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Yamaha 2007 XP500, Service Manual

The Yamaha 2007 XP500 Service Manual is essential for all owners seeking assistance with maintenance and repair of their vehicle. Download this manual for free at our website, ensuring you have access to the detailed instructions and guidance needed to keep your Yamaha XP500 in optimal condition.

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FRONT BRAKE

4-32

2. Check:

●

Brake master cylinder kit 

“

1

”

Damage/scratches/wear 

→

 Replace.

3. Check:

●

Brake master cylinder reservoir cap 

“

1

”

Cracks/damage 

→

 Replace.

●

Brake master cylinder reservoir diaphragm
holder 

“

2

”

●

Brake master cylinder reservoir diaphragm

“

3

”

Damage/wear 

→

 Replace.

4. Check:

●

Brake hoses
Cracks/damage/wear 

→

 Replace.

EAS22520

ASSEMBLING THE FRONT BRAKE MASTER 
CYLINDER

WARNING

EWA13520 

●

Before installation, all internal brake com-
ponents should be cleaned and lubricated

with clean or new brake fluid.

●

Never use solvents on internal brake com-
ponents.

1. Install:

●

Master cylinder kit 

“

1

”

●

Circlip 

“

2

”

 

●

Dust boot 

“

3

”

EAS22530

INSTALLING THE FRONT BRAKE MASTER 
CYLINDER

1. Install:

●

Brake master cylinder 

“

1

”

●

Brake master cylinder holder 

“

2

”

NOTE:

●

Install the brake master cylinder holder with the

“

UP

”

 mark facing up.

●

Align the end of the brake master cylinder hold-
er with the punch mark 

“

a

”

 on the handlebar.

●

First, tighten the upper bolt, then the lower bolt.

2. Install:

●

Copper washers 

“

1

”

 

●

Brake hose 

“

2

”

●

Union bolt 

“

3

”

Recommended fluid

DOT 4

Brake master cylinder holder bolt

10 Nm (1.0 m

•

kg, 7.2 ft

•

lb)

New

T

R

.

.

1

b

a

2

New

Summary of Contents for 2007 XP500

Page 1: ...SERVICE MANUAL XP500 15B 28197 E0 2007 XP500A ...

Page 2: ......

Page 3: ...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 ...

Page 4: ...ended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable ...

Page 5: ...Sub section titles appear in smaller print than the section title 2 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 3 Numbers are given in the order of the jobs in the exploded diagram A number indicates a disassem bly step 4 Symbols indicate parts to be lubricated or replaced 5 Refer to SYMBOLS A job instruction c...

Page 6: ... 14 15 16 LT New T R 1 2 3 4 5 6 7 8 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 Lithium soap based grease 14 Molybdenum disulfide grease 15 Apply locking agent LOCTITE 16 Replace the part ...

Page 7: ...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 EAS20110 TABLE OF CONTENTS ...

Page 8: ......

Page 9: ...I SYSTEM 1 3 OUTLINE OF ANTI LOCK BRAKE SYSTEM XP500A 1 4 MULTI FUNCTION DISPLAY 1 15 IMPORTANT INFORMATION 1 18 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 18 REPLACEMENT PARTS 1 18 GASKETS OIL SEALS AND O RINGS 1 18 LOCK WASHERS PLATES AND COTTER PINS 1 18 BEARINGS AND OIL SEALS 1 18 CIRCLIPS 1 19 CHECKING THE CONNECTIONS 1 20 SPECIAL TOOLS 1 21 ...

Page 10: ...ON EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts 1 1 ...

Page 11: ...ments for engines to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of a conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at al...

Page 12: ...injection duration the lesser the volume of fuel that is supplied The injection duration and the injection timing are controlled by the ECU engine Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air tem perature sensor coolant temperature sensor and O2 sensor enable the ECU engine to determine the injection duration The injectio...

Page 13: ...ront wheel brake and a left hand brake lever for operating the rear wheel brake When wheel lockup is detected during emergency braking hydraulic control is performed by the hy draulic system independently The ABS also includes a highly developed self diagnostic function The ABS detects any problem con ditions and allows normal braking even if the ABS is not operating properly When this occurs the ...

Page 14: ...icle continues to travel Side force The force on the tires which supports the vehicle when cornering Slip ratio When the brakes are applied slipping occurs between the tires and the road surface This causes a difference between the wheel speed and the chassis speed Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula 1 Rear brake master cylinder 2 H...

Page 15: ...re capabilities even on slippery road surfaces or less slippery road surfaces See figure B EAS15B1007 Wheel slip and hydraulic control The ECU ABS calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors In addition the ECU ABS calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed values The dif...

Page 16: ...raction there is available for braking This is true whether the vehicle is equipped with an ABS or not Therefore sudden braking while cornering is not recommended Excessive cornering force which an ABS cannot prevent could cause the tire to slip sideways WARNING EWA15B1003 The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straight ahead During ...

Page 17: ... are installed in the sensor housing for each wheel Sensor rotors 2 are installed inside the front and rear wheel hubs and rotate with the wheels Each sensor rotor has 40 serrations that face the sensor housing As the distance changes between the top and bottom of the serrations with the rotation of the wheels inductive electromotive force is generated in the wheel sensors Wheel rotation speed is ...

Page 18: ... 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 When a failure is detected in the ABS a malfunction code is stored in the memory of the ECU ABS for easy problem identification and troubleshooting NOTE Some types of failures are not recorded in the memory of the...

Page 19: ...he hydraulic unit and is located upper the ECU ABS 1 Software operation flow 2 Set the main switch to ON 3 Initialize 4 Self diagnosis when static 5 Self diagnosis when riding 6 Receive signals 7 Control operation 8 Depressurize pressurize A 8 1 000 of a second 1 1 Fail safe relay ...

Page 20: ...c pressure of the brake fluid and normal braking is resumed The fail safe relay is also activated by signals transmitted from the ECU ABS and operates simulta neously when the ABS starts to reduce the hydraulic pressure of the brake fluid If the solenoid relay is turned off the motor relay is also deactivated and the motor stops operating if there is a malfunction 1 Solenoid relay 2 Fail safe rela...

Page 21: ...ncreases and the brake fluid is sent to the brake caliper via port A and port B At this time the inlet and outlet check valves of the pump close the lines and brake fluid is not sent As a result the brake master cylinder directly pressurizes the brake caliper during normal braking When the brake lever is released the brake fluid in the brake caliper returns to the brake master cyl inder via port A...

Page 22: ...10 and the brake fluid is sent to the brake caliper via port C 13 and port D 11 and the buffer chamber As a result the hydraulic pressure in the brake caliper is re duced The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the fluid pressure pump linked to the pump motor 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Pump 5 Buffer chamber 6 Flow ...

Page 23: ...d port C 13 At this time the brake is pressurized at a constant speed regardless of the brake fluid pressure level since restriction of port A 7 changes so that a constant pressure difference is maintained between chamber A 20 and chamber B 21 of the flow control valve 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Pump 5 Buffer chamber 6 Flow control valve 7 Port A 8 Spool 9 Port B 10...

Page 24: ... bars 1 appear where the odometer and tripmeters are normally displayed the multi function display is malfunctioning Re place the entire multi function display Odometer and tripmeter modes Pushing the SELECT button switches the dis play between the odometer mode ODO and the tripmeter modes TRIP in the following or der ODO TRIP top TRIP bottom ODO When approximately 2 8 L 0 74 US gal 0 62 Imp gal o...

Page 25: ...ne cool CAUTION ECA10020 Do not operate the engine if it is overheated Oil change indicator OIL This indicator flashes at the initial 1000 km 600 mi then at 5000 km 3000 mi and every 5000 km 3000 mi thereafter to indicate that the en gine oil should be changed After changing the engine oil reset the oil change indicator Refer to CHANGING THE ENGINE OIL on page 3 13 If the engine oil is changed bef...

Page 26: ...rical circuits If any of those circuits are defective the multi function display will indicate a two digit er ror code If the multi function display indicates such an er ror code note the code number and then check the vehicle Refer to FUEL INJECTION SYS TEM on page 8 33 IMMOBILIZER SYSTEM on page 8 57 ABS ANTI LOCK BRAKE SYS TEM XP500A on page 8 65 CAUTION ECA11790 If the multi function display i...

Page 27: ... Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket surfac es oil seal lips and O rings must be cleaned 2 During reassembly properly oil all mating parts...

Page 28: ...ge the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways 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 Shaft ...

Page 29: ...al times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity with the pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at...

Page 30: ...rovided below to avoid any mistakes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 5 45 5 48 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 66 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 ...

Page 31: ...M 01348 5 55 5 57 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 32 Frok seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 62 Fork seal driver attachment ø41 90890 01381 Replacement 41 mm YM A5142 2 4 62 Steering nut wrench 90890 01403 Spanner wrench YU 33975 3 27 Tool name Tool No Illustration Reference pages YM A9409 7 YM A5142 4 ...

Page 32: ...482 5 45 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 32 5 33 Thickness gauge 90890 03079 Narrow gauge set YM 34483 3 3 Compression gauge 90890 03081 Engine compression tester YU 33223 3 11 Extension 90890 04082 3 11 Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 3 6 Tool name Tool No Illustration Reference pages 66 8 ...

Page 33: ... light 90890 03141 Inductive clamp timing light YU 03141 3 10 Test coupler adapter 90890 03149 4 50 4 51 Pressure gauge 90890 03153 3 15 7 7 Oil pressure adapter B 90890 03124 3 15 Carburetor angle driver 90890 03158 3 6 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 37 Fuel pressure adapter 90890 03181 7 7 Tool name Tool No Illustration Reference pages ...

Page 34: ...Bearing driver 40 mm YM 04058 6 10 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A 6 10 Universal clutch holder 90890 04086 YM 91042 5 45 5 48 Valve lapper 90890 04101 Valve lapping tool YM A8998 3 4 Valve guide remover ø4 90890 04111 Valve guide remover 4 0 mm YM 04111 5 19 Valve guide installer ø4 90890 04112 Valve guide installer 4 0 mm YM 04112 5 19 Tool name Tool No...

Page 35: ... 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 1215 90890 85505 5 34 5 68 Tool name Tool No Illustration Reference pages ...

Page 36: ...SPECIAL TOOLS 1 27 ...

Page 37: ...HTENING TORQUES 2 15 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 19 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 CHASSIS 2 22 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 33 CABLE ROUTING 2 35 ...

Page 38: ...rall length 2235 mm 88 0 in Overall width 775 mm 30 5 in Overall height 1410 mm 55 5 in Seat height 795 mm 31 3 in Wheelbase 1575 mm 62 0 in Ground clearance 130 mm 5 12 in Minimum turning radius 2800 mm 110 2 in Weight With oil and fuel XP500 227 0 kg 500 lb XP500A 232 0 kg 511 lb XP500W 225 0 kg 496 lb Maximum load XP500 188 kg 414 lb XP500A 183 kg 403 lb XP500W 190 kg 419 lb ...

Page 39: ...t With oil filter cartridge replacement 2 90 L 3 07 US qt 2 55 Imp qt Oil pressure hot 150 0 kPa 1200 r min 21 8 psi 1200 r min 1 50 kgf cm2 1200 r min Chain drive oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 70 L 0 74 US qt 0 62 Imp qt Oil filter type Paper Oil pump Oil pump type Trochoid 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 ...

Page 40: ...m 0 028 0 031 in Cylinder head Volume 14 97 15 57 cm3 0 91 0 95 cu in Warpage limit 0 03 mm 0 0012 in Camshaft Drive system Chain drive left Camshaft cap inside diameter 23 000 23 021 mm 0 9055 0 9063 in Camshaft journal diameter 22 967 22 980 mm 0 9042 0 9047 in Camshaft journal to camshaft cap clearance 0 020 0 054 mm 0 0008 0 0021 in Camshaft lobe dimensions Intake A 33 252 33 352 mm 1 3091 1 3...

Page 41: ...h B exhaust 1 140 1 980 mm 0 0449 0 0780 in Valve seat width C intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve seat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve margin thickness D intake 0 60 0 80 mm 0 0236 0 0315 in Valve margin thickness D exhaust 0 60 0 80 mm 0 0236 0 0315 in Valve stem diameter intake 3 975 3 990 mm 0 1565 0 1571 in Limit 3 945 mm 0 ...

Page 42: ...9 mm 1 40 in Limit 33 81 mm 1 33 in Installed length intake 30 39 mm 1 20 in Installed length exhaust 30 39 mm 1 20 in Spring rate K1 intake 18 84 N mm 107 60 lb in 1 92 kgf mm Spring rate K2 intake 24 52 N mm 140 01 lb in 2 50 kgf mm Spring rate K1 exhaust 18 84 N mm 107 60 lb in 1 92 kgf mm Spring rate K2 exhaust 24 52 N mm 140 01 lb in 2 50 kgf mm Spring tilt intake 2 5 1 6 mm Spring tilt exhau...

Page 43: ... 15 043 mm 0 5922 in Piston pin outside diameter 14 991 15 000 mm 0 5902 0 5906 in Limit 14 971 mm 0 5894 in Piston ring Top ring Ring type Barrel Dimensions B T 0 80 2 45 mm 0 03 0 10 in End gap installed 0 15 0 25 mm 0 0059 0 0098 in Limit 0 50 mm 0 0197 in Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Limit 0 100 mm 0 0039 in 2nd ring Ring type Plain Dimensions B T 0 80 2 50 mm 0 03 0 10 ...

Page 44: ...auge 0 040 0 082 mm 0 0016 0 0032 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green Balancer drive method Piston Clutch Clutch type Wet multiple disc automatic Clutch release method Automatic Friction plate thickness 2 75 3 05 mm 0 108 0 120 in Wear limit 2 65 mm 0 1043 in Plate quantity 5 pcs Clutch plate thickness 1 30 1 50 mm 0 051 0 059 in Plate quantity 4 pcs Warpage limit 0 10 mm 0 0039 i...

Page 45: ... Air filter element Dry element Fuel pump Pump type Electrical Model manufacturer 5VU AISAN Maximum consumption amperage 1 9 A Output pressure 246 0 254 0 kPa 35 7 36 8 psi 2 46 2 54 kgf cm2 Fuel injector Model quantity 1100 87B60 1100 87B70 Manufacturer AISAN Throttle body Type quantity ACW31 1 Manufacturer MIKUNI ID mark 5VU1 00 Idling condition Engine idling speed 1100 1300 r min Intake vacuum ...

Page 46: ...14 M C 55H Manufacturer model DUNLOP D252F Manufacturer model BRIDGESTONE TH01F Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 160 60R15 M C 67H Manufacturer model DUNLOP D252 Manufacturer model BRIDGESTONE TH01R Wear limit rear 1 6 mm 0 06 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 225 kPa 33 psi 2 25 kgf cm2 2 25 bar Rear 250 kPa 36 psi 2 5...

Page 47: ...ering Steering bearing type Angular bearing Center to lock angle left 38 5 Center to lock angle right 38 5 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 120 0 mm 4 72 in Fork spring free length 405 0 mm 15 94 in Limit 400 0 mm 15 75 in Collar length 145 0 mm 5 71 in Installed length 400 0 mm 15 75 in Spring rate K1 15 60 N mm 89 08 lb in ...

Page 48: ...pring stroke K1 0 0 28 8 mm 0 00 1 13 in Spring stroke K2 28 8 43 0 mm 1 13 1 69 in Optional spring available No Enclosed gas air pressure STD 4900 kPa 696 9 psi 49 0 kgf cm2 Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 0 mm 0 04 in ...

Page 49: ...Resistance 10 0 kΩ AC magneto Model manufacturer F4T383 MITSUBISHI Standard output 14 0 V350 W5000 r min Stator coil resistance 0 216 0 264 Ω Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer SH719AA SHINDENGEN Regulated voltage DC 14 1 14 9 V Rectifier capacity DC 25 0 A Withstand voltage 240 0 V Battery Model GT9B 4 Voltage capacity 12 V 8 0 Ah Specific gravity 1...

