Yamaha tmax XP500A Service Manual Download Page 131

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CHK

ADJ

FUEL TANK

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 projection

on the fuel pump with

the projection in the fuel tank.

• Tighten the bolts to the specified torque in

the proper tightening sequence as shown.

• Install the fuel pump in the direction shown in

the illustration.

FWD

New

4 Nm (0.4 m · kg, 2.9 ft · lb)

INSTALLING THE FUEL TANK

1. Install:

• fuel tank

NOTE:

Tighten the bolts to the specified torque in the
proper tightening sequence as shown.

2. Connect:

• fuel hose
• fuel breather hose
• fuel pump coupler

CAUTION:

• Be sure to connect the fuel hose by hand.

Do not forcefully connect the hose with
tools.

• When installing the fuel hose, make sure

that it is securely connected, and that the
fuel hose holders are in the correct posi-
tion, otherwise the fuel hose will not be
properly installed.

3. Install:

• fuel pump connector cover

FWD

10 Nm (1.0 m · kg, 7.2 ft · lb)

Summary of Contents for tmax XP500A

Page 1: ...2005 XP500 XP500A5VU5 AE1 SERVICE MANUAL ...

Page 2: ......

Page 3: ...P500A 2005 SERVICE MANUAL 2004 by Yamaha Motor Co Ltd First edition September 2004 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ... models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable NOTE _ Designs and specifications are subject to change without notice EAS00005 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety...

Page 5: ...page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates a disas...

Page 6: ...g fluid B Lubricant C Special tool D Tightening torque E Wear limit clearance F Engine speed G Electrical data Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points H Engine oil I Gear oil J Molybdenum disulfide oil K Wheel bearing grease L Lithium soap based grease M Molybdenum disulfide grease Symbols N to O in the exploded diagrams indicate the followin...

Page 7: ...S GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 FUEL INJECTION SYSTEM FI 7 ELECTRICAL SYSTEM ELEC 8 TROUBLESHOOTING TRBL SHTG 9 ...

Page 8: ......

Page 9: ...GEN INFO 1 ...

Page 10: ... 1 2 FI SYSTEM 1 3 OUTLINE OF ANTI LOCK BRAKE SYSTEM XP500A 1 4 INSTRUMENT FUNCTION 1 15 IMPORTANT INFORMATION 1 19 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 19 REPLACEMENT PARTS 1 19 GASKETS OIL SEALS AND O RINGS 1 19 LOCK WASHERS PLATES AND COTTER PINS 1 20 BEARINGS AND OIL SEALS 1 20 CIRCLIPS 1 20 CHECKING THE CONNECTIONS 1 21 SPECIAL TOOLS 1 22 ...

Page 11: ...GEN INFO ...

Page 12: ...N EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAS00018 MODEL LABEL The model label 2 is affixed to the storage box This information will be needed to order spare parts SCOOTER IDENTIFICATION ...

Page 13: ...nes 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 accommodate this need this model has adopted an electronically controlled fuel injection FI sys tem in place of a conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by usi...

Page 14: ...ser 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 temperature sensor coolant temperature sensor and O2 sensor enable the ECU engine to determine the injection duration The injection timing is determined thro...

Page 15: ... 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 hydraulic system independently EAS00877 The ABS also includes a highly developed self diagnostic function The ABS detects any problem conditions and allows normal braking even if the ABS is not operating properly When this occurs the ABS...

Page 16: ...ke master cylinder 2 Hydraulic unit 3 Hydraulic pump 4 ABS motor 5 Buffer chamber 6 Hydraulic control valve 7 Front brake master cylinder 8 Rear brake caliper 9 Front brake caliper 0 ECU ABS A Rear wheel sensor B Front wheel sensor C ABS warning light ...

Page 17: ...oth of the wheels has stopped but the vehicle 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 sur face 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 follow i...

Page 18: ...urface Less slippery road surface Controlling zone Slippery road surface Slip ratio EAS00875 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 sen sors In addition the ECU ABS calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed values The difference ...

Page 19: ...use the tire to slip sideways WARNING _ The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straight ahead During a turn sudden braking is liable to cause a loss of traction of the tires Even in vehicles equipped with an ABS overturn ing of the vehicle cannot be prevented if it is braked suddenly The ABS functions to prevent the tendency of the w...

Page 20: ...using 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 detected based on the frequency of this alter nating voltage 3 At high speed 4 At low speed 5 Wheel sensor 6 Sensor rotor 1 2 2 1 EAS00879 Hydraulic unit The hydraulic unit 1 is composed of a hydrau lic co...

Page 21: ... 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 troubleshoot ing NOTE _ Some types of failures are not recorded in the memory of the ECU ABS e g a drop in bat tery voltage 1 Software operation flow 2 Set the main switch to ON 3 Initialize 4 Self diagnosis when static 5 Self diagnosis when riding ...

Page 22: ...ydraulic pressure of the brake fluid and normal braking is resumed The ABS motor relay is also activated by signals transmitted from the ECU ABS and operates simultaneously 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 ABS moto...

Page 23: ... inder increases 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 vi...

Page 24: ...e orifice 0 and the brake fluid is sent to the brake caliper via port C C and port D A and the buffer chamber As a result the hydraulic pressure in the brake caliper is reduced 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 cyl inder 2 Brake light switch 3 ABS motor 4 Pump 5 Buffer chamber ...

Page 25: ...rt A 7 and port C C 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 J and cham ber B K of the flow control valve 1 Brake master cyl inder 2 Brake light switch 3 ABS motor 4 Pump 5 Buffer chamber 6 Flow control valve 7 Port A 8 Spool 9 P...

Page 26: ...nd ABS 3 a clock 4 an oil change indicator 5 a V belt replacement indicator 6 a fuel level warning symbol 7 a coolant temperature symbol 8 NOTE Be sure to turn the key to ON before using the SELECT 9 and RESET 0 buttons When the key is turned to ON all of the dis play segments of the multi function display will appear one after the other and then dis appear in order to test the electrical circuit ...

Page 27: ...efueling and traveling 5 km 3 mi Fuel meter With the key in the ON position the fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear towards E Empty as the fuel level decreases When the fuel level reaches the bottom segment near E the fuel level warn ing symbol and the bottom segment will flash Refuel as soon as possible CAUTION If the fuel leve...

Page 28: ... goes off 3 If the indicator does not come on check the electrical circuit Refer to SIGNALING SYSTEM in chapter 8 NOTE The oil change indicator may flash when the engine is revved with the scooter on the cen terstand but this does not indicate a malfunc tion To reset the oil change indicator light 1 Turn the key to ON 2 Hold the OIL CHANGE button 1 pushed for two to eight seconds 3 Release the OIL...

Page 29: ... replacement indica tor will come on for 1 4 seconds And the V belt replacement indicator will go off NOTE If the V belt is replaced before the V belt replacement indicator comes on i e before the V belt replacement interval has been reached the indicator must be reset after the V belt replacement for the next periodic V belt replacement to be indicated at the correct time Self diagnosis device Re...

Page 30: ...ean all of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance ...

Page 31: ...isible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION _ Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always re...

Page 32: ...nnect sev eral 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 revita...

Page 33: ... Illustration 90890 01235 YU 01235 Rotor holding tool This tool is used to hold the clutch assembly 90890 01268 YU 01268 Ring nut wrench This tool is used to loosen or tighten the steering ring nuts 90890 01304 YU 01304 Piston pin puller set This tool is used to remove the piston pins Radiator cap tester 90890 01325 YU 24460 01 Radiator cap tester adapter 90890 01352 YU 33984 Radiator cap tester R...

Page 34: ... nut wrench This tool is used to loosen or tighten the steering ring nuts 90890 01469 Oil filter wrench This tool is needed to loosen or tighten the oil filter cartridge 90890 01481 Sheave holder This tool is used to hold the sheave assembly when removing or installing the primary and secondary sheave 90890 01482 Clutch spring compressor This tool is used to remove or install the nut 90890 01701 Y...

Page 35: ...0 03112 YU 03112 C Pocket tester This tool is used to check the electrical system 90890 03141 YM 33277 B Timing light This tool is used to check the ignition tim ing 90890 03149 Test coupler adaptor This tool is used to check the ABS diag nosis Pressure gauge 90890 03153 Oil pressure adapter B 90890 03124 Pressure gauge Oil pressure adapter B These tools are used to measure fuel pressure and oil p...

Page 36: ...iver 90890 04058 YM 04058 Mechanical seal installer 90890 04078 YM 33221 A Middle driven shaft bearing driver Mechanical seal installer These tools are used to install the water pump seal 90890 04085 Damper rod holder 14 mm This tool is used to loosen or tighten the front wheel axle 90890 04086 YM 91042 Clutch holding tool This tool is needed to hold the clutch boss when removing or installing the...

Page 37: ...pressor Sheave fixed block This tool is used to hold the compression spring when removing or installing the secondary sheave nut 90890 04139 Plane bearing installer This tool is used to install the crankshaft journal bearings 90890 06754 YM 34487 Ignition checker This tool is used to check the ignition sys tem components Bond 90890 85505 Sealant ACC 11001 05 01 Yamaha bond No 1215 Sealant Quick Ga...

Page 38: ...SPEC 2 ...

Page 39: ...ERAL TIGHTENING TORQUE SPECIFICATIONS 2 18 TIGHTENING TORQUES 2 19 ENGINE TIGHTENING TORQUES 2 19 CHASSIS TIGHTENING TORQUES 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES 2 24 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES 2 26 OIL FLOW DIAGRAMS 2 27 COOLANT FLOW DIAGRAMS 2 31 CABLE ROUTING 2 32 XP500 2 39 XP500A 2 56 ...

Page 40: ...SPEC ...

Page 41: ... Overall height 1 410 mm 55 5 in Seat height 795 mm 31 3 in Wheelbase 1 575 mm 62 0 in Minimum ground clearance 130 mm 5 12 in Minimum turning radius 2 800 mm 110 2 in Weight Wet with oil and a full fuel tank 225 kg 496 lb XP500 230 kg 507 lb XP500A Maximum load total of cargo rider passenger and accessories 190 kg 419 lb XP500 185 kg 408 lb XP500A GENERAL SPECIFICATIONS ...

Page 42: ...e 70 C 158 F Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity Total including reserve 14 L 3 08 Imp gal 3 70 US gal Engine oil Lubrication system Dry sump Recommended oil SAE10W30 or SAE10W40 API service SE SF SG type or higher Quantity Total amount 3 6 L 3 17 Imp qt 3 81 US qt Without oil filter cartridge replace ment 2 8 L 2 46 Imp qt 2 96 US qt With oil filter cartridge r...

Page 43: ... 32 Imp qt 1 59 US qt Coolant reservoir capacity up to the maximum level mark 0 35 L 0 31 Imp qt 0 37 US qt Radiator cap opening pressure 107 9 137 3 kPa 1 08 1 37 kg cm2 15 6 19 9 psi Radiator core Width 330 mm 12 99 in Height 138 mm 5 43 in Depth 24 mm 0 94 in Thermostat Model manufacturer 4JH NIPPON THERMOSTAT Valve opening temperature 69 73 C 156 2 163 4 F Valve full open temperature 85 C 185 ...

Page 44: ...in Intake camshaft lobe dimensions Measurement A 33 252 33 352 mm 1 3091 1 3131 in 33 152 mm 1 3052 in Measurement B 24 956 25 056 mm 0 9825 0 9865 in 24 856 mm 0 9786 in Exhaust camshaft lobe dimensions Measurement A 33 252 33 352 mm 1 3091 1 3131 in 33 152 mm 1 3052 in Measurement B 24 956 25 056 mm 0 9825 0 9865 in 24 856 mm 0 9786 in Camshaft runout limit 0 03 mm 0 0012 in Timing chain Model n...

