
ENGINE SPECIFICATIONS
2-6
Wear limit
66.100 mm (2.6024 in)
Taper limit
0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance
0.020
–
0.045 mm (0.0008
–
0.0018 in)
Limit
0.15 mm (0.0059 in)
Diameter D
65.965
–
65.980 mm (2.5970
–
2.5976 in)
Height H
9.0 mm (0.35 in)
Offset
0.50 mm (0.0197 in)
Offset direction
Intake side
Piston pin bore inside diameter
15.002
–
15.013 mm (0.5906
–
0.5911 in)
Limit
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 in)
End gap (installed)
0.40
–
0.50 mm (0.0157
–
0.0197 in)
Limit
0.75 mm (0.0295 in)
Ring side clearance
0.020
–
0.055 mm (0.0008
–
0.0022 in)
Limit
0.100 mm (0.0039 in)
Oil ring
Dimensions (B
×
T)
1.50
×
2.00 mm (0.06
×
0.08 in)
H
D
T
B
B
T
Summary of Contents for 2007 XP500
Page 1: ...SERVICE MANUAL XP500 15B 28197 E0 2007 XP500A ...
Page 2: ......
Page 8: ......
Page 36: ...SPECIAL TOOLS 1 27 ...
Page 55: ...TIGHTENING TORQUES 2 18 Crankcase tightening sequence Cylinder head tightening sequence ...
Page 61: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ...
Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20410 LUBRICATION DIAGRAMS ...
Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ...
Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Oil strainer 2 Crankshaft ...
Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ...
Page 70: ...COOLING SYSTEM DIAGRAMS 2 33 EAS20420 COOLING SYSTEM DIAGRAMS ...
Page 72: ...CABLE ROUTING 2 35 EAS20430 CABLE ROUTING ...
Page 74: ...CABLE ROUTING 2 37 ...
Page 76: ...CABLE ROUTING 2 39 ...
Page 78: ...CABLE ROUTING 2 41 ...
Page 80: ...CABLE ROUTING 2 43 ...
Page 82: ...CABLE ROUTING 2 45 ...
Page 84: ...CABLE ROUTING 2 47 XP500 ...
Page 86: ...CABLE ROUTING 2 49 ...
Page 88: ...CABLE ROUTING 2 51 ...
Page 90: ...CABLE ROUTING 2 53 ...
Page 92: ...CABLE ROUTING 2 55 ...
Page 94: ...CABLE ROUTING 2 57 ...
Page 96: ...CABLE ROUTING 2 59 ...
Page 98: ...CABLE ROUTING 2 61 ...
Page 100: ...CABLE ROUTING 2 63 ...
Page 102: ...CABLE ROUTING 2 65 ...
Page 104: ...REPLACING THE HEADLIGHT BULBS 3 32 ADJUSTING THE HEADLIGHT BEAMS 3 32 ...
Page 138: ...ELECTRICAL SYSTEM 3 34 ...
Page 213: ...INSTALLING THE CHAIN DRIVE 5 75 ...
Page 262: ...CLUTCH 5 49 ...
Page 282: ...CRANKCASE AND CRANKSHAFT 5 69 ...
Page 290: ...CHAIN DRIVE TRANSMISSION 5 77 ...
Page 312: ...THROTTLE BODIES 7 9 ...
Page 316: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...
Page 320: ...ELECTRIC STARTING SYSTEM 8 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM XP500 ...
Page 322: ...ELECTRIC STARTING SYSTEM 8 7 XP500A ...
Page 326: ...ELECTRIC STARTING SYSTEM 8 11 ...
Page 330: ...CHARGING SYSTEM 8 15 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...
Page 331: ...CHARGING SYSTEM 8 16 2 AC magneto 3 Rectifier regulator 16 Battery 17 Main fuse ...
Page 333: ...CHARGING SYSTEM 8 18 ...
Page 334: ...LIGHTING SYSTEM 8 19 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...
Page 337: ...LIGHTING SYSTEM 8 22 ...
Page 338: ...SIGNALING SYSTEM 8 23 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...
Page 343: ...SIGNALING SYSTEM 8 28 ...
Page 344: ...COOLING SYSTEM 8 29 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...
Page 347: ...COOLING SYSTEM 8 32 ...
Page 348: ...FUEL INJECTION SYSTEM 8 33 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...
Page 372: ...IMMOBILIZER SYSTEM 8 57 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...
Page 382: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 67 EAS27740 ABS COMPONENTS CHART ...
Page 384: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 69 EAS27750 ABS CONNECTOR LOCATION CHART 2 1 6 5 3 4 7 ...
Page 392: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 77 EAS27810 BASIC PROCESS FOR TROUBLESHOOTING ...
Page 411: ...ABS ANTI LOCK BRAKE SYSTEM XP500A 8 96 ...
Page 414: ...ELECTRICAL COMPONENTS 8 99 1 2 3 4 5 6 7 8 9 10 11 12 13 ...
Page 419: ...ELECTRICAL COMPONENTS 8 104 ...
Page 445: ......
Page 446: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...