Page 50: ...diameter 28 0 mm 1 10 in Limit 27 0 mm 1 06 in Mica undercut depth 0 70 mm 0 03 in Starter relay Model manufacturer MS5F 561 JIDECO Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 2 pcs Model manufacturer YF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 15 1 25 Ω Performance 105 113 dB 2m Turn signal hazard relay Relay type Full transistor Model manufacturer FE246BH ...

Page 51: ...tem fuse 10 0 A ABS motor fuse XP500A 30 0 A ABS control unit fuse XP500A 5 0 A Backup fuse 10 0 A Reserve fuse 30 0 A Reserve fuse XP500 20 0 A XP500A 15 0 A XP500W 20 0 A Reserve fuse XP500 15 0 A XP500A 10 0 A XP500W 15 0 A Reserve fuse XP500 10 0 A XP500A 5 0 A XP500W 10 0 A ...

Page 52: ... m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 0 94 Item Thread size Q ty Tightening torque Remarks Spark plug M10 2 13 Nm 1 3 m kg 9 4 ft lb Cylinder head cover M6 10 10 Nm 1 0 m kg 7 2 ft lb Camshaft cap M6 12 10 Nm 1 0 m kg 7 2 ft lb Cylinder head and cylinder body M9 4 35 Nm 3 5 m kg 25 ft lb Cylinder h...

Page 53: ... Nm 1 0 m kg 7 2 ft lb Silencer assembly M6 2 9 Nm 0 9 m kg 6 5 ft lb Air filter case assembly M6 3 9 Nm 0 9 m kg 6 5 ft lb Exhaust pipe M8 4 20 Nm 2 0 m kg 14 ft lb Muffler M10 1 31 Nm 3 1 m kg 22 ft lb Muffler protector 1 M6 2 10 Nm 1 0 m kg 7 2 ft lb Muffler protector 2 M6 1 10 Nm 1 0 m kg 7 2 ft lb Crankcase M6 13 10 Nm 1 0 m kg 7 2 ft lb Crankcase M8 8 24 Nm 2 4 m kg 17 ft lb Engine oil drain...

Page 54: ...8 10 Nm 1 0 m kg 7 2 ft lb Chain drive case cover M6 2 7 Nm 0 7 m kg 5 1 ft lb Primary sheave assembly nut M20 1 160 Nm 16 0 m kg 115 ft lb BEL RAY assembly lube Secondary sheave spring seat M36 1 90 Nm 9 0 m kg 65 ft lb Secondary sheave assembly M18 1 90 Nm 9 0 m kg 65 ft lb Shell BT grease Primary bearing retainer M6 1 11 Nm 1 1 m kg 8 0 ft lb Secondary shaft bearing retainer M6 1 12 Nm 1 2 m kg...

Page 55: ...TIGHTENING TORQUES 2 18 Crankcase tightening sequence Cylinder head tightening sequence ...

Page 56: ... mounting nut upper M12 1 87 Nm 8 7 m kg 63 ft lb Engine mounting front mounting bolt lower M10 2 48 Nm 4 8 m kg 35 ft lb Engine mounting rear mounting nut M12 1 87 Nm 8 7 m kg 63 ft lb Front wheel axle M14 1 59 Nm 5 9 m kg 43 ft lb Front wheel axle pinch bolt M8 1 23 Nm 2 3 m kg 17 ft lb Rear wheel axle nut M14 1 100 Nm 10 0 m kg 72 ft lb Rear wheel axle pinch bolt M8 1 17 Nm 1 7 m kg 12 ft lb Fr...

Page 57: ... unit and front cowling M6 2 7 Nm 0 7 m kg 5 1 ft lb Tail brake light assembly and frame M6 2 7 Nm 0 7 m kg 5 1 ft lb Footrest board and frame M6 4 7 Nm 0 7 m kg 5 1 ft lb Upper side cover moulding and pas senger footrest M6 6 7 Nm 0 7 m kg 5 1 ft lb Rear side cover and frame M6 6 7 Nm 0 7 m kg 5 1 ft lb Leg shield footrest board and frame M6 2 7 Nm 0 7 m kg 5 1 ft lb Seat damper M8 1 16 Nm 1 6 m ...

Page 58: ...face Connecting rod bolts and nuts Crankshaft thrust surface Crankshaft journals Camshaft lobs Camshaft journals Camshaft cap Valve stems intake and exhaust Valve stem ends intake and exhaust Cylinder head nut Water pump impeller shaft Oil pump shaft Oil pump rotors inner and outer Oil pump O ring Oil cooler union bolt O ring fuel injector assembly Silicone oil Starter clutch idle gear inner surfa...

Page 59: ...d No 1215 Cylinder head cover guide stopper mating surface Yamaha bond No 1215 Right crankcase cover air duct seal mating surface Yamaha bond No 1215 Lubrication point Lubricant E LS E LS LS LS Lubrication point Lubricant Front wheel oil seal lip Steering bearings and oil seal lip Throttle grip inner surface and throttle cables Brake lever pivoting point and metal to metal moving parts left and ri...

Page 60: ...TION POINTS AND LUBRICANT TYPES 2 23 Rear shock absorber bearing and collar inner surface Swingarm oil seal lip and collar inner surface Rear shock absorber bolt front side Lubrication point Lubricant LS LS LS ...

Page 61: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART ...

Page 63: ...RT AND DIAGRAMS 2 26 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 Oil filter cartridge ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20410 LUBRICATION DIAGRAMS ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 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 Oil delivery pipe ...

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 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Clutch 2 Right main journal bearing 3 Main gallery plug ...

Page 70: ...COOLING SYSTEM DIAGRAMS 2 33 EAS20420 COOLING SYSTEM DIAGRAMS ...

Page 71: ...COOLING SYSTEM DIAGRAMS 2 34 1 Coolant reservoir 2 Thermostat 3 Radiator 4 Water pump 5 Radiator fan 6 Radiator cap 7 Fast idle plunger ...

Page 72: ...CABLE ROUTING 2 35 EAS20430 CABLE ROUTING ...

Page 73: ...right E Connect the turn signal light left and right F Route the horn lead through the wire guide G After passing the horn lead through the lead holder crimp the lead holder H Install a wire harness guide to hold down the wire harness I Route the throttle cables between handle under cover and upper bracket J Route the throttle cables through the hole of the lower handlebar cover K Connect the brak...

Page 74: ...CABLE ROUTING 2 37 ...

Page 75: ...r 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 lubri cating the grease to the cable end E Install the rear brake lock lever cable after turn ing the parking brake lever as illustration F Install the cable end Fa...

Page 76: ...CABLE ROUTING 2 39 ...

Page 77: ...guide of frame F 50 70 mm 1 97 2 76 in G 2 5 mm 0 08 0 20 in H Install the grommet to the footrest board securely I Install the grommet to the fuel tank securely J Make sure that the clip end faces to the front side K Install the grommet to the fuel tank securely after installing the hoses L Fasten the fuel hose and fuel pump lead with a hose holder making sure that there are no twists in the hose...

Page 78: ...CABLE ROUTING 2 41 ...

Page 79: ...lastic 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 Make sure that the seat lock cable do not lean over the storage box S Fasten the starter motor lead n...

Page 80: ...CABLE ROUTING 2 43 ...

Page 81: ...harness through the frame guide At this time place the protector for the handle cover inner side on the bottom side C Pass the fuel tank breather hose by the outside of the wire harness D Pass the wire harness by the outside of the rear footrest mounting boss When installing the rear footrest do not catch or pinch the A C magneto lead in the bracket E Fasten the wire harness to the frame with a pl...

Page 82: ...CABLE ROUTING 2 45 ...

Page 83: ...ht seat lock M Route the negative battery lead and the fuse box lead from the storage box opening to the bottom of the cross pipe N Route the fuse box lead above the starter motor lead O Place the rubber cover over the starter relay starter relay coupler positive battery lead termi nal and starter motor lead terminal P Align the plastic clamp with the white tape on the wire harness and fasten to t...

Page 84: ...CABLE ROUTING 2 47 XP500 ...

Page 85: ...rottle 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 The main switch lead couplers should not pro trude to the outside of the frame F Fasten the fuel injector leads with the plastic holder G Fasten the sidestand switch lead to the frame with a plastic holder H Fasten the rear brake hose to the stay 1 with ...

Page 86: ...CABLE ROUTING 2 49 ...

Page 87: ...lot in the speed sensor fits stopper on the outer tube I Make sure that the stopper touches the outer tube stay J Pass the speed sensor lead between the brake hose and front fork K Fasten the speed sensor lead to the center of brake hose holder L Install the hose holder to the innermost securely M Engage the hose holder rib more than 3 notch Face the hose holder projection to the back N Make sure ...

Page 88: ...CABLE ROUTING 2 51 ...

Page 89: ... to the headlight sub wire harness cowling side K Fasten the headlight and turn signal sub wire harness to the stay 1 with a plastic holder L Fasten the ECU engine lead ABS test coupler lead and headlight sub wire harness to the stay 1 with a plastic holder When fastening them using a plastic holder make sure not to cross the branch leads M Fasten the coolant reservoir hose to the stay 1 with a pl...

Page 90: ...CABLE ROUTING 2 53 ...

Page 91: ...rame above the mudguard AN 20 30 mm 0 79 1 18 in AO To the tail brake light AP Route the tail brake light switch lead under the seat lock cable wire harness and positive bat tery leads and then towards the inside of the vehicle AQ T stud for position setting AR Route the seat lock cable through the frame bracket side and under the wire harness AS Install the band fastened part between frame and st...

Page 92: ...CABLE ROUTING 2 55 ...

Page 93: ...le to the cable guide B Route the wire harness through the frame guide C Pass the fuel tank breather hose by the outside of the wire harness D Pass the wire harness by the outside of the rear footrest mounting boss When installing the rear footrest do not catch or pinch the A C magneto lead in the bracket E Fasten the wire harness to the frame with a plastic holder F Pass the storage box light swi...

Page 94: ...CABLE ROUTING 2 57 ...

Page 95: ...ber cover over the starter relay starter relay coupler positive battery lead termi nal and starter motor lead terminal O Align the plastic clamp with the white tape on the wire harness and fasten to the frame 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 out side of the frame bracket R Install the starter relay to the ma...

Page 96: ...CABLE ROUTING 2 59 ...

Page 97: ...en D Route the main switch lead over the tube of the stay 1 E Fasten the cooling system air bleed hose to the stay 1 with a plastic holder F After checking the ABS install the ABS test coupler into the stay 1 G The main switch lead couplers should not pro trude to the outside of the frame H Fasten the fuel injection leads with a plastic holder I Fasten the sidestand switch lead to the frame with a...

Page 98: ...CABLE ROUTING 2 61 ...

Page 99: ...2 76 3 94 in past the holder F 40 60 mm 1 57 2 36 in G 70 100 mm 2 76 3 94 in H Install the brake hose hydraulic unit to front brake caliper onto the hydraulic unit The brake hose and its union bolt hole are identified by white paint marks I Install the hydraulic unit solenoid coupler bracket onto the hydraulic unit making sure that the projections on the bracket are aligned with the edges of the ...

Page 100: ...CABLE ROUTING 2 63 ...

Page 101: ... F Install the stopper to lower bracket projection G Fasten the front wheel sensor lead to the center of brake hose holder H Fasten the front wheel sensor lead along the outside of the brake hose I Pass the front wheel sensor lead between the brake hose and front fork J Make sure that the stopper touches the outer tube stay K 30 40 mm 1 18 1 57 in L Make sure that brake pipe touches the projec tio...

Page 102: ...CABLE ROUTING 2 65 ...

Page 103: ...L 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 A...

Page 104: ...REPLACING THE HEADLIGHT BULBS 3 32 ADJUSTING THE HEADLIGHT BEAMS 3 32 ...

Page 105: ...th an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 4 Air filter element Clean Replace 5 V belt case...

Page 106: ...akage 18 Shock absorber assembly Check operation and shock absorber for oil leakage 19 Fuel injection Adjust engine idling speed and synchronization 20 Engine oil Change When the oil change indicator flashes every 5000 km Check oil level and vehicle for oil leakage Every 5000 km 21 Engine oil filter car tridge Replace 22 Cooling system Check coolant level and vehicle for coolant leakage Change Eve...

Page 107: ...ve Radiator Refer to RADIATOR on page 6 1 3 Remove Spark plug Cylinder head cover 1 Cylinder head cover gasket 4 Remove Throttle body Intake manifold Refer to THROTTLE BODIES on page 7 4 5 Remove Timing plug 1 6 Remove V belt case cover 1 7 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When piston 1 is at TDC on the compres sion stroke align the TDC m...

Page 108: ...amshafts from the cyl inder head tilt up the engine at least 25 NOTE Refer to CAMSHAFTS on page 5 6 When removing the timing chain and cam shafts fasten the timing chain with a wire to re trieve it if it falls into the crankcase 9 Adjust Valve clearance a Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 NOTE Cover the timing chain opening with a rag to prevent the valve pad from...

Page 109: ...e lifter with molybdenum disulfide oil The valve lifter must turn smoothly when rotat ed by hand Install the valve lifter and the valve pad in the correct place f Install the exhaust and intake camshafts tim ing chain and camshaft caps NOTE Refer to CAMSHAFTS on page 5 6 Lubricate the camshaft bearings camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshaft marks...

Page 110: ...tion a Turn the throttle body 1 air screw 1 and 2 air screw 2 Using the carburetor angle driv er 3 NOTE After each step rev the engine two or three times each time for less than a second and check the synchronization again If the air screw is removed turn the screw 3 4 turn in and be sure to synchronize the throttle body CAUTION ECA14900 Do not use the throttle valve adjusting screws to adjust the...

Page 111: ...pear except the clock and tripmeter displays dIAG appears on the clock LCD 3 Press the SELECT button to select the CO adjustment mode CO or the diagnostic mode dIAG 4 After selecting CO simultaneously press the SELECT 1 and RESET 2 buttons for 2 seconds or more to execute the selec tion 5 Press the SELECT 1 and RESET 2 buttons to select a cylinder NOTE The selected cylinder number appears on the c...

Page 112: ... Engine idling speed Out of specification Adjust 5 Adjust Engine idling speed a Turn the idle adjust screw 1 in direction a or b until the specified engine idling speed is obtained 6 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 8 EAS20630 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idling speed...

Page 113: ... Slide the rubber cover to its original position WARNING EWA15B1010 After adjusting the throttle cable free play turn the handle bar to the right and to the left to ensure that this does not cause the engine idling speed to change 4 Install Left side cover Center cover Refer to GENERAL CHASSIS on page 4 1 EAS20680 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1...

Page 114: ...nter cover Refer to GENERAL CHASSIS on page 4 1 EAS20700 CHECKING THE IGNITION TIMING 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 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 3 Ins...

Page 115: ...Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 3 3 Start the engine warm it up for several min utes and then turn it off 4 Disconnect Spark plug cap 5 Remove Spark plug CAUTION ECA13340 Before removing the spark plugs use com pressed air to blow away any dirt accumulat ed in the spark plug wells to prevent it from falling into the cylinders 6 Install Compression gauge 1 7 Measure Compres...

Page 116: ...ehicle is upright 2 Start the engine warm it up for several min utes 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 crank case 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 en...

Page 117: ...ller cap 1 Engine oil drain bolt 2 along with the gasket 4 Drain Engine oil completely from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil CAUTION ECA13390 Make sure the O ring 3 is positioned cor...