Page 45: ...433 in 1 6 mm 0 06 in Valve margin thickness D Intake 0 6 0 8 mm 0 0236 0 0315 in 0 5 mm 0 0197 in Exhaust 0 6 0 8 mm 0 0236 0 0315 in 0 5 mm 0 0197 in Valve stem diameter Intake 3 975 3 990 mm 0 1565 0 1571 in 3 945 mm 0 1553 in Exhaust 3 960 3 975 mm 0 1559 0 1565 in 3 930 mm 0 1547 in Valve guide inside diameter Intake 4 000 4 012 mm 0 1575 0 1580 in 4 050 mm 0 1594 in Exhaust 4 000 4 012 mm 0 ...

Page 46: ... 30 39 mm 1 20 in Exhaust 30 39 mm 1 20 in Spring rate K1 Intake 18 84 N mm 1 92 kg mm 107 60 lb in Exhaust 18 84 N mm 1 92 kg mm 107 60 lb in Spring rate K2 Intake 24 52 N mm 2 50 kg mm 140 01 lb in Exhaust 24 52 N mm 2 50 kg mm 140 01 lb in Compressed spring force installed Intake 91 2 104 9 N at 30 4 mm 9 3 10 7 kg at 30 4 mm 20 5 23 6 lb at 1 20 in Exhaust 91 2 104 9 N at 30 4 mm 9 3 10 7 kg a...

Page 47: ... 0020 in Maximum out of round 0 05 mm 0 0020 in Pistons Piston to cylinder clearance 0 020 0 045 mm 0 0008 0 0018 in 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 Piston pin bore in the piston Diameter 15 002 15 013 mm 0 5906 0 5911 in 15 043 mm 0 5922 in Offset 0 50 mm 0 0197 in Offset direction Intake side Piston pin Outside diameter 14 991 15 000 mm 0 59...

Page 48: ... in End gap installed 0 40 0 50 mm 0 0157 0 0197 in 0 75 mm 0 0295 in Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 10 mm 0 0039 in Oil ring Dimensions B T 1 50 2 00 mm 0 06 0 08 in End gap installed 0 10 0 35 mm 0 0039 0 0138 in Ring side clearance 0 040 0 160 mm 0 0016 0 0063 in Connecting rods Oil clearance using plastigauge 0 026 0 050 mm 0 0010 0 0020 in Bearing color code 1 Blue 2 Bl...

Page 49: ... in Bearing color code 1 Blue 2 Black 3 Brown 4 Green Balancer Balancer drive method Piston Clutch Clutch type Wet multiple disc automatic Clutch release method Automatic Friction plates Thickness 2 75 3 05 mm 0 108 0 120 in 2 65 mm 0 104 in Plate quantity 5 Clutch plate 1 Thickness 1 30 1 50 mm 0 05 0 06 in Plate quantity 4 Maximum warpage 0 10 mm 0 0039 in Clutch plate 2 Thickness 1 80 2 00 mm 0...

Page 50: ...stem Chain drive Secondary reduction ratio 41 25 40 29 2 262 Operation Centrifugal automatic type Maximum main axle runout 0 08 mm 0 0031 in Maximum drive axle runout 0 08 mm 0 0031 in Air filter type Dry element Fuel pump Pump type Electrical Model manufacturer 5VU AISAN Consumption amperage max 1 9 A Output pressure 246 254 kPa 2 46 2 54 kg cm2 35 0 36 1 psi Electronic fuel injection Model 1100 ...

Page 51: ...0 25 mm 0 01 in Rear wheel Wheel type Cast wheel Rim Size 15M C MT5 00 Material Aluminum Wheel travel 117 mm 4 61 in Wheel runout Maximum radial wheel runout 1 mm 0 04 in Maximum lateral wheel runout 0 5 mm 0 02 in Wheel axle bending limit 0 25 mm 0 01 in Front tire Tire type Tubeless Size 120 70R14 M C 55H Model manufacturer TH01F BRIDGESTONE D252F DUNLOP Tire pressure cold 0 90 kg 0 198 lbs 225 ...

Page 52: ...67 0 4 0 mm 10 51 0 16 in Minimum thickness 3 5 mm 0 14 in Maximum deflection 0 12 mm 0 0047 in Brake pad lining thickness 6 2 mm 0 24 in 0 8 mm 0 03 in Master cylinder inside diameter 14 00 mm 0 55 in Caliper cylinder inside diameter 30 16 mm 1 19 in and 25 40 mm 1 00 in Rear brake Brake type Single disc brake Operation Left hand operation Recommended fluid DOT4 Brake discs Diameter thickness 267...

Page 53: ...41 US qt Level 109 0 mm 4 29 in Inner tube outer diameter 41 0 mm 1 61 in Inner tube bending limit 0 2 mm 0 01 in Steering Steering bearing type Angular ball bearing Lock to lock angle left 38 5 Lock to lock angle right 38 5 Rear suspension Suspension type Swingarm Rear shock absorber assembly type Coil spring gas oil damper Rear shock absorber assembly travel 43 0 mm 1 69 in Spring Free length 19...

Page 54: ...the end of the swing arm Radial 1 0 mm 0 04 in Axial 1 0 mm 0 04 in Secondary drive chain Model manufacturer 23RH303 5 82ASM Borg warner Link quantity 82 Primary drive chain Model manufacturer 89HV302 5RCF 66 Borg warner Link quantity 66 Item Standard Limit ...

Page 55: ...4 in Primary coil resistance 1 87 2 53 Ω at 20 C 68 F Secondary coil resistance 12 18 kΩ at 20 C 68 F Spark plug cap Material Resin Resistance 10 0 kΩ at 20 C 68 F Charging system System type A C magneto Model manufacturer F4T383 MITSUBISHI Standard output 14 0 V 350 W 5 000 r min Stator coil resistance color 0 22 0 26 Ω at 20 C 68 F white white Rectifier regulator Regulator type Semiconductor sho...

Page 56: ...motor Model manufacturer SM 13 MITSUBA Power output 0 7 kW Brushes Overall length 12 0 mm 0 47 in 4 0 mm 0 16 in Spring force 7 65 10 01 N 780 1 021 gf 27 53 36 04 oz Commutator resistance 0 0015 0 0025 Ω at 20 C 68 F Commutator diameter 28 mm 1 10 in 27 mm 1 06 in Mica undercut 0 7 mm 0 03 in Starter relay Model manufacturer MS5F 561 JIDECO Amperage 180 A Coil resistance 4 18 4 62 Ω at 20 C 68 F ...

Page 57: ...0 310 0 326 kΩ Resistance at 110 C 230 F 0 140 0 144 kΩ Fuses Main fuse 30 A Headlight fuse 15 A Signaling system fuse 20 A XP500 15 A XP500A Ignition fuse 10 A Radiator fan motor fuse 15 A Lighting system fuse 10 A Fuel injection system fuse 10 A ABS motor fuse 30 A XP500A ABS control unit fuse 5 A XP500A Backup fuse storage box light immobilizer unit and meter assem bly 10 A Spare fuse 30 A Spar...

Page 58: ...fied tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Tighten ing torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb o...

Page 59: ...p housing cover Bolt M6 2 10 1 0 7 2 Water pump assembly Bolt M6 2 10 1 0 7 2 Coolant pipe Bolt M6 2 10 1 0 7 2 Radiator filler neck Bolt M6 1 7 0 7 5 1 Radiator drain bolt Screw M12 1 1 6 0 16 1 2 Water pump inlet pipe Bolt M6 1 10 1 0 7 2 Water pump outlet pipe Bolt M6 1 10 1 0 7 2 Thermostat cover Bolt M6 2 10 1 0 7 2 Oil pump assembly Bolt M6 3 10 1 0 7 2 Oil strainer assembly Bolt M6 2 10 1 0...

Page 60: ... 1 90 9 0 65 Clutch assembly Nut M16 1 65 6 5 47 Chain drive holder assembly Bolt M8 3 30 3 0 22 Chain drive drain bolt Bolt M12 1 20 2 0 14 Chain drive case outer Bolt M6 18 10 1 0 7 2 Chain drive case cover Bolt M6 2 7 0 7 5 1 Primary sheave assembly Nut M20 1 160 16 0 115 BEL RAY assembly lube Secondary sheave spring seat Nut M36 1 90 9 0 65 Secondary sheave assembly Nut M18 1 90 9 0 65 Shell B...

Page 61: ...2 21 SPEC TIGHTENING TORQUES Crankcase tightening sequence Cylinder head tightening sequence 1 8 M8 Bolt 9 21 M6 Bolt ...

Page 62: ... 43 Front wheel axle pinch bolt M8 23 2 3 17 Rear wheel axle nut M14 100 10 0 72 Rear wheel axle pinch bolt M8 17 1 7 12 Front brake caliper bracket M10 40 4 0 29 Front brake caliper retaining bolt M10 27 2 7 19 LS Front brake disc M8 18 1 8 13 LT Rear brake caliper bracket M10 40 4 0 29 Rear brake caliper retaining bolt M10 27 2 7 19 LS Rear brake disc M8 18 1 8 13 LT Rear wheel drive hub M10 69 ...

Page 63: ...er moulding and passenger foot rest M6 7 0 7 5 1 Rear side cover and frame M6 7 0 7 5 1 Leg shield footrest board and frame M6 7 0 7 5 1 Footrest board and frame M6 7 0 7 5 1 Seat damper M8 16 1 6 11 Fuel tank M6 10 1 0 7 2 Fuel pump M5 4 0 4 2 9 Grab bar M8 16 1 6 11 Seat lock M6 7 0 7 5 1 Storage box M6 10 1 0 7 2 Windshield M5 0 4 0 04 0 3 Coolant reservoir M6 4 0 4 2 9 Centerstand bracket M10 ...

Page 64: ...rnals E Camshaft lobs M Camshaft journals M Camshaft cap M Valve stems intake and exhaust M Valve stem ends intake and exhaust E Cylinder head nut E Water pump impeller shaft M Oil pump shaft E Oil pump rotors inner and outer E Oil pump O ring LS Oil cooler union bolt E O ring fuel injector assembly Silicone oil Starter clutch idle gear inner surface E Starter clutch E Main axle thrust surface or ...

Page 65: ...ssembly lube Swingarm pivot shaft bearing LS Crankcase mating surface Yamaha bond No 1215 A C magneto lead Yamaha bond No 1215 Cylinder head cover gasket mating surface Yamaha bond 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 ...

Page 66: ...rts left and right LS Parking brake lock lever cable and parking brake lock lever cable connec tion area LS Sidestand pivoting point metal to metal moving parts LS Centerstand shaft pivoting point and metal to metal moving parts LS Oil seal lip chain drive case LS Rear wheel drive hub spline LS Rear wheel oil seal lip LS Passenger footrest pivoting point LS Rear shock absorber bearing and collar i...

Page 67: ...2 27 SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Oil pump 2 Oil tank 3 Oil strainer 4 Relief valve 5 Oil cooler 6 Oil filter cartridge 7 Exhaust camshaft 8 Intake camshaft 9 Oil pipe 0 Oil delivery pipe ...

Page 68: ...2 28 SPEC OIL FLOW DIAGRAMS 1 Oil strainer 2 Crankshaft ...

Page 69: ...2 29 SPEC OIL FLOW DIAGRAMS 1 Clutch 2 Right main journal bearing 3 Main gallery plug ...

Page 70: ... SPEC OIL FLOW DIAGRAMS Exhaust camshaft Intake camshaft Piston cooler Crankshaft Oil tank Oil filter cartridge Oil cooler Relief valve Check valve Flush oil pump Suction oil pump Strainer Strainer Oil pan ...

