust: ● Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-8.
ENGINE Refer to “GENERAL CHASSIS” on page 4-1. 3. Adjust: ● Throttle cable free play b. Turn the adjusting nut “2” in direction “a” or “b” until the specified throttle cable free play is obtained. NOTE: Direction “a” Throttle cable free play is increased. Direction “b” Throttle cable free play is decreased. When the throttle is opened, the accelerator cable “1” is pulled. 1 c. Tighten the locknut “1”. 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Throttle body side a. Loosen the locknut “1” on the decelerator cable. b.
ENGINE into the cylinders. EAS20700 CHECKING THE IGNITION TIMING 4. Check: ● Spark plug type Incorrect → Change. NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. Manufacturer/model NGK/CR7E 1. Remove: ● Center cover ● Side cover (left and right) ● Left footrest board Refer to “GENERAL CHASSIS” on page 4-1. 2. Connect: ● Timing light “1” ● Digital tachometer 5.
ENGINE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed 1100–1300 r/min b. Check that the stationary pointer “a” is within the firing rang “b” on the A.C. magneto. Incorrect firing range → Check the ignition system. Refer to “ADJUSTING THE VALVE CLEARANCE” on page 3-3. 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Disconnect: ● Spark plug cap 5.
ENGINE 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Wait two minutes until the oil settles, and then check the oil level through the check window located at the bottom-left side of the crankcase. 4. Check: ● Engine oil level The engine oil level should be between the minimum level mark “a” and maximum level mark “b”. Below the minimum level mark → Add the recommended engine oil to the proper level. b.
ENGINE c 4. Drain: ● Engine oil (completely from the crankcase) 5. If the oil filter cartridge is also to be replaced, perform the following procedure. d a. Remove the oil filter cartridge “1” with an oil filter wrench “2”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Oil filter wrench 90890-01426 YU-38411 Oil filter wrench 90890-01469 YM-01469 NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. 5. Start the engine, warm it up for several minutes, and then turn it off. 6.
ENGINE 6. Check: ● Engine oil drain bolt gasket Damage → Replace. 7. Install: ● Engine oil drain bolt (along with the gasket) button, otherwise repeat the procedure. T. Engine oil drain bolt 43 Nm (4.3 m•kg, 31 ft•lb) R. 1 8. Fill: ● Crankcase (with the specified amount of the recommended engine oil) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Engine oil quantity Total amount 3.60 L (3.81 US qt) (3.17 Imp.qt) Without oil filter cartridge replacement 2.80 L (2.96 US qt) (2.46 Imp.
ENGINE ● Adapter “2” EAS20920 CLEANING THE AIR FILTER ELEMENT 1. Remove: ● Front cowling upper cover ● Windshield ● Front cowling inner panel Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: ● Air filter case cover “1” ● Air filter element Pressure gauge 90890-03153 Oil pressure adapter B 90890-03124 1 1 2 6. Measure: ● Engine oil pressure (at the following conditions) 3. Clean: ● Air filter element Apply compressed air to the outer surface of the air filter element. Oil pressure (hot) 150.
ENGINE 4. Clean: ● V-belt case air filter element Blow the compressed air to the outer surface of the V-belt case air filter element. stalled in the air filter case. ● Make sure the air filter is installed with its mesh side facing towards the rear of the vehicle. 6. Install: ● Front cowling inner panel ● Windshield ● Front cowling upper cover Refer to “GENERAL CHASSIS” on page 4-1. EAS20980 CLEANING THE V-BELT CASE AIR FILTER ELEMENT 1.
ENGINE 2. Check: ● Throttle body joints “1” Cracks/damage → Replace. ● Intake manifolds “2” Cracks/damage → Replace. Refer to “THROTTLE BODIES” on page 7-4. EAS21070 CHECKING THE CYLINDER HEAD BREATHER HOSE 1. Remove: ● Leg shield Refer to “GENERAL CHASSIS” on page 4-1. 2. Check: ● Cylinder head breather hose “1” Cracks/damage → Replace. Loose connection → Connect properly. 1 2 ECA15B1036 CAUTION: Make sure the cylinder head breather hose is routed correctly. 3.
ENGINE 2 a b 3 5 3 1 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Check: ● Coolant level 4 4. Install: ● Inner fender Refer to “GENERAL CHASSIS” on page 4-1. ● Right rear side cover Refer to “GENERAL CHASSIS” on page 4-1. NOTE: Before checking the coolant level, wait a few minutes until it settles. EAS21120 CHECKING THE COOLING SYSTEM 1. Remove: ● Footrest board (left and right) ● Leg shield ● Inner fender Refer to “GENERAL CHASSIS” on page 4-1. 2.
ENGINE Lower side cover mole (left and right) ● Inner fender Refer to “GENERAL CHASSIS” on page 4-1. 2. Disconnect: ● Coolant reservoir hose “1” ● 3. Drain: ● Coolant (from the coolant reservoir) 4. Remove: ● Radiator cap “1” EWA13030 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury.
ENGINE handled with special care. EWA13040 WARNING ● If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor. ● If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. ● If coolant is swallowed, induce vomiting and get immediate medical attention. 1 6. Drain: ● Coolant (from the engine and radiator) 7.
ENGINE 13.Install: ● Coolant reservoir cap 14.Start the engine, warm it up for several minutes, and then stop it. 15.Check: ● Coolant level Refer to “CHECKING THE COOLANT LEVEL” on page 3-18. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. 16.Install: ● Inner fender ● Lower side cover mole (left and right) ● Coolant reservoir cap access panel Refer to “GENERAL CHASSIS” on page 4-1.
CHASSIS the brake fluid and could cause vapor lock. EAS21140 CHASSIS ECA13540 CAUTION: EAS21240 CHECKING THE BRAKE FLUID LEVEL 1. Stand the vehicle on a level surface. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. NOTE: ● Place ● Make the vehicle on a suitable stand. sure the vehicle is upright.
CHASSIS EAS21280 EAS21320 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: ● Brake hose Cracks/damage/wear → Replace. ADJUSTING THE REAR BRAKE LOCK LEVER CABLE EWA15B2001 WARNING Do not apply the rear brake lock lever when riding. NOTE: ● Place the vehicle on a suitable stand. adjusting the rear brake lock lever, check the rear brake fluid level. ● Before 1.
CHASSIS EAS21350 B BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500) 1 EWA13100 WARNING Bleed the hydraulic brake system whenever: ● the system is disassembled. ● a brake hose is loosened, disconnected or replaced. ● the brake fluid level is very low. ● brake operation is faulty. 2 A. Front B. Rear NOTE: ● Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow.
CHASSIS der. 1st: Front brake caliper 2nd: Rear brake caliper B 1 EWA15B1006 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. 2 A. Front B. Rear NOTE: ● Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow. ● When bleeding the ABS, make sure there is always enough brake fluid before applying the brake.
CHASSIS eration. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21480 CHECKING THE CHAIN DRIVE OIL LEVEL 1. Stand the vehicle on a level surface. b NOTE: ● Place ● Make a the vehicle on a suitable stand. sure that the vehicle up right. 4. Install: ● Chain drive oil filler cap ● Chain drive case cover 2. Remove: ● Chain drive case cover “1” ● Chain drive oil filler cap “2” EAS21490 CHANGING THE CHAIN DRIVE OIL 1. Place a container under the chain drive. 2.
CHASSIS EAS21500 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the vehicle on a level surface. 1 2 EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 3 NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 4 b. Loosen the lower ring nut “4” and then tighten it to specification with a steering nut wrench “5”. 2. Check: ● Steering head Grasp the bottom of the front fork legs and gently rock the front fork.
CHASSIS b. Install a plastic locking tie “1” loosely around the end of the handlebar as shown. c. Hook a spring gauge “2” onto the plastic locking tie. e. Install the rubber washer “3”. f. Install the upper ring nut “2”. g. Finger tighten the upper ring nut “2”, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned “1”. h. Install the lock washer.
CHASSIS equals the ambient air temperature. ● The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. ● Operation of an overloaded vehicle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE VEHICLE. EAS21530 CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.
CHASSIS 1 Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire EWA14090 WARNING 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. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehicle. 2 1. Tire tread depth 2. Side wall Wear limit (front) 1.6 mm (0.
CHASSIS EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. 1 2 Recommended lubricant Lithium-soap-based grease EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. EAS21670 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: ● Wheel Damage/out-of-round → Replace.
ELECTRICAL SYSTEM 6. Install: ● Headlight bulb New Secure the new headlight bulb with the headlight bulb holder. EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” on page 8-97. ECA13690 CAUTION: Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
ELECTRICAL SYSTEM Left headlight Direction “c” Headlight beam moves to the right. Direction “d” Headlight beam moves to the left. Right headlight Direction “c” Headlight beam moves to the left. Direction “d” Headlight beam moves to the right.
ELECTRICAL SYSTEM 3-34
CHASSIS GENERAL CHASSIS..................................................................................... 4-1 FRONT WHEEL............................................................................................. 4-6 REMOVING THE FRONT WHEEL (XP500) ........................................... 4-10 Removing the front wheel (XP500A) ....................................................... 4-10 CHECKING THE FRONT WHEEL ..........................................................
ABS (Anti-Lock Brake System)................................................................... 4-47 REMOVING THE HYDRAULIC UNIT...................................................... 4-48 CHECKING THE HYDRAULIC UNIT ...................................................... 4-48 INSTALLING THE HYDRAULIC UNIT .................................................... 4-49 HYDRAULIC UNIT OPERATION TEST .................................................. 4-49 TRIAL RUN.....................................................
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Seat 2 1 Order 1 2 Job/Parts to remove Q’ty Fuel tank cap Fuel lid Seat Remarks 1 1 For installation, reverse the removal procedure.
GENERAL CHASSIS Front cowling 3 4 5 1 2 6 7 1 7 2 8 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order 1 2 3 4 5 6 7 8 Job/Parts to remove Q’ty Footrest board mat (left and right) Front side cover moulding (left and right) Rear view mirror (left and right) Front cowling upper cover Windshield Front cowling inner panel Headlight sub-wire harness coupler Front cowling 2 2 2 1 1 1 4 1 Remarks Disconnect. For installation, reverse the removal procedure.
GENERAL CHASSIS Side cover mouldings and leg shield 9 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 10 3 4 5 7 6 1 8 5 2 6 11 7 Nm (0.7 m • kg, 5.1 ft • Ib) 2 7 Nm (0.7 m • kg, 5.
GENERAL CHASSIS Rear covers and tail/brake light assembly 16 Nm (1.6 m • kg, 12 ft • Ib) 1 7 Nm (0.7 m • kg, 5.1 ft • Ib) 3 4 2 LT 5 LT 3 Order 1 2 3 4 5 7 Nm (0.7 m • kg, 5.1 ft • Ib) Job/Parts to remove Q’ty Seat Upper side cover mole (left/right) Grab bar Rear cover Rear side cover (left/right) Tail/brake light assembly coupler Tail/brake light assembly Remarks Open. 1 1 1/1 1 1 Disconnect. For installation, reverse the removal procedure.
GENERAL CHASSIS Strage box 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 9 12 6 10 13 11 4 5 5 13 7 8 2 13 16 Nm (1.6 m • kg, 12 ft • Ib) 3 7 Nm (0.7 m • kg, 5.
FRONT WHEEL EAS21880 FRONT WHEEL Removing the front wheel and brake disc (XP500) 40 Nm (4.0 m • kg, 29 ft • Ib) 59 Nm (5.9 m • kg, 43 ft • Ib) 40 Nm (4.0 m • kg, 29 ft • Ib) 1 3 1 23 Nm (2.3 m • kg, 17 ft • Ib) 2 (6) LT 6 7 LT LT (6) 8 5 4 Order 8 Job/Parts to remove 18 Nm (1.8 m • kg, 13 ft • Ib) Q’ty Remarks NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. Refer to “GENERAL CHASSIS” on page 4-1.
FRONT WHEEL Disassembling the front wheel (XP500) 1 2 3 2 Order 1 2 3 Job/Parts to remove Q’ty Oil seal Bearing Collar Remarks 1 2 1 For installation, reverse the removal procedure.
FRONT WHEEL Removing the front wheel and brake disc (XP500A) 1 2 40 Nm (4.0 m • kg, 29 ft • Ib) 59 Nm (5.9 m • kg, 43 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) 5 2 (6) 4 9 40 Nm (4.0 m • kg, 29 ft • Ib) 10 18 Nm (1.8 m • kg, 13 ft • Ib) 11 (6) 3 6 Order 11 8 Job/Parts to remove 30 Nm (3.0 m • kg, 22 ft • Ib) 7 Q’ty Remarks NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.
FRONT WHEEL Disassembling the front wheel (XP500A) LS 1 2 3 LS 2 1 Order 1 2 3 Job/Parts to remove Q’ty Oil seal Bearing Collar Remarks 2 2 1 For installation, reverse the removal procedure.
FRONT WHEEL Bends → Replace. EAS21900 REMOVING THE FRONT WHEEL (XP500) 1. Stand the vehicle on a level surface. EWA13460 WARNING EWA13120 Do not attempt to straighten a bent wheel axle. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: ● Front brake calipers NOTE: Do not squeeze the brake lever when removing the brake caliper. 2.
FRONT WHEEL the wheel bearing outer race and oil seal. 5. Replace: ● Wheel bearings New ● Oil seals New ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS22010 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR (XP500A) NOTE: ECA14450 To prevent damaging the wheel, place a rag “2” between the screwdriver and the wheel surface.
FRONT WHEEL b. When the front wheel stops, put an “X1” mark at the bottom of the wheel. Regulated resistance 1.2–1.6 kΩ at 20°C (68°F) Out of specification → Replace. c. Turn the front wheel 90° so that the “X1” mark is positioned as shown. d. Release the front wheel. e. When the wheel stops, put an “X2” mark at the bottom of the wheel. 3. Check: ● Front wheel sensor rotor “1” Cracks/damage → Replace the front wheel assembly.
FRONT WHEEL b. Turn the front wheel 90° so that the heavy spot is positioned as shown. NOTE: Make sure the speed sensor and the wheel hub are installed with the two projections meshed into the two slots respectively. c. If the heavy spot does not stay in that position, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced. 3. Install: ● Front wheel NOTE: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4.
FRONT WHEEL 5. Install: ● Front brake calipers 3. Tighten: ● Front wheel axle “1” Use the damper rod holder “2” ● Front wheel axle pinch bolt “3” EWA15B1009 WARNING Make sure the brake cable is routed properly. T. 6. Install: ● Front brake caliper bracket bolt “1” R. T. Front brake caliper bracket bolt 40 Nm (4.0 m•kg, 29 ft•lb) Front wheel axle 59 Nm (5.9 m•kg, 43 ft•lb) Front wheel axle pinch bolt 23 Nm (2.3 m•kg, 17 ft•lb) R.
FRONT WHEEL 2 1 NOTE: When installing the front wheel sensor, check the wheel sensor lead for twists and the sensor electrode for foreign materials. ECA14480 CAUTION: To route the front wheel sensor lead, refer to “CABLE ROUTING” on page 2-35. 5. Check: ● Front wheel sensor installation Check if the wheel sensor housing is installed properly. 6. Check: ● Front wheel sensor installation Check if the wheel sensor housing is installed properly. Refer to “[D-1] MAINTENANCE OF THE ECU (ABS)” on page 8-72.