Page 118: ...r light before the periodic oil change interval has been reached follow the above procedure but note that the indicator light will come on for 1 4 seconds after releasing the OIL CHANGE button otherwise repeat the procedure EAS20820 MEASURING THE ENGINE OIL PRESSURE 1 Check Engine oil level Below the minimum level mark Add the recommended engine oil to the proper level 2 Remove Left lower side cov...

Page 119: ...ket CAUTION ECA1B706 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect carburetor synchronization leading to poor engine per formance and possible overheating NOTE Make sure the air filter element is properly in Pressure gauge 90890 031...

Page 120: ...ter element Blow the compressed air to the outer surface of the V belt case air filter element 5 Check V belt case air filter element Damage Replace CAUTION ECA13440 Since the V belt case air filter element is a dry type do not let grease or water contact it 6 Install V belt case air filter element V belt case air filter cover seal V belt case air filter cover V belt case air filter cover screw 7 ...

Page 121: ...est board Refer to GENERAL CHASSIS on page 4 1 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 CAUTION ECA15B1036 Make sure the cylinder head breather hose is routed correctly 3 Install Leg shield Refer to GENERAL CHASSIS on page 4 1 EAS21080 CHEC...

Page 122: ...and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several min utes and then turn it off 4 Check Coolant level NOTE Before checking the coolant level wait a few minutes until it settles EAS21120 CHECKING THE COOLING SYSTEM 1 Remove Footrest board left a...

Page 123: ... WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual p...

Page 124: ...olant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 11 Install Radia...

Page 125: ...NG THE COOLANT LEV EL 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 Front side cover mole left and right Left footrest board mat Refer to GENERAL CHASSIS on page 4 1 ...

Page 126: ...ill significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately NOTE In order to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal EAS21250 CHECKING THE FRONT BRAKE PADS The follow...

Page 127: ...AKE LOCK LEVER CABLE WARNING EWA15B2001 Do not apply the rear brake lock lever when riding NOTE Place the vehicle on a suitable stand Before adjusting the rear brake lock lever check the rear brake fluid level 1 Measure Rear brake lock lever cable length a Out of specification Adjust 2 Adjust Rear brake lock lever cable length a Turn the adjusting nut 1 in direction b or c until the rear brake loc...

Page 128: ...e diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully pull the brake lever and hold it in posi tion g Loosen the bleed screw NOTE Loosening the bleed screw will release the pres sure and cause the brake lever to contact the ...

Page 129: ...he bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully squeeze the brake lever and do not re lease it g Loosen the bleed screw NOTE Loosening the bleed screw will release the pres sure and cause the brake levers to contact the handlebar h Tighten the bleed screw and then release the brake lever i Repeat steps e to h until all of the air ...

Page 130: ...imum level mark Add the recommended transfer oil to the proper level 4 Install Chain drive oil filler cap Chain drive case cover EAS21490 CHANGING THE CHAIN DRIVE OIL 1 Place a container under the chain drive 2 Remove Chain drive oil drain bolt 1 Chain drive oil filler cap Completely drain the chain drive of its oil 3 Check Drain bolt gasket Damage Replace 4 Install Chain drive oil drain bolt 5 Fi...

Page 131: ...her 1 the upper ring nut 2 and the rubber washer 3 b Loosen the lower ring nut 4 and then tighten it to specification with a steering nut wrench 5 NOTE Set the torque wrench at a right angle to the steering nut wrench c Loosen the lower ring nut 4 completely then tighten it to specification WARNING EWA13140 Do not overtighten the lower ring nut d Check the steering head for looseness or binding by...

Page 132: ...pring gauge 2 onto the plastic lock ing tie d Hold the spring gauge at a 45 angle from the handlebar pull the spring gauge and then record the measurement when the handlebar starts to run e Repeat the above procedure on the opposite handlebar f If the steering head tension is out of specifi cation both handlebars should be within specification remove the upper bracket and loosen or tighten the upp...

Page 133: ...ure The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and ac cessories and the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE Total weight of rider passenger cargo and ac cessories WARNING EWA13190 It is dangerous to ride with a worn out tire Wh...

Page 134: ...d of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a d...

Page 135: ...ble 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to me...

Page 136: ... bulb Secure the new headlight bulb with the head light bulb holder CAUTION ECA13690 Avoid touching the glass part of the head light 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 If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 7 Install Headligh...

Page 137: ... 3 33 Left headlight Right headlight Direction c Headlight beam moves to the right Direction d Headlight beam moves to the left Direction c Headlight beam moves to the left Direction d Headlight beam moves to the right ...

Page 138: ...ELECTRICAL SYSTEM 3 34 ...

Page 139: ...CS 4 26 REPLACING THE FRONT BRAKE PADS 4 27 REMOVING THE FRONT BRAKE CALIPERS 4 28 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 29 CHECKING THE FRONT BRAKE CALIPERS 4 29 ASSEMBLING THE FRONT BRAKE CALIPERS 4 30 INSTALLING THE FRONT BRAKE CALIPERS 4 30 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 31 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 31 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 32 INSTALLING T...

Page 140: ...LEGS 4 59 DISASSEMBLING THE FRONT FORK LEGS 4 59 CHECKING THE FRONT FORK LEGS 4 60 ASSEMBLING THE FRONT FORK LEGS 4 61 INSTALLING THE FRONT FORK LEGS 4 63 STEERING HEAD 4 64 REMOVING THE LOWER BRACKET 4 66 CHECKING THE STEERING HEAD 4 66 INSTALLING THE STEERING HEAD 4 67 REAR SHOCK ABSORBER ASSEMBLY 4 68 HANDLING THE REAR SHOCK ABSORBER 4 69 DISPOSING OF A REAR SHOCK ABSORBER 4 69 REMOVING THE REA...

Page 141: ...GENERAL CHASSIS 4 1 EAS21830 GENERAL CHASSIS Seat Order Job Parts to remove Q ty Remarks Fuel tank cap 1 Fuel lid 1 2 Seat 1 For installation reverse the removal proce dure 1 2 ...

Page 142: ...Front side cover moulding left and right 2 3 Rear view mirror left and right 2 4 Front cowling upper cover 1 5 Windshield 1 6 Front cowling inner panel 1 7 Headlight sub wire harness coupler 4 Disconnect 8 Front cowling 1 For installation reverse the removal proce dure 5 4 3 2 8 2 6 7 7 1 1 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 143: ...er 1 4 Hinge cover 1 5 Side cover left and right 2 6 Footrest board left and right 2 7 Coolant reservoir cap access panel 1 8 Meter assembly coupler 1 Disconnect 9 Meter assembly 1 10 Leg shield 1 11 Inner fender 1 For installation reverse the removal proce dure 10 3 4 1 7 6 8 5 1 9 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 11 2 7 Nm 0 7 m kg 5 1 ft Ib 2 6 5 ...

Page 144: ... Upper side cover mole left right 1 Grab bar 1 2 Rear cover 1 3 Rear side cover left right 1 1 4 Tail brake light assembly coupler 1 Disconnect 5 Tail brake light assembly 1 For installation reverse the removal proce dure 7 Nm 0 7 m kg 5 1 ft Ib 4 5 LT LT 7 Nm 0 7 m kg 5 1 ft Ib 1 3 2 16 Nm 1 6 m kg 12 ft Ib 3 ...

Page 145: ... box assembly 1 7 ABS motor fuse box 1 XP500A 8 Storage box light connector 2 Disconnect 9 Fuel tank cover 1 10 Storage box light 1 11 Storage box 1 12 Storage box light switch coupler 1 Disconnect 13 Hinge damper 2 1 For installation reverse the removal proce dure 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 9 13 12 13 7 2 13 3 7 Nm 0 7 m kg 5 1 ft Ib 16 Nm 1 6 m kg 12 ft Ib 7 Nm 0 7 m kg 5 ...

Page 146: ...er cover Refer to GENERAL CHASSIS on page 4 1 1 Front brake caliper left and right 2 2 Front wheel axle pinch bolt 1 Loosen 3 Front wheel axle 1 4 Front wheel 1 5 Speed sensor 1 6 Collar 1 7 Dust cover 1 8 Brake disc 2 For installation reverse the removal proce dure 2 3 5 4 8 8 6 1 6 7 1 LT LT LT 6 18 Nm 1 8 m kg 13 ft Ib 40 Nm 4 0 m kg 29 ft Ib 23 Nm 2 3 m kg 17 ft Ib 40 Nm 4 0 m kg 29 ft Ib 59 N...

Page 147: ...FRONT WHEEL 4 7 Disassembling the front wheel XP500 Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Bearing 2 3 Collar 1 For installation reverse the removal proce dure 1 2 3 2 ...

Page 148: ...ke caliper left and right 2 3 Front wheel sensor 1 4 Front wheel axle pinch bolt 1 Loosen 5 Front wheel axle 1 6 Front wheel 1 7 Sensor housing 1 8 Collar left 1 9 Collar right 1 10 Dust cover 1 11 Brake disc 2 For installation reverse the removal proce dure 30 Nm 3 0 m kg 22 ft Ib 18 Nm 1 8 m kg 13 ft Ib 40 Nm 4 0 m kg 29 ft Ib 11 8 7 3 6 2 40 Nm 4 0 m kg 29 ft Ib 11 10 9 6 5 4 6 59 Nm 5 9 m kg 4...

Page 149: ...FRONT WHEEL 4 9 Disassembling the front wheel XP500A Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Bearing 2 3 Collar 1 For installation reverse the removal proce dure LS LS 1 2 3 1 2 ...

Page 150: ...el sensor Front brake calipers CAUTION ECA15B1041 Be sure not to contact the sensor electrode to any metal part when removing the front wheel sensor from the sensor housing Do not operate the brake lever and brake pedal when removing the brake calipers 3 Elevate Front wheel NOTE Place the vehicle on a suitable stand so that the front wheel is elevated EAS21920 CHECKING THE FRONT WHEEL 1 Check Whee...

Page 151: ...at matches the diameter of the wheel bearing outer race and oil seal EAS22010 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR XP500A CAUTION ECA14450 Handle the ABS components with care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The ABS wheel sensor cannot be disas sembled Do not attempt to disassemble it If faulty replace with a new...

Page 152: ...ove Balancing weight s 2 Find Front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel 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 f Repeat steps d through f several...

Page 153: ...Speedometer drive gear Speedometer driven gear 2 Install Speed sensor to front wheel NOTE Make sure the speed sensor and the wheel hub are installed with the two projections meshed into the two slots respectively 3 Install Front wheel NOTE Make sure the slot a in the speedometer gear unit fits over the stopper b on the outer tube 4 Tighten Wheel axle 1 Use the damper rod holder 2 Wheel axle pinch ...

Page 154: ...ge to the inner sensor rotor and wheel sen sor 3 Tighten Front wheel axle 1 Use the damper rod holder 2 Front wheel axle pinch bolt 3 CAUTION ECA15B1018 Before tightening the wheel axle pinch bolt push down hand on the handlebar several times and check if the front fork rebounds smoothly 4 Install Front wheel sensor 1 Front wheel sensor lead holder Brake caliper 2 Brake hose holder Front brake cal...

Page 155: ...ials CAUTION ECA14480 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 1 2 ...

Page 156: ...rear wheel is elevated 1 Rear brake caliper 1 2 Chain drive case cover 1 3 Rear wheel axle pinch bolt 1 Loosen 4 Rear wheel axle nut washer 1 1 5 Rear wheel axle 1 6 Collar 1 7 Rear wheel 1 8 Spacer 1 For installation reverse the removal proce dure 1 2 4 6 7 8 100 Nm 10 0 m kg 72 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 40 Nm 4 0 m kg 29 ft Ib 3 5 17 Nm 1 7 m kg 12 ft Ib ...

Page 157: ... sensor coupler 1 Disconnect 2 Rear wheel sensor 1 3 Brake caliper 1 4 Chain drive case cover 1 5 Rear wheel axle pinch bolt 1 Loosen 6 Rear wheel axle nut washer 1 1 7 Rear wheel axle 1 8 Collar 1 9 Sensor housing 1 10 Collar 1 11 Rear wheel 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 10 11 8 17 Nm 1 7 m kg 12 ft Ib 30 Nm 3 0 m kg 22 ft Ib 40 Nm 4 0 m kg 29 ft Ib 100 Nm 10...

Page 158: ...ear wheel Order Job Parts to remove Q ty Remarks 1 Brake disc 1 2 Rear wheel drive hub 1 3 O ring 1 4 Oil seal 1 5 Bearing 2 For installation reverse the removal proce dure 4 5 5 1 2 3 6 4 18 Nm 1 8 m kg 13 ft Ib 69 Nm 6 9 m kg 50 ft Ib ...

Page 159: ...Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 10 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 29 and CHECKING THE WHEELS on page 3 31 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 10 EAS15B4567 CHECKING THE REAR WHEEL DRIVE HUB 1 Check Rear wheel drive hub 1 Cracks damage Replace EAS22200 MAINTENANCE OF T...

Page 160: ... Install Rear wheel sensor 1 NOTE When installing the rear wheel sensor check the rear wheel sensor lead for twists and the sensor electrode for foreign materials CAUTION ECA14500 To route the rear wheel sensor lead refer to CABLE ROUTING on page 2 35 3 Connect Rear wheel sensor coupler 1 Rear wheel sensor lead holder 2 Clamp 3 CAUTION ECA14500 To route the rear wheel sensor lead refer to CABLE RO...

Page 161: ...ove Q ty Remarks 1 Front brake caliper retaining bolt lower 1 2 Front brake caliper retaining bolt upper 1 3 Brake caliper 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake pad spring 1 7 Brake pad spring 2 For installation reverse the removal proce dure 1 2 3 4 5 6 7 5 4 7 27 Nm 2 7 m kg 20 ft Ib ...

Page 162: ...cap 1 2 Brake master cylinder reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch connector 2 6 Union bolt 1 7 Brake hose 1 8 Copper washer 2 9 Brake master cylinder holder 1 10 Brake master cylinder 1 11 Front brake light switch 1 For installation reverse the removal proce dure 4 5 9 1 2 3 10 7 6 8 8 11 10 Nm 1 0 m kg 7 2 ft Ib 7 N...

Page 163: ...ssembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 1 2 3 4 ...

Page 164: ...hose 1 4 Front brake caliper retaining bolt lower 1 5 Front brake caliper retaining bolt upper 1 6 Brake caliper 1 7 Brake pad 2 8 Brake pad shim 2 9 Brake pad spring 1 10 Brake pad spring 2 11 Front brake caliper bracket bolt 2 2 12 Brake caliper bracket 1 For installation reverse the removal proce dure 1 3 4 5 6 7 10 10 8 8 12 9 2 2 11 11 40 Nm 4 0 m kg 29 ft Ib 27 Nm 2 7 m kg 20 ft Ib 30 Nm 3 0...

Page 165: ...ake calipers Order Job Parts to remove Q ty Remarks 1 Bleed screw 1 2 Dust seal 2 3 Brake caliper piston seal 2 4 Brake caliper piston 2 5 Brake caliper body 1 For assembly reverse the disassembly pro cedure 2 3 4 3 4 5 1 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 166: ...re applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 6 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left o...

Page 167: ...ces sary to disconnect the brake hose or disassem ble the brake caliper 1 Remove Front brake caliper retaining bolts 1 Brake caliper 2 2 Remove Brake pad springs 1 Brake pads 2 Brake pad shims 3 Brake pad spring 4 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Install Brake pad spring 1 Brake pad springs 2 Brake pad shims 3 Brake pads 4 NOTE Always install ...

Page 168: ... any excess grease 6 Install Brake caliper 1 Front brake caliper retaining bolts 2 7 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 8 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM XP500 on page 3 24 EAS22300 REMOVI...

Page 169: ...ul not to get injured when the pis ton is expelled from the brake master cylin der Never try to pry out the brake caliper pis ton b Remove the brake caliper piston seals EAS22390 CHECKING THE FRONT BRAKE CALIPERS 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Crac...