Page 71: ...2 31 SPEC COOLANT FLOW DIAGRAMS EAS00035 COOLANT FLOW DIAGRAMS 1 Coolant reservoir 2 Thermostat 3 Radiator 4 Water pump 5 Radiator fan 6 Radiator cap 7 Fast idle plunger 1 2 3 5 6 2 3 6 4 7 ...

Page 72: ...om being pulled out by the headlight assembly left and right É Connect the headlight sub wire harness to the wire harness on top of the stay left and right After making the connection push the coupler between the front cowling and the air filter case Ê Connect the taped headlight lead coupler to the headlight s white marked side left side high beam side For GB the right side is the high beam side ...

Page 73: ...harness guide to hold down the wire harness Ð Route the throttle cables between handle under cover and upper bracket Ñ Route the throttle cables through the hole of the lower handlebar cover Ò Connect the brake light switch lead through the handlebar switch side Ó Fasten the handlebar switch lead to the handle bar using a plastic band The fastening location is the bend area on the bottom of the ha...

Page 74: ...2 34 SPEC CABLE ROUTING Õ Fasten the right handlebar switch leads to the handlebar with a plastic band Ö Route the rear brake hose and left handlebar switch leads over the wire harness ...

Page 75: ...bar and the upper bracket É Fasten the wire harness by sliding the plastic holder on the wire harness onto the stud on the handlebar Ê Fasten the grommets on the brake hoses with the holder Ë Install the rear brake lock lever cable after lubri cating the grease to the cable end Ì Install the rear brake lock lever cable after turn ing the parking brake lever as illustration Í Install the cable end ...

Page 76: ...ear footrest assembly C Fuel tank breather hose D Hose holder E Hose holder F Fuel hose G Fuel pump lead H Hose guide I Roll over valve assembly J Holder K Fuel pump L Fuel pump bracket M Fuel hose connector cover 1 2 4 3 1 3 6 4 2 5 Î Õ Õ Õ Õ Ô Ö A C A B F H E F E F F I J D D E E K L 3 Î Ê Ë Ì Í C C D E F G C D D Ñ Ò Ð Ï È 5 4 3 2 1 3 9 8 6 7 É Ï F F MØ Ó B B A 0 Ð Tighten the fuel tank comp bolt...

Page 77: ... 2 76 in Î 2 5 mm 0 08 0 20 in Ï Install the grommet to the footrest board securely Ð Install the grommet to the fuel tank securely Ñ Make sure that the clip end faces to the front side Ò Install the grommet to the fuel tank securely after installing the hoses Ó Fasten the fuel hose and fuel pump lead with a hose holder making sure that there are no twists in the hose or lead 1 2 4 3 1 3 6 4 2 5 Î...

Page 78: ...uel hose to the inside of the frame guide Ø After connecting the fuel hose connector to the fuel tank install the fuel hose connector cover completely onto the connector Install and remove the fuel hose connector and cover manually Do not use tools 1 2 4 3 1 3 6 4 2 5 Î Õ Õ Õ Õ Ô Ö A C A B F H E F E F F I J D D E E K L 3 Î Ê Ë Ì Í C C D E F G C D D Ñ Ò Ð Ï È 5 4 3 2 1 3 9 8 6 7 É Ï F F MØ Ó B B A ...

Page 79: ...tor lead C Rectifier regulator D Starting circuit cut off relay 1 E Turn signal hazard relay F O2 sensor G V belt replacement indicator reset coupler H O2 sensor coupler I Fuel pump lead J Fuel tank breather hose J A A B B C C D D E E F F J A A B B C C D D B B E E F F G G H H I I 1 4 6 8 A È É ÊË Ì Í Î Ï Ð Ñ Ò Ó Ô 0 B M L B L G G H H I I J J O N P L O N B L Q K O M Û Ý E F Ü Û AG Õ Ö Ø Ù Ú B C D G...

Page 80: ...cable between wire harness and frame Ê Use the plastic holder on the back of the frame to hold the radiator fan motor lead Ë Connect the wire harness wire taped area to the T stud of frame Ì Pass the main switch lead between stay 1 and seat lock cable J A A B B C C D D E E F F J A A B B C C D D B B E E F F G G H H I I 1 4 6 8 A È É ÊË Ì Í Î Ï Ð Ñ Ò Ó Ô 0 B M L B L G G H H I I J J O N P L O N B L Q...

Page 81: ...older Ñ Fasten the ECU engine lead to the stay 1 with a plastic holder When fastening them using a plastic holder make sure not to cross the branch leads Ò Fasten the coolant reservoir hose to the stay 1 with a plastic holder Ó Route the ignition coil lead through the inside of the ignition coil bracket Ô Fasten the radiator fan motor lead and sidestand switch lead to the frame with a plastic hold...

Page 82: ... lock cable right to the frame with a plastic holder Û Fasten the starter motor lead and negative bat tery lead to the frame with a plastic holder Ü Fasten the wire harness to the frame with the plastic band The buckle of the plastic band should be facing towards the storage box Ý Insert the seat lock cable and the cylinder mounting rubber into the frame stay J A A B B C C D D E E F F J A A B B C ...

Page 83: ...ensor lead and V belt replace ment indicator reset coupler lead to the frame with a plastic holder Pass the wire harness and seat lock cable in the frame holder Pass the rear brake lock lever cable under the coolant pipe 40 50 mm 1 57 1 97 in Fasten the O2 sensor lead to the frame with a plastic band Pass the O2 sensor lead to the lead guide A A A B A C A D A E J A A B B C C D D E E F F J A A B B ...

Page 84: ...e and storage box Route the seat lock cable through the frame bracket side and under the wire harness T stud for position setting A F A G A H A I A J J A A B B C C D D E E F F J A A B B C C D D B B E E F F G G H H I I 1 4 6 8 A È É ÊË Ì Í Î Ï Ð Ñ Ò Ó Ô 0 B M L B L G G H H I I J J O N P L O N B L Q K O M Û Ý E F Ü Û AG Õ Ö Ø Ù Ú B C D G H I Þ Á K AD AF Ü O M N K S N M O K O M N AJ AI O 0 A 2 3 5 7 ...

Page 85: ...se 7 Coolant hose 8 Sidestand switch 9 Fast idle outlet hose 0 Radiator outlet hose A Crankcase breather hose B Throttle cable accelerator cable single locknut È Pass the rear brake lock lever cable to the cable guide É Route the wire harness through the frame guide At this time place the protector for the handle cover inner side on the bottom side Ê Ë Ì Í Î 2 È É 5 8 B Ï 1 3 4 7 6 9 0 A ...

Page 86: ...e rear footrest do not catch or pinch the A C magneto lead in the bracket Ì Fasten the wire harness to the frame with a plas tic holder Í Pass the storage box light switch lead by the front of the frame back stay pipe Î Fasten the sidestand switch lead to the frame with a plastic holder Ï Pass the speed sensor lead to the lead holder 2 locations Ê Ë Ì Í Î 2 È É 5 8 B Ï 1 3 4 7 6 9 0 A ...

Page 87: ...0 Rectifier regulator A Seat lock B Battery C Positive battery lead D Fuel pump lead E Fuel overflow hose F Intake air pressure sensor G Meter assembly coupler H Intake air temperature sensor I Seat lock cable J Wire harness K Storage box light connector L Fuel injector lead 2 M Frame B B A A B B Ï C AI ß Ó Ò Ô Õ Ö Ø Ù Ú Û Ü Ý Þ C A A 6 7 I J C 1 6 I 7 D D L M A A Ð Ñ Î Í D D AF AE AH F G H É È É ...

Page 88: ... a plastic holder Ì Fasten the rear brake lock lever cable to the frame with a plastic holder Í Be sure not to pinch the storage box light switch lead when installing the fuel tank Î Connect the fuel injector leads and intake air pressure sensor lead storage box light switch lead to the pipe guide with a plastic holder Con nect the couplers in right side of the holder B B A A B B Ï C AI ß Ó Ò Ô Õ ...

Page 89: ...k to the right seat lock Ô Route the negative battery lead and the fuse box lead from the storage box opening to the bottom of the cross pipe Õ Route the fuse box lead above the starter motor lead Ö Place the rubber cover over the starter relay starter relay coupler positive battery lead termi nal and starter motor lead terminal Align the plastic clamp with the white tape on the wire harness and f...

Page 90: ... plastic holder Ü Route the positive battery lead through the under the seat lock cable Ý Fasten the wire harness to the frame with a plas tic holder Þ Connect the seat lock cable gray to the left seat lock ß Install the fuse box assembly to the storage box À Install the storage box light switch to the storage box Á To the rear brake caliper B B A A B B Ï C AI ß Ó Ò Ô Õ Ö Ø Ù Ú Û Ü Ý Þ C A A 6 7 I...

Page 91: ...frame 10 15 mm 0 39 0 59 in Route the wire harness through the wire guide Pass the speed sensor lead under the stay 1 and cross pipe and then over the brake hose guide Place the speed sensor lead between the ribs of the air filter case Pass the wire harness over the wire guide Connect the storage box light lead connectors to the storage box light with the leads routed downward A A A B A C A D A E ...

Page 92: ... cable 9 Rear brake hose 0 Speed sensor lead È Pass the rear brake lock lever cable on the front side of throttle cable É Position of clamp Ê Position the relay straighten Ë Fasten the cooling system air bleed hose to the stay 1 with a plastic holder Ì The main switch lead couplers should not pro trude to the outside of the frame Í Fasten the fuel injector leads with the plastic holder È É Ê É Ë Ì...

Page 93: ...Î Fasten the sidestand switch lead to the frame with a plastic holder Ï Fasten the rear brake hose to the stay 1 with a plastic holder Ð Route the throttle cable through the cable holder È É Ê É Ë Ì Î Ï Ð 2 4 5 6 7 8 9 1 3 0 Í ...

Page 94: ...ke hose É 50 60 mm 1 97 2 36 in Ê Turn the handlebar completely to the right and then fasten the brake hose and speed sensor lead together with the plastic holder Ë Install the stopper to lower bracket projection Ì Fasten the speed sensor lead along the outside of the brake hose Í 30 40 mm 1 18 1 57 in A B C C D D D D C C Ö Õ Ó Ô Ò Ð Ï Î Í Ì Ñ Ë Ê É È Ì È Ø Ö 4 5 3 2 Ù 1 A B 1 2 6 7 9 2 7 2 9 7 8 ...

Page 95: ...the innermost securely Ô Engage the hose holder rib more than 3 notch Face the hose holder projection to the back Õ Make sure that the white paint on the brake hose faces to back right side only Ö Install the stopper to the stay 1 Fasten the front brake hose and rear brake hose with a hose holder Ø Make sure that the brake hose joint touches the projection of the outer tube Ù Make sure that the br...

Page 96: ...ter motor lead E Rectifier regulator F Starting circuit cut off relay 2 G Starting circuit cut off relay 1 H Turn signal hazard relay I O2 sensor J V belt replacement indicator reset coupler Ð Ñ Ò A A B B D D F F J J K K H H C C E E G G I I P P C B O Q D R T D D T P U U U P U V S W N X P Q Q N A A B B B 9 8 7 Ó Ô Õ Ö Ï 6 5 2 1 Î Í Ì Ë Ê É È AR AD AC AG AA AL AJ AN AE AS S M N Y U U Q P P P Q U K J...

Page 97: ...nsor lead U Frame V Storage box W V belt replacement indicator reset coupler lead X O2 sensor lead Y Fuel hose Ð Ñ Ò A A B B D D F F J J K K H H C C E E G G I I P P C B O Q D R T D D T P U U U P U V S W N X P Q Q N A A B B B 9 8 7 Ó Ô Õ Ö Ï 6 5 2 1 Î Í Ì Ë Ê É È AR AD AC AG AA AL AJ AN AE AS S M N Y U U Q P P P Q U K J J I H H C D D G G E E F F C I K Ø Ù Ú Û Ü D E G F H I À ß Ý Þ Ý AI N L K J C 4 ...

