
PERIODIC MAINTENANCE
3-24
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a. Remove the lock washer “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”.
TIP
• Set a torque wrench at a right angle to the
steering nut wrench.
• Move the steering to the left and right a cou-
ple of time to check that it moves smoothly.
c. Loosen the lower ring nut 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 turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to “STEERING HEAD” on page 4-89.
e. Install the rubber washer “3”.
f.
Install the upper ring nut “2”.
g. Finger tighten the upper ring nut “2”, then
align the slots of both ring nuts. If neces-
sary, hold the lower ring nut and tighten the
upper ring nut until their slots are aligned.
h. Install the lock washer “1”.
TIP
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Upper bracket
Refer to “STEERING HEAD” on page 4-
89.
EAS30840
CHECKING THE CHASSIS FASTENERS
Make sure that all nuts, bolts, and screws are
properly tightened.
Refer to “CHASSIS TIGHTENING TORQUES”
on page 2-18.
EAS21700
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
EAS30850
CHECKING THE SIDESTAND
1. Check:
• Sidestand operation
Check that the sidestand moves
smoothly.
Rough movement
→
Repair or replace.
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
Lower ring nut (initial tightening
torque)
52 Nm (5.2 m·kgf, 38 ft·lbf)
Lower ring nut (final tightening
torque)
14 Nm (1.4 m·kgf, 10 ft·lbf)
5
4
Recommended lubricant
Silicone grease
Summary of Contents for 2012 TMAX XP500A
Page 1: ...SERVICE MANUAL XP500A 2012 59C 28197 E1 ...
Page 6: ......
Page 8: ......
Page 54: ...SPECIAL TOOLS 1 45 ...
Page 79: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ...
Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20410 LUBRICATION DIAGRAMS ...
Page 84: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ...
Page 86: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ...
Page 88: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 ...
Page 90: ...COOLING SYSTEM DIAGRAMS 2 35 EAS20420 COOLING SYSTEM DIAGRAMS ...
Page 92: ...COOLING SYSTEM DIAGRAMS 2 37 ...
Page 94: ...CABLE ROUTING 2 39 EAS20430 CABLE ROUTING Handlebar top side view ...
Page 96: ...CABLE ROUTING 2 41 Handlebar front side and left side view ...
Page 98: ...CABLE ROUTING 2 43 Front brake front side and left side view ...
Page 100: ...CABLE ROUTING 2 45 Frame front side view ...
Page 102: ...CABLE ROUTING 2 47 Frame left side view ...
Page 104: ...CABLE ROUTING 2 49 Frame right side view ...
Page 106: ...CABLE ROUTING 2 51 Rear frame top side and right side view ...
Page 108: ...CABLE ROUTING 2 53 Rear brake top side and left side view ...
Page 110: ...CABLE ROUTING 2 55 Throttle body left side view ...
Page 112: ...CABLE ROUTING 2 57 Fuel tank top side left side and right side view ...
Page 114: ...CABLE ROUTING 2 59 Hydraulic unit top side and front side view ...
Page 116: ...CABLE ROUTING 2 61 ...
Page 119: ......
Page 154: ...PERIODIC MAINTENANCE 3 35 ...
Page 258: ...SWINGARM 4 101 ...
Page 329: ...OIL PUMP 5 68 ECA13890 After tightening the bolts make sure the oil pump turns smoothly ...
Page 346: ...TRANSMISSION 5 85 ...
Page 371: ...THROTTLE BODY 7 10 Throttle position sensor screw 3 5 Nm 0 35 m kgf 2 5 ft lbf ...
Page 372: ...THROTTLE BODY 7 11 ...
Page 375: ......
Page 376: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...
Page 380: ...ELECTRIC STARTING SYSTEM 8 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...
Page 386: ...CHARGING SYSTEM 8 11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...
Page 389: ...CHARGING SYSTEM 8 14 ...
Page 390: ...LIGHTING SYSTEM 8 15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...
Page 394: ...SIGNALING SYSTEM 8 19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...
Page 399: ...SIGNALING SYSTEM 8 24 ...
Page 400: ...COOLING SYSTEM 8 25 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...
Page 404: ...FUEL INJECTION SYSTEM 8 29 EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...
Page 445: ...FUEL INJECTION SYSTEM 8 70 ...
Page 446: ...FUEL PUMP SYSTEM 8 71 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...
Page 449: ...FUEL PUMP SYSTEM 8 74 ...
Page 450: ...IMMOBILIZER SYSTEM 8 75 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...
Page 459: ...IMMOBILIZER SYSTEM 8 84 ...
Page 460: ...ABS ANTI LOCK BRAKE SYSTEM 8 85 EAS28790 ABS ANTI LOCK BRAKE SYSTEM EAS27730 CIRCUIT DIAGRAM ...
Page 462: ...ABS ANTI LOCK BRAKE SYSTEM 8 87 EAS27740 ABS COMPONENTS CHART ...
Page 464: ...ABS ANTI LOCK BRAKE SYSTEM 8 89 EAS27750 ABS COUPLER LOCATION CHART ...
Page 468: ...ABS ANTI LOCK BRAKE SYSTEM 8 93 EAS27810 BASIC PROCESS FOR TROUBLESHOOTING ...
Page 493: ...ABS ANTI LOCK BRAKE SYSTEM 8 118 ...
Page 494: ...ELECTRICAL COMPONENTS 8 119 EAS27973 ELECTRICAL COMPONENTS ...
Page 496: ...ELECTRICAL COMPONENTS 8 121 ...
Page 498: ...ELECTRICAL COMPONENTS 8 123 EAS27981 CHECKING THE SWITCHES ...
Page 527: ......
Page 528: ......