REAR WHEEL EAS22030 REAR WHEEL Removing the rear wheel (XP500) 40 Nm (4.0 m • kg, 29 ft • Ib) 17 Nm (1.7 m • kg, 12 ft • Ib) 5 3 2 6 8 4 1 7 100 Nm (10.0 m • kg, 72 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Parts to remove Q’ty Remarks NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
REAR WHEEL Removing the rear wheel (XP500A) 40 Nm (4.0 m • kg, 29 ft • Ib) 1 7 17 Nm (1.7 m • kg, 12 ft • Ib) 5 30 Nm (3.0 m • kg, 22 ft • Ib) 2 8 4 8 6 9 10 3 100 Nm (10.0 m • kg, 72 ft • Ib) 11 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Parts to remove Q’ty Remarks NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
REAR WHEEL Disassembling the rear wheel 4 5 18 Nm (1.8 m • kg, 13 ft • Ib) (6) 5 3 (4) 1 2 69 Nm (6.9 m • kg, 50 ft • Ib) Order 1 2 3 4 5 Job/Parts to remove Q’ty Brake disc Rear wheel drive hub O-ring Oil seal Bearing Remarks 1 1 1 1 2 For installation, reverse the removal procedure.
REAR WHEEL 3. Measure: ● Radial wheel runout ● Lateral wheel runout Refer to “CHECKING THE FRONT WHEEL” on page 4-10. EAS28760 REMOVING THE REAR WHEEL (XP500) 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. EAS15B4567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: ● Rear wheel drive hub “1” Cracks/damage → Replace. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2.
REAR WHEEL NOTE: ● Align the slot “a” of the sensor housing “1” with the projection “b” of the collar “2”, and then assemble them. ● After installation, check that the projection “c” of the collar is inserted into the slot “d” of the sensor housing. 1 2 3 3 2 3 c ECA14500 CAUTION: a b To route the rear wheel sensor lead, refer to “CABLE ROUTING” on page 2-35. 4. Check: ● Rear wheel sensor installation Check if the wheel sensor housing is installed properly.
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 27 Nm (2.7 m • kg, 20 ft • Ib) 2 3 7 6 4 4 7 1 5 5 Order 1 2 3 4 5 6 7 Job/Parts to remove Q’ty Front brake caliper retaining bolt (lower) Front brake caliper retaining bolt (upper) Brake caliper Brake pad Brake pad shim Brake pad spring Brake pad spring Remarks 1 1 1 2 2 1 2 For installation, reverse the removal procedure.
FRONT BRAKE Removing the front brake master cylinder 1 Nm (0.1 m • kg, 0.7 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 1 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 9 3 10 8 5 6 8 7 4 11 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Parts to remove Q’ty Upper handlebar cover Refer to “HANDLEBAR” on page 4-53 Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” on page 3-24.
FRONT BRAKE Disassembling the front brake master cylinder 4 3 2 1 Order 1 2 3 4 Job/Parts to remove Q’ty Dust boot Circlip Brake master cylinder kit Brake master cylinder body Remarks 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT BRAKE Removing the front brake calipers 8 10 9 8 7 10 12 1 3 2 11 2 6 5 11 4 27 Nm (2.7 m • kg, 20 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 40 Nm (4.0 m • kg, 29 ft • Ib) Order Job/Parts to remove Q’ty Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” on page 3-24.
FRONT BRAKE Disassembling the front brake calipers 6 Nm (0.6 m • kg, 4.3 ft • Ib) 3 2 4 1 5 3 4 Order 1 2 3 4 5 Job/Parts to remove Q’ty Bleed screw Dust seal Brake caliper piston seal Brake caliper piston Brake caliper body Remarks 1 2 2 2 1 For assembly, reverse the disassembly procedure.
FRONT BRAKE EAS22220 INTRODUCTION Brake disc deflection limit 0.12 mm (0.0047 in) EWA14100 WARNING ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Disc brake components rarely require disassembly. 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.
FRONT BRAKE 4 2 3 d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc. 1 3 3. Measure: ● Brake pad wear limit “a” Out of specification → Replace the brake pads as a set. Brake pad lining thickness (inner) 6.2 mm (0.24 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (outer) 6.2 mm (0.24 in) Limit 0.8 mm (0.
FRONT BRAKE 2 3 3 4 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. 6. Install: ● Brake caliper “1” ● Front brake caliper retaining bolts “2” T. Brake caliper retaining bolt 27 Nm (2.7 m•kg, 19 ft•lb) R. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. T. 7.
FRONT BRAKE brake calipers. ton. NOTE: Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: ● Union bolt “1” ● Copper washers “2” ● Brake hose a b. Remove the brake caliper piston seals. 2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1 EAS22390 CHECKING THE FRONT BRAKE CALIPERS Recommended brake component replacement schedule NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.
FRONT BRAKE 2. Check: ● Brake caliper brackets “1” Cracks/damage → Replace. 2. Install: ● Brake caliper bracket T. Brake caliper bracket bolt 40 Nm (4.0 m•kg, 29 ft•lb) R. EAS22440 1 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. 1. Install: ● Brake caliper “1” (temporarily) ● Copper washers New ● Brake hose “2” ● Union bolt “3” EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS EWA13620 T. WARNING Brake hose union bolt 30 Nm (3.
FRONT BRAKE 3. Install: ● Brake pads ● Brake pad springs ● Brake caliper retaining bolt ● Brake caliper ● Brake hose holder T. Brake caliper retaining bolt 27 Nm (2.7 m•kg, 19 ft•lb) R. Refer to “REPLACING THE FRONT BRAKE PADS” on page 4-27. 4. Fill: ● Brake master cylinder reservoir (with the specified amount of the recommended brake fluid) 7. Check: ● Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” on page 3-24.
FRONT BRAKE with clean or new brake fluid. ● Never use solvents on internal brake components. Recommended fluid DOT 4 1. Install: ● Master cylinder kit “1” ● Circlip “2” New ● Dust boot “3” 2. Check: ● Brake master cylinder kit “1” Damage/scratches/wear → Replace. EAS22530 T. Brake master cylinder holder bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) R. 3. Check: ● Brake master cylinder reservoir cap “1” Cracks/damage → Replace.
FRONT BRAKE any spilt brake fluid immediately. T. Brake hose union bolt 30 Nm (3.0 m•kg, 22 ft•lb) R. 4. Bleed: ● Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” on page 3-24. 5. Check: ● Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-22. EWA13530 WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” on page 2-35.
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 5 2 4 5 2 3 1 40 Nm (4.0 m • kg, 29 ft • Ib) 27 Nm (2.7 m • kg, 20 ft • Ib) 6 Order 1 2 3 4 5 6 Job/Parts to remove Q’ty Rear brake caliper retaining bolt Rear brake caliper bracket bolt Brake caliper Brake pad Brake pad spring Brake caliper bracket Remarks 1 2 1 2 2 1 For installation, reverse the removal procedure.
REAR BRAKE Removing the rear brake master cylinder 30 Nm (3.0 m • kg, 22 ft • Ib) 1 Nm (0.1 m • kg, 0.7 ft • Ib) 1 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 9 3 10 8 6 5 8 7 4 11 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Parts to remove Q’ty Upper handlebar cover Refer to “HANDLEBAR” on page 4-53 Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” on page 3-24.
REAR BRAKE Disassembling the rear brake master cylinder 4 3 2 1 Order 1 2 3 4 Job/Parts to remove Q’ty Dust boot Circlip Brake master cylinder kit Brake master cylinder body Remarks 1 1 1 1 For assembly, reverse the disassembly procedure.
REAR BRAKE Removing the rear brake calipers 30 Nm (3.0 m • kg, 22 ft • Ib) 5 11 2 6 10 7 6 12 4 11 12 3 8 9 1 8 40 Nm (4.0 m • kg, 29 ft • Ib) 27 Nm (2.7 m • kg, 20 ft • Ib) 13 22 Nm (2.2 m • kg, 16 ft • Ib) Order Job/Parts to remove Q’ty Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” on page 3-24.
REAR BRAKE Disassembling the rear brake calipers 2 4 6 Nm (0.6 m • kg, 4.3 ft • Ib) 1 3 5 Order 1 2 3 4 5 Job/Parts to remove Q’ty Brake caliper piston Dust seal Piston seal Bleed screw Brake caliper body Remarks 1 1 1 1 1 For assembly, reverse the disassembly procedure.
REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit 4.5 mm (0.18 in) EWA14100 WARNING 5. Adjust: ● Brake disc deflection Refer to “CHECKING THE FRONT BRAKE DISCS” on page 4-26. Brake disc bolt 18 Nm (1.8 m•kg, 13 ft•lb) LOCTITE® T. R. Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: ● Never disassemble brake components unless absolutely necessary.
REAR BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ pads as a set. 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. Brake pad lining thickness (inner) 8.3 mm (0.33 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (outer) 8.3 mm (0.33 in) Limit 0.8 mm (0.03 in) 1 2 b.
REAR BRAKE NOTE: Align the projection “c” on the piston side of the brake pad with the lower recess in the brake caliper piston. A B 9. Check: ● Brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” on page 3-24. c A. Up B. Down EAS22590 REMOVING THE REAR BRAKE CALIPER ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 5.
REAR BRAKE (brake caliper body) Obstruction → Blow out with compressed air. EWA13610 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston seals. 2 1 3 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Operate the rear brake lock lever “4” continuously in the direction shown by the arrow until the piston comes out. 2. Check: ● Brake caliper brackets “1” Cracks/damage → Replace. 4 b. Remove the dust seal and brake caliper piston seal.
REAR BRAKE with the brake caliper body as shown in the illustration. b 2 a 3 1 1 2. Remove: ● Brake caliper 3. Install: ● Brake pads ● Brake pad springs ● Brake caliper retaining bolt ● Brake caliper ● Brake hose holder Refer to “REPLACING THE REAR BRAKE PADS” on page 4-39. 1 a b T. Brake caliper retaining bolt 27 Nm (2.7 m•kg, 19 ft•lb) R. EAS22670 4. Fill: ● Brake fluid reservoir (with the specified amount of the recommended brake fluid) INSTALLING THE REAR BRAKE CALIPER 1.
REAR BRAKE 5. Bleed: ● Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” on page 3-24. 6. Check: ● Brake fluid level Below the minimum level mark “a”→ Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-22. EAS22710 CHECKING THE REAR BRAKE MASTER CYLINDER The following procedure applies to the both of the brake master cylinders. 1. Check: ● Brake master cylinder “1” Damage/scratches/wear → Replace.
REAR BRAKE Holder bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: ● Install the brake master cylinder holder with the “UP” mark facing up “a”. ● Align the brake master cylinder with the projection “b” on the handlebar. ● First, tighten the upper bolt, then the lower bolt. 4. Check: ● Brake hoses Cracks/damage/wear → Replace.
REAR BRAKE Below the minimum level mark “a”→ Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-22. 6. Check: ● Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” on page 3-24. 3. Fill: ● Brake fluid reservoir (to the maximum level mark) Recommended fluid DOT 4 EWA13090 WARNING ● Use only the designated brake fluid.
ABS (Anti-Lock Brake System) EAS22760 ABS (Anti-Lock Brake System) Removing the hydraulic unit 16 Nm (1.6 m • kg, 12 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 9 10 9 7 3 12 4 3 8 7 5 6 5 1 2 12 12 13 11 16 Nm (1.6 m • kg, 12 ft • Ib) Order Job/Parts to remove Q’ty Front cowling Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” on page 3-24. Brake fluid 1 2 3 4 5 6 7 8 9 10 11 12 13 Remarks Refer to “GENERAL CHASSIS” on page 4-1. Drain.
ABS (Anti-Lock Brake System) EAS22770 ● REMOVING THE HYDRAULIC UNIT Brake hose “4” (to the rear brake caliper) 4 ECA15B1020 CAUTION: Do not remove the hydraulic unit to check the resistance of the solenoid valves and the ABS motor for continuity. 2 3 1 NOTE: Do not operate the brake lever while removing the brake hoses. ECA14530 CAUTION: When removing the brake hoses, cover the area around the hydraulic unit to catch any spilt brake fluid. Do not allow the brake fluid to contact other parts.
ABS (Anti-Lock Brake System) 1 3 2 1 4 EWA13940 EAS22770c WARNING INSTALLING THE HYDRAULIC UNIT Proceed in the reverse order of disassembly. Pay attention to the following items. 1. Install: ● Hydraulic unit The brake hoses to the front and rear brake calipers can be distinguished by the rubber at the end of each hose. Be sure to connect each brake hose to the correct union bolt hole. T. Hydraulic unit bracket bolt 16 Nm (1.6 m•kg, 11 ft•lb) ECA14760 R.
ABS (Anti-Lock Brake System) Hydraulic unit operation test 1 7. Set the main switch to “ON”. EWA15B1001 NOTE: WARNING After setting the main switch to “ON”, wait (approximately 2 seconds) until the ABS warning light goes off. Securely support the vehicle so that there is no danger of it falling over. 1. Place the vehicle on the centerstand. 2. Set the main switch to “OFF”. 3. Remove: ● Battery cover Refer to “FUEL TANK” in chapter “3”. 4. Check: ● Battery voltage Lower than 12.
ABS (Anti-Lock Brake System) 10.After the pulsating action has stopped in the front brake lever, it is generated in the rear brake lever “1” 0.5 second after and continues for approximately 1 second. ● Battery voltage Lower than 12.8 V → Charge or replace the battery. Battery voltage Higher than 12.8 V NOTE: Be sure to continue to operate the brake levers even after the pulsating action has stopped. 1 NOTE: ● If the battery voltage is lower than 12.
ABS (Anti-Lock Brake System) unit. ● If the operation of the hydraulic unit is normal, delete all of the malfunction codes. EAS22820 TRIAL RUN After all checks and services are completed, always ensure the vehicle has no problems by performing the trial running at a speed of faster than 10 km/h. 7. Check: ● Hydraulic unit operation When the main switch is set to “ON”, the ABS warning light comes on for 2 seconds, goes off for 3 seconds, then starts flashing.
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 1 26 Nm (2.6 m • kg, 19 ft • Ib) 9 23 Nm (2.3 m • kg, 17 ft • Ib) 15 5 17 18 17 4 7 5 10 Nm (1.0 m • kg, 7.2 ft • Ib) 3 8 10 13 2 11 14 16 6 10 Nm (1.0 m • kg, 7.2 ft • Ib) 11 3 6 19 12 26 Nm (2.
HANDLEBAR Removing the handlebar 1 26 Nm (2.6 m • kg, 19 ft • Ib) 9 23 Nm (2.3 m • kg, 17 ft • Ib) 15 5 17 18 17 4 7 5 10 Nm (1.0 m • kg, 7.2 ft • Ib) 3 8 10 13 2 11 14 16 6 10 Nm (1.0 m • kg, 7.2 ft • Ib) 11 3 6 19 12 26 Nm (2.6 m • kg, 19 ft • Ib) Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal procedure.