Page 98: ... the outside of the frame Í Fasten the wire harness main switch lead and seat lock cable with the plastic band under the stay 1 Be sure to fasten the seat lock cable on the metal section of the outer cable Î Pass the main switch lead between stay 1 and seat lock cable Ï Fasten the wire harness and ECU engine lead to the stay 1 with a holder Ð Ñ Ò A A B B D D F F J J K K H H C C E E G G I I P P C B...

Page 99: ...ay 1 with a plastic holder When fastening them using a plastic holder make sure not to cross the branch leads Ô Fasten the coolant reservoir hose to the stay 1 with a plastic holder Õ Route the ignition coil lead through the inside of the ignition coil bracket Ö Use the plastic holder on the back of the frame to hold the radiator fan motor lead Ð Ñ Ò A A B B D D F F J J K K H H C C E E G G I I P P...

Page 100: ...le do not lean over the storage box Ü Fasten the starter motor lead negative battery lead and seat lock cable left to the frame with a plastic holder Ý Fasten the starter motor lead and negative bat tery lead to the frame with a plastic holder Þ Insert the seat lock cable and the cylinder mounting rubber into the frame stay ß Pass the O2 sensor lead to the lead guide Ð Ñ Ò A A B B D D F F J J K K ...

Page 101: ...o the frame with a plastic holder Pass the wire harness and seat lock cable in the frame holder Pass the rear brake lock lever cable under the coolant pipe 40 50 mm 1 57 1 97 in Fasten the wire harness to the frame with the plastic band The buckle of the plastic band should be facing towards the storage box A A A B A C A D A E A F Ð Ñ Ò A A B B D D F F J J K K H H C C E E G G I I P P C B O Q D R T...

Page 102: ...e frame above the mudguard Insert the tail brake light coupler between the wire harness and the seat lock cable left 20 30 mm 0 79 1 18 in To the tail brake light 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 A G A H A I A J A K A L A M A N A O A P Ð Ñ Ò A A B B D D F F J J K K H H C C E E G G I ...

Page 103: ...rt between frame and storage box A Q A R A S Ð Ñ Ò A A B B D D F F J J K K H H C C E E G G I I P P C B O Q D R T D D T P U U U P U V S W N X P Q Q N A A B B B 9 8 7 Ó Ô Õ Ö Ï 6 5 2 1 Î Í Ì Ë Ê É È AR AD AC AG AA AL AJ AN AE AS S M N Y U U Q P P P Q U K J J I H H C D D G G E E F F C I K Ø Ù Ú Û Ü D E G F H I À ß Ý Þ Ý AI N L K J C 4 3 0 A M AF AO AP AM AB Á AH AK AQ ...

Page 104: ...ther hose 7 Coolant hose 8 Sidestand switch 9 Fast idle outlet hose 0 Radiator outlet hose A Crankcase breather hose B Throttle cable accelerator cable single locknut È Pass the rear brake lock lever cable to the cable guide É Route the wire harness through the frame guide Ê Pass the fuel tank breather hose by the outside of the wire harness 2 5 8 B È É Ê Ë Ì Î Ï Í 1 3 4 6 7 9 0 A ...

Page 105: ...the A C magneto lead in the bracket Ì Fasten the wire harness to the frame with a plas tic holder Í Pass the storage box light switch lead by the front of the frame back stay pipe Î Fasten the sidestand switch lead to the frame with a plastic holder Ï Pass the front wheel sensor lead to the lead holder 2 locations 2 5 8 B È É Ê Ë Ì Î Ï Í 1 3 4 6 7 9 0 A ...

Page 106: ...lead B Battery C Seat lock D Positive battery lead E Fuel pump lead F Fuel overflow hose G Intake air pressure sensor H Hydraulic unit solenoid coupler I ABS motor coupler J Meter assembly coupler K Intake air temperature sensor L Frame M Fuel injector lead 2 N Seat lock cable O Wire harness P Storage box light connector D L M O N D A A B B C C 1 É AH I J K H G F AG AF AE AD AC AB AA A 8 D C B A Ó...

Page 107: ...he rear brake lock lever cable to the frame with a plastic holder Î Be sure not to pinch the storage box light switch lead when installing the fuel tank Ï Connect the fuel injector leads and intake air pressure sensor lead storage box light switch lead to the pipe guide with a plastic holder Con nect the couplers in right side of the holder Ð Pass the wire harness and seat lock cable through the g...

Page 108: ...over the starter relay starter relay coupler positive battery lead termi nal and starter motor lead terminal Ö Align the plastic clamp with the white tape on the wire harness and fasten to the frame Fasten the wire harness and seat lock cable to the frame with a plastic holder Ø Pass the wire harness lead and cable the out side of the frame bracket Ù Install the starter relay to the mad guard D L ...

Page 109: ...storage box ß Connect the ABS motor fuse box to the fuse box 2 À Install the storage box light switch to the storage box Á Fasten the negative battery lead and the starter motor lead to the frame with a plastic holder Fasten the fuel tank breather hose to the frame with a plastic holder To the rear brake caliper To the storage box light switch on the seat hinge A A A B A C D L M O N D A A B B C C ...

Page 110: ... sensor lead under the stay 1 and cross pipe Place the front wheel sensor lead between the ribs of the air filter case Fasten the protective tube around the lean angle cut off switch lead to the stay 1 with a plastic band Face the end of the plastic band downward Pass the wire harness over the wire guide Connect the storage box light lead connectors to the storage box light with the leads routed d...

Page 111: ...2 9 Radiator fan motor lead 0 Sidestand switch lead A Spark plug lead 1 B Rear brake lock lever cable C Stay 1 D Rear brake hose E Hydraulic unit F Hydraulic unit solenoid coupler G Front wheel sensor coupler È Pass the rear brake lock lever cable on the front side of throttle cable É Position of clamp Ê Position the relay straighten 4 6 8 9 0 A B C D È É Ê Ô Ì Ë Î Í Ð Ñ Ò Ó É 1 2 3 5 7 E F G Ï ...

Page 112: ...ame Ï Fasten the fuel injection leads with a plastic holder Ð Fasten the sidestand switch lead to the frame with a plastic holder Ñ Fasten the storage box light switch lead to the frame with a plastic clamp Face the clamp clasp to the up side Ò Route the rear brake lock lever cable to the left of the bracket welded to the stay 1 Ó Fasten the rear brake hose to the stay 1 with a plastic holder Ô Ro...

Page 113: ...o rear brake caliper A Brake hose hydraulic unit to front brake caliper È Route the front wheel sensor lead in front of the brake hose hydraulic unit to front brake cali pers as shown in the illustration É Fasten the grommets on the front wheel sensor lead and brake hose hydraulic unit to front brake calipers with the holder Ê Install the holder with its projections inserted into the slots in the ...

Page 114: ... 70 100 mm 2 76 3 94 in past the holder Í 40 60 mm 1 57 2 36 in Î 70 100 mm 2 76 3 94 in Ï 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 Ð Install the hydraulic unit solenoid coupler bracket onto the hydraulic unit making sure that the pro jections on the bracket are aligned with the e...

Page 115: ... of the upper and lower ECU ABS brackets Ó Fasten the grommets on the brake hose front brake master cylinder to hydraulic unit and the brake hose rear brake master cylinder to hydraulic unit with the brake hose holder Ô When tightening the union bolt make sure that the brake hose contacts the left side of the stop per on the hydraulic unit Õ Install the hydraulic unit overflow hose onto the hydrau...

Page 116: ...tion to the back É Make sure that the white paint on the brake hose faces to back right side only Ê Install the hose holder to the innermost securely Ë Turn the handlebar completely to the right and then fasten the brake hose and front wheel sen sor lead together with the plastic holder Ì Fasten the front wheel sensor lead along the inside of the brake hose B B A A A A B B Ì Ë Í Î Ï Ð Ñ Ï Ò Ó Ô È ...

Page 117: ...hose and front fork Ñ Make sure that the stopper touches the outer tube stay Ò 30 40 mm 1 18 1 57 in Ó Make sure that brake pipe touches the projec tion Ô Make sure that the slot in the sensor housing fits stopper on the outer tube Õ Make sure that the brake hose holder touches the projection of the outer tube Ö Make sure that the brake hose joint touches the projection of the outer tube B B A A A...

Page 118: ......

Page 119: ...CHK ADJ 3 ...

Page 120: ...20 ADJUSTING THE ENGINE IDLING SPEED 3 22 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 23 CHECKING THE SPARK PLUGS 3 25 CHECKING THE IGNITION TIMING 3 26 MEASURING THE COMPRESSION PRESSURE 3 27 CHECKING THE ENGINE OIL LEVEL 3 30 CHANGING THE ENGINE OIL 3 30 MEASURING THE ENGINE OIL PRESSURE 3 33 CLEANING THE AIR FILTER ELEMENT 3 34 CLEANING THE V BELT CASE AIR FILTER ELEMENT 3 35 CHECKING THE THROTTLE...

Page 121: ...SYSTEM XP500A 3 50 CHECKING AND ADJUSTING THE STEERING HEAD 3 53 CHECKING THE FRONT FORK 3 56 CHECKING THE TIRES 3 57 CHECKING THE WHEELS 3 59 CHECKING AND LUBRICATING THE CABLES 3 60 LUBRICATING THE LEVERS 3 60 LUBRICATING THE CENTERSTAND 3 60 LUBRICATING THE SIDESTAND 3 61 ELECTRICAL SYSTEM 3 62 CHECKING AND CHARGING THE BATTERY 3 62 CHECKING THE FUSES 3 67 REPLACING THE HEADLIGHT BULBS 3 70 ADJ...

Page 122: ...MAINTENANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line See page 3 37 Check fuel hoses for cracks or damage 2 Spark plugs See page 3 25 Check condition Clean and regap Replace 3 Valves See page 3 11 Check valve clearance Adjust Every 40000 km 4 Air filter element See page 3 34 Clean Replace 5 V belt case air fil ter elements See page 3 35 Clean Replace 6 Front brake See pag...

Page 123: ...Check operation and shock absorber for oil leak age 19 Electronic fuel injection See page 3 17 3 22 Adjust engine idling speed and synchronization 20 Engine oil See page 3 30 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 cartridge See page 3 30 Replace 22 Cooling system See page 3 39 3 40 3 41 Check coolant...

Page 124: ...3 3 CHK ADJ SEAT SEAT 1 2 Order Job Part Q ty Remarks Removing the seat Removing the parts in the order listed 1 Fuel lid 1 2 Seat 1 For installation reverse the removal pro cedure ...

Page 125: ...ts in the order listed 1 Footrest board mat left and right 2 2 Front side cover moulding left and right 2 3 Rearview 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 pro cedure ...

Page 126: ...order listed 1 Upper side cover mole left and right 2 2 Lower side cover mole left and right 2 3 Center cover 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 pro cedure ...

Page 127: ...e light assembly Removing the parts in the order listed Seat Open Upper side cover mole left and right Refer to SIDE COVER MOULDINGS AND LEG SHIELD 1 Grab bar 1 2 Rear cover 1 3 Rear side cover left and right 2 4 Tail brake light assembly coupler 1 Disconnect 5 Tail brake light assembly 1 For installation reverse the removal pro cedure ...

Page 128: ...7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the fuel tank Remove the parts in the order listed 1 Battery cover 1 2 Negative battery lead 1 Disconnect 3 Positive battery lead 1 Disconnect 4 Battery 1 5 Fuse box assembly coupler 2 Disconnect 6 Fuse 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 St...