Page 170: ...Brake caliper piston 3 2 Install Brake caliper bracket EAS22440 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Brake caliper 1 temporarily Copper washers Brake hose 2 Union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 35 CAUTION ECA14170 When installing ...

Page 171: ... always clean up any spilt brake fluid immediately 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 7 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDR...

Page 172: ...e cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents 1 Install Master cylinder kit 1 Circlip 2 Dust boot 3 EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 Brake master cylinder holder 2 NOTE Install the brake master cylinder holder with the UP mark facing up Align the end of the brake master cylinder hold er w...

Page 173: ...xing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fl...

Page 174: ... remove Q ty Remarks 1 Rear brake caliper retaining bolt 1 2 Rear brake caliper bracket bolt 2 3 Brake caliper 1 4 Brake pad 2 5 Brake pad spring 2 6 Brake caliper bracket 1 For installation reverse the removal proce dure 1 2 3 4 5 6 2 5 27 Nm 2 7 m kg 20 ft Ib 40 Nm 4 0 m kg 29 ft Ib ...

Page 175: ...cap 1 2 Brake master cylinder reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Rear brake light switch connector 2 6 Union bolt 1 7 Brake hose 1 8 Copper washer 2 9 Brake master cylinder holder 1 10 Brake master cylinder 1 11 Rear brake light switch 1 For installation reverse the removal proce dure 11 7 6 8 8 10 1 2 3 9 5 4 30 Nm 3 0 m kg 22 ft Ib 7 Nm 0...

Page 176: ...ssembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 4 1 2 3 ...

Page 177: ...1 3 Pin 1 4 Spring 1 5 Union bolt 1 6 Copper washer 2 7 Brake hose 1 8 Rear brake caliper retaining bolt 2 9 Brake caliper 1 10 Brake pad 2 11 Brake pad spring 2 12 Rear brake caliper bracket bolt 2 13 Brake caliper bracket 1 For installation reverse the removal proce dure 22 Nm 2 2 m kg 16 ft Ib 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 12 12 11 13 10 11 5 2 7 6 6 4 ...

Page 178: ... rear brake calipers Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Dust seal 1 3 Piston seal 1 4 Bleed screw 1 5 Brake caliper body 1 For assembly reverse the disassembly pro cedure 4 5 1 2 3 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 179: ...eel Refer to REAR WHEEL on page 4 16 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 26 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAK...

Page 180: ...r bleed screw and then turn the brake caliper piston 3 clock wise until section a of the brake caliper pis ton is level with the surface of the brake caliper body NOTE Align the recesses b in the brake caliper piston with the brake caliper body as shown in the illus tration c Tighten the brake caliper bleed screw d Install new brake pads new pad springs and the rear brake caliper Brake pad lining ...

Page 181: ...r spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM XP500 on page 3 24 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Nut 1 Rear brake lock lever cable 2 Pin 3 Spring 4 Union bolt 5 Copper washers 6 Brake hose 7 NOTE Put the end of the brake hose into a container and p...

Page 182: ...e caliper brackets 1 Cracks damage Replace EAS22660 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston sea...

Page 183: ...ir with the specified amount of the recom mended brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refillin...

Page 184: ...KE MASTER CYLINDER NOTE Before disassembling the rear brake master cyl inder drain the brake fluid from the entire brake system 1 Remove Union bolt 1 Copper washers 2 Brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22710 CHECKING THE REAR BRAKE MASTER CYLINDER The following procedure applies to the both of the brak...

Page 185: ...ojec tion b on the handlebar First tighten the upper bolt then the lower bolt 2 Install Copper washers 1 Brake hoses 2 Union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 35 NOTE While holding the brake hose tighten the union bolt as shown Turn the handlebar to the left and to the right to make sure that the brake ...

Page 186: ...e fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 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 re...

Page 187: ...pler wire harness side 1 2 ABS motor coupler 1 3 Union bolt Copper washer 1 2 4 Front brake hose 1 5 Union bolt Copper washer 1 2 6 Front brake hose 1 7 Union bolt Copper washer 1 2 8 Rear brake hose 1 9 Union bolt Copper washer 1 2 10 Rear brake hose 1 11 ABS motor breather hose 1 12 Nut 3 13 Hydraulic unit 1 For installation reverse the removal proce dure 5 6 5 3 4 3 7 8 7 9 10 9 1 13 11 2 12 12...

Page 188: ...erefore always clean up any spilt brake fluid immediately Do not allow any brake fluid to contact the couplers Brake fluid may damage the cou plers and cause bad contacts If the union bolts for the hydraulic unit have been removed be sure to tighten them to the specified torque and bleed the brake system 1 Remove Brake hose 1 from the front brake master cylinder Brake hose 2 to the front brake cal...

Page 189: ...ipers 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 CAUTION ECA14760 To route the front and rear brake hoses refer to CABLE ROUTING on page 2 35 4 Fill Brake master cylinder reservoir 5 Bleed the brake system 6 Check the operation of the hydraulic unit ac cording to the brake lever and the brake ped al response Refer to...

Page 190: ... the test coupler adaptor 1 to the test coupler 2 6 Set the engine stop switch 1 to 7 Set the main switch to ON NOTE After setting the main switch to ON wait ap proximately 2 seconds until the ABS warning light goes off 8 Push the start switch 2 for at least 4 sec onds CAUTION ECA15B1008 Do not operate the brake levers 9 After releasing the start switch operate the brake levers simultaneously NOTE...

Page 191: ...ulic unit 12 Set the main switch to OFF 13 Remove the test coupler adaptor from the test coupler 14 Set the main switch to ON 15 Set the engine stop switch to Hydraulic unit operation test 2 WARNING EWA15B1001 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 Front cowling Battery Refer to FUEL TA...

Page 192: ... brake lever returns to its home position before the rear brake le ver returns to its home position If the rear brake lever returns to its home position before the front brake lever does check that the brake hoses are connected correctly to the hydraulic unit If either the brake levers returns to its home position slowly check that the brake hoses are connected correctly to the hydraulic unit If t...

Page 193: ...ke master cylinder 1 10 Rear brake light switch connector 2 Disconnect 11 Parking brake lever Holder 1 1 12 Rear brake lock lever cable 1 Disconnect 13 Left handlebar switch 1 14 Rear brake master cylinder holder 1 15 Rear brake master cylinder 1 16 Handlebar grip 1 17 Upper handlebar holder 2 18 Handlebar 2 19 Lower handlebar cover 1 3 11 12 16 13 10 11 14 15 18 17 1 19 6 6 2 8 5 7 3 4 17 9 5 10 ...

Page 194: ...proce dure Removing the handlebar Order Job Parts to remove Q ty Remarks 3 11 12 16 13 10 11 14 15 18 17 1 19 6 6 2 8 5 7 3 4 17 9 5 10 Nm 1 0 m kg 7 2 ft Ib 26 Nm 2 6 m kg 19 ft Ib 23 Nm 2 3 m kg 17 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 26 Nm 2 6 m kg 19 ft Ib ...

Page 195: ...per handlebar holders 2 CAUTION ECA14250 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 If there is any contact with the fuel tank adjust the handlebar position NOTE The upper handlebar holders should be in stalled with the arrow marks a facing forward A Align the match marks b on the handlebar with t...

Page 196: ...UP a mark facing up Align the front brake master cylinder with the projection b in the handlebar First tighten the upper bolt then the lower bolt 8 Install Throttle grip Throttle cables NOTE Lubricate the inside of the throttle grip with a thin coat of lithium soap based grease and install it onto the handlebar 9 Install Right handlebar switch 1 WARNING EWA13720 Make sure the throttle grip operate...

Page 197: ...U ABS For XP500A Refer to ABS ANTI LOCK BRAKE SYS TEM XP500A on page 8 65 1 Front fender 1 2 Front brake caliper 2 3 Horn coupler 2 Disconnect 4 Horn 2 5 Upper bracket pinch bolt 2 Loosen 6 Cap bolt 1 Loosen 7 Lower bracket pinch bolt 4 Loosen 8 Front fork leg 2 For installation reverse the removal proce dure 23 Nm 2 3 m kg 17 ft Ib 40 Nm 4 0 m kg 29 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 m kg 5 1...

Page 198: ...ng 1 6 Damper rod assembly bolt 1 7 Copper washer 1 8 Damper rod assembly 1 9 Rebound spring 1 10 Oil flow stopper 1 11 Inner tube 1 12 Inner tube bushing 1 13 Dust seal 1 14 Oil seal clip 1 15 Oil seal 1 16 Washer 1 17 Outer tube bushing 1 For assembly reverse the disassembly pro cedure 13 14 15 16 17 10 7 6 12 11 9 1 2 3 4 5 8 23 Nm 2 3 m kg 17 ft Ib LT ...

Page 199: ...ront fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Dust seal 1 Oil seal clip 2 with a flat head screwdriver CAUTION ECA14180 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 2 Drain Fork oil NOTE Stroke the...

Page 200: ...above procedure as the oil flow stopper will be damaged EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube 1 Outer tube 2 Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod 1...

Page 201: ...down the inner tube 2 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Install Oil flow stopper 1 3 Lubricate Inner tube s outer surface 2 4 Install Outer tube onto the inner tube Copper washer Damper rod assembly bolt 5 Tighten Damper rod assembly bolt 1 NOTE Apply the locking agent LOCTITE to the threads of the damper rod assembly bolt While holding...

Page 202: ... cover the top of the front fork leg with a plastic bag 4 to protect the oil seal during installation 8 Install Oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove 9 Install Dust seal 1 with the fork seal driver weight 2 10 Fill Front fork leg with the specified amount of the recom mended fork oil a Frok seal driver weight 90890 01367 Replacement hammer YM A9...

Page 203: ...G THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts NOTE Make sure the inner fork tube is flush with the top of the handlebar holder 2 Tighten Lower bracket pinch bolt 1 Cap bolt 2 Upper bracket pinch bolt 3 Quantity 512 0 cm3 17 31 US oz 18 06 Imp oz Recommended oil Fork oil 7 5W ...

Page 204: ...HANDLEBAR on page 4 53 1 Horn bracket 1 2 Brake hose holder 1 3 Steering stem nut 1 4 Upper bracket 1 5 Lock washer 1 6 Upper ring nut 1 7 Rubber washer 1 8 Lower ring nut 1 9 Bearing cover 1 10 Bearing outer race 1 11 Upper bearing 1 12 Bearing inner race 1 13 Bearing outer race 1 14 Lower bearing 1 1 16 17 15 14 13 2 3 4 5 6 7 8 9 12 11 10 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 110 Nm 1...

Page 205: ...r installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks 1 16 17 15 14 13 2 3 4 5 6 7 8 9 12 11 10 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 110 Nm 11 0 m kg 80 ft Ib 52 Nm 5 2 m kg 38 ft Ib 20 Nm 2 0 m kg 15 ft Ib 1st 2nd ...

Page 206: ...ck Bearings 1 Bearing races 2 Damage pitting Replace 3 Replace Bearings Bearing races a Remove the bearing races from the steering head pipe with a long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new rubber seal and new bearing races CAUTION ECA14270 If the bearing race is not installed properly the steering head pipe could be dam...

Page 207: ...her 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 27 3 Install Upper bracket 1 Steering stem nut 2 NOTE Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 57 NOTE Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut 2 Recommended lubricant Lithium soap based grease Steer...

Page 208: ...der Job Parts to remove Q ty Remarks Muffler Refer to ENGINE REMOVAL on page 5 1 1 Bolt 1 2 Lock washer 1 3 Collar 1 4 Bolt Nut 1 1 5 Rear shock absorber 1 6 Collar 1 7 Washer 1 8 Spacer 1 9 Bearing 2 For installation reverse the removal proce dure 5 6 8 9 9 7 4 1 2 3 4 68 Nm 6 8 m kg 49 ft Ib 53 Nm 5 3 m kg 38 ft Ib ...

Page 209: ...ar shock absorber at a point 15 20 mm from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23210 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 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 rear wheel ...

Page 210: ...tall Lock washer 1 5 Tighten Bolt front side 2 NOTE When installing the rear shock absorber as sembly lift up the swingarm Bend the lock washer 2 tab along a flat side of the bolt 1 Bolt rear side 53 Nm 5 3 m kg 38 ft lb Bolt front side 2 68 Nm 6 8 m kg 48 ft lb T R New T R ...

Page 211: ... CHECKING THE VALVE LIFTERS 5 22 INSTALLING THE VALVES 5 22 CYLINDER AND PISTONS 5 25 REMOVING THE PISTON 5 26 CHECKING THE CYLINDERS AND PISTONS 5 26 CHECKING THE PISTON RINGS 5 27 CHECKING THE PISTON PIN 5 28 INSTALLING THE PISTONS AND CYLINDERS 5 28 GENERATOR AND STARTER CLUTCH 5 30 REMOVING THE A C MAGNETO ROTOR 5 32 CHECKING THE STARTER CLUTCH 5 32 INSTALLING THE A C MAGNETO ROTOR 5 33 ELECTR...

Page 212: ...HEAVE WEIGHTS 5 55 CHECKING THE SLIDER 5 56 CHECKING THE SECONDARY SHEAVE 5 56 ASSEMBLING THE PRIMARY SHEAVE 5 56 ASSEMBLING THE SECONDARY SHEAVE 5 56 INSTALLING THE PRIMARY SHEAVE ASSEMBLY SECONDARY SHEAVE ASSEMBLY AND V BELT 5 57 CRANKCASE AND CRANKSHAFT 5 59 DISASSEMBLING THE CRANKCASE 5 62 REMOVING THE CRANKSHAFT JOURNAL BEARING 5 62 REMOVING THE CONNECTING RODS 5 62 CHECKING THE CRANKCASE 5 6...

Page 213: ...INSTALLING THE CHAIN DRIVE 5 75 ...

Page 214: ...nner fender Refer to GENERAL CHASSIS on page 4 1 1 O2 sensor coupler 1 2 Protector 1 1 3 O2 sensor 1 4 Protector 2 1 5 Muffler assembly 1 6 Gasket 2 For installation reverse the removal proce dure 10 Nm 1 0 m kg 7 2 ft Ib 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 45 Nm 4 5 m kg 33 ft Ib 2 4 5 3 6 6 1 ...

Page 215: ...e oil Drain Refer to CHECKING THE CHAIN DRIVE OIL LEVEL on page 3 26 Thermostat outlet hose coolant pipe oil filter cartridge Refer to RADIATOR on page 6 1 V belt case air filter element left water pump inlet pipe water pump outlet pipe Refer to WATER PUMP on page 6 7 Throttle body injector Refer to THROTTLE BODIES on page 7 4 Rear shock absorber Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 68 ...

Page 216: ... 5 A C magneto lead 2 Disconnect 6 Intake air temperature sensor hose 1 Disconnect 7 Right passenger footrest 1 For assembly reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks 6 4 5 5 2 1 1 3 7 5 Nm 0 5 m kg 3 6 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 23 Nm 2 3 m kg 17 ft Ib ...

Page 217: ...emarks 1 Front lower mounting bolt Washer 4 4 2 Spacer 1 3 Front upper mounting bolt Nut 1 1 4 Rear mounting bolt Nut 1 1 5 Engine 1 For installation reverse the removal proce dure 1 1 5 3 4 4 3 1 1 2 48 Nm 4 8 m kg 35 ft Ib 87 Nm 8 7 m kg 63 ft Ib 48 Nm 4 8 m kg 35 ft Ib ...

Page 218: ... spacer 3 Front lower mounting bolts 4 NOTE Do not fully tighten the bolts 2 Tighten Rear mounting nut 1 Front upper mounting nut 2 Front lower mounting bolts Rear mounting nut 87 Nm 8 7 m kg 63 ft lb Front upper mounting nut 87 Nm 8 7 m kg 63 ft lb Front lower mounting bolts 48 Nm 4 8 m kg 35 ft lb 1 2 4 1 2 4 3 T R T R T R ...