HANDLEBAR EAS22860 ● REMOVING THE HANDLEBARS 1. Stand the vehicle on a level surface. Upper handlebar holders “2” EWA13120 T. R. WARNING Upper handlebar holder bolt 23 Nm (2.3 m•kg, 17 ft•lb) ECA14250 Securely support the vehicle so that there is no danger of it falling over. CAUTION: ● First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. ● Turn the handlebar all the way to the left and right.
HANDLEBAR T. R. Rear brake master cylinder holder bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 b NOTE: ● Install the rear brake master cylinder holder with the “UP” mark facing up “a”. ● Align the rear brake master cylinder with the projection “b” in the handlebar. ● First, tighten the upper bolt, then the lower bolt. b a 2 8. Install: ● Throttle grip ● Throttle cables 1 NOTE: Lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar. a 9.
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 24 Nm (2.4 m • kg, 17 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) 6 5 7 3 30 Nm (3.0 m • kg, 22 ft • Ib) 4 3 4 6 2 8 40 Nm (4.0 m • kg, 29 ft • Ib) 2 1 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order 7 Nm (0.7 m • kg, 5.1 ft • Ib) Job/Parts to remove Q’ty Front cowling/leg shield Handlebar cover (upper and lower) Front wheel ECU (ABS) 1 2 3 4 5 6 7 8 Remarks Refer to “GENERAL CHASSIS” on page 4-1. Refer to “HANDLEBAR” on page 4-53.
FRONT FORK Disassembling the front fork legs 1 2 9 13 14 15 3 16 4 17 5 10 11 8 12 7 6 LT 23 Nm (2.
FRONT FORK (with a flat-head screwdriver) EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 ECA14180 CAUTION: Do not scratch the inner tube. NOTE: ● Do not remove the fork leg protector from the outer tube. ● If the front fork leg protector must be removed, always install a new one. WARNING Securely support the vehicle so that there is no danger of it falling over.
FRONT FORK tube as this may dangerously weaken it. 4. Remove: ● Inner tube ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully. 2. Measure: ● Spring free length “a” Out of specification → Replace. Fork spring free length 405.0 mm (15.94 in) Limit 400.0 mm (15.
FRONT FORK ● Inner tube’s outer surface “2” Recommended oil Fork oil 7.5W or equivalent 2 EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1 EWA13660 4. Install: ● Outer tube (onto the inner tube) ● Copper washer New ● Damper rod assembly bolt 5. Tighten: ● Damper rod assembly bolt “1” WARNING ● Make sure the oil levels in both front fork legs are equal. ● Uneven oil levels can result in poor handling and a loss of stability. NOTE: ● When T.
FRONT FORK Frok seal driver weight 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø41) 90890-01381 Replacement 41 mm YM-A5142-2 8. Install: ● Oil seal clip “1” NOTE: Adjust the oil seal clip so that it fits into the outer tube’s groove. 7. Install: ● Oil seal New “1” (with the fork seal driver weight “2” and fork seal driver attachment “3”) ECA14220 CAUTION: Make sure the numbered side of the oil seal faces up. 9.
FRONT FORK T. Quantity 512.0 cm3 (17.31 US oz) (18.06 Imp.oz) Recommended oil Fork oil 7.5W or equivalent Lower bracket pinch bolt 23 Nm (2.3 m•kg, 17 ft•lb) R. ● Cap bolt “2” T. Cap bolt 24 Nm (2.4 m•kg, 17 ft•lb) R. Level 109.0 mm (4.29 in) ● Upper bracket pinch bolt “3” NOTE: filling the front fork leg, keep it upright. filling, slowly pump the front fork leg up and down to distribute the fork oil. T. ● While R. ● After 11.
STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 13 110 Nm (11.0 m • kg, 80 ft • Ib) 14 15 7 Nm (0.7 m • kg, 5.1 ft • Ib) 2 17 3 16 4 5 6 7 8 9 12 11 10 1 1st 52 Nm (5.2 m • kg, 38 ft • Ib) 2nd 20 Nm (2.0 m • kg, 15 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Parts to remove Q’ty Front cowling 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Remarks Refer to “GENERAL CHASSIS” on page 4-1. Refer to “FRONT WHEEL” on page 4-6. Refer to “FRONT FORK” on page 4-57.
STEERING HEAD Removing the lower bracket 13 110 Nm (11.0 m • kg, 80 ft • Ib) 14 15 7 Nm (0.7 m • kg, 5.1 ft • Ib) 2 17 3 16 4 5 6 7 8 9 12 11 10 1 1st 52 Nm (5.2 m • kg, 38 ft • Ib) 2nd 20 Nm (2.0 m • kg, 15 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order 15 16 17 Job/Parts to remove Q’ty Bearing inner race Rubber seal Lower bracket Remarks 1 1 1 For installation, reverse the removal procedure.
STEERING HEAD EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: ● Upper bracket 3. Remove: ● Lock washer “1” ● Upper ring nut “2” ● Rubber washer “3” ● Lower ring nut “4” (with the steering nut wrench) 3. Replace: ● Bearings ● Bearing races ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the bearing races from the steering head pipe with a long rod “1” and hammer. b.
STEERING HEAD Refer to “FRONT FORK” on page 4-57. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTE: 4. Check: ● Upper bracket ● Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. Temporarily tighten the upper and lower bracket pinch bolts. 5. Tighten: ● Steering stem nut “2” T. EAS23140 R. INSTALLING THE STEERING HEAD 1. Lubricate: ● Upper bearing ● Lower bearing ● Bearing races Recommended lubricant Lithium-soap-based grease 2.
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 53 Nm (5.3 m • kg, 38 ft • Ib) 4 4 9 6 8 7 3 9 2 1 5 68 Nm (6.8 m • kg, 49 ft • Ib) Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Q’ty Muffler Bolt Lock washer Collar Bolt/Nut Rear shock absorber Collar Washer Spacer Bearing Remarks Refer to “ENGINE REMOVAL” on page 5-1. 1 1 1 1/1 1 1 1 1 2 For installation, reverse the removal procedure.
REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. EWA13740 WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber.
REAR SHOCK ABSORBER ASSEMBLY 3. Tighten: ● Bolt (rear side) “1” ● Nut “3” T. Bolt (rear side) 53 Nm (5.3 m•kg, 38 ft•lb) R. 4. Install: ● Lock washer “1” New 5. Tighten: ● Bolt (front side) “2” T. Bolt (front side) “2” 68 Nm (6.8 m•kg, 48 ft•lb) R. NOTE: ● When installing the rear shock absorber assembly, lift up the swingarm. ● Bend the lock washer “2” tab along a flat side of the bolt “1”.
ENGINE ENGINE REMOVAL ...................................................................................... 5-1 INSTALLING THE ENGINE..................................................................... 5-5 CAMSHAFTS................................................................................................. 5-6 REMOVING THE CAMSHAFTS.............................................................. 5-8 CHECKING THE CAMSHAFTS ..............................................................
CLUTCH ........................................................................................................ 5-43 REMOVING THE CLUTCH ..................................................................... 5-45 DISASSEMBLING THE CLUTCH ........................................................... 5-45 CHECKING THE FRICTION PLATES..................................................... 5-46 CHECKING THE CLUTCH PLATES ....................................................... 5-46 CHECKING THE CLUTCH SPRING PLATE...
INSTALLING THE CHAIN DRIVE ...........................................................
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe 1 10 Nm (1.0 m • kg, 7.2 ft • Ib) 5 3 45 Nm (4.5 m • kg, 33 ft • Ib) 4 6 2 6 10 Nm (1.0 m • kg, 7.2 ft • Ib) 31 Nm (3.1 m • kg, 22 ft • Ib) 20 Nm (2.0 m • kg, 15 ft • Ib) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page 4-1.
ENGINE REMOVAL Disconnecting the leads and hoses 5 Nm (0.5 m • kg, 3.6 ft • Ib) 2 5 4 5 6 7 1 23 Nm (2.3 m • kg, 17 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 3 Order Job/Parts to remove Q’ty Refer to “GENERAL CHASSIS” on page 4-1. Refer to “GENERAL CHASSIS” on page 4-1. Refer to “FUEL TANK” on page 7-1. Drain. Refer to “CHANGING THE ENGINE OIL” on page 3-13. Drain. Refer to “CHANGING THE COOLANT” on page 3-19. Drain. Refer to “CHECKING THE CHAIN DRIVE OIL LEVEL” on page 3-26.
ENGINE REMOVAL Disconnecting the leads and hoses 5 Nm (0.5 m • kg, 3.6 ft • Ib) 2 5 4 5 6 7 1 23 Nm (2.3 m • kg, 17 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 3 Order 2 3 4 5 6 7 Job/Parts to remove Q’ty Starter motor lead Battery negative lead Coolant temperature sensor coupler A.C. magneto lead Intake air temperature sensor hose Right passenger footrest 1 1 1 2 1 1 Remarks Disconnect. Disconnect. Disconnect. For assembly, reverse the removal procedure.
ENGINE REMOVAL Removing the engine 87 Nm (8.7 m • kg, 63 ft • Ib) 48 Nm (4.8 m • kg, 35 ft • Ib) 4 1 1 3 4 3 1 1 2 48 Nm (4.8 m • kg, 35 ft • Ib) 5 Order 1 2 3 4 5 Job/Parts to remove Q’ty Front lower mounting bolt/Washer Spacer Front upper mounting bolt/Nut Rear mounting bolt/Nut Engine Remarks 4/4 1 1/1 1/1 1 For installation, reverse the removal procedure.
ENGINE REMOVAL EAS23720 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. 4 1 2 1 2 4 3 2. Tighten: ● Rear mounting nut “1” T. Rear mounting nut 87 Nm (8.7 m•kg, 63 ft•lb) R. ● Front upper mounting nut “2” T. Front upper mounting nut 87 Nm (8.7 m•kg, 63 ft•lb) R. ● Front lower mounting bolts T. Front lower mounting bolts 48 Nm (4.
CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 13 Nm (1.3 m • kg, 9.4 ft • Ib) 4 3 4 1 2 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order 1 2 3 4 Job/Parts to remove Q’ty Engine Intake manifold Spark plug Cylinder head cover Cylinder head cover gasket Dowel pin Remarks Refer to “ENGINE REMOVAL” on page 5-1. Refer to “THROTTLE BODIES” on page 7-4. 2 1 1 2 For installation, reverse the removal procedure.
CAMSHAFTS Removing the camshafts 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 E 2 M 4 3 M 5 4 3 6 4 Order 1 2 3 Job/Parts to remove Q’ty Timing chain tensioner Timing chain tensioner gasket Camshaft cap Remarks 1 1 2 NOTE: 4 Dowel pin 4 5 6 Intake camshaft Exhaust camshaft 1 1 During removal, the dowel pins may still be connected to the camshaft cap. For installation, reverse the removal procedure.
CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: ● Timing plug “1” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Remove: ● Timing chain tensioner “1” ● Timing chain tensioner gasket “2” 2. Align: ● “I”mark “a” on the A.C. magneto rotor (with the stationary pointer “b” on the A.C. magneto cover) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. 1 2 4. Remove: ECA15B1022 CAUTION: Before removing the camshafts from the cylinder head, tilt up the engine at least 25°. b.
CAMSHAFTS 5. Remove: ● Intake camshaft “1” ● Exhaust camshaft “2” Camshaft lobe dimension limit Intake A 33.252–33.352 mm (1.3091–1.3131 in) Limit 33.152 mm (1.3052 in) Intake B 24.956–25.056 mm (0.9825–0.9865 in) Limit 24.856 mm (0.9786 in) Exhaust A 33.252–33.352 mm (1.3091–1.3131 in) Limit 33.152 mm (1.3052 in) Exhaust B 24.956–25.056 mm (0.9825–0.9865 in) Limit 24.856 mm (0.9786 in) NOTE: To prevent the timing chain from falling into the crankcase, faster it with a wire “3”. 1 2 3 6.
CAMSHAFTS 4. Measure: ● Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Measure: ● Camshaft journal diameter “a” Out of specification → Replace the camshaft. Within specification → Replace the cylinder head and the camshaft caps as a set. Camshaft-journal-to-camshaft-cap clearance 0.020–0.054 mm (0.0008–0.0021 in) Camshaft journal diameter 22.967–22.980 mm (0.9042–0.9047 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
CAMSHAFTS b 2 a 1 b. Lock the timing chain tensioner rod “1” by setting the circlip “3” to groove“4” while pushing the timing chain tensioner rod. a. 1/4 tooth b. Correct 1. Timing chain roller 2. Camshaft sprocket 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). 3 4 c. Push the timing chain tensioner rod “c”. d.
CAMSHAFTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1 2. Install: ● Dowel pins ● Intake camshaft cap “1” ● Exhaust camshaft cap “2” ● Camshaft cap bolts 2 T. Camshaft cap bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) R. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compression stroke, align the “I” mark “a” on the A.C. magneto rotor with the stationary pointer “b” on the A.C. magneto cover.
CAMSHAFTS ting the circlip “3” into groove“4” while pushing the timing chain tensioner rod. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Turn: ● Crankshaft (several turns counterclockwise) 5. Check: ● “I”mark “a” Make sure that the “I” mark is aligned with the stationary pointer “b”. ● Camshaft sprocket alignment marks “c” ● Make sure that the camshaft sprocket alignment mark is aligned with the cylinder head mating surface “d”. Out of alignment → Reinstall. Refer to the installation steps above. 3 4 c.
CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m • kg, 7.2 ft • Ib) 46 Nm (4.6 m • kg, 33 ft • Ib) 3 2 1 35 Nm (3.5 m • kg, 25 ft • Ib) Order 1 2 3 Job/Parts to remove Q’ty Intake and exhaust camshafts Cylinder head Cylinder head gasket Dowel pin Remarks Refer to “CAMSHAFTS” on page 5-6. 1 1 2 For installation, reverse the removal procedure.
CYLINDER HEAD ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS15B420a REMOVING THE CYLINDER HEAD 1. Remove: ● Cylinder head bolts ● Cylinder head nuts a. Place a straightedge “1” and a thickness gauge “2” across the cylinder head. 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. EAS24160 CHECKING THE CYLINDER HEAD 1. Eliminate: ● Combustion chamber carbon deposits (with a rounded scraper) b.
CYLINDER HEAD ● Cylinder head nuts “2” T. Cylinder head nut 46 Nm (4.6 m•kg, 33 ft•lb) R. ● Cylinder head bolts “3” T. Cylinder head bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) R. NOTE: ● Apply engine oil onto the threads of the cylinder head nuts. ● Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them in two stages.
VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs 1 2 3 4 5 6 1 2 3 7 4 5 6 7 8 8 Order 1 2 3 4 5 6 7 8 9 10 Job/Parts to remove Q’ty Cylinder head Valve lifter Valve pad Valve cotter Valve retainer Valve spring Valve stem seal Valve spring seat Valve guide Intake valve Exhaust valve 10 9 Remarks Refer to “CYLINDER HEAD” on page 5-14. 8 8 16 8 8 8 8 8 4 4 For installation, reverse the removal procedure.
VALVES AND VALVE SPRINGS 3. Remove: ● Valve cotters “1” EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor “2” and the valve spring compressor attachment “3”. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
VALVES AND VALVE SPRINGS remover “1”. 1. Measure: ● Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” Valve stem diameter “b” Valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) b.