Page 129: ...Job Part Q ty Remarks 14 Fuel pump coupler 1 Disconnect Refer to REMOVING THE FUEL TANK and INSTALLING THE FUEL TANK 15 Fuel hose connector cover 1 16 Fuel hose 1 17 Fuel tank breather hose 1 18 Fuel pump bracket 1 Refer to REMOVING THE FUEL PUMP and INSTALLING THE FUEL PUMP 19 Fuel pump 1 20 Fuel pump gasket 1 21 Fuel tank cap 1 22 Fuel overflow tray fuel overflow hose 1 1 23 Fuel tank 1 Refer to...

Page 130: ...Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses since there may be fuel remaining in it Do not disconnect the fuel hose except the fuel hose connector of the fuel pump feeding side NOTE Before removing the hoses place a few rags in the area under where it will be removed 4 Remove fuel tank 3 4 2 1 REMOVING THE FUEL PUMP 1 Remove fuel pump bracket fuel ...

Page 131: ...ion shown in the illustration 1 2 3 4 5 6 FWD a New T R 4 Nm 0 4 m kg 2 9 ft lb INSTALLING THE FUEL TANK 1 Install fuel tank NOTE Tighten the bolts to the specified torque in the proper tightening sequence as shown 2 Connect fuel hose fuel breather hose fuel pump coupler CAUTION Be sure to connect the fuel hose by hand Do not forcefully connect the hose with tools When installing the fuel hose mak...

Page 132: ...djusted the piston must be at top dead center TDC on the compression stroke 1 Remove front cowling Refer to FRONT COWLING footrest boards leg shield inner fender Refer to SIDE COVER MOULDINGS AND LEG SHIELD 2 Remove radiator Refer to RADIATOR AND OIL COOLER in chapter 6 3 Remove spark plug cylinder head cover 1 cylinder head cover gasket 4 Remove throttle body intake manifold Refer to THROTTLE BOD...

Page 133: ... piston is at TDC the alignment mark c on the intake cam shaft sprocket and the alignment mark d on the exhaust camshaft sprocket must align with the cylinder head mating surface as shown in the illustration c Measure the valve clearance with a thick ness gauge 1 NOTE If the valve clearance is incorrect record the measured reading Measure the valve clearance in the following sequence d Turn the cr...

Page 134: ... prevent the valve pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place b Select the proper valve pad from the follow ing table NOTE The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter Since valve pads of various sizes are origi nally i...

Page 135: ... and row intersect is the new valve pad number NOTE The new valve pad number is only an approxi mation The valve clearance must be mea sured again and the above steps should be repeated if the measurement is still incorrect e Install the new valve pad 1 and the valve lifter 2 NOTE Apply molybdenum disulfide to the valve pad Lubricate the valve lifter with molybdenum disulfide oil The valve lifter ...

Page 136: ...aust camshaft Align the camshaft sprocket marks with the edge of the cylinder head Turn the crankshaft counterclockwise sev eral turns to seat the parts g Measure the valve clearance again h If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained T R Camshaft cap bolt 10 Nm 1 0 m kg 7 2 ft lb ADJUSTING THE ...

Page 137: ...3 1 27 230 235 240 1 28 1 32 235 240 1 33 1 37 240 MEASURED VALVE CLEARANCE ORIGINAL VALVE PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 0 03 0 07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0 08 0 12 120 ...

Page 138: ... engine idling speed should be properly adjusted and the ignition timing should be checked 1 Stand the scooter on a level surface NOTE Place the scooter on a suitable stand 2 Remove seat Refer to SEAT center cover side cover left and right Refer to SIDE COVER MOULDINGS AND LEG SHIELD 3 Remove synchronizing pipe caps 1 1 4 Install vacuum gauge 1 onto the synchronizing pipe 5 Start the engine and le...

Page 139: ...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 Do not use the throttle valve adjusting screws to adjust the throttle body synchro nization NOTE The difference in vacuum pressure between two throttle bodies should not exceed 1 3 kPa 10 mmHg 0 38 inHg 8 Measure engine idling speed Out ...

Page 140: ...HAUST GAS VOLUME NOTE Be sure to set the CO density level to stan dard and then adjust the exhaust gas volume 1 Turn the main switch to OFF and set the engine stop switch to 2 Simultaneously press and hold the SELECT 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 displa...

Page 141: ...tment volume by pressing the SELECT 1 and RESET 2 buttons NOTE The CO adjustment volume appears on the tripmeter LCD To decrease the CO adjustment volume press the RESET button To increase the CO adjustment volume press the SELECT button 8 Release the switch to execute the selection 9 Simultaneously press the SELECT and RESET buttons to return to the cylinder selection step 5 10 Turn the main swit...

Page 142: ...just Refer to ADJUSTING THE ENGINE IDLING SPEED Pocket tester 90890 03112 YU 03112 C Oil temperature 70 C 158 F Engine idling speed 1 100 1 300 r min 1 6 Install CO HC tester 1 sampling probe 2 NOTE Since it is necessary to insert the sampling Probe 600 mm 23 6 in into the exhaust pipe be sure to use a heat resistant rubber tube as shown in the illustration Be sure to set the heat resistant rubber...

Page 143: ...tion should be adjusted properly and the engine should have adequate compression 1 Remove right side cover Refer to SIDE COVER MOULDINGS AND LEG SHIELD 2 Start the engine and let it warm up for sev eral minutes 3 Check engine idling speed Out of specification Adjust 4 Adjust engine idling speed a Turn the Idle adjust screw 1 in direction a or b until the specified engine idling speed is obtained C...

Page 144: ...t the flange of the throttle grip 3 5 mm 0 12 0 20 in EAS00055 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idling speed and throttle bodies synchronization should be adjusted properly 1 Check throttle cable free play a Out of specification Adjust 2 Remove center cover left side cover Refer to SIDE COVER MOULDINGS AND LEG SHIELD Throttle ca...

Page 145: ...ained d Tighten the locknuts NOTE If the specified throttle cable free play cannot be obtained on the throttle body side of the cable use the adjusting nut on the handlebar side Direction a Throttle cable free play is decreased Direction b Throttle cable free play is increased Handlebar side a Slide back the rubber cover b Loosen the locknut 1 c Turn the adjusting nut 2 in direction a or b until t...

Page 146: ...r cover Refer to SIDE COVER MOULDINGS AND LEG SHIELD CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove center cover side cover left and right inner fender Refer to SIDE COVER MOULDINGS AND LEG SHIELD 2 Disconnect spark plug caps 3 Remove spark plugs CAUTION Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compress...

Page 147: ... the spark plug clean the spark plug and gasket surface 9 Connect spark plug caps 10 Install Inner fender side cover left and right center cover Refer to SIDE COVER MOULDINGS AND LEG SHIELD EAS00062 CHECKING THE IGNITION TIMING NOTE Prior to checking the ignition timing check the wiring connections of the entire ignition sys tem Make sure that all connections are tight and free of corrosion 1 Remo...

Page 148: ...ary pointer a is within the firing rang b on the A C magneto Incorrect firing range Check the ignition system NOTE The ignition timing is not adjustable 5 Install timing plug 6 Install left footrest board side cover left and right center cover Refer to SIDE COVER MOULDINGS AND LEG SHIELD Engine idling speed 1 100 1 300 r min a b T R 8 Nm 0 8 m kg 5 8 ft lb EAS00065 MEASURING THE COMPRESSION PRESSU...

Page 149: ...k plug cap 5 Remove spark plug CAUTION Before removing the spark plugs use com pressed air to blow away any dirt accumu lated in the spark plug wells to prevent it from falling into the cylinders 6 Install compression gauge 1 7 Measure compression pressure Out of specification Refer to steps c and d Compression gauge 90890 03081 YU 33223 Extension 90890 04082 Compression pressure at 360 r min at s...

Page 150: ...ead valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification pour a teaspoonful engine of oil into the spark plug bore and measure again Refer to the following table 8 Install spark plug 9 Connect spark plug cap 10 Install inner fender footrest board left and right Refer to SIDE COVER MOULDINGS AND LEG SHIELD Com...

Page 151: ... the minimum level mark Add the recommended engine oil to the proper level CAUTION Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD c or higher and do not use oils labeled ENERGY CON SERVING II d or higher Do not allow foreign materials to enter the crankcase Reco...

Page 152: ...lter wrench 2 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil CAUTION Make sure that the O ring is positioned cor rectly in the groove of the oil filter car tridge c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench 6 Check engine oil drain bolt gasket Damage Replace 7 Install engine oil drain bolt along with the gasket Oil fil...

Page 153: ... go off NOTE If the engine oil is changed before the oil change indicator light comes on i e before the periodic oil change interval has been reached the indicator light must be reset after the oil change for the next periodic oil change to be indicated at the correct time To reset the oil change indicator light before the periodic oil change interval has been reached follow the above procedure bu...

Page 154: ...Start the engine warm it up for several min utes and then turn it off CAUTION When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 4 Remove main gallery plug 1 O ring WARNING The engine muffler and engine oil are extremely hot 5 Install pressure gauge 1 oil pr...

Page 155: ...C 158 F Engine oil pressure Possible causes Below specification Faulty oil pump Clogged oil filter Leaking oil passage Broken or damaged oil seal Above specification Leaking oil passage Faulty oil filter Oil viscosity too high New T R 12 Nm 1 2 m kg 8 7 ft lb CLEANING THE AIR FILTER ELEMENT 1 Remove front cowling upper cover windshield front cowling inner panel Refer to FRONT COWLING 2 Remove air ...

Page 156: ...ill also affect the carburetor tuning leading to poor engine performance and possible overheat ing NOTE When installing the air filter element into the air filter case cover be sure their sealing surfaces are aligned to prevent any air leaks 6 Install front cowling inner panel windshield front cowling upper cover Refer to FRONT COWLING CLEANING THE V BELT CASE AIR FILTER ELEMENT 1 Remove left uppe...

Page 157: ...ck V belt case air filter element Damage Replace CAUTION 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 right V belt case air filter cover V belt case cover 2 V belt case air filter element left 7 Install left footrest board left upper side cover mole Refer to SIDE COVER MOULDINGS AND LEG SHIELD T R 7 Nm 0 7 m k...

Page 158: ...e Refer to THROTTLE BODY in chapter 7 3 Install leg shield Refer to SIDE COVER MOULDINGS AND LEG SHIELD 1 2 EAS00097 CHECKING THE FUEL HOSES AND FUEL TANK BREATHER HOSE The following procedure applies to all of the fuel hoses and fuel tank breather hose 1 Remove right footrest board right upper side cover mole Refer to SIDE COVER MOULDINGS AND LEG SHIELD 2 Check fuel hose 1 fuel tank breather hose...

Page 159: ...he following procedure applies to all of the exhaust pipes and gaskets 1 Remove right rear side cover Refer to REAR COVERS AND TAIL BRAKE LIGHT ASSEMBLY inner fender Refer to SIDE COVER MOULDINGS AND LEG SHIELD 2 Check exhaust pipes 1 muffler 2 Cracks damage Replace gasket 3 Exhaust gas leaks Replace 3 Check tightening torque T R Exhaust pipe nut 4 20 Nm 2 0 m kg 14 ft lb Muffler nut 5 31 Nm 3 1 m...

Page 160: ...oolant level should be between the maximum level mark a and minimum level marks b Below the minimum level mark Add the recommended coolant to the proper level CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and correct the antifreeze concentration of the coolant Use only distilled water Soft water may be used if distill...

Page 161: ...HIELD 2 Check radiator 1 radiator inlet hose 2 radiator outlet hose 3 oil cooler inlet hose 4 oil cooler outlet hose 5 thermostat outlet hose 6 water pump 7 water pump inlet pipe 8 water pump outlet pipe 9 Cracks damage Replace Refer to COOLING SYSTEM in chapter 6 3 Install inner fender leg shield footrest board left and right Refer to SIDE COVER MOULDINGS AND LEG SHIELD ...