Page 219: ...y Remarks Engine Refer to ENGINE REMOVAL on page 5 1 Intake manifold Refer to THROTTLE BODIES on page 7 4 1 Spark plug 2 2 Cylinder head cover 1 3 Cylinder head cover gasket 1 4 Dowel pin 2 For installation reverse the removal proce dure 13 Nm 1 3 m kg 9 4 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 3 4 2 1 4 ...

Page 220: ...2 Timing chain tensioner gasket 1 3 Camshaft cap 2 4 Dowel pin 4 NOTE During removal the dowel pins may still be connected to the camshaft cap 5 Intake camshaft 1 6 Exhaust camshaft 1 For installation reverse the removal proce dure M E M 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 3 6 4 5 4 4 2 1 3 ...

Page 221: ...o be sure that the piston is at TDC the alignment mark c on the intake camshaft sprocket and the alignment mark d on the ex haust camshaft sprocket must align with the cylinder head mating surface as shown in the illustration 3 Remove Timing chain tensioner 1 Timing chain tensioner gasket 2 4 Remove CAUTION ECA15B1022 Before removing the camshafts from the cyl inder head tilt up the engine at leas...

Page 222: ...shaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the camshaft 3 Measure Camshaft runout Out of specification Replace 1 2 3 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 ...

Page 223: ...shaft cap clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 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 EAS23950 CHECKING THE TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain g...

Page 224: ...While pushing the timing chain tensioner rod a turn it clockwise b with the timing chain ten sioner body 2 until if stops b Lock the timing chain tensioner rod 1 by set ting the circlip 3 to groove 4 while pushing the timing chain tensioner rod c Push the timing chain tensioner rod c d Make sure that the timing chain tensioner rod comes out d of the timing chain tensioner housing smoothly If there...

Page 225: ...15B1024 Do not turn the crankshaft when installing the camshafts to avoid damage or improper valve timing 2 Install Dowel pins Intake camshaft cap 1 Exhaust camshaft cap 2 Camshaft cap bolts CAUTION ECA15B1025 The camshaft cap bolts must be tightened evenly or damage to the cylinder head cam shaft cap and camshafts will result NOTE Lubricate the camshaft cap bolt threads with en gine oil 3 Install...

Page 226: ...wise 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 align ment mark is aligned with the cylinder head mating surface d Out of alignment Reinstall Refer to the installation steps above 6 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 3 ...

Page 227: ...Job Parts to remove Q ty Remarks Intake and exhaust camshafts Refer to CAMSHAFTS on page 5 6 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal proce dure 10 Nm 1 0 m kg 7 2 ft Ib 46 Nm 4 6 m kg 33 ft Ib 35 Nm 3 5 m kg 25 ft Ib 1 2 3 ...

Page 228: ...ineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern...

Page 229: ...Apply engine oil onto the threads of the cylin der head nuts Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them in two stages Cylinder head nut 46 Nm 4 6 m kg 33 ft lb Cylinder head bolts 10 Nm 1 0 m kg 7 2 ft lb T R T R ...

Page 230: ...e Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 14 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve retainer 8 5 Valve spring 8 6 Valve stem seal 8 7 Valve spring seat 8 8 Valve guide 8 9 Intake valve 4 10 Exhaust valve 4 For installation reverse the removal proce dure 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 8 ...

Page 231: ... 20 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 3 Remove Valve cotters 1 NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 4 Remove Upper spring seat 1 Valve spring 2 Valve stem seal 3 Lower spring seat ...

Page 232: ...he valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear a...

Page 233: ...VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b Valve margin thickness Valve margin thickness D intake 0 60 0 80 mm 0 0236 0 0315 i...

Page 234: ...ead 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 be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound f...

Page 235: ...he following procedure applies to all of the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant 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 1 Installed length Intake 91 2 104 9 N 9 3 10 7 kg 20 5 23 6 lb a...

Page 236: ...ssor attachment 3 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter CAUTION ECA15B1026 After making sure that the valve pads are ful ly inserted install the valve lifte...

Page 237: ...LVES AND VALVE SPRINGS 5 24 so that the pads do not fall NOTE The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position ...

Page 238: ...ob Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 14 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 4 6 Piston pin 2 7 Piston 2 8 Piston ring set 2 For installation reverse the removal proce dure 4 4 2 5 8 7 1 6 5 3 ...

Page 239: ... remove it with the piston pin puller set 4 2 Remove Top ring 2nd ring Oil ring 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 EAS15B4256 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cyli...

Page 240: ...deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown 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 ...

Page 241: ... bore clearance Out of specification Replace the piston pin and piston as a set EAS24470 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis tons and cylinders 1 Install Top ring 2nd ring Oil ring a 10 mm 0 39 in Piston ring end gap End gap installed 0 15 0 25 mm 0 0059 0 0098 in Limit 0 50 mm 0 0197 in End gap installed 0 40 0 50 mm 0 0157 0 0197 in Limit 0 75 m...

Page 242: ...ankcase opening with a clean rag to prevent the piston pin clip from falling into the crank case 3 Install Gasket 1 Dowel pins 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant 5 Offset Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown 6 Install Cylinder Timing chain guide exhaust side NOTE Pass the timing chain through the timing chain cavity New New Recomm...

Page 243: ...HANGING THE ENGINE OIL on page 3 13 Water pump assembly Refer to WATER PUMP on page 6 7 1 Starter coil assembly coupler 2 Disconnect 2 A C magneto cover 1 3 A C magneto cover gasket 1 4 Dowel pin 2 5 Oil tank 1 6 Gasket 1 7 Dowel pin 2 8 Oil strainer 1 9 Starter coil assembly 1 10 A C magneto rotor nut 1 11 Spacer 1 12 A C magneto rotor 1 18 17 13 16 15 12 11 10 4 9 3 8 4 1 2 7 6 5 7 7 14 10 Nm 1 ...

Page 244: ...gear 1 18 Washer 1 For installation reverse the removal proce dure Removing the starter clutch and A C magneto rotor Order Job Parts to remove Q ty Remarks 18 17 13 16 15 12 11 10 4 9 3 8 4 1 2 7 6 5 7 7 14 10 Nm 1 0 m kg 7 2 ft Ib 60 Nm 6 0 m kg 43 ft Ib 120 30 Nm 3 0 m kg 22 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 245: ...eel 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 mag neto rotor Make sure after installing the hold ing bolts that the clearance between the flywheel puller and the A C magneto rotor is the same everywhere If necessary one hold ing bolt maybe turned out slightly to adjust the flywheel puller s position CAUTION ECA15...

Page 246: ...0 INSTALLING THE A C MAGNETO ROTOR 1 Install Woodruff key A C magneto rotor 1 Spacer 2 A C magneto rotor nut 3 NOTE When installing the pickup coil rotor align the pin 2 in the crankshaft sprocket with the groove a in the A C magneto rotor 2 Tighten A C magneto rotor nut 1 NOTE While holding the generator rotor 2 with the rotor holding tool 3 tighten the pickup coil ro tor bolt Do not allow the sh...

Page 247: ...nkshaft position sensor lead grommet 4 Install A C magneto rotor cover NOTE Tighten the A C magneto rotor cover bolts in stages and in a crisscross pattern Yamaha bond No 1215 Three Bond No 1215 90890 85505 A C magneto rotor cover bolt 10 Nm 1 0 m kg 7 2 ft lb T R ...

Page 248: ...starter motor Order Job Parts to remove Q ty Remarks Fuel tank Refer to FUEL TANK on page 7 1 1 Negative battery lead 1 2 Starter motor lead 1 3 Starter motor 1 For installation reverse the removal proce dure 1 2 3 10 Nm 1 0 m kg 7 2 ft Ib 5 Nm 0 5 m kg 3 6 ft Ib ...

Page 249: ...to remove Q ty Remarks 1 Front bracket 1 2 O ring 2 3 Shims 1 4 Lock washer 1 5 Oil seal 1 6 Bearing 1 7 Rear bracket 1 8 Shims 1 9 Brush holder set 1 10 Armature assembly 1 11 Starter motor yoke 1 For assembly reverse the disassembly pro cedure 1 2 6 5 4 3 7 9 8 10 11 2 ...

Page 250: ...mmutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush Limit 27 0 mm 1 06 in Mica undercut depth 0 70 m...

Page 251: ...ter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 NOTE Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers EAS24810 INSTALLING THE STARTER MOTOR 1 Install Starter motor Starter motor bolts 2 Connect Starter motor lead Brush spring force 7 65 10 01 N 27 54 36 03 oz 780 1021 gf Starter motor bolt 10 Nm 1 0 m kg 7 2...

Page 252: ...NG THE COOLANT on page 3 19 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 13 A C magneto cover Starter clutch gear Refer to GENERATOR AND STARTER CLUTCH on page 5 30 1 Oil pump assembly 1 2 Oil pump drive chain 1 3 O ring 2 4 Oil delivery pipe 1 5 Oil delivery pipe 1 6 Relief valve assembly 1 For installation reverse the removal proce dure 6 5 4 1 2 3 3 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm...

Page 253: ...ve Q ty Remarks 1 Oil pump housing 1 2 Oil pump outer rotor 2 3 Oil pump inner rotor 2 4 Pin 2 5 Dowel pin 4 6 Oil pump housing center 1 7 Washer 1 8 Oil pump cover 1 9 Oil pump driven gear 1 For installation reverse the removal proce dure 1 5 3 2 4 9 8 4 2 3 5 6 7 ...

Page 254: ...l pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 O ring 4 Damage wear Replace the defective part s 1 Inner rotor 2 Outer rotor 3 Oil pump housing 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 cl...

Page 255: ...4368a CHECKING THE OIL PUMP DRIVE CHAIN 1 Check Oil pump drive chain Cracks stiffness Replace the oil pump chain oil pump drive and driven sprocket as a set EAS25000 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Pins Inner rotors NOTE When installing the inner rotor align the pin 1 in the oil pump shaft with the groove a in the ...

Page 256: ...utch Order Job Parts to remove Q ty Remarks A C magneto cover Refer to GENERATOR AND STARTER CLUTCH on page 5 30 1 Clutch assembly nut 1 2 Clutch assembly 1 3 Washer 1 For installation reverse the removal proce dure 1 2 65 Nm 6 5 m kg 47 ft Ib 3 ...

Page 257: ... plate 2 2 6 Clutch damper spring 1 6 7 Friction plate 5 8 Clutch plate 1 4 9 Clutch spring 6 10 Thrust plate 1 11 Clutch boss nut 1 12 Primary drive gear 1 13 Bearing 2 14 Clutch boss 1 15 Collar 1 16 Weight 12 17 Clutch housing 1 For assembly reverse the removal proce dure E E E E 1 2 3 4 7 7 7 7 9 10 6 5 6 8 8 8 6 5 13 13 14 15 12 16 11 17 90 Nm 9 0 m kg 65 ft Ib ...

Page 258: ... Clutch damper spring 2 Pressure plate Clutch plate 2 Friction plate Clutch plate 1 Clutch damper spring 1 Thrust plate Clutch springs NOTE One to three holes a are drilled in the spring stopper plate to adjust the balance of the clutch assembly Before removing the spring stopper plate make alignment marks on both the plate and the clutch housing so that the plate can be reinstalled in its origina...

Page 259: ...easure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch 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 Measure Clutch spring free height Out of specification Replace the clutch plate spring 3 Measure Clutch damper spring 1 b Out...

Page 260: ...the clutch boss splines will cause er ratic clutch operation EAS25170 CHECKING THE PRESSURE PLATE 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch boss splines will cause er ratic clutch operation EAS15B4286b CHECKING THE WEIGHT 1 Check Weight Cracks wear scaling chipping Replace Out of specification Replace Clutch spring height c 4 70 mm 0 19 in M...

Page 261: ...1 1 Clutch plate 2 2 Friction plate 3 Clutch plate 1 4 EAS15B4286c INSTALLING THE CLUTCH 1 Install Clutch assembly 1 Clutch assembly nut 2 NOTE Align the a and b during reassembly While holding the clutch assembly with the ro tor holding tool 3 tighten the clutch assembly nut Recommended lubricant Engine oil Clutch boss nut 90 Nm 9 0 m kg 65 ft lb Universal clutch holder 90890 04086 YM 91042 T R 1...

Page 262: ...CLUTCH 5 49 ...

Page 263: ... 2 1 3 V belt case air filter cover 1 4 V belt case air filter element 1 5 Lead holder 1 6 V belt case 1 7 V belt case gasket 1 8 Bearing retainer 1 9 Bearing 1 10 Circlip 1 11 Oil seal 1 12 Bearing 1 For installation reverse the removal proce dure 2 3 1 6 7 9 8 10 11 12 4 5 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 11 Nm 1 1 m kg 8 0 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 24...

Page 264: ...nut 1 7 Secondary sheave assembly 1 8 Collar 1 9 O ring 1 10 V belt 1 11 Right crankcase cover 1 12 V belt case air duct joint clamp 1 13 V belt case air duct 1 14 Plate 1 15 V belt case air duct seal 1 For installation reverse the removal proce dure 10 7 6 2 1 3 2 9 8 12 13 15 14 11 4 5 90 Nm 9 0 m kg 65 ft Ib 160 Nm 16 0 m kg 116 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 24 Nm 2 4 ...

Page 265: ...RANSMISSION 5 52 Disassembling the primary sheave Order Job Parts to remove Q ty Remarks 1 Cam 1 2 silinder 4 3 Weight 8 4 Primary sliding sheave 1 5 Collar 1 For installation reverse the disassembly procedure 4 3 5 1 2 ...

Page 266: ...e Q ty Remarks 1 Secondary sheave spring seat nut 1 2 Upper spring seat 1 3 Compression spring 1 4 Spring seat 1 5 Secondary sliding sheave 1 6 Oil seal 1 7 O ring 2 8 Guide pin 4 9 Secondary fixed sheave 1 For assembly reverse the disassembly pro cedure 1 2 3 4 6 7 5 8 9 90 Nm 9 0 m kg 65 ft Ib ...

Page 267: ...eave assembly and then tighten the bolts to open the secondary sheave assembly EAS24630 REMOVING THE SECONDARY SHEAVE 1 Remove Secondary sheave assembly 1 Primary sheave assembly 2 V belt 3 NOTE Before removal apply a and b alignment marks Align these marks during reassembly Remove the primary sliding sheave second ary sheave assembly and V belt together 2 Remove Primary fixed sheave 1 EAS15B4002 ...

Page 268: ...HEAVE 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 EAS15B4003 CHECKING THE V BELT CASE AIR DUCT 1 Check V belt case air duct Cracks damage Replace EAS24690 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri mary sheave weights 1 Check Primary sheave weight Cracks da...

Page 269: ...Damage wear Replace the secondary fixed and sliding sheaves as a set 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 NOTE Do not apply the grease inside of the primary sheave EAS24730 ASSEMBLING THE SECONDARY SHEAVE 1 Lubricate Secondary fixed sheave shaft s outer and in ner surfaces 1 Seconda...

Page 270: ... belt case air duct 2 with the slot b on the V belt case air duct joint clamp 1 Align the projection c in the V belt case air duct joint clamp 1 with the slot d in the right crankcase cover 3 2 Install primary fixed sheave 1 V belt 2 secondary sheave assembly 3 CAUTION ECA15B1004 Do not allow grease to contact the V belt pri mary and secondary pulleys NOTE When installing the belt screw M6 more th...

Page 271: ... nut 1 CAUTION ECA15B1005 Before tightening the nut to remount the primary sheave make sure that the serra tions of the cam are fitted firmly into the serrations of the crankshaft Also make sure that cam is properly seated Apply grease to the thread and seat of the primary sheave nut NOTE While holding the primary sheave with the sheave holder 2 tighten the primary sheave nut 1 Secondary sheave nu...

