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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 ................................................ 3-3
SYNCHRONIZING THE THROTTLE BODIES........................................ 3-5
ADJUSTING THE EXHAUST GAS VOLUME ......................................... 3-7
ADJUSTING THE ENGINE IDLING SPEED ........................................... 3-8
ADJUSTING THE THROTTLE CABLE FREE PLAY .............................. 3-8
CHECKING THE SPARK PLUGS ........................................................... 3-9
CHECKING THE IGNITION TIMING....................................................... 3-10
MEASURING THE COMPRESSION PRESSURE.................................. 3-11
CHECKING THE ENGINE OIL LEVEL.................................................... 3-12
CHANGING THE ENGINE OIL ............................................................... 3-13
MEASURING THE ENGINE OIL PRESSURE ........................................ 3-14
CLEANING THE AIR FILTER ELEMENT................................................ 3-15
CLEANING THE V-BELT CASE AIR FILTER ELEMENT ....................... 3-16
CHECKING THE THROTTLE BODY JOINTS AND INTAKE
MANIFOLDS.......................................................................................... 3-16
CHECKING THE FUEL HOSES AND FUEL TANK BREATHER
HOSE .................................................................................................... 3-17
CHECKING THE CYLINDER HEAD BREATHER HOSE ....................... 3-17
CHECKING THE EXHAUST SYSTEM.................................................... 3-17
CHECKING THE COOLANT LEVEL....................................................... 3-18
CHECKING THE COOLING SYSTEM .................................................... 3-18
CHANGING THE COOLANT................................................................... 3-19
CHASSIS ....................................................................................................... 3-22
CHECKING THE BRAKE FLUID LEVEL................................................. 3-22
CHECKING THE FRONT BRAKE PADS ................................................ 3-22
CHECKING THE REAR BRAKE PADS .................................................. 3-22
CHECKING THE FRONT BRAKE HOSES ............................................. 3-23
CHECKING THE REAR BRAKE HOSE .................................................. 3-23
ADJUSTING THE REAR BRAKE LOCK LEVER CABLE ....................... 3-23
BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500) ..................... 3-24
CHECKING THE CHAIN DRIVE OIL LEVEL .......................................... 3-26
CHANGING THE CHAIN DRIVE OIL ...................................................... 3-26
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-27
CHECKING THE FRONT FORK ............................................................. 3-29
CHECKING THE TIRES.......................................................................... 3-29
CHECKING THE WHEELS ..................................................................... 3-31
CHECKING AND LUBRICATING THE CABLES .................................... 3-31
LUBRICATING THE LEVERS ................................................................. 3-31
LUBRICATING THE SIDESTAND........................................................... 3-31
LUBRICATING THE CENTERSTAND .................................................... 3-31
ELECTRICAL SYSTEM................................................................................. 3-32
CHECKING AND CHARGING THE BATTERY....................................... 3-32
CHECKING THE FUSES ........................................................................ 3-32
Summary of Contents for 2007 XP500
Page 1: ...SERVICE MANUAL XP500 15B 28197 E0 2007 XP500A ...
Page 2: ......
Page 8: ......
Page 36: ...SPECIAL TOOLS 1 27 ...
Page 55: ...TIGHTENING TORQUES 2 18 Crankcase tightening sequence Cylinder head tightening sequence ...
Page 61: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ...
Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20410 LUBRICATION DIAGRAMS ...
Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ...
Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Oil strainer 2 Crankshaft ...
Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ...
Page 70: ...COOLING SYSTEM DIAGRAMS 2 33 EAS20420 COOLING SYSTEM DIAGRAMS ...
Page 72: ...CABLE ROUTING 2 35 EAS20430 CABLE ROUTING ...
Page 74: ...CABLE ROUTING 2 37 ...
Page 76: ...CABLE ROUTING 2 39 ...
Page 78: ...CABLE ROUTING 2 41 ...
Page 80: ...CABLE ROUTING 2 43 ...
Page 82: ...CABLE ROUTING 2 45 ...
Page 84: ...CABLE ROUTING 2 47 XP500 ...
Page 86: ...CABLE ROUTING 2 49 ...
Page 88: ...CABLE ROUTING 2 51 ...
Page 90: ...CABLE ROUTING 2 53 ...
Page 92: ...CABLE ROUTING 2 55 ...
Page 94: ...CABLE ROUTING 2 57 ...
Page 96: ...CABLE ROUTING 2 59 ...
Page 98: ...CABLE ROUTING 2 61 ...
Page 100: ...CABLE ROUTING 2 63 ...
Page 102: ...CABLE ROUTING 2 65 ...
Page 104: ...REPLACING THE HEADLIGHT BULBS 3 32 ADJUSTING THE HEADLIGHT BEAMS 3 32 ...
Page 138: ...ELECTRICAL SYSTEM 3 34 ...
Page 213: ...INSTALLING THE CHAIN DRIVE 5 75 ...
Page 262: ...CLUTCH 5 49 ...
Page 282: ...CRANKCASE AND CRANKSHAFT 5 69 ...
Page 290: ...CHAIN DRIVE TRANSMISSION 5 77 ...
Page 312: ...THROTTLE BODIES 7 9 ...
Page 316: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...
Page 320: ...ELECTRIC STARTING SYSTEM 8 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM XP500 ...
Page 322: ...ELECTRIC STARTING SYSTEM 8 7 XP500A ...
Page 326: ...ELECTRIC STARTING SYSTEM 8 11 ...
Page 330: ...CHARGING SYSTEM 8 15 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...
Page 331: ...CHARGING SYSTEM 8 16 2 AC magneto 3 Rectifier regulator 16 Battery 17 Main fuse ...
Page 333: ...CHARGING SYSTEM 8 18 ...
Page 334: ...LIGHTING SYSTEM 8 19 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...
Page 337: ...LIGHTING SYSTEM 8 22 ...
Page 338: ...SIGNALING SYSTEM 8 23 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...
Page 343: ...SIGNALING SYSTEM 8 28 ...
Page 344: ...COOLING SYSTEM 8 29 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...
Page 347: ...COOLING SYSTEM 8 32 ...
Page 348: ...FUEL INJECTION SYSTEM 8 33 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...
Page 372: ...IMMOBILIZER SYSTEM 8 57 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...
Page 382: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 67 EAS27740 ABS COMPONENTS CHART ...
Page 384: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 69 EAS27750 ABS CONNECTOR LOCATION CHART 2 1 6 5 3 4 7 ...
Page 392: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 77 EAS27810 BASIC PROCESS FOR TROUBLESHOOTING ...
Page 411: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 96 ...
Page 414: ...ELECTRICAL COMPONENTS 8 99 1 2 3 4 5 6 7 8 9 10 11 12 13 ...
Page 419: ...ELECTRICAL COMPONENTS 8 104 ...
Page 445: ......
Page 446: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...