Page 162: ...diator is under pressure Therefore do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the h...

Page 163: ... If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomiting and get immediate medical attention CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Recommended antifreeze High qu...

Page 164: ... 14 Start the engine warm it up for several min utes and then turn it off 15 Check coolant level Refer to CHECKING THE COOLANT LEVEL NOTE Before checking the coolant level wait a few minutes until it settles 16 Install inner fender lower side cover mole left and right coolant reservoir cap access panel Refer to SIDE COVER MOULDINGS AND LEG SHIELD front side cover mole left and right left footrest ...

Page 165: ... drive oil to the proper level 5 Install chain drive oil filler cap chain drive case cover Recommended chain drive oil SAE 80 API GL 4 Hypoid gear oil T R 7 Nm 0 7 m kg 5 1 ft lb CHANGING THE CHAIN DRIVE OIL 1 Place a container under the chain drive 2 Remove chain drive case cover chain drive oil filler cap chain drive oil drain bolt 1 Completely drain the chain drive of its oil 3 Check drain bolt...

Page 166: ...ain drive oil with the specified amount of the recom mended chain drive oil 6 Check chain drive oil level Refer to CHECKING THE CHAIN DRIVE OIL LEVEL Quantity 0 70 L 0 62 Imp qt 0 74 US qt CHECKING THE CHAIN DRIVE OIL LEVEL ...

Page 167: ...le length a Slowly apply the rear brake several times b Turn the adjusting nut 1 until rear brake lock lever cable length a is 42 44 mm 1 65 1 73 in with the rear brake lock lever released c Set the rear brake lock lever wait more than 5 minutes and then release the rear brake lock lever d Turn the adjusting nut 1 until rear brake lock lever cable length a is 45 47mm 1 77 1 85 in with the rear bra...

Page 168: ...sing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage ...

Page 169: ...uch the brake disc Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 4 È Front brake É Rear brake Brake pad wear limit 0 8 mm 0 03 in È É EAS00132 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and clamps 1 Check brake hose Cracks damage wear Replace 2 Check brake hose clamp Loose connection Tighten 3 Hold the scooter upright and apply th...

Page 170: ...e Ignoring this precaution could allow air to enter the hydraulic brake system considerably length ening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed hydraulic brake system a Fill the brake master cylinder reservoir to the proper level with t...

Page 171: ...have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification k Fill the brake fluid reservoir to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL WARNING After bleeding the hydraulic brake system check the brake operation T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb EAS00892 BLEEDING THE BRAKE SYSTEM XP500A WARNING _ Always bleed the brake system when the...

Page 172: ...llow air to enter the ABS considerably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed ABS a Fill the brake master cylinder reservoir to the proper level with the recommended brake fluid b Install the brake master cylinder reservoir ...

Page 173: ...nit Refer to D 6 3 1 Hydraulic unit operation test 1 in chapter 4 CAUTION Make sure that the main switch is set to OFF before checking the operation of the hydraulic unit k After operating the ABS repeat steps e to i and then fill the primary circuit with 60 cm3 2 11 Imp oz 2 03 US oz of the rec ommended brake fluid l Tighten the bleed screw to the specified torque m Fill the brake fluid reservoir...

Page 174: ...t there is no danger of it falling over NOTE Place the scooter on a suitable stand so that the front wheel is elevated 2 Check steering head Grasp the bottom of the front fork legs and gently rock the front fork Looseness binding Adjust the steering head 3 Remove handlebar Refer to HANDLEBAR in chapter 4 4 Loosen upper bracket pinch bolts 1 5 Remove steering stem nut 1 upper bracket 2 ...

Page 175: ...g the front fork all the way in both directions If any binding is felt remove the lower bracket and inspect the upper and lower bearings Refer to STEERING HEAD in chapter 4 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 4 and tighten the upper ring nut until their slots ...

Page 176: ... d Hold the spring gauge at a 45 angle from the handlebar pull the spring gauge and record the measurement when the handle bar starts to turn e Repeat the above procedure on the oppo site 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 upper ring nut g Reinstall the upper bracket and...

Page 177: ...so that there is no danger of it falling over 2 Check inner tube Damage scratches Replace oil seal Oil leakage Replace 3 Hold the scooter upright and apply the front brake 4 Check front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK in chapter 4 ...

Page 178: ...an overloaded scooter could cause tire damage an accident or an injury NEVER OVERLOAD THE SCOOTER Total weight of rider passenger cargo and accessories WARNING It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately Basic weight with oil and a full fuel tank 225 kg 496 lb XP500 230 kg 507 lb XP500A Maximum load 190 kg 419 lb XP500 185 kg...

Page 179: ...red in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement È Tire É Wheel After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same des...

Page 180: ...n of rotation mark 1 Install the tire with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check wheel Damage out of round Replace WARNING Never attempt to make any repairs to the wheel NOTE After a tire or wheel has been changed or replaced always balance the wheel M...

Page 181: ...e sheath Damage Replace 2 Check cable operation Unsmooth operation Lubricate NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device Recommended lubricant Engine oil or a suitable cable lubricant EAS00171 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers Recommended lubricant Lithiu...

Page 182: ...3 61 CHK ADJ LUBRICATING THE SIDESTAND EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of sidestand Recommended lubricant Lithium soap based grease ...

Page 183: ...yte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION _ This is a sealed battery Never remove the sealing cap...

Page 184: ...to the battery termi nals NOTE _ The charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive termi nal is disconnected No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example Example c Open circuit voltage 12 0 V d Charging time 6...

Page 185: ...nected 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 termi nal and that they are not shorted A cor roded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to ...

Page 186: ...tandard charg ing amperage exceeded NO YES If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes ...

Page 187: ...ches 15 V Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes before measuring its open circuit voltage NOTE Set th...

Page 188: ...h Loose connection Connect properly 9 Lubricate battery terminals 10 Install battery cover Refer to FUEL TANK Recommended lubricant Dielectric grease EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses CAUTION To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove grab bar rear cover Refer to REAR COVERS AND TAIL BRAKE LIGH...

Page 189: ...o Ω 1 b If the pocket tester indicates replace the fuse Pocket tester 90890 03112 YU 03112 C 4 Replace blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage c Set the main switch to ON and verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit È XP500 É XP500A È É ...

Page 190: ...6 Install battery cover Refer to FUEL TANK rear cover grab bar Refer to REAR COVERS AND TAIL BRAKE LIGHT ASSEMBLY Item Amperage Q ty Main fuse 30 A 1 Headlight fuse 15 A 1 Signaling system fuse 20 A XP500 15 A XP500A 1 1 Ignition fuse 10 A 1 Radiator fan motor fuse 15 A 1 Lighting system fuse 10 A 1 Fuel injection sys tem fuse 10 A 1 ABS motor fuse 30 A XP500A 1 ABS control unit fuse 5A XP500A 1 B...

Page 191: ...headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 6 Install headlight bulb Secure the new headlight bulb with the headlight bulb holder CAUTION 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 I...

Page 192: ...WLING EAS00184 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically a Turn the adjusting screws 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is lowered 2 Adjust headlight beam horizontally a Turn the adjusting screws 2 in direction c or d Direction c Headlight beam moves to the right Direction d Headlight beam moves to the left ...

Page 193: ......

Page 194: ...CHAS 4 ...

Page 195: ...THE FRONT WHEEL STATIC BALANCE 4 11 INSTALLING THE FRONT WHEEL XP500 4 13 INSTALLING THE FRONT WHEEL AND FRONT WHEEL SENSOR XP500A 4 14 REAR WHEEL AND BRAKE DISC 4 16 REMOVING THE REAR WHEEL XP500 4 20 REMOVING THE REAR WHEEL AND REAR WHEEL SENSOR XP500A 4 20 CHECKING THE REAR WHEEL SENSOR AND SENSOR ROTOR XP500A 4 21 CHECKING THE REAR WHEEL 4 21 CHECKING THE REAR WHEEL DRIVE HUB 4 21 ADJUSTING TH...

Page 196: ...SEMBLING THE REAR BRAKE CALIPER 4 51 CHECKING THE FRONT AND REAR BRAKE CALIPER 4 52 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER 4 54 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 4 56 ECU ABS AND FAIL SAFE RELAY XP500A 4 60 HYDRAULIC UNIT XP500A 4 61 REMOVING THE HYDRAULIC UNIT 4 64 CHECKING THE HYDRAULIC UNIT 4 64 INSTALLING THE HYDRAULIC UNIT 4 65 HANDLEBAR 4 67 REMOVING THE HANDLEBAR 4...

Page 197: ...BSORBER AND GAS CYLINDER 4 90 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 91 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 4 91 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 92 ANTI LOCK BRAKE SYSTEM XP500A 4 93 ABS COMPONENTS 4 93 CIRCUIT DIAGRAM 4 95 CAUTIONS FOR OPERATION 4 97 TROUBLESHOOTING 4 98 ...

Page 198: ...CHAS ...

Page 199: ...heel and brake disc XP500 Remove the parts in the order listed NOTE Place the scooter on a suitable stand so that the front wheel is elevated 1 Front brake caliper left and right 2 Refer to REMOVING THE FRONT WHEEL XP500 and INSTALL ING THE FRONT WHEEL XP500 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 ins...

Page 200: ...FRONT WHEEL AND BRAKE DISC Order Job Part Q ty Remarks Disassembling the front wheel XP500 Remove the parts in the order listed 1 Oil seal 1 2 Bearing 2 3 Collar 1 For assembly reverse the disassembly procedure ...

Page 201: ...disc XP500A Remove the parts in the order listed NOTE Place the scooter on a suitable stand so that the front wheel is elevated Front cowling upper cover Refer to COVER AND PANEL in chap ter 3 1 Front wheel sensor coupler 1 Disconnect Refer to REMOVING THE FRONT WHEEL AND FRONT WHEEL SENSOR XP500A and INSTALLING THE FRONT WHEEL AND FRONT WHEEL SENSOR XP500A 2 Front brake caliper left and right 2 3...

Page 202: ...b T R 30 Nm 3 0 m kg 22 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib LT 6 6 1 2 3 7 8 11 6 11 10 9 4 5 2 LT T R 18 Nm 1 8 m kg 13 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib Order Job Part Q ty Remarks 8 Collar left 1 9 Collar right 1 10 Dust cover 1 11 Brake disc 2 For installation reverse the removal procedure ...

Page 203: ...EEL AND BRAKE DISC 1 2 3 2 1 LS LS Order Job Part Q ty Remarks Disassembling the front wheel XP500A Remove the parts in the order listed 1 Oil seal 2 2 Bearing 2 3 Collar 1 For assembly reverse the disassembly procedure ...

Page 204: ...osen front wheel axle pinch bolt 1 front wheel axle 2 Use the damper rod holder 3 4 Elevate front wheel NOTE Place the scooter on a suitable stand so that the front wheel is elevated EAS00520 REMOVING THE FRONT WHEEL AND FRONT WHEEL SENSOR XP500A ABS wheel sensor and sensor rotor CAUTION _ Handle the ABS components with care since they have been accurately adjusted Keep them away from dirt and do ...

Page 205: ...ON _ Be sure not to contact the sensor elec trode to any metal part when removing the front wheel sensor from the sensor housing Do not operate the brake lever when removing the brake caliper 3 Remove front brake calipers NOTE Do not squeeze the brake lever when remov ing the brake caliper 1 2 3 4 Loosen wheel axle pinch bolt 1 front wheel axle 2 Use the damper rod holder 3 5 Elevate front wheel N...