Page 272: ...LUTCH on page 5 30 Clutch Refer to CLUTCH on page 5 43 Oil pump Refer to OIL PUMP on page 5 39 Right crankcase cover Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 50 1 Centerstand assembly 1 2 Timing chain 1 3 Timing chain guide intake side 1 4 Left crankcase 1 5 Dowel pin 2 6 Crankshaft assembly 1 7 Balancer cylinder 1 8 Right crankcase 1 9 Oil strainer 1 10 Dowel pin 2 8 10 7 4 5 1 11 3 2 9 ...

Page 273: ...on reverse the removal proce dure Removing the crankshaft assembly Order Job Parts to remove Q ty Remarks 8 10 7 4 5 1 11 3 2 9 11 6 10 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 24 Nm 2 4 m kg 17 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 58 Nm 5 8 m kg 42 ft Ib ...

Page 274: ...ecting rod 2 2 Connecting rod balancer 1 3 Connecting rod cap 3 4 Big end bearing 3 5 Circlip 2 6 Piston pin 1 7 Balancer piston 1 8 Crankshaft 1 For installation reverse the removal proce dure 1 3 4 4 1 4 4 3 4 5 6 5 2 3 7 4 8 16 Nm 1 6 m kg 12 ft Ib 90 16 Nm 1 6 m kg 12 ft Ib 90 60 Nm 6 0 m kg 43 ft Ib ...

Page 275: ...NG THE CRANKSHAFT JOURNAL BEARING 1 Remove Crankshaft assembly Crankshaft main journal bearings 1 NOTE Remove the main journal bearing by the plane bearing installer 2 NOTE Identify the position of each crankshaft main journal bearing so that it can be reinstalled in its original place EAS26010 REMOVING THE CONNECTING RODS The following procedure applies to all of the con necting rods 1 Remove Con...

Page 276: ...end bearing clear ance and prevent engine damage the big end bearings must be installed in their origi nal positions c Clean the big end bearings crankshaft pins and the inside of the connecting rod halves d Install the big end upper bearing into the con necting rod and the big end lower bearing into the connecting rod cap NOTE Align the projections a on the big end bearings with the notches b in ...

Page 277: ...mpressed Plastigauge width e on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select re placement big end bearings 4 Select Big end bearings P1 P2 P3 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 cranks...

Page 278: ...er a of each main journal at two places If it is out of spec ification replace the crankshaft m Measure the inside diameter b of each jour nal bearing at two places n If journal bearing inside diameter is 45 03 and crankshaft journal outside diameter is 44 98 then the main journal oil clearance is If the oil clearance is out of specification se lect a replacement bearings 6 Select Crankshaft journ...

Page 279: ...arings NOTE Attach the crankshaft main journal bearing to the plane bearing installer 1 2 Install Crankshaft main journal bearings 2 NOTE Align the projection a on the bearing with the projection b on the crankcase Place an iron 3 plate beneath the crankcase and press fit until the end of the plain bearing installer touches the iron plate J1 crankcase J1 crankshaft web 4 2 black Bearing color code...

Page 280: ...ten Connecting rod nuts NOTE Apply molybdenum disulfide grease to the rod cap bolt threads and nut surfaces WARNING EWA13390 Replace the connecting rod bolts and nuts with new ones Clean the connecting rod bolts and nuts NOTE Tighten the connecting rod bolts using the fol lowing procedure b Clean the connecting rod bolts and nuts c Tighten the connecting rod nuts with a torque wrench d Put a mark ...

Page 281: ... final torque is reached If the tightening is interrupted 57 63 Nm 5 7 6 3 m kg 41 45 ft lb loosen the nut to less than 57 Nm 5 7 m kg 41 ft lb and start again EAS15B4004 INSTALLING THE CRANKSHAFT 1 Install Crankshaft assembly 1 Balancer piston cylinder 2 CAUTION ECA15B1003 To avoid scratching the crankshaft and to ease the installation procedure apply grease onto the oil seal lips and apply engin...

Page 282: ...CRANKCASE AND CRANKSHAFT 5 69 ...

Page 283: ...emarks Left crankcase Refer to CHECKING THE CRANKCASE on page 5 62 1 Secondary shaft 1 2 Main axle 1 3 Primary driven gear 1 4 First pinion gear 1 5 Washer 1 6 Drive axle 1 7 First wheel gear 1 8 Circlip 1 9 Bearing 5 10 Oil seal 2 For installation reverse the removal proce dure 10 9 7 8 6 9 10 9 3 2 4 5 9 9 1 12 Nm 1 2 m kg 8 7 ft Ib ...

Page 284: ...l gauge Out of specification Replace the main axle 2 Measure Drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle 3 Measure Secondary shaft runout with a centering device and dial gauge Out of specification Replace the second ary shaft 4 Check Transmission gear movement Rough movement Replace the defective part s 5 Check Circlips Bends damage loosene...

Page 285: ... 68 Rear brake caliper rear wheel Refer to REAR WHEEL on page 4 16 1 Rear brake hose rear brake lock lever cable holder 1 1 2 Cover 1 3 Nut 1 4 Washer 1 5 Swingarm 1 6 Dowel pin 2 7 Pivot shaft 1 8 Collar 1 9 Oil seal 1 10 Bearing 1 11 Left rear footrest 1 12 Chain drive assembly 1 13 Chain drive holder assembly 1 1 12 13 6 11 14 7 8 9 10 4 3 2 5 10 Nm 1 0 m kg 7 2 ft Ib 40 Nm 4 0 m kg 29 ft Ib 7 ...

Page 286: ...val proce dure Removing primary and secondary drive chains Order Job Parts to remove Q ty Remarks 1 12 13 6 11 14 7 8 9 10 4 3 2 5 10 Nm 1 0 m kg 7 2 ft Ib 40 Nm 4 0 m kg 29 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 100 Nm 10 0 m kg 72 ft Ib 30 Nm 3 0 m kg 22 ft Ib 23 Nm 2 3 m kg 17 ft Ib ...

Page 287: ... drive chain 1 3 Secondary drive gear 1 4 Secondary driven gear 1 5 Middle shaft 1 6 Primary drive chain 1 7 Primary drive gear 1 8 Primary driven gear 1 9 Bearing 5 10 Oil seal 4 11 Collar 1 12 Chain drive case inner 1 13 Retainer 1 For installation reverse the removal proce dure 2 4 9 10 11 1 9 9 3 6 7 9 5 8 10 9 10 13 12 10 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 288: ... gear 3 Primary secondary driven gear 4 Secondary drive gear 5 Secondary driven gear 6 Damage wear Replace the respective drive gears and respective drive chains as a set EAS15B4008 ASSEMBLING THE CHAIN DRIVE ASSEMBLY 1 Install Chain drive case outer 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 cri...

Page 289: ...e 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 Check Chain drive oil level Refer to CHECKING THE CHAIN DRIVE OIL LEVEL on page 3 26 Swingarm bolt 40 Nm 4 0 m kg 29 ft lb Pivot shaft 7 Nm 0 7 m kg 5 1 ft lb Nut 100 Nm 10 0 m kg 72 ft lb T R T R ...

Page 290: ...CHAIN DRIVE TRANSMISSION 5 77 ...

Page 291: ... THE OIL COOLER 6 3 INSTALLING THE OIL COOLER AND RADIATOR 6 3 THERMOSTAT 6 5 CHECKING THE THERMOSTAT 6 6 INSTALLING THE THERMOSTAT ASSEMBLY 6 6 WATER PUMP 6 7 DISASSEMBLING THE WATER PUMP 6 9 CHECKING THE WATER PUMP 6 9 ASSEMBLING THE WATER PUMP 6 9 INSTALLING THE WATER PUMP 6 11 ...

Page 292: ... reservoir hose 1 2 Coolant reservoir 1 3 Cooling system air bleed hose 1 4 Oil cooler outlet hose 1 5 Radiator inlet hose 1 6 Thermostat outlet hose 1 Disconnect 7 Coolant pipe 1 8 Fast idle outlet hose 1 Disconnect 9 Radiator outlet hose 1 Disconnect 10 Radiator fan motor coupler 1 Disconnect 11 Radiator filler neck 1 12 Radiator filler hose 1 13 Stay 1 1 16 17 4 18 2 5 7 6 3 9 8 14 13 15 10 11 ...

Page 293: ...let hose 1 Disconnect 18 Oil cooler 1 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Q ty Remarks 1 16 17 4 18 2 5 7 6 3 9 8 14 13 15 10 11 12 17 Nm 1 7 m kg 12 ft Ib 63 Nm 6 3 m kg 45 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 294: ...on Check and repair Refer to COOLING SYSTEM on page 8 29 EAS15B4458 CHECKING THE OIL COOLER 1 Check Oil cooler Cracks damage Replace 2 Check Oil cooler inlet hose Oil cooler outlet hose Cracks damage wear Replace EAS26400 INSTALLING THE OIL COOLER AND RADIATOR 1 Clean Mating surfaces of the oil cooler and the crankcase with a cloth dampened with lacquer thinner 2 Install O ring Oil cooler 1 Oil co...

Page 295: ...he recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 13 4 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 to the radia tor b Apply 100 kPa 1 0 kg cm2 14 22 psi of pressure c Measure the indicated pressure with the gauge 5 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE...

Page 296: ... page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 1 Thermostat outlet hose 1 Disconnect 2 Coolant temperature sensor coupler 1 Disconnect 3 Coolant temperature sensor 1 4 Copper washer 1 5 Thermostat cover 1 6 Thermostat 1 For installation reverse the removal proce dure 1 5 6 2 3 4 10 Nm 1 0 m kg 7 2 ft Ib 18 Nm 1 8 m kg 13 ft Ib ...

Page 297: ...Thermostat housing cover Cracks tears Replace EAS26480 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat Thermostat cover NOTE Install the thermostat with its breather hole a facing forward 2 Install Copper washer Coolant temperature sensor 3 Fill the coolant with the specified amount Cooling system Refer to CHANGING THE COOLANT on page 3 19 4 Check Cooling system Leaks Repair or replace the...

Page 298: ... on page 3 19 1 V belt case air filter element clamp joint 1 2 V belt case air filter element left 1 3 Generator cover protector cover 1 4 Generator cover protector 1 5 Oil cooler inlet hose 1 6 Coolant hose 1 7 Radiator outlet hose 1 8 Water pump inlet pipe 1 9 Water pump outlet pipe 1 10 Water pump assembly 1 For installation reverse the removal proce dure 1 4 3 2 10 8 7 9 5 6 10 Nm 1 0 m kg 7 2...

Page 299: ... shaft unless the coolant level is extremely low or coolant contains engine oil 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Water pump seal 1 6 Bearing 1 7 Oil seal 1 8 Water pump housing 1 For assembly reverse the disassembly pro cedure 8 3 6 2 7 5 4 1 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 300: ...amper 2 from the impeller with a thin flat head screwdriver NOTE Do not scratch the impeller shaft EAS26550 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 2 Impeller shaft 3 Water pump seal 4 Oil seal 5 Rubber damper Rubber damper holder Cracks damage wear Replace EAS26570 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 to the water pump housing NOTE Install the oil s...

Page 301: ...er damper holder 2 NOTE Before installing the rubber damper apply tap water or coolant onto its outer surface 5 Measure Tilt Out of specification Repeat steps 3 and 4 CAUTION ECA15B1030 Make sure that the rubber damper and rub ber damper holder are flush with the impel ler Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 90890 04058 Bear...

Page 302: ...m with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 3 Check Cooling system Leaks Repair or replace any faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 1 Straightedge 2 Impeller Water pump assembly bolt 10 Nm 1 0 m kg 7 2 ft lb T R a b ...

Page 303: ... TANK 7 2 REMOVING THE FUEL PUMP 7 2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 2 THROTTLE BODIES 7 4 CHECKING THE INJECTORS 7 7 CHECKING THE THROTTLE BODIES 7 7 CHECKING THE PRESSURE REGULATOR OPERATION 7 7 ADJUSTING THE THROTTLE POSITION SENSOR 7 7 ...

Page 304: ... Fuel pump coupler 1 2 Fuel hose connector cover 1 3 Fuel hose 1 4 Fuel tank breather hose 1 5 Fuel pump bracket 1 6 Fuel pump 1 7 Fuel pump gasket 1 8 Fuel tank cap 1 9 Fuel overflow tray fuel over flow hose 1 1 10 Fuel tank 1 For installation reverse the removal proce dure 10 Nm 1 0 m kg 7 2 ft Ib 4 Nm 0 4 m kg 2 9 ft Ib 9 7 2 3 8 5 4 6 10 1 ...

Page 305: ...1 Remove Fuel pump bracket Fuel pump Fuel pump gasket CAUTION ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26710 INSTALLING THE FUEL PUMP 1 Install Fuel pump gasket Fuel pump Fuel pump bracket NOTE Do not damage the installation surfaces of the fuel tank when installing the fuel pump Always use a new fuel pump gasket Align the pro...

Page 306: ... 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 posi tion otherwise the fuel hose will not be properly installed 3 Install Fuel pump connector cover ...

Page 307: ...le cable 2 Disconnect 7 Fast idle inlet hose 1 Disconnect 8 Fast idle outlet hose 1 Disconnect 9 Throttle position sensor coupler 1 Disconnect 10 Throttle body assembly 1 11 Fuel injector coupler 2 Disconnect 12 Intake air pressure sensor coupler 1 Disconnect 13 Intake air pressure sensor 1 14 Fuel injector with fuel hose 2 15 Intake manifold 2 2 3 5 3 4 4 1 6 8 7 15 15 14 11 11 14 10 9 13 12 11 1...

Page 308: ... the removal proce dure Removing the throttle bodies Order Job Parts to remove Q ty Remarks 2 3 5 3 4 4 1 6 8 7 15 15 14 11 11 14 10 9 13 12 11 11 12 Nm 1 2 m kg 8 7 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 9 Nm 0 9 m kg 6 5 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 309: ...TE 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 Throttle position sensor 1 2 Fast idle plunger 1 3 Idle adjust screw 1 4 Air screw 2 For installation reverse the removal proce dure 1 2 2 4 3 ...

Page 310: ...ngine f Measure the fuel pressure Out of specification Check the fuel hose connection or replace the fuel pump g Turn the main switch to OFF h Remove the pressure gauge and fuel pres sure adapter NOTE Before removing the special tools place a few rags in the area under where it will be removed i Install the fuel hose j Install the fuel hose connector cover fuel tank cover and seat Refer to GENERAL...

Page 311: ... throttle position sensor angle so that the voltage is within the specified range g After adjusting the throttle position sensor an gle tighten the throttle position sensor screws Tester positive probe Yellow 1 Negative tester probe Black Blue 2 Throttle position sensor voltage closed position 0 63 0 73V Yellow Black Blue 1 2 ...

Page 312: ...THROTTLE BODIES 7 9 ...

Page 313: ... CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 FUEL INJECTION SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 ECU SELF DIAGNOSTIC FUNCTION 8 35 FAIL SAFE ACTIONS SUBSTITUTE CHARACTERISTICS OPERATION CONTROL 8 35 TROUBLESHOOTING METHOD 8 38 DIAGNOSTIC MODE 8 38 TROUBLESHOOTING DETAILS 8 45 IMMOBILIZER SYSTEM 8 57 CIRCUIT DIAGRAM 8 57 GENERAL INFORMATION 8 59 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS 8 5...