VALVES AND VALVE SPRINGS place the oil seal. Valve stem runout Valve stem runout 0.040 mm (0.0016 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: ● Carbon deposits (from the valve face and valve seat) 4. Check: ● Valve face Pitting/wear → Grind the valve face. ● Valve stem end Mushroom shape or diameter larger than the body of the valve stem → Replace the valve. 5. Measure: ● Valve margin thickness “a” Out of specification → Replace the valve.
VALVES AND VALVE SPRINGS onto the valve face. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. 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 impression. d. Measure the valve seat width.
VALVES AND VALVE SPRINGS Valve spring free length Free length (intake) 35.59 mm (1.40 in) Limit 33.81 mm (1.33 in) Free length (exhaust) 35.59 mm (1.40 in) Limit 33.81 mm (1.33 in) EAS24320 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters. 1. Check: ● Valve lifter Damage/scratches → Replace the valve lifters and cylinder head. 2. Measure: ● Compressed valve spring force “a” Out of specification → Replace the valve spring.
VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attachment 90890-04114 Valve spring compressor adapter 19.5 mm YM-04114 3. Install: ● Valve “1” ● Lower spring seat “2” ● Valve stem seal “3” ● Valve spring “4” ● Upper spring seat “5” (into the cylinder head) NOTE: ● Make sure each valve is installed in its original place. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.
VALVES AND VALVE SPRINGS so that the pads do not fall. NOTE: ● The valve lifter must move smoothly when rotated with a finger. ● Each valve lifter and valve pad must be reinstalled in its original position.
CYLINDER AND PISTONS EAS24370 CYLINDER AND PISTONS Removing the cylinder and pistons 4 4 2 3 5 5 6 7 8 1 Order 1 2 3 4 5 6 7 8 Job/Parts to remove Q’ty Cylinder head Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Piston ring set Remarks Refer to “CYLINDER HEAD” on page 5-14. 1 1 1 2 4 2 2 2 For installation, reverse the removal procedure.
CYLINDER AND PISTONS EAS24380 REMOVING THE PISTON The following procedure applies to all of the pistons. 1. Remove: ● Piston pin clips “1” ● Piston pin “2” ● Piston “3” NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. ECA13810 CAUTION: Do not use a hammer to drive the piston pin out.
CYLINDER AND PISTONS cylinder, and replace the piston and piston rings as a set. Bore “C” Bore 66.000–66.010 mm (2.5984–2.5988 in) Taper limit “T” Taper limit 0.050 mm (0.0020 in) Out of round “R” Out of round limit 0.050 mm (0.0020 in) “C”= maximum of D1–D6 “T”= (maximum of D1 or D2)—(maximum of D5 or D6) “R” = maximum of D1, D3 or D5 . minimum of D2, D4 or D6 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS24430 CHECKING THE PISTON RINGS 1.
CYLINDER AND PISTONS 3. Measure: ● Piston pin bore diameter “b” Out of specification → Replace the piston. a. 10 mm (0.39 in) 3. Measure: ● Piston ring end gap Out of specification → Replace the piston ring. Piston pin bore inside diameter 15.002–15.013 mm (0.5906–0.5911 in) Limit 15.043 mm (0.5922 in) NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings. Piston ring end gap End gap (installed) 0.15–0.25 mm (0.0059–0.
CYLINDER AND PISTONS NOTE: ● Be sure to install the top and 2nd rings so that the manufacturers marks or numbers face up. Cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: ● Top ring ● 2nd ring ● Oil ring Offset the piston ring end gaps as shown. 2. Install: ● Piston ● Piston pin ● Piston pin clips New NOTE: ● Apply engine oil onto the piston pin. sure the arrow mark “a” on the piston points towards the exhaust side of the engine.
GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the starter clutch and A.C. magneto rotor 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) (7) 5 7 14 1 4 3 2 7 8 6 16 18 15 17 9 13 12 4 11 30 Nm (3.0 m • kg, 22 ft • Ib) Order 10 60 Nm (6.
GENERATOR AND STARTER CLUTCH Removing the starter clutch and A.C. magneto rotor 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) (7) 5 7 14 1 4 3 2 7 8 6 16 18 15 17 9 13 12 4 11 30 Nm (3.0 m • kg, 22 ft • Ib) Order 13 14 15 16 17 18 10 60 Nm (6.0 m • kg, 43 ft • Ib) + 120˚ Job/Parts to remove Q’ty Starter clutch Woodruff key Starter clutch idle gear shaft Starter clutch idle gear Starter clutch gear Washer 10 Nm (1.0 m • kg, 7.
GENERATOR AND STARTER CLUTCH EAS24530 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. 3. Remove: ● A.C. magneto rotor “1” (with the flywheel puller set “2”) ● Woodruff key NOTE: ● Remove the A.C. magneto rotor “1” using the flywheel puller. ● Center the flywheel puller over the A.C. magneto rotor.
GENERATOR AND STARTER CLUTCH ● Starter clutch gear Burrs/chips/roughness/wear → Replace the defective part(s). “a” in the A.C magneto rotor. 2. Tighten: ● A.C magneto rotor nut “1” 3. Check: ● Starter clutch operation A.C magneto rotor nut 60 Nm (6.0 m•kg, 43 ft•lb) R. a. Install the starter clutch drive gear “1” onto the starter clutch “2” and hold the starter clutch. b.
GENERATOR AND STARTER CLUTCH 3. Apply: ● Sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 (Three Bond No.1215®) 90890-85505 4. Install: ● A.C. magneto rotor cover T. A.C. magneto rotor cover bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) R. NOTE: Tighten the A.C. magneto rotor cover bolts in stages and in a crisscross pattern.
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m • kg, 7.2 ft • Ib) 5 Nm (0.5 m • kg, 3.6 ft • Ib) 2 1 Order 1 2 3 3 Job/Parts to remove Q’ty Fuel tank Negative battery lead Starter motor lead Starter motor Remarks Refer to “FUEL TANK” on page 7-1. 1 1 1 For installation, reverse the removal procedure.
ELECTRIC STARTER Disassembling the starter motor 3 2 5 6 4 1 7 9 8 11 10 2 Order 1 2 3 4 5 6 7 8 9 10 11 Job/Parts to remove Q’ty Front bracket O-ring Shims Lock washer Oil seal Bearing Rear bracket Shims Brush holder set Armature assembly Starter motor yoke Remarks 1 2 1 1 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
ELECTRIC STARTER with the pocket tester. EAS24790 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. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Limit 27.0 mm (1.06 in) Armature coil Commutator resistance “1” 0.0015–0.
ELECTRIC STARTER 2. Connect: ● Starter motor lead springs as a set. Brush spring force 7.65–10.01 N (27.54–36.03 oz) (780–1021 gf) 7. Check: ● Gear teeth Damage/wear → Replace the gear. 8. Check: ● Bearing“1” ● Oil seal“2” Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1.
OIL PUMP EAS24900 OIL PUMP Removing the oil pump 10 Nm (1.0 m • kg, 7.2 ft • Ib) 4 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 3 3 5 6 Order 2 Job/Parts to remove Q’ty Left side panel/lower side cover moulding/footrest board Coolant Engine oil A.C. magneto cover/Starter clutch gear 1 2 3 4 5 6 Oil pump assembly Oil pump drive chain O-ring Oil delivery pipe Oil delivery pipe Relief valve assembly Remarks Refer to “GENERAL CHASSIS” on page 4-1. Drain. Refer to “CHANGING THE COOLANT” on page 3-19. Drain.
OIL PUMP Disassembling the oil pump 6 3 7 5 2 4 8 9 1 5 3 2 4 Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Q’ty Oil pump housing Oil pump outer rotor Oil pump inner rotor Pin Dowel pin Oil pump housing center Washer Oil pump cover Oil pump driven gear Remarks 1 2 2 2 4 1 1 1 1 For installation, reverse the removal procedure.
OIL PUMP EAS24960 CHECKING THE OIL PUMP 1. Check: ● Oil pump drive gear “1” ● Oil pump housing “2” ● Oil pump cover “3” Cracks/damage/wear → Replace the defective part(s). Inner-rotor-to-outer-rotor-tip clearance 0.040–0.120 mm (0.0016–0.0047 in) Limit 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing clearance 0.045–0.085 mm (0.0018–0.0033 in) Limit 0.155 mm (0.0061 in) Oil-pump-housing-to-inner-and-outer-rotor clearance 0.11–0.23 mm (0.0043–0.0091 in) Limit 0.30 mm (0.0118 in) 3.
OIL PUMP 2. Install: ● Pins ● Inner rotors EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes. 1. Check: ● Oil delivery pipe “1” Damage → Replace. Obstruction → Wash and blow out with compressed air. NOTE: When installing the inner rotor, align the pin “1” in the oil pump shaft with the groove “a” in the inner rotor. 1 a 1 a 3. Check: ● Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-41. EAS24990 CHECKING THE OIL STRAINER 1.
CLUTCH EAS25060 CLUTCH Removing the clutch 65 Nm (6.5 m • kg, 47 ft • Ib) 3 2 1 Order Job/Parts to remove Q’ty A.C. magneto cover 1 2 3 Remarks Refer to “GENERATOR AND STARTER CLUTCH” on page 5-30. Clutch assembly nut Clutch assembly Washer 1 1 1 For installation, reverse the removal procedure.
CLUTCH Disassembling the clutch 16 17 90 Nm (9.
CLUTCH EAS25070 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. ● Align these marks during reassembly. 2.
CLUTCH Warpage limit 0.10 mm (0.0039 in) 1 2 3 EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: ● Friction plate Damage/wear → Replace the friction plates as a set. 2. Measure: ● Friction plate thickness Out of specification → Replace the friction plates as a set. EAS25130 CHECKING THE CLUTCH SPRING PLATE The following procedure applies to all of the clutch springs. 1. Check: ● Clutch plate spring Damage → Replace. 2.
CLUTCH EAS25160 Clutch spring height “c” 4.70 mm (0.19 in) Minimum height 4.40 mm (0.17 in) Clutch spring height “b” 3.30 mm (0.13 in) Minimum height 2.9 mm (0.11 in) 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. EAS25170 CHECKING THE PRESSURE PLATE 1. Check: ● Clutch boss splines Damage/pitting/wear → Replace the clutch boss.
CLUTCH EAS15B4586b ASSEMBLING THE CLUTCH 1. Lubricate: ● Friction plates ● Clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: ● Clutch boss ● Primary drive gear ● Clutch boss nut “1” 3. Tighten: ● Clutch boss nut T. Clutch boss nut 90 Nm (9.0 m•kg, 65 ft•lb) R. NOTE: While holding the clutch boss “2” with the clutch holding tool “3”, tighten the clutch boss nut. A. Engine side Universal clutch holder 90890-04086 YM-91042 EAS15B4286c INSTALLING THE CLUTCH 1.
CLUTCH 5-49
V-BELT AUTOMATIC TRANSMISSION EAS24610 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 4 8 3 11 12 2 10 9 11 Nm (1.1 m • kg, 8.0 ft • Ib) 7 6 1 7 Nm (0.7 m • kg, 5.
V-BELT AUTOMATIC TRANSMISSION Removing the V-belt and primary/secondary sheave 24 Nm (2.4 m • kg, 17 ft • Ib) 13 10 Nm (1.0 m • kg, 7.2 ft • Ib) 12 15 24 Nm (2.4 m • kg, 17 ft • Ib) 10 14 11 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 89 6 1 3 2 2 1 5 90 Nm (9.0 m • kg, 65 ft • Ib) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 4 1 160 Nm (16.
V-BELT AUTOMATIC TRANSMISSION Disassembling the primary sheave 4 3 5 1 2 Order 1 2 3 4 5 Job/Parts to remove Q’ty Cam silinder Weight Primary sliding sheave Collar Remarks 1 4 8 1 1 For installation, reverse the disassembly procedure.
V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave 9 5 8 7 1 2 3 4 6 90 Nm (9.0 m • kg, 65 ft • Ib) Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Q’ty Secondary sheave spring seat nut Upper spring seat Compression spring Spring seat Secondary sliding sheave Oil seal O-ring Guide pin Secondary fixed sheave Remarks 1 1 1 1 1 1 2 4 1 For assembly, reverse the disassembly procedure.
V-BELT AUTOMATIC TRANSMISSION EAS24620 EAS24630 REMOVING THE PRIMARY SHEAVE 1. Remove: ● Primary sheave nut “1” ● Secondary sheave nut “2” REMOVING THE SECONDARY SHEAVE 1. Remove: ● Secondary sheave assembly “1” ● Primary sheave assembly “2” ● V-belt “3” NOTE: While holding the primary and secondary sheave with the sheave holder, loosen the nut. NOTE: ● Before removal, apply “a” and “b” alignment marks. ● Align these marks during reassembly.
V-BELT AUTOMATIC TRANSMISSION EAS24640 DISASSEMBLING THE SECONDARY SHEAVE 1. Remove: ● Spring seat “1” NOTE: Install the sheave spring compressor “2” onto the secondary sheave as shown. Then, compress the spring, and remove the secondary sheave spring seat nut “1” with locknut wrench “3”. EAS24680 CHECKING THE PRIMARY SHEAVE 1. Check: ● Primary sliding sheave “1” ● Primary fixed sheave “2” Cracks/damage/wear → Replace the primary sliding sheave and primary fixed sheave as a set.
V-BELT AUTOMATIC TRANSMISSION EAS24720 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: ● Primary fixed sheave ● Primary sliding sheave ● Collar ● Weights ● Sliders ● Cam 2. Install: ● Weights “1” ● Sliders “2” ● Cam “3” EAS24700 CHECKING THE SLIDER 1. Check: ● Slider “1” Cracks/damage/wear → Replace. NOTE: Do not apply the grease inside of the primary sheave. 1 2 3 EAS24710 CHECKING THE SECONDARY SHEAVE 1.
V-BELT AUTOMATIC TRANSMISSION T. 3. Install: ● Guide pin “2” 4. Lubricate: ● Guide pin groove “3” ● O-ring New (with the recommended lubricant) R. Secondary sheave spring seat nut 90 Nm (9.0 m•kg, 65 ft•lb) Recommended lubricant BEL-RAY assembly lube EAS15B4009 5. Install: ● Spring seat “1” ● Compression spring “2” ● Upper spring seat “3” INSTALLING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY SHEAVE ASSEMBLY AND V-BELT 1.
V-BELT AUTOMATIC TRANSMISSION ● Install the V-belt and secondary sheave assembly onto the primary sheave side. ● Align the “a” and “b” during reassembly. 1 2 5. Tighten: ● Primary sheave nut “1” Primary sheave nut 160 Nm (16.0 m•kg, 115 ft•lb) ECA15B1005 CAUTION: ● Before tightening the nut to remount the primary sheave, make sure that the serrations of the cam are fitted firmly into the serrations of the crankshaft. Also, make sure that cam is properly seated.
CRANKCASE AND CRANKSHAFT EAS25960 CRANKCASE AND CRANKSHAFT Removing the crankshaft assembly 7 10 8 10 Nm (1.0 m • kg, 7.2 ft • Ib) 58 Nm (5.8 m • kg, 42 ft • Ib) 5 4 10 6 11 9 3 11 2 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 55 Nm (5.5 m • kg, 40 ft • Ib) 1 24 Nm (2.4 m • kg, 17 ft • Ib) Order Job/Parts to remove Q’ty Engine Cylinder head Cylinder/piston Starter clutch/A.C.