Page 206: ... front wheel Damage wear Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 3 Measure front wheel radial runout 1 front wheel lateral runout 2 Over the specified limits Replace Front wheel radial runout limit 1 mm 0 04 in Front wheel lateral runout limit 0 5 mm 0 02 in 4 Check wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings oil seals Damage wea...

Page 207: ...UTION Do not contact the wheel bearing center race 4 or balls 5 Contact should be made only with the outer race 6 NOTE Use a socket 7 that matches the diameter of the wheel bearing outer race and oil seal New New EAS00528 CHECKING THE BRAKE DISC The following procedure applies to all of the brake discs 1 Check brake disc Damage galling Replace 2 Measure brake disc deflection Out of specification C...

Page 208: ...t a few different locations Out of specification Replace Minimum brake disc thickness Front 3 5 mm 0 14 in Rear 4 5 mm 0 18 in 4 Adjust brake disc deflection a Remove the brake disc b Rotate the brake disc by one bolt hole c Install the brake disc NOTE Tighten the brake disc bolts in stages and in a crisscross pattern d Measure the brake disc deflection e If out of specification repeat the adjustm...

Page 209: ... probe Terminal 2 Out of specification Replace 3 Check front wheel sensor rotor 1 Cracks damage Replace the front wheel assembly NOTE The wheel sensor rotor of the scooter cannot be replaced as a single unit To replace the sensor rotor replace the wheel assembly Regulated resistance 1 2 1 6 kΩ at 20 C 68 F 1 EAS00548 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE After replacing the tire wheel or b...

Page 210: ...to rest at the same spot h The spot where all the marks come to rest is the front wheel s heavy spot X 3 Adjust front wheel static balance a Install a balancing weight 1 onto the rim exactly opposite the heavy spot X NOTE Start with the lightest weight b Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weigh...

Page 211: ...eshed into the two slots respectively 3 Install front wheel front wheel axle front wheel axle pinch bolt NOTE Make sure that the slot a in the speedometer gear unit fits over the stopper b on the front fork outer tube 4 Tighten front wheel axle 1 Use the damper rod holder 2 front wheel axle pinch bolt 3 CAUTION Before tightening the wheel axle pinch bolt push down hand on the handlebar several tim...

Page 212: ...FRONT WHEEL AND FRONT WHEEL SENSOR XP500A 1 Lubricate oil seal lips 2 Install front wheel front wheel axle front wheel axle pinch bolt NOTE _ Align the slot in the sensor housing with the projection of the front fork before assembly CAUTION _ Make sure there are no foreign materials in the wheel hub Foreign materials cause damage to the inner sensor rotor and front wheel sensor Recommended lubrica...

Page 213: ...m 2 3 m kg 17 ft lb 4 Install front wheel sensor 1 front wheel sensor lead guide front brake caliper 2 NOTE _ When installing the front wheel sensor check the wheel sensor lead for twists and the sensor electrode for foreign materials CAUTION _ To route the front wheel sensor lead refer to CABLE ROUTING in chapter 2 5 Check front wheel sensor installation Check if the wheel sensor housing is insta...

Page 214: ...e parts in the order listed NOTE Place the scooter on a suitable stand so that the 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 pro cedure ...

Page 215: ...he scooter on a suitable stand so that the rear wheel is elevated Tail brake light assembly Refer to COVER AND PANEL in chap ter 3 1 Rear wheel sensor coupler 1 Disconnect Refer to REMOVING THE REAR WHEEL AND REAR WHEEL SENSOR XP500A and INSTALL ING THE REAR WHEEL SENSOR XP500A 2 Rear wheel sensor 1 3 Brake caliper 1 4 Chain drive case cover 1 ...

Page 216: ...le pinch bolt 1 Loosen Refer to INSTALLING THE REAR WHEEL SEN SOR XP500A 6 Rear wheel axle nut washer 1 1 7 Rear wheel axle 1 8 Collar 1 Refer to INSTALLING THE REAR WHEEL SENSOR XP500A 9 Sensor housing 1 10 Collar 1 11 Rear wheel 1 For installation reverse the removal pro cedure ...

Page 217: ...BRAKE DISC Order Job Part Q ty Remarks Disassembling the rear wheel Remove the parts in the order listed 1 Brake disc 1 2 Rear wheel drive hub 1 3 O ring 1 4 Oil seal 1 5 Bearing 2 For assembly reverse the disassembly procedure ...

Page 218: ...EAR WHEEL AND REAR WHEEL SENSOR XP500A CAUTION Be sure not to contact the sensor elec trode to any metal part when removing the front wheel sensor from the sensor housing Do not operate the brake lever when removing the brake caliper 1 Stand the scooter on a level surface WARNING _ Securely support the scooter so that there is no danger of it falling over NOTE _ Place the scooter on a suitable sta...

Page 219: ...R ROTOR XP500A EAS00565 CHECKING THE REAR WHEEL 1 Check wheel axle rear wheel wheel bearings oil seals Refer to CHECKING THE FRONT WHEEL 2 Check tire rear wheel Damage wear Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 3 Measure rear wheel radial runout rear wheel lateral runout Refer to CHECKING THE FRONT WHEEL EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1 Check rear whe...

Page 220: ... wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE INSTALLING THE REAR WHEEL SENSOR XP500A 1 Install rear wheel NOTE Align the slot a of the sensor housing 1 with the projection b of the collar 2 and then assemble them Align the slot c of the collar with the rib d of the swingarm 3 and then assemble them CAUTION Make sure there are no foreign materials in the wheel hub Foreign...

Page 221: ...the rear wheel sensor lead refer to CABLE ROUTING in chapter 2 1 T R 30 Nm 3 0 m kg 22 ft lb 3 Connect rear wheel sensor coupler 1 rear wheel sensor lead holder 2 clamps 3 CAUTION _ To route the rear wheel sensor lead refer to CABLE ROUTING in chapter 2 4 Check rear wheel sensor installation Check if the wheel sensor housing is installed properly Refer to D 4 Maintenance of the rear wheel sensor a...

Page 222: ...emarks Removing the front brake pads Remove the parts in the order listed 1 Front brake caliper retaining bolt lower 1 Refer to REPLACING THE FRONT BRAKE PADS 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 pro cedure ...

Page 223: ...ear brake pads Remove the parts in the order listed 1 Rear brake caliper retaining bolt 1 2 Rear brake caliper bracket bolt 2 3 Brake caliper 1 Refer to REPLACING THE REAR BRAKE PADS 4 Brake pad 2 5 Brake pad spring 2 6 Brake caliper bracket 1 For installation reverse the removal pro cedure ...

Page 224: ...e fluid for cleaning brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury First aid for brake fluid entering the eyes Flush with water for 15 minutes and get immediate medical attention EAS00581 REPLACING THE FRONT BRAKE PADS NOTE When repla...

Page 225: ...stic hose 5 tightly to the bleed screw 6 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new brake pads new brake shims and new brake pad springs 5 Lubricate front brake caliper retaining bolts CAUTION Do not allow grease to contact the brake pads Remove any ...

Page 226: ...FLUID LEVEL in chapter 3 8 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM XP500 and BLEED ING THE BRAKE SYSTEM XP500A in chapter 3 EAS00583 REPLACING THE REAR BRAKE PADS NOTE When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Remove rear brake caliper retaining b...

Page 227: ... thickness a Out of specification Replace the brake pads as a set Minimum brake pad thickness 0 8 mm 0 03 in 4 Install brake pad springs 1 brake pads 2 rear brake caliper bracket 3 to brake caliper NOTE Always install new brake pads and new brake pad springs as a set 1 1 2 New New New 3 New New ...

Page 228: ...iper pis ton is level with the surface of the brake caliper body NOTE Align the recesses b in the brake caliper pis ton with the brake caliper body as shown in the illustration c Tighten the brake caliper bleed screw d Install new brake pads new pad springs and the rear brake caliper NOTE Align the projection c on the piston side of the brake pad with the lower recess in the brake caliper piston È...

Page 229: ...s 8 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 in chapter 3 9 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM XP500 and BLEED ING THE BRAKE SYSTEM XP500A in chapter 3 Recommended lubricant Lithium soap based grease T R 27 Nm ...

Page 230: ...ster cylinder Remove the parts in the order listed Upper handlebar cover Refer to HANDLEBAR Brake fluid Drain 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir dia phragm holder 1 3 Brake master cylinder reservoir dia phragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect ...

Page 231: ...to DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER and ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLIN DER 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 pro cedure ...

Page 232: ...Job Part Q ty Remarks Disassembling the front brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 For assembly reverse the disassembly procedure ...

Page 233: ...ter cyl inder Remove the parts in the order listed Upper handlebar cover Refer to HANDLEBAR Brake fluid Drain 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir dia phragm holder 1 3 Brake master cylinder reservoir dia phragm 1 4 Brake lever 1 5 Rear brake light switch connector 2 Disconnect ...

Page 234: ...r to DISASSEMBLING THE REAR BRAKE MASTER CYLINDER and ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER 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 pro cedure ...

Page 235: ... Job Part Q ty Remarks Disassembling the rear brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 For assembly reverse the disassembly procedure ...

Page 236: ... 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS00589 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER NOTE Before disassembling the rear brake master cylinder 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 t...

Page 237: ...rake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air È Front É Rear È É 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 Damage wear Replace brake master cylinder reservoir diaphragm 3 Damage wear Replace 4 Check brake h...

Page 238: ...ts on internal brake components 1 Install brake master cylinder kit 1 circlip 2 dust boot 3 Recommended brake fluid DOT 4 New 2 Install brake master cylinder 1 brake master cylinder holder 2 holder bolts NOTE Install the brake master cylinder holder with the UP mark facing up a Align the brake master cylinder with the pro jection b in the handlebar First tighten the upper bolt then the lower bolt ...

Page 239: ...s the projection a on the brake master cylinder 4 Connect front brake light switch connector 5 Fill brake master cylinder reservoir with the specified amount of the recom mended brake fluid WARNING 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 th...

Page 240: ...he proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 8 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM XP500 and BLEED ING THE BRAKE SYSTEM XP500A in chapter 3 EAS00600 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER WARNING Before installation all internal brake com ponents should be cleaned and lubric...

Page 241: ...per washer 1 brake hose 2 union bolt 3 WARNING Proper brake hose routing is essential to insure safe scooter operation Refer to CABLE ROUTING in chapter 2 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 hose does not touch other parts e g wire harness cables leads Correct if necessary CAUTION When install...

Page 242: ...ater will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM XP500 and BLEED ING THE BRAKE SYSTEM XP500A in chapter 3 6 Check brake fluid level Below the minimum level mark a...

Page 243: ...move the parts in the order listed Brake fluid Drain 1 Union bolt 1 Refer to DISASSEMBLING THE FRONT BRAKE CALIPER and ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER 2 Copper washer 2 3 Brake hose 1 4 Front brake caliper retaining bolt lower 1 Refer to ASSEMBLING AND INSTALL ING THE FRONT BRAKE CALIPER 5 Front brake caliper retaining bolt upper 1 6 Brake caliper 1 7 Brake pad 2 8 Brake pad shim...

Page 244: ...40 Nm 4 0 m kg 29 ft Ib 11 T R 30 Nm 3 0 m kg 22 ft Ib 11 Order Job Part Q ty Remarks 11 Front brake caliper bracket bolt 2 2 Refer to ASSEMBLING AND INSTALL ING THE FRONT BRAKE CALIPER 12 Brake caliper bracket 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 245: ...cali per Remove the parts in the order listed 1 Bleed screw 1 2 Dust seal 2 Refer to DISASSEMBLING THE FRONT BRAKE CALIPER and ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER 3 Brake caliper piston seal 2 4 Brake caliper piston 2 5 Brake caliper body 1 For assembly reverse the disassembly procedure ...