Page 314: ...IN SWITCH IS SET TO ON 8 82 C 2 ABS WARNING LIGHT AND ALL OTHER INDICATORS DO NOT COME ON 8 82 C 3 ABS WARNING LIGHT FLASHES 8 83 C 4 ABS WARNING LIGHT FLASHES EVERY 0 5 SECOND 8 83 C 5 DIAGNOSIS BY THE MALFUNCTION CODE 8 83 D 6 4 DELETING THE MALFUNCTION CODE 8 93 D 6 6 DELETE FUNCTION TEST 8 94 D 6 FINAL CHECK 8 95 ELECTRICAL COMPONENTS 8 97 CHECKING THE SWITCHES 8 101 CHECKING THE BULBS AND BUL...

Page 315: ...E 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 8 121 ...

Page 316: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 317: ...rankshaft 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 Lean angle sensor ...

Page 318: ...PARK PLUGS on page 3 9 NG Re gap or replace the spark plug OK 4 Check the spark plug gap Refer to CHECKING THE SPARK PLUG GAP on page 8 113 OK Ignition system is OK NG 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAPS on page 8 112 NG Replace the spark plug caps OK 6 Check the ignition coils Refer to CHECKING THE IGNITION COIL on page 8 113 NG Replace the ignition coils OK 7 Check t...

Page 319: ...ode Refer to CHECKING THE RELAYS on page 8 110 NG Replace the starting circuit cut off relay 1 OK 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 114 NG Replace the lean angle sensor OK 13 Check the entire ignition system s wir ing Refer to CIRCUIT DIAGRAM on page 8 1 NG Properly connect or repair the ignition system s wiring OK Replace the ECU ...

Page 320: ...ELECTRIC STARTING SYSTEM 8 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM XP500 ...

Page 321: ...naling 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 Rear brake light switch ...

Page 322: ...ELECTRIC STARTING SYSTEM 8 7 XP500A ...

Page 323: ... 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 Rear brake light switch ...

Page 324: ...the handlebar the brake light switch is closed and the side stand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting cir...

Page 325: ...tery 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 Starter motor ...

Page 326: ...ELECTRIC STARTING SYSTEM 8 11 ...

Page 327: ... 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 Starter motor ...

Page 328: ...starter motor Refer to CHECKING THE STARTER MOTOR on page 5 37 NG Repair or replace the starter motor OK 5 Check the starting circuit cut off relay 1 Refer to CHECKING THE RELAYS on page 8 110 NG Replace the starting circuit cut off relay 1 OK 6 Check the starting circuit cut off relay 1 Diode Refer to CHECKING THE RELAYS on page 8 110 NG Replace the starting circuit cut off relay 1 OK 7 Check the...

Page 329: ...h Refer to CHECKING THE SWITCHES on page 8 101 NG Replace the brake light switch OK 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 101 NG Replace the right handlebar switch OK 14 Check the entire starting system s wir ing Refer to CIRCUIT DIAGRAM on page 8 5 NG Properly connect or repair the starting system s wiring OK The starting system circuit is OK ...

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 332: ...Refer to CHECKING AND CHARG ING THE BATTERY on page 8 107 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 115 NG Replace the stator assembly OK 4 Check the charging voltage Refer to CHECKING THE CHARG ING VOLTAGE on page 8 116 OK Charging voltage is OK NG 5 Check the entire charging system s wiring Refer to CIRCU...

Page 333: ...CHARGING SYSTEM 8 18 ...

Page 334: ...LIGHTING SYSTEM 8 19 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 335: ... 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 High beam indicator light ...

Page 336: ...ND CHARG ING THE BATTERY on page 8 107 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 101 NG Replace the main switch OK 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 101 NG Replace the left handlebar switch OK 6 Check the pass switch Refer to CHECKING THE SWITCHES on page 8 101 NG Replace the l...

Page 337: ...LIGHTING SYSTEM 8 22 ...

Page 338: ...SIGNALING SYSTEM 8 23 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 339: ...ay 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 Front turn signal light left 69 V belt replacement reset coupler 72 Multi function display 73 Speedometer 74 Tachometer 75 Engine oil change indicator light 76 V belt replacement indicator light 77 Engine t...

Page 340: ...ce the fuse s OK 2 Check the battery Refer to CHECKING AND CHARG ING THE BATTERY on page 8 107 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 101 NG Replace the main switch OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 23 NG Properly connect or repair the signaling system s wiri...

Page 341: ...i cator light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 105 NG Replace the turn signal indicator light bulb socket or both OK 2 Check the turn signal switch Refer to CHECKING THE SWITCHES on page 8 101 NG Replace the left handlebar switch OK 3 Check the hazard switch Refer to CHECKING THE SWITCHES on page 8 101 NG Replace the right handlebar switch OK 4 Check the turn ...

Page 342: ...SENDER on page 8 117 NG Replace the fuel pump assembly OK 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 OK Replace the meter assembly 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 117 NG Replace the speed sensor OK 2 Check the entire signaling system s wiring Refer to CIRCUIT DI...

Page 343: ...SIGNALING SYSTEM 8 28 ...

Page 344: ...COOLING SYSTEM 8 29 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...

Page 345: ...STEM 8 30 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 Multi function display ...

Page 346: ...ain switch Refer to CHECKING THE SWITCHES on page 8 101 NG Replace the main switch OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 118 NG Replace the radiator fan motor OK 5 Check the radiator fan motor relay Refer to CHECKING THE RELAYS on page 8 110 NG Replace the radiator fan motor relay OK 6 Check the coolant temperature sensor Refer to CHECKING THE COOLAN...

Page 347: ...COOLING SYSTEM 8 32 ...

Page 348: ...FUEL INJECTION SYSTEM 8 33 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 349: ... 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 Throttle position sensor 40 Lean angle sensor 41 Speed sensor 47 Radiator fan motor relay 51 Headlight relay 72 Multi function di...

Page 350: ... is present and the start switch is pushed Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for 1 4 seconds after the main switch has been turned to ON and when the start switch is being pushed If the warning light does not come on under these con ditions the warning light bulb may be defective EAS27382 FAIL SAFE ACTIONS SUBSTITUTE CHARACTERISTIC...

Page 351: ...and switch to the ECU engine Unable Unable 21 Coolant temperature sensor Coolant temperature sensor open or short circuit detected Able Able 22 Intake air temperature sensor Intake air temperature sensor open or short circuit detected Able Able 24 O2 sensor No normal signal is received from the O2 sensor Able Able 30 Lean angle sensor Latch up detected No normal signal is received from the lean an...

Page 352: ...e 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 Unable Unable Er 3 ECU engine internal malfunction output signal error Data from the ECU engine cannot be received correctly Unable Unable Er 4 ECU engine internal malfunction input signal error Non registered data has been received from the ...

Page 353: ... 1 Turn the main switch to OFF and set the en gine stop switch to 2 Disconnect the wire harness coupler from the fuel pump 3 Simultaneously press and hold the SE LECT 1 and RESET 2 buttons turn the main switch to ON and continue to press the buttons for 8 seconds or more NOTE All displays on the meter disappear except the clock and tripmeter displays dIAG appears on the clock LCD 4 Press the SELEC...

Page 354: ...ata representing the operating condi tions 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 set it to OFF and then set it to again 9 Turn the main switch to to cancel the di agnostic mode 01 70 01 70 1 ...

Page 355: ...ive throttle position sensor Malfunction in ECU engine Improperly installed throttle position sen sor 01 16 Stuck throttle position sensor detected Stuck throttle position sensor Malfunction in ECU engine 01 19 Open circuit is detected in the input line from the sidestand switch to the ECU engine Open or short circuit in wire harness Malfunction in ECU engine 20 21 Coolant temperature sen sor open...

Page 356: ...ory 60 46 Power supply to the fuel injec tion system is not normal Malfunction in the charging system Refer to CHARGING SYSTEM on page 8 15 50 Faulty ECU engine memory When this malfunction is detected in the ECU engine the fault code number might not appear on the meter Malfunction in ECU engine The program and data are not properly written on or read from the internal memory Er 1 No signals are ...

Page 357: ...era ture Compare the actually mea sured intake air temperature with the meter display value 2 06 Coolant temperature Displays the coolant tempera ture Compare the actually mea sured coolant temperature with the meter display value 07 Vehicle speed pulse 0 999 Check that the number changes integrating when the rear wheels are rotated 08 Lean angle sensor Remove the lean angle sen sor and incline it...

Page 358: ... method Diagnos tic monitori ng code No Item Actuation Checking method 30 Ignition coil Actuates the ignition coil for five times every second Illuminates the engine trouble warning light Check the spark five times Connect an ignition checker 36 Injector 1 Actuates the injector 1 for five times every second Illuminates the engine trouble warning light Check the operating sound of the injector 1 fi...

Page 359: ...tuates the headlight relay for five times every five second ON 2 seconds OFF 3 sec onds Illuminates the engine trouble warning light Check the operating sound of the headlight relay five times 57 Grip warmer relay Actuates the grip warmer relay the light is off when the relay is off and the light is on when the relay is on Illuminates the engine trouble warning light Check the operating sound of t...

Page 360: ...tom No normal signals are received from the crankshaft position sensor Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of crankshaft position sensor Check the installed area for loose ness or pinching Cranking the engine 2 Connected state of connector Crankshaft position sensor coupler Main wire harness ECU engine coup...

Page 361: ...pler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Cranking the engine 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler Black Blue Black Blue Pink White Pink White Blue Blue 3 Defective intake air press...

Page 362: ... oper ating it at idle 2 Intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connected state of connector Intake air pressure sensor coupler Main wire harness ECU engine coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction ...

Page 363: ...may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between sensor coupler and ECU engine coupler Black Blue Black Blue Yellow Yellow Blue Blue 4 Throttle position sensor lead wire open cir cuit output voltage check Check for open cir...

Page 364: ...code No 19 Symptom Open circuit is detected in the input line from the sidestand switch to the ECU engine Diagnostic code No 20 Sidestand switch Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connected state of connector Main wire harness ECU engine coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler I...

Page 365: ... of connector Coolant temperature sensor coupler Main wire harness ECU engine coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler Black Blue Black Blue...

Page 366: ...f connector Intake air temperature sensor cou pler Main wire harness ECU engine coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler Black Blue Black Bl...

Page 367: ...ect it securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler Black Blue Black Blue Gray Green Gray Green Red Blue Red Blue Black Black 4 Check fuel pressure Refer to CHECKING THE PRES SURE REGULATOR OPERATION on page 7 7 5 Defective O2 sensor Replace if defective Fault code No 30 Symptom Latch up detected No n...

Page 368: ...Repair or replace if there is an open or short circuit Between ignition coil coupler and ECU coupler Orange Orange Red Black Red Black 3 Defective ignition coil Execute the diagnostic monitor ing mode Code No 30 Replace if defective Refer to CHECKING THE IGNI TION COIL on page 8 113 Fault code No 37 Symptom Engine speed is high when the engine is idling Diagnostic monitoring code No 01 Throttle po...

Page 369: ...ult code No 43 Symptom The ECU engine is unable to monitor the battery voltage Diagnostic code No 50 Fuel injection system relay Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connected state of connector Fuel injection system relay coupler Main wire harness ECU engine coupler Check the coupler for any pins that may have pulled out Check the locking condit...

Page 370: ...use Check or maintenance job Reinstatement method 1 Malfunction in ECU engine Execute the diagnostic monitor ing mode Code No 60 Check the faulty cylinder If there are multiple cylinders the number of the faulty cylinders appears alternately at 2 sec ond intervals Readjust the CO of the dis played cylinder Refer to ADJUSTING THE EX HAUST GAS VOLUME on page 3 7 Replace ECU engine if defec tive Turn...

Page 371: ...ARGING THE BATTERY on page 8 107 3 The malfunction of the rectifier regulator Replace if defective Refer to CHARGING SYSTEM on page 8 15 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery terminal and main switch coupler Red Red Between main switch coupler and fuse box coupler Brown Blue Brown Blue Between fuse box coupler and ECU engine ...

Page 372: ...IMMOBILIZER SYSTEM 8 57 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...

Page 373: ... 58 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 Multi function meter ...

Page 374: ...ey is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is high ly recommended to use either standard key for driving and to keep the code re registering key in a safe plac...

Page 375: ...ill start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Standby mode Standard key registration Standard key registration is required when a standard key is lost and needs to be replaced or when Parts to be replaced Key registration requirement Main switch immobilizer u...

Page 376: ... remove the key and within 5 sec onds insert the second standard key to be registered into the main switch NOTE If he immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered the registration mode is deactivated If this occurs the second standard key cannot be registered and steps 2 to 4 need to be repeated to register both standard keys 5 Turn the mai...

Page 377: ...f the immobilizer system indicator light stops flashing 5 seconds after the first stan dard key is registered the second standard key cannot be registered 1 Check the fuses Main ignition and backup Refer to CHECKING THE FUSES on page 8 106 NG Replace the fuse s OK 2 Check the battery Refer to CHECKING AND CHARG ING THE BATTERY on page 8 107 NG Clean the battery terminals Recharge or replace the ba...

Page 378: ...IZER UNIT Codes cannot be transmitted between the ECU and the immobilizer unit Noise interference or dis connected lead cable Interference due to radio wave noise Disconnected commu nication harness Immobilizer unit mal function ECU malfunction Check the wire harness and con nector Replace the main switch immobi lizer unit Replace the ECU 54 IMMOBILIZER UNIT Codes transmitted between the ECU and t...

Page 379: ...ec ON and 1 5 sec OFF Digit of 1 Cycles of 0 5 sec ON and 0 5 sec OFF Example fault code 52 56 ECU Undefinition code is received Noise interference or dis connected lead cable Check the wire harness and con nector Replace the main switch immobi lizer unit Replace the ECU Fault code Part Symptom Cause Action ...

Page 380: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 65 EAS28790 ABS ANTI LOCK BRAKE SYSTEM XP500A EAS27730 CIRCUIT DIAGRAM ...

Page 381: ...arting 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 warning light ...

Page 382: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 67 EAS27740 ABS COMPONENTS CHART ...

Page 383: ...STEM XP500A 8 68 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 Front disc rotor ...

Page 384: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 69 EAS27750 ABS CONNECTOR LOCATION CHART 2 1 6 5 3 4 7 ...

Page 385: ... ANTI LOCK BRAKE SYSTEM XP500A 8 70 1 ABS test coupler 2 ECU ABS coupler 3 Front wheel sensor coupler 4 Fail safe relay coupler 5 Hydraulic unit coupler 6 Rear wheel sensor coupler 7 Multi function coupler ...

Page 386: ...ing the ECU ABS and fail safe relay Order Job Parts to remove Q ty Remarks Front cowling Refer to GENERAL CHASSIS on page 4 1 1 Fail safe relay coupler 1 Disconnect 2 Fail safe relay 1 3 Upper ECU ABS bracket 1 4 ECU ABS coupler 1 Disconnect 5 ECU ABS 1 5 4 4 3 1 2 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 387: ...elay Check for continuity between terminals 7 and 8 of the solenoid relay Positive tester probe Terminal 7 Negative tester probe Terminal 8 Tester reading is Replace the fail safe relay Connect the positive battery terminal to termi nal 7 and the negative battery terminal to terminal 8 and then check for continuity be tween terminals 4 and 5 of the solenoid re lay Positive tester probe Terminal 4 ...

Page 388: ...EAS15B4887d D 5 MAINTENANCE OF THE HYDRAULIC UNIT CAUTION ECA15B1006 Do not remove the hydraulic unit to check the resistance of the solenoid valves and the ABS motor for continuity Checking the resistance of the solenoid valves and ABS motor for continuity CAUTION ECA15B1007 When check the hydraulic unit solenoid relay and ABS motor do not remove the brake hoses 1 Measure Resistance of the soleno...

Page 389: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 74 Positive tester probe Terminal 1 Negative tester probe Terminal 2 No continuity Replace the hydraulic unit There is continuity ...