CRANKCASE AND CRANKSHAFT Removing the crankshaft assembly 7 10 8 10 Nm (1.0 m • kg, 7.2 ft • Ib) 58 Nm (5.8 m • kg, 42 ft • Ib) 5 4 10 6 11 9 3 11 2 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 55 Nm (5.5 m • kg, 40 ft • Ib) 1 24 Nm (2.4 m • kg, 17 ft • Ib) Order 11 Job/Parts to remove Q’ty Crankshaft main journal bearing Remarks 2 For installation, reverse the removal procedure.
CRANKCASE AND CRANKSHAFT Removing the connecting rod 7 16 Nm (1.6 m • kg, 12 ft • Ib) + 90˚ 5 3 6 2 5 8 4 3 4 4 4 1 4 3 4 1 16 Nm (1.6 m • kg, 12 ft • Ib) + 90˚ 60 Nm (6.0 m • kg, 43 ft • Ib) Order 1 2 3 4 5 6 7 8 Job/Parts to remove Q’ty Connecting rod Connecting rod (balancer) Connecting rod cap Big end bearing Circlip Piston pin Balancer piston Crankshaft Remarks 2 1 3 3 2 1 1 1 For installation, reverse the removal procedure.
CRANKCASE AND CRANKSHAFT EAS25560 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. Remove: ● Left crankcase ECA13900 NOTE: CAUTION: Identify the position of each crankshaft main journal bearing so that it can be reinstalled in its original place. Tap on one side of the crankcase with a soft-face hammer.
CRANKCASE AND CRANKSHAFT 3. Check: ● Crankcase Cracks/damage → Replace. ● Oil delivery passages Obstruction → Blow out with compressed air. Journal oil clearance (using plastigauge®) 0.040–0.082 mm (0.0016–0.0032 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS15B4207 CHECKING THE TIMING CHAIN 1. Check: ● Timing chain Damage/stiffness → Replace the timing chain and camshaft sprockets as a set. The following procedure applies to all of the connecting rods.
CRANKCASE AND CRANKSHAFT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Select: ● Big end bearings (“P ”,“P ”,“P ”) 1 2 3 NOTE: ● The numbers “A” stamped into the crankshaft web and the numbers “1” on the connecting rods are used to determine the replacement big end bearing sizes. ● “P1”,“P2”,“P3” refer to the bearings shown in the crankshaft illustration. g. Tighten the connecting rod nuts. ECA15B1040 CAUTION: ● When tightening the connecting rod nuts, be sure to use an F-type torque wrench.
CRANKCASE AND CRANKSHAFT Bearing color code 1.Blue 2.Black 3.Brown 4.Green m. Measure the inside diameter “b” of each journal bearing at two places. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Measure: ● Crankshaft-journal-to-crankshaft-journal bearing clearance. Out of specification → Replace the crankshaft journal bearings. Crankshaft-journal-to-crankshaft-journal bearing clearance 0.04–0.082 mm (0.0016–0.0032 in) n. If journal bearing inside diameter is “45.03” and crankshaft journal outside diameter is “44.
CRANKCASE AND CRANKSHAFT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS25630 INSTALLING THE CRANKSHAFT MAIN JOURNAL BEARING 1. Attach: ● Crankshaft main journal bearings NOTE: Attach the crankshaft main journal bearing to the plane bearing installer “1”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. For example, if the crankcase “J1”and the crankshaft web “J1” numbers are “4” and “2” respectively, then the bearing size for “J1” is: Bearing size for “J1”: “J1” (crankcase)– “J1” (crankshaft web) = 4–2 = (black) Bearing color code 1.Blue, 2.
CRANKCASE AND CRANKSHAFT EAS26150 INSTALLING THE CONNECTING RODS 1. Install: ● Big end bearings “1” NOTE: ● Align the projections “a” on the big end bearings with the notches “b” in the connecting rods and connecting rod caps. ● Be sure to reinstall each big end bearing in its original place. 4. Tighten: ● Connecting rod nuts NOTE: Apply molybdenum disulfide grease to the rod cap bolt threads and nut surfaces.
CRANKCASE AND CRANKSHAFT connecting rod bolt and nut with a new one and perform the procedure again. T. R. ECA15B1028 CAUTION: ● Tighten Balancer piston cylinder bolt 58 Nm (5.8 m•kg, 42 ft•lb) ECA15B1003 CAUTION: the nut until it is at the specified an- To avoid scratching the crankshaft and to ease the installation procedure, apply grease onto the oil seal lips and apply engine oil onto each bearing. gles. ● Do not use a torque wrench to tighten the connecting rod nut to the specified angle.
CRANKCASE AND CRANKSHAFT 5-69
TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 9 7 8 6 9 9 10 5 4 2 9 3 1 9 12 Nm (1.2 m • kg, 8.7 ft • Ib) Order Job/Parts to remove Q’ty Left crankcase 1 2 3 4 5 6 7 8 9 10 Remarks Refer to “CHECKING THE CRANKCASE” on page 5-62. Secondary shaft Main axle Primary driven gear First pinion gear Washer Drive axle First wheel gear Circlip Bearing Oil seal 1 1 1 1 1 1 1 1 5 2 For installation, reverse the removal procedure.
TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: ● Left crankcase Refer to “CRANKCASE AND CRANKSHAFT” on page 5-59. 2. Remove: ● Secondary shaft; “1” ● Main axle“2” ● Drive axle“3” ● Primary driven gear“4” ● First wheel gear“5” ● First pinion gear 3. Measure: ● Secondary shaft runout (with a centering device and dial gauge) Out of specification → Replace the secondary shaft. Maximum secondary shaft runout 0.08 mm (0.0031 in) EAS26300 CHECKING THE TRANSMISSION 1.
CHAIN DRIVE TRANSMISSION EAS24750 CHAIN DRIVE TRANSMISSION Removing primary and secondary drive chains 23 Nm (2.3 m • kg, 17 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 100 Nm (10.0 m • kg, 72 ft • Ib) 14 8 7 10 9 3 2 4 11 13 6 5 1 40 Nm (4.0 m • kg, 29 ft • Ib) 12 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Parts to remove Q’ty Chain drive oil DRIVE OIL LEVEL” on page 3-26. Refer to “REAR SHOCK ABSORBER ASSEMBLY” on page 4-68. Refer to “REAR WHEEL” on page 4-16.
CHAIN DRIVE TRANSMISSION Removing primary and secondary drive chains 23 Nm (2.3 m • kg, 17 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 100 Nm (10.0 m • kg, 72 ft • Ib) 14 8 7 10 9 3 2 4 13 11 6 5 1 40 Nm (4.0 m • kg, 29 ft • Ib) 12 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order 14 Job/Parts to remove Q’ty O-ring Remarks 1 For installation, reverse the removal procedure.
CHAIN DRIVE TRANSMISSION Removing primary and secondary drive chains 6 10 13 12 10 7 9 3 9 9 8 10 5 9 9 11 4 10 1 10 Nm (1.0 m • kg, 7.
CHAIN DRIVE TRANSMISSION EAS15B4006 CHECKING THE SWINGARM 1. Check: ● swingarm “1” Damage/wear → Replace. 2. Check: ● Pivot shaft “1” ● Collar ● Bearing ● Oil seal Damage/wear → Replace. EAS15B4008 ASSEMBLING THE CHAIN DRIVE ASSEMBLY 1. Install: ● Chain drive case (outer) Chain drive case bolt 10 Nm (1.0 m E kg, 7.2 ft E lb) NOTE: First, tighten the chain drive case bolts that are numbered in the illustration in the order shown, and then tighten the unnumbered bolts in a crisscross pattern.
CHAIN DRIVE TRANSMISSION 2. Tighten: ● Swingarm bolt T. Swingarm bolt 40 Nm (4.0 m•kg, 29 ft•lb) R. 3. Adjust: ● Pivot shaft ● Nut T. R. Pivot shaft 7 Nm (0.7 m•kg, 5.1 ft•lb) Nut 100 Nm (10.0 m•kg, 72 ft•lb) NOTE: ● With your fingers, screw in the pivot shaft until it touches the collar and then tighten the pivot shaft to the tightening torque. ● Tighten the nut to the tightening torque. ● Install the shock absorber and rear wheel after the swingarm is installed. 4. Fill: ● Chain drive oil 5.
CHAIN DRIVE TRANSMISSION 5-77
COOLING SYSTEM RADIATOR .................................................................................................... 6-1 CHECKING THE RADIATOR.................................................................. 6-3 CHECKING THE OIL COOLER .............................................................. 6-3 INSTALLING THE OIL COOLER AND RADIATOR ................................ 6-3 THERMOSTAT ..............................................................................................
RADIATOR EAS26380 RADIATOR Removing the radiator 6 7 3 9 5 2 8 14 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 17 15 16 4 18 11 63 Nm (6.3 m • kg, 45 ft • Ib) 17 Nm (1.7 m • kg, 12 ft • Ib) Order 12 Job/Parts to remove 13 10 Q’ty Leg shield/footrest board/inner fender Engine oil Coolant 1 2 3 4 5 6 7 8 9 10 11 12 13 Remarks Refer to “GENERAL CHASSIS” on page 4-1. Drain. Refer to “CHANGING THE ENGINE OIL” on page 3-13. Drain.
RADIATOR Removing the radiator 6 7 3 9 5 2 8 14 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 17 15 16 4 18 11 63 Nm (6.3 m • kg, 45 ft • Ib) 17 Nm (1.7 m • kg, 12 ft • Ib) Order 14 15 16 17 18 12 Job/Parts to remove 13 10 Q’ty Radiator Radiator fan Oil filter cartridge Oil cooler inlet hose Oil cooler 1 1 1 1 1 Remarks Disconnect. For installation, reverse the removal procedure.
RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: ● Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: ● Radiator fan Damage → Replace. Malfunction → Check and repair. Refer to “COOLING SYSTEM” on page 8-29. EAS15B4458 CHECKING THE OIL COOLER 1.
RADIATOR NOTE: Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 ● Before installing the oil cooler, lubricate the oil cooler bolt with engine oil. ● Make sure that the O-ring is positioned properly. ● Align the projection “a” on the oil cooler with the slot “b” in the crankcase. b. Apply 100 kPa (1.0 kg/cm2, 14.22 psi) of pressure. c. Measure the indicated pressure with the gauge.
THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly 18 Nm (1.8 m • kg, 13 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 2 5 3 6 4 Order Job/Part Q’ty Center cover/side cover Coolant 1 2 3 4 5 6 Thermostat outlet hose Coolant temperature sensor coupler Coolant temperature sensor Copper washer Thermostat cover Thermostat 1 1 1 1 1 1 Remarks Refer to “GENERAL CHASSIS” on page 4-1. Drain. Refer to “CHANGING THE COOLANT” on page 3-19. Disconnect. Disconnect.
THERMOSTAT EAS26450 CHECKING THE THERMOSTAT 1. Check: ● Thermostat Does not open at 70.5–73.5°C (159–164°F) → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: ● Thermostat housing cover Cracks/tears → Replace. EAS26480 INSTALLING THE THERMOSTAT ASSEMBLY 1. Install: ● Thermostat ● Thermostat cover T. Bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) R. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. b. Slowly heat the water. c. Place a thermometer “3” in the coolant. d.
WATER PUMP EAS26500 WATER PUMP Removing the water pump 1 4 3 2 10 5 6 9 7 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 8 Order Job/Parts to remove Q’ty Left upper side cover moulding/left footrest board Coolant 1 2 3 4 5 6 7 8 9 10 Remarks Refer to “GENERAL CHASSIS” on page 4-1. Drain. Refer to “CHANGING THE COOLANT” on page 3-19.
WATER PUMP Disassembling the water pump 10 Nm (1.0 m • kg, 7.2 ft • Ib) 3 6 7 8 5 2 4 1 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Parts to remove Q’ty Remarks NOTE: It is not necessary to remove the impeller shaft, unless the coolant level is extremely low or coolant contains engine oil. 1 2 3 4 5 6 7 8 Water pump housing cover O-ring Circlip Impeller shaft Water pump seal Bearing Oil seal Water pump housing 1 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
WATER PUMP 4. Remove: ● Rubber damper holder “1” ● Rubber damper “2” (from the impeller, with a thin, flat-head screwdriver) EAS26510 DISASSEMBLING THE WATER PUMP 1. Remove: ● Water pump seal “1” NOTE: Remove the water pump seal from the inside of the water pump housing. NOTE: Do not scratch the impeller shaft. a. Water pump housing EAS26550 CHECKING THE WATER PUMP 1.
WATER PUMP a 1 2. Install: ● Bearing “1” A. Push down 3. Install: ● Water pump seal “1” New ECA15B1029 4. Install: ● Rubber damper “1” New ● Rubber damper holder “2” New CAUTION: NOTE: Never apply oil or grease onto the water pump seal surface. Before installing the rubber damper, apply tap water or coolant onto its outer surface. NOTE: ● Install the water pump seal with the special tools. ● Before installing the water pump seal, apply Yamaha bond No.
WATER PUMP 1. Straightedge 2. Impeller EAS26600 INSTALLING THE WATER PUMP 1. Install: ● Water pump assembly T. Water pump assembly bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) R. NOTE: Align the projection “a” at the oil pump shaft and water pump shaft groove “b”. a b 2. Fill: ● Cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” on page 3-19. 3. Check: ● Cooling system Leaks → Repair or replace any faulty part. 4.
FUEL SYSTEM FUEL TANK................................................................................................... 7-1 REMOVING THE FUEL TANK ................................................................ 7-2 REMOVING THE FUEL PUMP ............................................................... 7-2 INSTALLING THE FUEL PUMP.............................................................. 7-2 INSTALLING THE FUEL TANK............................................................... 7-2 THROTTLE BODIES .....
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 4 Nm (0.4 m • kg, 2.9 ft • Ib) 5 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 3 6 8 7 9 1 4 10 Order Job/Parts to remove Q’ty Strage box 1 2 3 4 5 6 7 8 9 10 Remarks Refer to “GENERAL CHASSIS” on page 4-1.
FUEL TANK EAS26710 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” ● Fuel tank breather hose “4” INSTALLING THE FUEL PUMP 1. Install: ● Fuel pump gasket New ● Fuel pump ● Fuel pump bracket T. EAS26630 Fuel pump bracket bolt 4 Nm (0.4 m•kg, 2.9 ft • lb) R.
FUEL TANK Fuel breather hose ● Fuel pump coupler ● ECA15B1032 CAUTION: ● Be sure to connect the fuel hose by hand. Do not forcefully connect the hose with tools. ● When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct position, otherwise the fuel hose will not be properly installed. 3.
THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies 10 Nm (1.0 m • kg, 7.2 ft • Ib) 13 9 11 12 12 Nm (1.2 m • kg, 8.7 ft • Ib) 11 14 14 11 11 2 15 10 4 3 5 15 3 7 4 8 1 6 10 Nm (1.0 m • kg, 7.2 ft • Ib) 9 Nm (0.9 m • kg, 6.