Page 390: ... are possible Previously occurred error phenomenon can be checked since it also installs the memory for storing malfunction history In case malfunctions are detected It is disabled to call the malfunction code by using the malfunction display since the ABS warning light already goes on Connect the test coupler adapter to the test connector connect a pocket tester to the terminal of light green lea...

Page 391: ...ed regular batteries only A Malfunction check by the ABS warning light B Detail check of malfunction Results by self diagnosis are displayed by the multifunction display or a pocket tester according to the ECU s operation C Supposing the malfunction cause and position Find the malfunction cause by reasoning the place and situation where it occurred D ABS system services Execute the final check aft...

Page 392: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 77 EAS27810 BASIC PROCESS FOR TROUBLESHOOTING ...

Page 393: ...pect or replace the battery 2 Malfunction codes displayed Check the malfunction codes using the ABS test coupler adaptor Perform troubleshooting corresponding to the malfunction codes B 5 3 Wire harness ECU ABS and meter coupler are disconnected Connect the coupler securely until a click sound is heard 4 Check the disconnection between the ECU ABS and meter ABS warning light Check the conductivity...

Page 394: ...s used when checking the ABS warning light circuit To ground the T C terminal connect the test coupler adapter A with the test coupler Before con necting check if the battery is sufficiently charged EAS27860 B 4 MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS PAST MALFUNCTION Check the location of test coupler 1 Remove the protective cap and connect the ABS test coupler adapter 2 to the test coupler T...

Page 395: ...uel injection system malfunctions or adjusting the exhaust gas volume the ABS malfunction codes are not displayed EAS27870 B 5 MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS PRESENT MALFUNCTION NOTE Before proceeding to read the part of Arrangement and the function of test coupler Remove the side cowling right and check the location of test coupler Connect the test coupler adapter with the test coupl...

Page 396: ...ple 10 digits 1 digit pattern of tester reading is shown below 1 ABS test coupler 2 Lock plate 3 Protective cap 4 Grounding 5 T C terminal 6 T F terminal 7 ABS warning light terminal white red 8 Test coupler adapter 9 Light green 10 Black 11 White red ...

Page 397: ...ight terminal white red of the test coupler adaptor or connect the warning light terminal to the negative battery terminal If the ABS warning light comes on the wire harness ABS system circuit may be disconnected If the ABS warning light does not come on the ABS warning light lead may be disconnected or the contact of the ABS warning light may be defective Remove the ECU ABS coupler and check the ...

Page 398: ...B3015 C 4 ABS WARNING LIGHT FLASHES EVERY 0 5 SECOND 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 condi tions when the ABS warning light comes on 1 Voltage ...

Page 399: ...nuity in the front 15 or rear 16 wheel sensor circuits Continuity of sensor circuits ABS wireharness circuit Connection of sensor coupler Malfunction codes 15 front wheel sensor and 16 rear wheel sensor 21 Disconnection and short circuit of hydraulic unit solenoid Wire harness circuit Hydraulic unit solenoid coupler Hydraulic unit solenoid Battery terminal is disconnect Malfunction code 21 31 Disc...

Page 400: ...dragging Hydraulic unit operation test 2 D 6 3 2 Front wheel brake line Malfunction code 41 42 Rear wheel will not recover from the locking tendency even though the sig nal is continuously transmitted from the ECU ABS to release the hydrau lic state when the battery voltage is normal Brake dragging Hydraulic unit operation test 2 D 6 3 2 Rear wheel brake line Malfunction code 42 51 Front wheel wil...

Page 401: ...econds then goes off With the rear wheel stopped the front wheel was rotated at a speed faster than 11 km h This is not a malfunction Signal is not generated at the rear wheel sensor Rear wheel sensor is not installed properly D 4 Rear wheel sensor rotor is defective D 4 Rear wheel sensor circuit is short circuited Rear sensor or lead is short circuited D 4 Wire harness ABS sensor circuit is short...

Page 402: ...l sensor or 16 rear wheel sensor is dis played the malfunction code will be overwritten from 15 to 11 front wheel sensor signal or from 16 to 12 rear wheel sensor signal Malfunction code 21 Disconnection and short circuit of hydraulic unit solenoid 1 Hydraulic unit solenoid coupler Check if the hydraulic unit solenoid coupler terminal is disconnected Refer to ABS CONNECTOR LOCATION CHART on page 8...

Page 403: ...etween 1 and 2 and between 1 and 3 of the hydraulic unit solenoid cir cuits for continuity 4 Fale safe relay Check if the fail safe relay operates correctly D 2 5 Wire harness Check for continuity between the red terminal of the fail safe relay coupler and the positive battery terminal Remove the ABS fuse and check for continuity between the brown white 1 lead of the fail safe relay coupler and th...

Page 404: ...re harness ABS and the wire harness ABS end terminal A shown in the illus tration of the ABS motor fuse terminal in the side of the stay Refer to ABS CONNECTOR LOCA TION CHART on page 8 69 Check for continuity between the positive battery terminal and the battery end of the ABS motor fuse terminal terminal B shown in the above illustration Remove the ECU ABS and the fail safe relay from the wire h...

Page 405: ...ally check the brake fluid in the brake master cylinder reservoir and the fluid for water foreign materials solidification and contamination Check for air in the brake hose lines 4 Brake hose lines Check the brake hose lines for kinks and deterioration WARNING EWA15B3005 Only use genuine Yamaha parts Using other brake pipes hoses and union bolts may close the brake hose lines Check that the connec...

Page 406: ...nd check the fluid for water foreign materials solidification and contamination Check for air in the brake hose lines 4 Brake hose lines Check the brake hose lines for kinks and deterioration particularly between the hydraulic unit and the rear brake caliper WARNING EWA15B3005 Only use genuine Yamaha parts Using other brake pipes hoses and union bolts may close the brake hose lines Check that the ...

Page 407: ...1 Rotation of the front wheel Refer to Malfunction code 41 2 Brake master cylinder and brake caliper Refer to Malfunction code 41 3 Brake fluid Refer to Malfunction code 41 4 Brake hose lines Refer to Malfunction code 41 5 Hydraulic unit solenoid coupler terminals Refer to Malfunction code 41 6 Hydraulic unit Refer to Malfunction code 41 7 Battery voltage Measure the battery voltage Malfunction co...

Page 408: ...odes NOTE The ABS error code is not displayed during the diagnosis of the fuel injection 3 Turn the engine stop switch off CAUTION ECA15B3026 If the starter switch is pushed without turning the engine stop switch off it may damage the starting motor gears or other parts therefore be sure to turn it off 4 Push the starter switch 2 more than 10 times in 4 seconds to delete the malfunction codes NOTE...

Page 409: ...ction code when the service work is finished EAS15B3038 D 6 6 DELETE FUNCTION TEST 1 Place the vehicle on the centerstand 2 Set the main switch to OFF 3 Connect the test coupler adapter to the test coupler 4 Set the main switch to ON 5 Check ECU ABS voltage Connect the pocket tester DC 20 V to the ECU ABS coupler Tester positive probe Brown White 1 Tester negative probe Black 2 Lower than 12 8 V C...

Page 410: ... switch 8 If the above mentioned check are within specification replace the ECU ABS EAS15B3016 D 6 FINAL CHECK Checking procedures 1 Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 22 2 Check the wheel sensor housings and wheel sensors for proper installation Refer to FRONT WHEEL on page 4 6 and REAR WHE...

Page 411: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 96 ...

Page 412: ...ELECTRICAL COMPONENTS 8 97 EAS27970 ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 ...

Page 413: ...ircuit 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 Radiator fan motor relay ...

Page 414: ...ELECTRICAL COMPONENTS 8 99 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 415: ...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 ECU engine ...

Page 416: ...S 1 3 4 5 2 PASS Y R Y Y G L B NR N NL Dg Br W Ch B Y L Y P B B P R Y Br W L B BLUE L Y G Ch B Y Y Dg R L G B B BLUE OFF ON P Br R Br L R R Br L Br R LW B R WR B Ch DgL YBr L Br W R W Br R B B G Y L W BROWN Ch Br W L Y Dg Br L BLACK G Y Br 6 7 8 9 10 11 12 13 ...

Page 417: ...s 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 Fuse ...

Page 418: ...rth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustra tion similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE indicates a continuity of electricity between switch terminals i e a closed cir...

Page 419: ...ELECTRICAL COMPONENTS 8 104 ...

Page 420: ...The following procedure applies to all of the bulbs 1 Remove Bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down CAUTION ECA14380 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of...

Page 421: ...The following procedure applies to all of the fus es CAUTION ECA13680 To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove Grab bar Rear cover Battery cover Refer to GENERAL CHASSIS on page 4 1 2 Check Fuse a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Ω 1 b If the pocket tester indicates rep...

Page 422: ...ical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion CAUTION ECA13660 This is a sealed battery Never remove the sealing caps because the balance between cells will not be maintained and battery per formance will deteriorate Charging time charging amperage and charging voltage for an MF battery a...

Page 423: ...hi cle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal an...

Page 424: ...ltage prior to charging NOTE Voltage should be measured 30 minutes after the machine is stopped b Connect a charger and AMP meter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery NOTE If the current is lower than the standard charging current written on the battery This type of bat tery charger cannot charge the MF...

Page 425: ...an motor relay Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Relay operation Continuity No continuity between 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity OK No continuity Replace 1 Positive battery t...

Page 426: ...ltage Out of specification Replace a Connect the pocket tester DC 20 V to the turn signal hazard relay terminal as shown b Turn the main switch to ON c Measure the turn signal hazard relay output voltage 1 Positive battery terminal 2 Negative battery terminal 3 Tester positive probe 4 Negative tester probe Result Continuity OK No continuity Replace Turn signal hazard relay input voltage DC 12 V Po...

Page 427: ...ING THE SPARK PLUG CAPS The following procedure applies to all of the spark plug caps 1 Check Spark plug cap resistance Out of specification Replace a Remove the spark plug cap from the spark plug lead b Connect the pocket tester Ω 1k to the spark plug cap as shown c Measure the spark plug cap resistance Pocket tester 90890 03112 Analog pocket tester YU 03112 C Continuity Positive tester probe Red...

Page 428: ...ance EAS28080b CHECKING THE SPARK PLUG GAP 1 Check Ignition spark gap Out of specification Replace a Disconnect the spark plug cap 1 from the spark plug b Connect the ignition checker dynamic spark tester 2 as shown c Set the main switch to ON d Measure the ignition spark gap a Primary coil resistance 1 87 2 53 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Red B...

Page 429: ...istance EAS28130 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor from the bracket 2 Check Lean angle sensor out put voltage Out of specification Replace a Connect the lean angle sensor coupler to the wireharness b Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown 1 Spark plug gap Crankshaft position sensor resis tance 189 231 Ω Gy B Pocket tester 90890 03112 Ana...

Page 430: ...he bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity 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 a Connect the pocket tester Ω 1 to the stat...

Page 431: ... the charging voltage EAS28180 CHECKING THE HORN 1 Check Horn voltage Out of specification Properly connect or re pair the signaling system s wiring a Connect the pocket tester 20V DC to the horn terminal b Turn the main switch to ON c Measure the voltage DC 12 V of brown at the horn coupler Rectifier regulator input voltage above 14 V at 5000 r min Pocket tester 90890 03112 Analog pocket tester Y...

Page 432: ...Replace a Connect the pocket tester Ω 1 to the fuel sender terminal as shown b Measure the fuel sender resistance EAS28240 CHECKING THE SPEED SENSOR 1 Check Speed sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown Fuel sender resistance up posi tion F A 19 21Ω at 20 C 68 F Fuel sender resistance down po siti...

Page 433: ... Remove Coolant temperature sensor Refer to THERMOSTAT on page 6 5 WARNING EWA14130 Handle the coolant temperature sensor with special care Never subject the coolant temperature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 1k to the cool ant temperature sens...

Page 434: ...ttle position sensor from the throttle body c Connect the pocket tester Ω 1k to the throttle position sensor as shown d Measure the throttle position sensor resis tance Out of specification Replace the throttle position sensor e Connect the pocket tester to the throttle posi tion sensor as shown f While slowly opening the throttle check that the throttle position sensor resistance is with in the s...

Page 435: ...NG THE INTAKE AIR TEMPERATURE SENSOR WARNING EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 1 Check Intake air temperature sensor voltage Out of specification Replace a Connect the pocket tester DC 20V to the in take air temperature sensor terminal as sho...

Page 436: ...upler voltage Out of specification Replace a Connect the pocket tester 20V DC to the meter assembly coupler wire harness side as shown b Turn the main switch to ON c Measure the voltage of gray 1 and black 2 at the meter assembly coupler Tester positive probe Pink White 1 Negative tester probe Black Blue 2 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Tester positive probe Black 1 Nega...

Page 437: ...STARTING FAILURE HARD STARTING 9 1 INCORRECT ENGINE IDLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 3 ...

Page 438: ...ole body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery 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 ...

Page 439: ...nce 1 V belt V belt slips Oil or grease on the V belt 2 Primary sliding sheave Faulty operation Worn pin groove Worn pin 3 Clutch shoe s 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 Primary fixed sheave Worn primary fixed sheave 4 Primary sliding sheave Worn primary sliding sheav...

Page 440: ...y tightened ring nut Bent steering stem Damaged ball bearing or bearing race 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...

Page 441: ...wn 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 Faulty turn signal relay Burnt out turn signal bulb Turn signal blinks quickly Incorrect turn signal bulb Faulty turn signal relay Burnt out turn signal bulb Horn does not sound Improperly adjusted horn Damaged or faulty hor...

Page 442: ...ensor 40 Lean angle cut off switch 41 Speed sensor 42 Grip warmer switch optional 43 Grip warmer relay optional 44 Grip warmer optional 45 Auxiliary DC jack fuse 46 Auxiliary DC jack 47 Radiator fan motor relay 48 Radiator fan motor 49 Turn signal hazard relay 50 Horn 51 Headlight relay 52 Left handlebar switch 53 Pass switch 54 Dimmer switch 55 Horn switch 56 Turn signal switch 57 Rear brake ligh...

Page 443: ...itch 44 ABS test coupler 45 ECU ABS 46 Front wheel sensor 47 Rear wheel sensor 48 Fail safe relay 49 Hydraulic unit 50 Grip warmer switch optional 51 Grip warmer relay optional 52 Grip warmer optional 53 Auxiliary DC jack fuse 54 Auxiliary DC jack 55 Radiator fan motor relay 56 Radiator fan motor 57 Turn signal hazard relay 58 Horn 59 Headlight relay 60 Left handlebar switch 61 Pass switch 62 Dimm...

Page 444: ... 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 Black P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue White W B White Black W R White Red W Y White Yellow Y B Yellow Black Y G Yellow Gr...

Page 445: ......

Page 446: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 447: ...XP500 2007 WIRING DIAGRAM XP500 2007 SCHÉMA DE CÂBLAGE XP500 2007 SCHALTPLAN SCHEMA ELETTRICO XP500 2007 DIAGRAMA ELÉCTRICO DE LA XP500 2007 ...

Page 448: ...XP500A 2007 WIRING DIAGRAM XP500A 2007 SCHÉMA DE CÂBLAGE XP500A 2007 SCHALTPLAN SCHEMA ELETTRICO XP500A 2007 DIAGRAMA ELÉCTRICO DE LA XP500A 2007 ...

Page 449: ...XP500 2007 WIRING DIAGRAM XP500 2007 SCHÉMA DE CÂBLAGE XP500 2007 SCHALTPLAN SCHEMA ELETTRICO XP500 2007 DIAGRAMA ELÉCTRICO DE LA XP500 2007 ...

Page 450: ...XP500A 2007 WIRING DIAGRAM XP500A 2007 SCHÉMA DE CÂBLAGE XP500A 2007 SCHALTPLAN SCHEMA ELETTRICO XP500A 2007 DIAGRAMA ELÉCTRICO DE LA XP500A 2007 ...

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