THROTTLE BODIES Removing the throttle bodies 10 Nm (1.0 m • kg, 7.2 ft • Ib) 13 9 11 12 12 Nm (1.2 m • kg, 8.7 ft • Ib) 11 14 14 11 11 2 15 10 4 3 5 15 3 7 4 8 1 6 10 Nm (1.0 m • kg, 7.2 ft • Ib) 9 Nm (0.9 m • kg, 6.5 ft • Ib) Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal procedure.
THROTTLE BODIES Disassembling the throttle bodies 1 3 2 2 4 Order Job/Parts to remove Q’ty Remarks 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. 1 2 3 4 Throttle position sensor Fast idle plunger Idle adjust screw Air screw 1 1 1 2 For installation, reverse the removal procedure.
THROTTLE BODIES EAS26980 CHECKING THE INJECTORS 1. Check: ● Injectors Damage → Replace. 1 3 2 d. Set the main switch to “ON” and the engine stop switch to “ ”. e. Start the engine. f. Measure the fuel pressure. Out of specification → Check the fuel hose connection or replace the fuel pump. EAS26990 CHECKING THE THROTTLE BODIES 1. Check: ● Throttle bodies Cracks/damage → Replace the throttle bodies as a set. 2. Check: ● Fuel passages Obstructions → Clean. Fuel pressure 240–260 kPa (240–2.
THROTTLE BODIES Tester positive probe Yellow “1” Negative tester probe Black/Blue “2” 2 1 d. Measure the throttle position sensor voltage. e. Loosen the throttle position sensor screws “3”. f. Adjust the throttle position sensor angle so that the voltage is within the specified range. Throttle position sensor voltage (closed position) 0.63–0.73V (Yellow–Black/Blue ) g. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws.
THROTTLE BODIES 7-9
ELECTRICAL SYSTEM IGNITION SYSTEM ....................................................................................... 8-1 CIRCUIT DIAGRAM ................................................................................ 8-1 TROUBLESHOOTING ............................................................................ 8-3 ELECTRIC STARTING SYSTEM .................................................................. 8-5 CIRCUIT DIAGRAM ............................................................................
[D-1] MAINTENANCE OF THE ECU (ABS) ............................................ 8-72 [D-2] MAINTENANCE OF THE ABS FAIL-SAFE RELAY ....................... 8-72 [D-3] MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR ................................................................................. 8-73 [D-5] MAINTENANCE OF THE HYDRAULIC UNIT ................................ 8-73 ABS TROUBLESHOOTING OUTLINE.................................................... 8-75 BASIC INSTRUCTION FOR TROUBLESHOOTING ....
CHECKING THE COOLANT TEMPERATURE SENSOR....................... 8-118 CHECKING THE THROTTLE POSITION SENSOR ............................... 8-119 CHECKING THE INTAKE AIR PRESSURE SENSOR ........................... 8-120 CHECKING THE INTAKE AIR TEMPERATURE SENSOR .................... 8-120 CHECKING THE V-BELT RESET COUPLER ........................................
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM 8-1
IGNITION SYSTEM 1. Crankshaft position sensor 4. Main switch 13. Ignition fuse 16. Battery 17. Main fuse 21. Starting circuit cut-off relay 1 26. Engine stop switch 29. Sidestand switch 30. ECU (engine) 31. Ignition coil 32. Spark plug 40.
IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: Before troubleshooting, remove the following part(s): 1.Battery cover 2.Rear cover 3.Front cowling 4.Leg shield 5.Footrest board 6.Inner fender 1. Check the fuses. (Main and ignition) Refer to “CHECKING THE FUSES” on page 8-106. NG→ Replace the fuse(s). OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-107. NG→ ● Clean the battery terminals.
IGNITION SYSTEM 10. Check the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 8-101. NG→ Replace the sidestand switch. NG→ Replace the starting circuit cut-off relay 1. NG→ Replace the lean angle sensor. NG→ Properly connect or repair the ignition system’s wiring OK↓ 11. Check the starting circuit cut-off relay 1 (Diode). Refer to “CHECKING THE RELAYS” on page 8-110. OK↓ 12. Check the lean angle sensor. Refer to “CHECKING THE LEAN ANGLE SENSOR” on page 8-114. OK↓ 13.
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM XP500 8-5
ELECTRIC STARTING SYSTEM 4. Main switch 11. Signaling system fuse 13. Ignition fuse 16. Battery 17. Main fuse 18. Starter relay 19. Starter motor 20. Diode 21. Starting circuit cut-off relay 1 25. Start switch 26. Engine stop switch 28. Front brake light switch 29. Sidestand switch 57.
ELECTRIC STARTING SYSTEM XP500A 8-7
ELECTRIC STARTING SYSTEM 4. Main switch 12. Signaling system fuse 14. Ignition fuse 17. Battery 19. Main fuse 20. Starter relay 21. Starter motor 22. Diode 23. Starting circuit cut-off relay 2 24. Starting circuit cut-off relay 1 28. Start switch 29. Engine stop switch 31. Front brake light switch 32. Sidestand switch 65.
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 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 at least one of the following conditions is met: ● A brake lever is pulled to the handlebar (the brake light switch is closed) and the side-stand is up (the sidestand switch is closed).
ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Starting circuit cut-off relay 1 7. Sidestand switch 8. Signaling system fuse 9. Front brake switch 10. Rear brake switch 11. Start switch 12. Starter relay 13.
ELECTRIC STARTING SYSTEM 8-11
ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Signaling system fuse 5. Ignition fuse 6. Engine stop switch 7. Starting circuit cut-off relay 1 8. Front brake switch 9. Rear brake switch 10. Sidestand switch 11. Starting circuit cut-off relay 2 12. Start switch 13. Starter relay 14.
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: Before troubleshooting, remove the following part(s): 1.Front cowling 2.Leg shield 3.Fotrest board 4.Fuel tank 1. Check the fuses. (Main and ignition) Refer to “CHECKING THE FUSES” on page 8-106. NG→ Replace the fuse(s). OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-107. NG→ ● Clean the battery terminals. or replace the battery. ● Recharge OK↓ 3.
ELECTRIC STARTING SYSTEM OK↓ 11. Check the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 8-101. NG→ Replace the sidestand switch. NG→ Replace the brake light switch. NG→ Replace the right handlebar switch. NG→ Properly connect or repair the starting system’s wiring OK↓ 12. Check the brake light switch. Refer to “CHECKING THE SWITCHES” on page 8-101. OK↓ 13. Check the start switch. Refer to “CHECKING THE SWITCHES” on page 8-101. OK↓ 14. Check the entire starting system’s wiring.
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-15
CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 16. Battery 17.
CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. NOTE: Before troubleshooting, remove the following part(s): 1.Rear cover 2.Battery cover 3.Left side cover moulding 4.Left side cover 1. Check the fuse. (Main) Refer to “CHECKING THE FUSES” on page 8-106. NG→ Replace the fuse. OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-107. NG→ ● Clean the battery terminals. or replace the battery. ● Recharge OK↓ 3. Check the stator coil.
CHARGING SYSTEM 8-18
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-19
LIGHTING SYSTEM 4. Main switch 6. Strage box light switch 7. Strage box light 10. Back-up fuse 11. Signal fuse 12. Headlight fuse 15. Lighting system fuse 16. Battery 17. Main fuse 30. ECU (engine) 51. Headlight relay 53. Pass switch 54. Dimmer switch 61. Tail/brake light 62. Licence plate light 66. Auxiliary light 67. Headlight (high beam) 68. Headlight (low beam) 78. Meter light 79.
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, strage box light, license light or meter light. NOTE: Before troubleshooting, remove the following part(s): 1.Battery cover 2.Rear cover 3.Front cowling 4.Handlebar cover 1. Check the each bulbs and bulb sockets condition. Refer to “CHECKING THE BULBS AND BULB SOCKETS” on page 8-105. NG→ Replace the bulb(s) and bulb socket(s). NG→ Replace the fuse(s). OK↓ 2. Check the fuses.
LIGHTING SYSTEM 8-22
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-23
SIGNALING SYSTEM 4. Main switch 10. Backup fuse (storage box light, immobilizer unit and meter assembly) 11. Signaling system fuse 15. Lighting system fuse 16. Battery 17. Main fuse 23. Fuel pump 27. Hazard switch 28. Front brake light switch 30. ECU (engine) 41. Speed sensor 49. Turn signal/hazard relay 50. Horn 55. Horn switch 56. Turn signal switch 57. Rear brake light switch 59. Rear turn signal light (right) 60. Rear turn signal light (left) 61. Tail/brake light 63. Front turn signal light (right) 64.
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING ● Any of the following fail to light: turn signal light, brake light or an indicator light. ● The horn fails to sound. ● The speedometer fails to operate. ● The V-belt replacement indicator fails to come on. ● The fuel meter(meter assembly) fails to operate. NOTE: Before troubleshooting, remove the following part(s): 1.Battery cover 2.Rear cover 3.Front cowling 4.Handlebar cover 1. Check the fuses.
SIGNALING SYSTEM The tail/brake light fails to come on. 1. Check the tail/brake light bulb and socket. Refer to “CHECKING THE BULBS AND BULB SOCKETS” on page 8-105. NG→ Replace the tail/brake light bulb, socket or both. NG→ Replace the brake light switch. NG→ Properly connect or repair the signaling system’s wiring. OK↓ 2. Check the brake light switch. Refer to “CHECKING THE SWITCHES” on page 8-101. OK↓ 3. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-23.
SIGNALING SYSTEM 2. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-23. NG→ Properly connect or repair the signaling system’s wiring. NG→ Replace the fuel pump assembly. NG→ Properly connect or repair the signaling system’s wiring. OK↓ Replace the meter assembly. The fuel meter fails to come. 1. Check the fuel sender. Refer to “CHECKING THE FUEL SENDER” on page 8-117. OK↓ 2. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-23.
SIGNALING SYSTEM 8-28
COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-29
COOLING SYSTEM 4. Main switch 13. Ignition fuse 14. Radiator fan motor fuse 16. Battery 17. Main fuse 30. ECU (engine) 33. Coolant temperature sensor 47. Radiator fan motor relay 48. Radiator fan motor 72.
COOLING SYSTEM EAS27320 TROUBLESHOOTING NOTE: Before troubleshooting, remove the following part(s): 1.Battery cover 2.Rear cover 3.Footrest board 4.Leg shield 5.Inner fender 1. Check the fuses. (Main, ignition and radiator fan motor) Refer to “CHECKING THE FUSES” on page 8-106. NG→ Replace the fuse(s). NG→ ● Clean the ● Recharge NG→ Replace the main switch. NG→ Replace the radiator fan motor. NG→ Replace the radiator fan motor relay. NG→ Replace the coolant temperature sensor.
COOLING SYSTEM 8-32
FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-33
FUEL INJECTION SYSTEM 1. Crankshaft position sensor 4. Main switch 9. Electrical fuel injection fuse 12. Headlight fuse 13. Ignition fuse 16. Battery 17. Main fuse 21. Starter circuit cut-off relay 1 22. Fuel injection system relay 23. Fuel pump 26. Engine stop switch 29. Sidestand switch 30. ECU (engine) 31. Ignition coil 32. Spark plug 33. Coolant temperature sensor 34. Intake air temperature sensor 35. Fuel injector #1 36. Fuel injector #2 37. Intake air pressure sensor 38. O2 sensor 39.
FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU (engine) is equipped with a self-diagnostic function in order to ensure that the fuel injection 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.
FUEL INJECTION SYSTEM that enable the engine to continue to operate or stop operating, depending on the conditions. The ECU (engine) takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value, and the other in which the ECU (engine) directly operates an actuator. Details on the fail-safe actions are given in the table below. Self-Diagnostic Function Fault code No.
FUEL INJECTION SYSTEM Communication error with the meter Fault code No. Item Symptom Able / unable to start Able / unable to drive Er-1 ECU (engine) internal malfunction (output signal error) No signals are received from the ECU (engine). Unable Unable Er-2 ECU (engine) internal malfunction (output signal error) No signals are received from the ECU (engine) within the specified duration.
FUEL INJECTION SYSTEM If malfunction the sensors or actuators, repair or replace it. If not malfunction the sensors and actuators, check and repair the engine inner parts. EAS27400 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on. 1. Check: ● Fault code number EAS27431 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.
FUEL INJECTION SYSTEM bers. 01 70 1 70 01 8. Verify the operation of the sensor or actuator. ● Sensor operation The data representing the operating conditions of the sensor appears on the trip LCD. ● Actuator operation Set the engine stop switch to “ ” to operate the actuator. NOTE: If the engine stop switch is set to “ “OFF”, and then set it to “ ” again. 9. Turn the main switch to “ agnostic mode.
FUEL INJECTION SYSTEM Diagnostic code table Fault code No. Symptom Probable cause of malfunction Diagnostic code No. Open or short circuit in wire harness. Defective crankshaft position sensor. ● Malfunction in pickup rotor. ● Malfunction in ECU (engine). ● Improperly installed sensor. — Open or short circuit in wire sub lead. ● Open or short circuit in wire harness. ● Defective intake air pressure sensor. ● Malfunction in ECU (engine).
FUEL INJECTION SYSTEM Fault code No. Symptom Probable cause of malfunction Diagnostic code No. Open or short circuit in wire harness. Malfunction in ignition coil. ● Malfunction in ECU (engine). ● Malfunction in a component of ignition cut-off circuit system. 30 Stuck the FID valve (when fully open). Malfunction in ECU (engine). 01 ● ● 33 Malfunction detected in the primary wire of the ignition coil. 37 Faulty the FID valve. 41 Lean angle sensor-open or short circuit detected.
FUEL INJECTION SYSTEM Sensor operation table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “DIAGNOSTIC MONITORING MODE”. Diagnos tic monitori ng code No. 01 Item Meter display Checking method Throttle angle ● Fully closed position (15–16) Check with throttle fully closed. ● Fully opened position (97–102) Check with throttle fully open. 03 Pressure difference (atmospheric pressure-intake air pressure) Displays the intake air pressure.
FUEL INJECTION SYSTEM Diagnos tic monitori ng code No. 61 Item Meter display Malfunction history code display — ● No history 00 ● History exists 12-50 (Fault detection code) ● 62 70 Checking method (If code numbers more than one are detected, the display alternates every two seconds to show all the detected code numbers. When all code numbers are shown, the display repeats the same process.
FUEL INJECTION SYSTEM Diagnos tic monitori ng code No. 51 52 57 Item Actuation Checking method Radiator fan motor relay Actuates the radiator fan motor relay for five cycles every five-second. (ON 2 seconds, OFF 3 seconds) Illuminates the engine trouble warning light. Check the operating sound of the Radiator fan motor relay five times. Headlight relay Actuates the headlight relay for five times every five-second. (ON 2 seconds, OFF 3 seconds) Illuminates the engine trouble warning light.
FUEL INJECTION SYSTEM EAS27471 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the meter display according to the reinstatement method. Fault code No.: Code number displayed on the meter when the engine failed to work normally.
FUEL INJECTION SYSTEM Fault code No. 13 Diagnostic code No. Symptom Intake air pressure sensor-open or short circuit detected. 03 Intake air pressure sensor Order Item/components and probable cause Check or maintenance job 1 ● Connected state of connector Intake air pressure sensor coupler ● Main wire harness ECU (engine) coupler ● Reinstatement method Check the coupler for any pins Cranking the engine. that may have pulled out. ● Check the locking condition of the coupler.
FUEL INJECTION SYSTEM Fault code No. 14 Diagnostic code No. Symptom Intake air pressure sensor-pipe system malfunction (clogged or detached hose). 03 Intake air pressure sensor Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Intake air pressure sensor hose ● Check the Intake air pressure sensor hose condition. ● Repair or replace the sensor hose. Starting the engine and operating it at idle.
FUEL INJECTION SYSTEM Fault code No. 15 Diagnostic code No. Symptom Throttle position sensor-open or short circuit detected. 01 Throttle position sensor Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of throttle position sensor. ● Check the installed area for looseness or pinching. ● Check that is installed in the specified position. Turning the main switch ON.
FUEL INJECTION SYSTEM Fault code No. 16 Diagnostic monitoring code No. Symptom Stuck throttle position sensor detected. 01 Throttle position sensor Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of throttle position sensor. ● Check the installed area for looseness or pinching. ● Check that is installed in the specified position. Reinstated by starting the engine, operating it at idle, and then racing it.
FUEL INJECTION SYSTEM Fault code No. 21 Diagnostic code No. Symptom Coolant temperature sensor-open or short circuit detected. 06 Coolant temperature sensor Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of coolant temperature sensor Check the installed area for looseness or pinching. Turning the main switch ON.
FUEL INJECTION SYSTEM Fault code No. 22 Diagnostic code No. Symptom Intake air temperature sensor-open or short circuit detected. 05 Intake air temperature sensor Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of intake air temperature sensor Check the installed area for looseness or pinching. Turning the main switch ON.
FUEL INJECTION SYSTEM Fault code No. 24 Diagnostic code No. Symptom No normal signal is received from the O2 sensor. — Order Item/components and probable cause Check or maintenance job 1 Installed condition of O2 sensor Check the installed area for looseness or pinching. 2 Connected state of connector O2 sensor coupler ● Main wire harness ECU (engine) coupler ● 3 Open or short circuit in wire harness.
FUEL INJECTION SYSTEM Fault code No. 33 Diagnostic code No. Symptom Malfunction detected in the primary wire of the ignition coil. 30 Ignition coil Order Item/components and probable cause Check or maintenance job 1 ● Connected state of connector Ignition coil primary side coupler (Orange) ● Main wire harness ECU (engine) coupler ● Check the coupler for any pins Starting the engine and operthat may have pulled out. ating it at idle. ● Check the locking condition of the coupler.
FUEL INJECTION SYSTEM Fault code No. 41 Diagnostic code No. Symptom Lean angle sensor-open or short circuit detected. 08 Lean angle sensor Order Item/components and probable cause Check or maintenance job 1 ● Connected state of connector Lean angle sensor coupler ● Main wire harness ECU (engine) coupler ● Check the coupler for any pins Reinstated immediately when it that may have pulled out. becomes normal. ● Check the locking condition of the coupler.
FUEL INJECTION SYSTEM Fault code No. 44 Diagnostic code No. Symptom Error is detected while reading or writing on EEPROM (CO adjustment value). 60 EEPROM improper cylinder indication Order Item/components and probable cause Check or maintenance job 1 ● Malfunction in ECU (engine) Reinstatement method Execute the diagnostic monitor- Turning the main switch ON ing mode. (Code No. 60) ● Check the faulty cylinder.
FUEL INJECTION SYSTEM Fault code No. 46 Diagnostic monitoring code No. Symptom Power supply to the FI system relay is not normal. — — Order Item/components and probable cause Check or maintenance job 1 ● Connected state of connector. ● Main wire harness ECU (engine) coupler Check the coupler for any pins Starting the engine and operthat may have pulled out. ating it at idle. ● Check the locking condition of the coupler. ● If there is a malfunction, repair it and connect it securely.
IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-57
IMMOBILIZER SYSTEM 4. Main switch 5. Immobilizer unit 10. Backup fuse (storage box light, immobilizer unit and meter assembly) 13. Ignition fuse 16. Battery 17. Main fuse 30. ECU (engine) 71. Immobilizer system indicator light 72.
IMMOBILIZER SYSTEM EAS27671 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys.
IMMOBILIZER SYSTEM Parts to be replaced Main switch/ immobilizer unit Main Immobilize switch r unit √ √ Immobilizer unit is defective √ √ Code re-registering key and standard keys Code re-registering key and standard keys Code re-registering key and standard keys √ √ Key registration requirement New standard key √ ECU is defective Main switch is defective ECU Accessory lock* and key √ Standard key is lost All keys have been lost (including code re-registering key) Standard key √ Accessory
IMMOBILIZER SYSTEM the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. NOTE: Do not start the engine with a standard key that has not been registered. If the main switch is turned “ON” with a standard key that has not been registered, the immobilizer system indicator light flashes to indicate fault code “52”. (Refer to “SELF-DIAGNOSIS FAULT CODE INDICATION” on page 8-62). 1. Check that the immobilizer system indicator light signals the standby mode. 2.
IMMOBILIZER SYSTEM Standard key code voiding method a. b. c. d. e. f. g. Remaining standard key h. Registration mode Main switch “ON” Main switch “OFF” LED on LED off Less than 5.0 s Code re-registering key A. If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered, the second standard key cannot be registered. EAS27701 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. 1.
IMMOBILIZER SYSTEM Fault code Part Symptom Cause Action 51 IMMOBILIZER UNIT Code cannot be transmitted between the key and immobilizer unit. ● Radio wave interference caused by objects around the keys and antennas. ● Immobilizer unit malfunction. ● Key malfunction. ● Keep magnets, metal objects, and other immobilizer system keys away form the keys and antennas. ● Replace the main switch/immobilizer unit. ● Replace the key.
IMMOBILIZER SYSTEM Fault code 56 Part ECU Symptom Cause Undefinition code is received. Noise interference or disconnected lead/cable. Immobilizer system indicator light fault code indication Digit of 10 : Cycles of “1” sec. ON and 1.5 sec. OFF. Digit of “1” : Cycles of 0.5 sec. ON and 0.5 sec. OFF. Example: fault code 52 8-64 Action Check the wire harness and connector. ● Replace the main switch/immobilizer unit. ● Replace the ECU.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27730 CIRCUIT DIAGRAM 8-65
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 4. Main switch 9. ABS control unit fuse 12. Signaling system fuse 17. Battery 18. ABS motor fuse 19. Main fuse 23. Starting circuit cut-off relay 2 24. Starting circuit cut-off relay 1 28. Start switch 29. Engine stop switch 31. Front brake light switch 32. ECU (engine) 44. ABS test coupler 45. ECU (ABS) 46. Front wheel sensor 47. Rear wheel sensor 48. Fail-safe relay 58. Hydraulic unit 65. Rear brake light switch 69. Tail/brake light 72. Multi-function display 90.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27740 ABS COMPONENTS CHART 8-67
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 1. ABS warning light 2. Fail-safe relay 3. Electronic control unit (ECU) 4. Hydraulic unit 5. Rear disc rotor 6. Rear brake caliper 7. Rear wheel sensor 8. Front brake caliper 9. Front wheel sensor 10.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27750 ABS CONNECTOR LOCATION CHART 1 3 4 2 6 7 5 8-69
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 1. 2. 3. 4. 5. 6. 7.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27760 ECU (ABS) AND FAIL-SAFE RELAY CHART Removing the ECU (ABS) and fail-safe relay 2 1 3 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 4 4 Order Job/Parts to remove Q’ty Front cowling 1 2 3 4 5 Fail-safe relay coupler Fail-safe relay Upper ECU (ABS) bracket ECU (ABS) coupler ECU (ABS) 1 1 1 1 1 8-71 Remarks Refer to “GENERAL CHASSIS” on page 4-1. Disconnect. Disconnect.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27770 [D-1] MAINTENANCE OF THE ECU (ABS) Checking the ECU (ABS) 1. Check: ● Terminals “1” of the ECU (ABS) Cracks/damages → Replace ECU (ABS) ● Terminals “2” of the ECU (ABS) coupler Connection defective, contaminated, come-off → Correct or clean. Solenoid relay resistance 150–450 Ω Tester reading is “∞”. → Replace the fail-safe relay. NOTE: If the ECU (ABS) couplers are clogged with mud or dirt, clean with compressed air.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Connect the positive battery terminal to terminal “6” and the negative battery terminal to terminal “1”, and then check for continuity between terminals “2” and “5” of the ABS motor relay. Positive tester probe → Terminal “2” Negative tester probe → Terminal “5” Tester reading is “∞”. → Replace the fail-safe relay. ● When connecting the battery and the ABS motor relay terminals, be careful not to short-circuit the positive and negative battery terminals.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Positive tester probe Terminal “1” Negative tester probe Terminal “2” There is continuity. No continuity → Replace the hydraulic unit.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27790 ABS TROUBLESHOOTING OUTLINE This section describes the troubleshooting about ABS in details. Read carefully this service manual before repairing various malfunctions, understand and perform the service. Electronic control unit (ECU) has the self diagnostic function. When failures occur in the system, the ABS warning light on the meter assembly indicates a malfunction.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) ● Malfunction history in ECU (ABS) is recorded. Delete it when the service is finished. (This is because the past malfunction contents will be redundantly displayed when the same malfunction occurred again.) EAS27800 BASIC INSTRUCTION FOR TROUBLESHOOTING EWA14030 WARNING ● Execute ● Use the troubleshooting on each malfunction from [A] to [D] in sequence. the sufficiently charged regular batteries only.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING 8-77
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) NOTE: Do not delete the malfunction code during the troubleshooting procedures. Be sure to delete it when the service is finished. EWA14050 WARNING Always execute the “final check” when the components related to ABS are checked and serviced. EAS27830 [A] ABS MALFUNCTION CHECK USING THE ABS WARNING LIGHT Turn the main switch to “ON”. (Do not start the engine.) 1. The ABS warning light does not come on. [B-1] 2. The ABS warning light remains on. [B-2] 3.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) NOTE: When the test coupler adaptor is connected to test coupler, the T/C terminal is grounded. 2. No → [C-3] Arrangement and the function of test couplers ● ECU becomes the malfunction diagnostic mode when the T/C terminal is grounded. ● Malfunction code which the ECU generated in the malfunction diagnostic mode (rise and fall of voltage) is output at the T/F terminal. ● ABS warning light terminal is used when checking the ABS warning light circuit.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) warning light flashes every 0.5 second for more than 6 seconds. → [C-4, C-5] If the ABS warning light flashes every 0.5 second, the malfunction code of a past malfunction has not been stored in the memory of the ECU (ABS). If a malfunction code is displayed on the multifunction display, the ABS warning light flashes. Make sure that the customer understands the possible conditions when the ABS warning light comes on.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 1. 2. 3. 4. 5. 6. 7. ABS warning light terminal (white/red) 8. Test coupler adapter 9. (Light green) 10. (Black) 11. (White/red) ABS test coupler Lock plate Protective cap Grounding T/C terminal T/F terminal As an example, “10 digits/1 digit pattern” of tester reading is shown below.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) C. Time (second) A. This example is the pattern which shows malfunction code 12. B. This example is the pattern which shows malfunction code 21. EAS15B3011 [C] DETERMINING THE CAUSE AND LOCATION OF THE MALFUNCTION EAS15B3012 [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. Visual check ● Check the ABS fuse. Determine the cause of the blown fuse and repair. Replace with a new fuse.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Check the battery voltage. (Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-107.) ● Check if the main fuse or signal fuse is blown. If the main fuse is blown, determine the cause and repair. Replace with a new fuse. (Refer to “CHECKING THE FUSES” on page 8-106.) 2. Check the connections. ● Check that the main fuse coupler is securely connected. ● Check that the main switch coupler is securely connected.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Malfunction code Problem Front wheel sensor signal is not received properly. 11* Rear wheel sensor signal is not received properly.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Malfunction code 34 41 42 51 52 Present malfunction (test always indicates 12 V) Problem Check point Fail-safe relay ● ABS wireharness circuit ● ABS motor circuit Defective operation of the ABS motor is detected. (ABS motor keeps running and will not stop.) ● Front wheel will not recover from the locking tendency even though the signal is continuously transmitted from the ECU (ABS) to release the hydraulic state (when the battery voltage is normal).
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Front wheel sensor lead or internal circuit is broken. → [D-3] ● Wire harness (ABS) sensor circuit is broken. → (Refer to “CIRCUIT DIAGRAM” on page 8-65.) ● ECU (ABS) coupler terminal is disconnected. → [D-1] 2. ABS warning light goes on for 2 seconds then goes off. ● With the front wheel stopped, the rear wheel was rotated for more than 20 seconds. This is not a malfunction. ● Signal is not generated at the front wheel sensor.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Check for flaws on the teeth surfaces of the front or rear wheel sensor rotors. Also, check for any foreign materials. → [D-3, 4] 3. Sensor output has dropped. ● Sensor signal output may drop due to failure of the bearings, wheel axle, rear brake caliper bracket wheel or sensor housing of (front) the front or rear wheel. Check these components when installed for looseness, distortion, and bends.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Check if the hydraulic unit solenoid coupler located in the front cowling is connected properly. 3. Wire harness (ABS system circuit) ● Check the pink/white leads between the ECU (ABS) and the fail-safe relay for continuity. (Refer to “CIRCUIT DIAGRAM”.) ● ECU (ABS) coupler terminal (pink/white) is disconnected. → [D-1] ● Check the red leads between “1” and “2”, and between “1” and “3” of the hydraulic unit solenoid circuits for continuity. ● 4. Front solenoid 5.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) Malfunction code 32 (Circuit malfunction of ECU (ABS) is detected. Upstream side of the solenoid relay.) NOTE: Check following the steps in sequence. 1. Fail-safe relay ● Check if the fail-safe relay operates correctly. → [D-2] 2. Wire harness (ABS system circuit) ● Disconnect the couplers from the fail-safe relay and the ECU (ABS), and then check the insulation of the fail-safe relay coupler between the red and red terminals.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) (ABS) coupler and the red/white terminal of the ABS motor coupler. → [D-1] ● Remove the fail-safe relay and check for continuity between the red/white terminal of the ABS motor coupler of the wire harness (ABS) and the positive battery terminal. 3. Fail-safe relay ● Check if the fail-safe relay operates correctly.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 5. Hydraulic unit solenoid coupler terminal ● Check if the front and rear hydraulic unit solenoid coupler terminals (hydraulic unit and wire harness [ABS]) are reversed. Terminal color Solenoid side Wire harness side (ABS) Front Red, Green Red, White Rear Red, White Red, Green 6. Hydraulic unit If the malfunction is not corrected after performing steps 1 to 5, replace the hydraulic unit. Be sure to connect the brake hoses and couplers correctly and securely.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 1 2 5. Hydraulic unit solenoid coupler terminal ● Check if the front and rear hydraulic unit solenoid coupler terminals (hydraulic unit and wire harness [ABS]) are reversed. Terminal color Solenoid side Wire harness side (ABS) Front Red, green Red, white Rear Red, white Red, green 6. Hydraulic unit If the malfunction is not corrected after performing steps 1 to 5, replace the hydraulic unit.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 4. Brake hose lines Refer to “Malfunction code 42”. 5. Hydraulic unit solenoid coupler terminals Refer to “Malfunction code 42”. 6. Hydraulic unit Refer to “Malfunction code 42”. 7. Battery voltage Measure the battery voltage. EAS15B3036 [D-6-4] DELETING THE MALFUNCTION CODE 1. Connect the test coupler adapter “1” to the test coupler “2”. Refer to “[B-5] MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PRESENT MALFUNCTION)” 2 1 2. Turn the main switch on.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) a. b. c. d. e. f. g. h. ABS warning light ON Main switch on Main switch off Flashing 2 seconds 3 seconds 0.5 seconds 7. Turn the main switch off. 8. Disconnect the test coupler adaptor from the test coupler and install the protective cap onto the test coupler. NOTE: Do not forget to install the protective cap onto the test coupler.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 6. Check: ● ECU (ABS)-to-start-switch-lead continuity Connect the pocket tester (Ω × 1) to the ECU (ABS) coupler and start switch coupler. Tester positive probe → Green/White “1” (ECU (ABS)) Tester negative probe → Green/White “2” (start switch) No continuity → Replace or repair the wire harness. 7. Check: ● ECU (ABS) voltage Connect the pocket tester (DC 20 V) to the ECU (ABS) coupler.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) 8-96
ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 22 21 1 2 3 20 4 5 19 6 7 18 17 16 8 9 10 15 14 12 13 8-97 11
ELECTRICAL COMPONENTS 1. Front brake light switch 2. Rear brake light switch 3. Turn signal/hazard relay 4. Starting circuit cut-off relay 1 5. Starting circuit cut-off relay 2 (XP500A) 6. Battery 7. Fuse box 8. Main fuse 9. Starter relay 10. Rectifier/regulator 11. Sidestand switch 12. Crankshaft position sensor 13. Stator coil 14. Radiator fan 15. Speed sensor (XP500) 16. Throttle position sensor 17. Ignition coil 18. Horn 19. Lean angle sensor 20. Fuel injection system relay 21. Headlight relay 22.
ELECTRICAL COMPONENTS 3 2 5 4 1 6 13 7 12 9 8 10 11 8-99
ELECTRICAL COMPONENTS 1. ECU (ABS) (XP500A) 2. Fail-safe relay (XP500A) 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) 9. O2 sensor 10. Hydraulic unit (XP500A) 11. Front wheel sensor (XP500A) 12. Intake air temperature sensor 13.
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 9 8 2 1 Y L/B G R/Y Y – PASS Br/R R Br/L 3 L/W B R Br/L Br/R ON OFF P – 10 R/W R/B Ch Br/W Dg 11 NR N NL 4 Ch Br/W DgL/Y Br/L B/Y 5 L/Y 12 P B – Br Br/W P B L/B R/Y Y G L/Y Dg Ch B/Y G/Y Dg Br/W Ch Br/L L/Y (BLACK) (BLUE) 6 B B (BLUE) 7 13 R L/G 8-101 G/Y R/B R/W L/W B Br (BROWN)
ELECTRICAL COMPONENTS 1. Pass switch 2. Dimmer switch 3. Turn signal switch 4. Horn switch 5. Rear brake light switch 6. Sidestand switch 7. Storage box light switch 8. Main switch 9. Start switch 10. Engine stop switch 11. Hazard switch 12. Front brake light switch 13.
ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
ELECTRICAL COMPONENTS 8-104
ELECTRICAL COMPONENTS EAS27990 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly connect. No continuity → Repair or replace the bulb, bulb socket or both. Types of bulbs The bulbs used on this vehicle are shown in the illustration on the left.
ELECTRICAL COMPONENTS 2. Check: ● Fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. 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 Analog pocket tester YU-03112-C b. If the pocket tester indicates “∞”, replace the fuse.
ELECTRICAL COMPONENTS Fuses Amperage rating Q’ty Main 30A 1 Headlight 15A 1 Signal 20A (XP500) 15A (XP500A) 1 Ignition 10A 1 Radiator fan motor 15A 1 Hazard 10A 1 Fuel injection 10A 1 Backup 10A 1 ABS motor (XP500A) 30A 1 ABS control unit (XP500A) 5A 1 Backup fuse (storage box light, immobilizer unit, and meter assembly) 10A 1 Reserve 30A 1 Reserve 20A (XP500) 1 Reserve 15A 1 Reserve 10A 1 Reserve 5A (XP500A) 1 and contain electrolyte which is made of pois
ELECTRICAL COMPONENTS 2. Disconnect: ● Battery leads (from the battery terminals) 5. Charge: ● Battery (refer to the appropriate charging method illustration) ECA13640 CAUTION: EWA13300 First, disconnect the negative battery lead “1”, and then positive battery lead “2”. WARNING Do not quick charge a battery. ECA13670 2 CAUTION: 1 ● Never remove the MF battery sealing caps.
ELECTRICAL COMPONENTS the machine is stopped. b. Connect a charged and AMP meter to the battery and start charging. NOTE: c. Make sure that the current is higher than the standard charging current written on the battery. NOTE: Set the charging voltage at 16–17 V.If the setting is lower, charging will be insufficient. If too high, the battery will be over-charged. If the current is lower than the standard charging current written on the battery, This type of battery charger cannot charge the MF battery.
ELECTRICAL COMPONENTS Refer to “GENERAL CHASSIS” on page 4-1. Result Continuity → OK No continuity → Replace. EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, replace the relay. Starting circuit cut-off relay 2 (XP500A) Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1. Disconnect the relay from the wire harness. 2. Connect the pocket tester (Ω× 1) and battery (12 V) to the relay terminal as shown.
ELECTRICAL COMPONENTS Headlight relay 1. 2. 3. 4. b. Turn the main switch to “ON”. c. Measure the turn signal/hazard relay input voltage. Positive battery terminal Negative battery terminal Tester positive probe Negative tester probe ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: ● Turn signal/hazard relay output voltage Out of specification → Replace. Result Continuity → OK No continuity → Replace. Turn signal/hazard relay output voltage DC 12 V EAS15B1010 CHECKING THE TURN SIGNAL/HAZARD RELAY 1.
ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28050 CHECKING THE DIODE 1. Check: ● Starting circuit cut-off relay 1 diode Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Continuity Positive tester Black “1” Negative tester green “2” No continuity Positive tester Black “2” Negative tester green “1” NOTE: When you switch the positive and negative tester probes, the readings in the above chart will be reversed.
ELECTRICAL COMPONENTS EAS28080 CHECKING THE IGNITION COIL 1. Check: ● Primary coil resistance Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Primary coil resistance 1.87–2.53 Ω ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the ignition coil connectors from the ignition coil terminals. b. Connect the pocket tester (Ω × 1) to the ignition coil as shown.
ELECTRICAL COMPONENTS 1. Spark plug gap e. Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs. b. Measure the crankshaft position sensor resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28130 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1. Disconnect: ● Crankshaft position sensor coupler (from the wire harness) 2. Check: ● Crankshaft position sensor resistance Out of specification → Replace the crankshaft position sensor.
ELECTRICAL COMPONENTS c. When turn the lean angle sensor to 45°. d. Measure the lean angle sensor out put voltage. b. Check the starter motor operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28150 CHECKING THE STATOR COIL 1. Disconnect: ● Stator coil coupler (from the wire harness) 2. Check: ● Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.22–0.26 kΩ at 20 °C (68 °F) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS15B1011 CHECKING THE STARTER MOTOR OPERATION 1.
ELECTRICAL COMPONENTS b. Measure the stator coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28170 CHECKING THE CHARGING VOLTAGE 1. Check: ● Charging voltage Out of specification → Correct the stator coil condition. Refer to “CHECKING THE STATOR COIL” on page 8-115. c. Start the engine and let it run at approximately 5000 r/min. d. Measure the charging voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28180 CHECKING THE HORN 1.
ELECTRICAL COMPONENTS Positive tester probe Green “1” Negative tester probe Black “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: ● Operation of the horn The horn fails to sound → check the step (3). ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the horn coupler at the horn. b. Connect a jumper lead “1” to the brown terminal in the horn coupler and the horn terminal. 2 B B G R/L 1 1 A 1 c. Turn the main switch to “ON”. d. Check that the horn does sound. B ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28230 CHECKING THE FUEL SENDER 1.
ELECTRICAL COMPONENTS Tester positive probe White “1” Negative tester probe Black/Blue “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28260 CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: ● Coolant temperature sensor Refer to “THERMOSTAT” on page 6-5. EWA14130 WARNING ● Handle the coolant temperature sensor with special care. ● Never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor is dropped, replace it. b. Turn the main switch to “ON”. c.
ELECTRICAL COMPONENTS Tester positive probe Blue “1” Negative tester probe Black/Blue “2” 2 b. Immerse the coolant temperature sensor in a container filled with coolant “2”. NOTE: Make sure the coolant temperature sensor terminals do not get wet. c. Place a thermometer “3” in the coolant. d. Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table. e. Check the coolant temperature sensor for continuity at the temperatures indicated in the table. 3 1 d.
ELECTRICAL COMPONENTS abruptly → Replace the throttle position sensor. The slot is worn or broken → Replace the throttle position sensor. 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 resistance (0.52–0.9)–(4.0–6.0) kΩ at 20 °C (68 °F) (Yellow–Black/Blue ) b. Turn the main switch to “ON”. c. Measure the intake air pressure sensor output voltage.
ELECTRICAL COMPONENTS Tester positive probe Pink/White “1” Negative tester probe Black/Blue “2” 1 2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Set the main switch to “ON”. c. Measure the intake air temperature sensor voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: ● Intake air temperature sensor 2. Check: ● V-belt reset coupler voltage Out of specification → Replace. V-belt reset coupler voltage 12V ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (20V DC) to the meter assembly coupler (wire harness side) as shown.
TROUBLESHOOTING TROUBLESHOOTING................................................................................... 9-1 GENERAL INFORMATION ..................................................................... 9-1 STARTING FAILURE/HARD STARTING................................................ 9-1 INCORRECT ENGINE IDLING SPEED .................................................. 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......................... 9-2 FAULTY CLUTCH ................................................
TROUBLESHOOTING Faulty battery 2. Fuse(s) ● Blown, damaged or incorrect fuse ● Improperly installed fuse 3. Spark plug(s) ● Incorrect spark plug gap ● Incorrect spark plug heat range ● Fouled spark plug ● Worn or damaged electrode ● Worn or damaged insulator ● Faulty spark plug cap 4. Ignition coil(s) ● Cracked or broken ignition coil body ● Broken or shorted primary or secondary coils ● Faulty spark plug lead 5. Ignition system ● Faulty ECU (engine) ● Faulty crankshaft position sensor 6.
TROUBLESHOOTING 2. Spark plug(s) ● Incorrect spark plug gap ● Incorrect spark plug heat range ● Fouled spark plug ● Worn or damaged electrode ● Worn or damaged insulator ● Faulty spark plug cap 3. Ignition coil(s) ● Faulty spark plug lead 4. Ignition system ● Faulty ECU (engine) ● Faulty crankshaft position sensor Bent, damaged or worn clutch shoe Poor speed performance 1. V-belt ● Oil or grease on the V-belt 2. Primary pulley weight(s) ● Faulty operation ● Worn primary pulley weight 3.
TROUBLESHOOTING Incorrect spark plug gap ● Incorrect spark plug heat range 2. Ignition system ● Faulty ECU (engine) 3. Front fork leg(s) ● Uneven oil levels (both front fork legs) ● Unevenly tensioned fork spring (both front fork legs) ● Broken fork spring ● Bent or damaged inner tube ● Bent or damaged outer tube 4. Swingarm ● Worn bearing or bushing ● Bent or damaged swingarm 5. Rear shock absorber assembly(-ies) ● Faulty rear shock absorber spring ● Leaking oil or gas 6.
TROUBLESHOOTING ● Incorrectly adjusted rear brake light switch ● Tail/brake light bulb life expired Turn signal does not come on ● Faulty turn signal switch ● Faulty turn signal relay ● Burnt-out turn signal bulb ● Incorrect connection ● Damaged or faulty wire harness ● Improperly grounded circuit ● Faulty battery ● Blown, damaged or incorrect fuse Turn signal blinks slowly ● Faulty turn signal relay ● Faulty main switch ● Faulty turn signal switch ● Incorrect turn signal bulb Turn signal remains lit ● Fau
EAS28740 WIRING DIAGRAM 2007 XP500 WIRING DIAGRAM 1.Crankshaft position sensor 2.A.C. magneto 3.Rectifier/regulator 4.Main switch 5.Immobilizer unit 6.Storage box light switch 7.Storage box light 8.Fuse box 9.Fuel injection system fuse 10.Backup fuse (storage box light, immobilizer unit and meter assembly) 11.Signaling system fuse 12.Headlight fuse 13.Ignition fuse 14.Radiator fan motor fuse 15.Lighting system fuse 16.Battery 17.Main fuse 18.Starter relay 19.Starter motor 20.Diode 21.
2007 XP500A WIRING DIAGRAM 1.Crankshaft position sensor 2.A.C. magneto 3.Rectifier/regulator 4.Main switch 5.Immobilizer unit 6.Storage box light switch 7.Storage box light 8.Fuse box 9.ABS control unit fuse 10.Fuel injection system fuse 11.Backup fuse (storage box light, immobilizer unit and meter assembly) 12.Signaling system fuse 13.Headlight fuse 14.Ignition fuse 15.Radiator fan motor fuse 16.Lighting system fuse 17.Battery 18.ABS motor fuse 19.Main fuse 20.Starter relay 21.Starter motor 22.Diode 23.
EAS28750 COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray L Blue O Orange P Pink R Red Sb Sky blue W White Y Yellow B/G Black/Green B/L Black/Blue B/R Black/Red B/W Black/White B/Y Black/Yellow Br/G Brown/Green Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White G/B Green/Black G/R Green/Red G/W Green/White G/Y Green/Yellow Gy/G Gray/Green Gy/R Gray/Red L/B Blue/Black L/R Blue/Red L/W Blue/White L/Y Blue/Yellow O/B Orange/Bl
YAMAHA MOTOR CO., LTD.
XP500 2007 WIRING DIAGRAM XP500 2007 SCHÉMA DE CÂBLAGE XP500 2007 SCHALTPLAN SCHEMA ELETTRICO XP500 2007 DIAGRAMA ELÉCTRICO DE LA XP500 2007
XP500A 2007 WIRING DIAGRAM XP500A 2007 SCHÉMA DE CÂBLAGE XP500A 2007 SCHALTPLAN SCHEMA ELETTRICO XP500A 2007 DIAGRAMA ELÉCTRICO DE LA XP500A 2007
XP500 2007 WIRING DIAGRAM XP500 2007 SCHÉMA DE CÂBLAGE XP500 2007 SCHALTPLAN SCHEMA ELETTRICO XP500 2007 DIAGRAMA ELÉCTRICO DE LA XP500 2007
XP500A 2007 WIRING DIAGRAM XP500A 2007 SCHÉMA DE CÂBLAGE XP500A 2007 SCHALTPLAN SCHEMA ELETTRICO XP500A 2007 DIAGRAMA ELÉCTRICO DE LA XP500A 2007