Page 246: ... Refer to DISASSEMBLING THE REAR BRAKE CALIPER 2 Rear brake lock lever cable 1 3 Pin 1 4 Spring 1 5 Union bolt 1 Refer to DISASSEMBLING THE REAR BRAKE CALIPER and ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 6 Copper washer 2 7 Brake hose 1 8 Rear brake caliper retaining bolt 2 Refer to ASSEMBLING AND INSTALL ING THE REAR BRAKE CALIPER 9 Brake caliper 1 10 Brake pad 2 ...

Page 247: ...Q ty Remarks 11 Brake pad spring 2 Refer to ASSEMBLING AND INSTALL ING THE REAR BRAKE CALIPER 12 Rear brake caliper bracket bolt 2 13 Brake caliper bracket 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 248: ...assembling the rear brake cali per Remove the parts in the order listed 1 Brake caliper piston 1 Refer to DISASSEMBLING THE REAR BRAKE CALIPER and ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 2 Dust seal 1 3 Piston seal 1 4 Bleed screw 1 5 Brake caliper body 1 For assembly reverse the disassembly procedure ...

Page 249: ...er pistons 1 dust seals 2 brake caliper piston seals 3 a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper WARNING Cover the brake caliper pistons with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper Never try to pry out the brake caliper pis tons b Remove the dust seal and brake caliper pis ton seals a...

Page 250: ...Remove brake caliper piston 1 dust seal 2 brake caliper piston seal 3 a Turn the parking brake lever 4 continues until piston remove b Remove the dust seal and brake caliper pis ton seal EAS00631 CHECKING THE FRONT AND REAR BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and...

Page 251: ...ar Replace the brake cali per brake caliper body 3 Cracks damage Replace the brake cali per brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING Whenever a brake caliper is disassembled replace the piston seals È Front É Rear È É 2 Check brake caliper bracket 1 Cracks damage Replace È Front É Rear 1 È É ...

Page 252: ... brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper piston seals 1 dust seals 2 brake caliper pistons 3 2 Install brake caliper bracket 3 Install brake caliper 1 temporarily copper washers brake hose 2 union bolt 3 WARNING _ Proper brake hose routing is essential to insure safe scooter operation Refer to CABLE ROUTING in chapter 2 CAUTION _ When installing the brake h...

Page 253: ...he same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction 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 boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic ...

Page 254: ... XP500 and BLEED ING THE BRAKE SYSTEM XP500A in chapter 3 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING _ Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components as they will cause the piston seals to swell and distort Whenever a brake caliper is disassem bled replace the brake cali...

Page 255: ... shown in the illustration 1 a 1 b 3 Install brake caliper bracket 4 Install brake caliper 1 temporarily copper washers brake hose 2 union bolt 3 WARNING _ Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING in chapter 2 CAUTION When installing the brake hose onto the brake caliper make sure the brake pipe touches the projection a on the brake cali per 5 ...

Page 256: ... type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up...

Page 257: ...E FLUID LEVEL in chapter 3 10 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM XP500 and BLEED ING THE BRAKE SYSTEM XP500A in chapter 3 11 Install spring pin rear brake lock lever cable nut 12 Adjust rear brake lock lever cable length Refer to ADJUSTING THE REAR BRAKE LOCK LEVER CABLE in chapter 3 ...

Page 258: ...rt Q ty Remarks Removing the ECU ABS and fail safe relay XP500A Remove the parts in the order listed Front cowling Refer to COVER AND PANEL in chap ter 3 1 Fail safe relay coupler 1 Disconnect 2 Fail safe relay 1 3 Upper ECU ABS bracket 1 4 ECU ABS coupler 2 Disconnect 5 ECU ABS 1 For installation reverse the removal pro cedure ...

Page 259: ... unit XP500A Remove the parts in the order listed Front cowling Refer to COVER AND PANEL in chap ter 3 Brake fluid Drain 1 Hydraulic unit solenoid coupler wire harness side 1 Disconnect 2 ABS motor coupler 1 Disconnect 3 Union bolt copper washer 1 2 4 Front brake hose 1 front brake master cylinder to hydraulic unit 5 Union bolt copper washer 1 2 6 Front brake hose 1 hydraulic unit to front brake c...

Page 260: ...5 3 4 3 7 8 7 9 10 9 1 13 11 2 12 12 T R 16 Nm 1 6 m kg 11 ft Ib 12 New New New New New New New New Order Job Part Q ty Remarks 9 Union bolt copper washer 1 2 10 Rear brake hose 1 hydraulic unit to rear brake caliper 11 ABS motor breather hose 1 12 Nut 3 13 Hydraulic unit 1 For installation reverse the removal pro cedure ...

Page 261: ...t 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 one Do not set the main switch to ON when removing the hydraulic unit Do not clean with compressed air Do not reuse the brake fluid Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Do not...

Page 262: ... removing the brake hoses CAUTION _ When removing the brake hoses cover the area around the hydraulic unit to catch any spilt brake fluid Do not allow the brake fluid to contact other parts 3 4 2 1 2 Remove hydraulic unit 1 NOTE _ To avoid brake fluid leakage and to prevent foreign materials from entering the hydraulic unit insert a rubber plug a or a bolt M10 1 25 into each union bolt hole 1 CHEC...

Page 263: ...er plugs or bolts M10 1 25 installed in the union bolt holes before installing the hydraulic unit T R 16 Nm 1 6 m kg 11 ft lb 2 Remove rubber plugs or bolts M10 1 25 3 Install copper washers brake hose 1 to the rear brake caliper brake hose 2 from the rear brake master cylinder brake hose 3 to the front brake caliper brake hose 4 from the front brake master cylinder union bolts WARNING _ The brake...

Page 264: ...d the brake system 6 Check the operation of the hydraulic unit according to the brake levers response Refer to D 6 3 1 Hydraulic unit operation test 1 CAUTION _ Always check the operation of the hydrau lic unit according to the brake levers response Recommended brake fluid DOT 4 ...

Page 265: ...per handlebar cover 1 2 Band 3 3 Grip end 2 4 Front brake light switch connector 2 Disconnect 5 Right handlebar switch 1 Refer to INSTALLING THE HANDLEBAR 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Front brake master cylinder holder 1 9 Front brake master cylinder 1 10 Rear brake light switch connector 2 Disconnect ...

Page 266: ... 1 Disconnect 13 Left handlebar switch 1 14 Rear brake master cylinder holder 1 15 Rear brake master cylinder 1 16 Handlebar grip 1 Refer to REMOVING THE HANDLE BAR and INSTALLING THE HANDLE BAR 17 Upper handlebar holder 2 Refer to INSTALLING THE HANDLE BAR 18 Handlebar 1 19 Lower handlebar cover 1 For installation reverse the removal pro cedure ...

Page 267: ...ressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar CHECKING THE HANDLEBAR 1 Check handlebar Bends cracks damage Replace WARNING Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS00671 INSTALLING THE HANDLEBAR 1 Stand the scooter on a level surface WARNING Securely support the scooter so that there is no danger of ...

Page 268: ...p grip end a Apply a thin coat of rubber adhesive onto the left end of the handlebar b Slide the handlebar grip over the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried 4 Install rear brake master cylinder 1 rear brake master cylinder holder 2 NOTE Install the rear brake master cylind...

Page 269: ...andlebar b 1 a 7 Install front brake master cylinder 1 front brake master cylinder holder 2 NOTE Install the front brake master cylinder holder with the 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 ...

Page 270: ...the right handlebar switch with the hole b in the handlebar 10 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 11 Adjust rear brake lock lever cable length Refer to ADJUSTING THE REAR BRAKE LOCK LEVER CABLE in chapter 3 Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in ...

Page 271: ...rocedure applies to both of the front fork legs Front cowling leg shield Refer to COVER AND PANEL in chap ter 3 Handlebar cover upper and lower Refer to HANDLEBAR Front wheel Refer to FRONT WHEEL AND BRAKE DISC ECU ABS For XP500A Refer to FRONT AND REAR BRAKES 1 Front fender 1 2 Front brake caliper 2 3 Horn coupler 2 Disconnect 4 Horn 2 ...

Page 272: ...y Remarks 5 Upper bracket pinch bolt 2 Loosen Refer to REMOVING THE FRONT FORK LEGS and INSTALLING THE FRONT FORK LEGS 6 Cap bolt 1 Loosen 7 Lower bracket pinch bolt 4 Loosen 8 Front fork leg 2 For installation reverse the removal pro cedure ...

Page 273: ...wing procedure applies to both of the front fork legs 1 Cap bolt 1 Refer to DISASSEMBLING THE FRONT FORK LEGS and ASSEM BLING THE FRONT FORK LEGS 2 O ring 1 3 Spacer 1 4 Fork spring seat 1 5 Fork spring 1 6 Damper rod assembly bolt 1 7 Copper washer 1 8 Damper rod assembly 1 9 Rebound spring 1 0 Oil flow stopper 1 A Inner tube 1 ...

Page 274: ... ty Remarks B Inner tube bushing 1 Refer to DISASSEMBLING THE FRONT FORK LEGS and ASSEM BLING THE FRONT FORK LEGS C Dust seal 1 D Oil seal clip 1 E Oil seal 1 F Washer 1 G Outer tube bushing 1 For assembly reverse the disassembly procedure ...

Page 275: ... on a suitable stand so that the front wheel is elevated 2 Loosen upper bracket pinch bolt 1 cap bolt 2 3 Loosen lower bracket pinch bolts 1 WARNING Before loosening the upper and lower bracket pinch bolts support the front fork leg 4 Remove front fork leg EAS00652 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 ...

Page 276: ...4 YM 01300 T handle 90890 01326 YM 01326 4 Remove inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but care fully CAUTION Excessive force will damage the oil seal and bushing A damaged oil seal or bush ing must be replaced Avoid bottoming the inner...

Page 277: ...Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure spring free length a Over the specified limit Replace Spring free length limit 405 0 mm 15 94 in Limit 400 0 mm 15 75 in 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air oil flow stopper 2 Damage Replace 4 Check cap bolt O ring Damage wear Replace ...

Page 278: ...nner tube bushing outer tube bushing oil seal dust seal Before assembling the front fork leg make sure that all of the components are clean 1 Install damper rod 1 rebound spring 2 CAUTION Allow the damper rod to slide slowly down the inner tube 3 until it protrudes 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 ...

Page 279: ...lt 23 Nm 2 3 m kg 17 ft lb LOCTITE Damper rod holder 90890 01294 YM 01300 T handle 90890 01326 YM 01326 6 Install outer tube bushing 1 washer 2 with the fork seal driver weight 3 and fork seal driver attachment 4 Fork seal driver weight 90890 01367 YM A5142 4 Fork seal driver attachment 41 mm 90890 01381 YM A5142 2 New 7 Install oil seal 1 with the fork seal driver weight 2 and fork seal driver at...

Page 280: ...be 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 NOTE While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil Fork seal driver weight 90890 01367 YM A5142 4 Quantity each front fork leg 0 512 L 0 451 Imp qt 0 541 US qt Front ...

Page 281: ... ring with grease Temporarily tighten the cap bolt EAS00663 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install front fork leg NOTE Pull up the inner tube until it stops 2 Tighten lower bracket pinch bolt 1 cap bolt 2 upper bracket pinch bolt 3 1 T R 23 Nm 2 3 m kg 17 ft lb T R 24 Nm 2 4 m kg 17 ft lb T R 30 Nm 3 0 m kg 22 ft lb ...

Page 282: ...to COVER AND PANEL in chap ter 3 Front wheel Refer to FRONT WHEEL AND BRAKE DISC Front fork legs Refer to FRONT FORK Handlebar Refer to HANDLEBAR 1 Horn bracket 1 2 Brake hose holder 1 3 Steering stem nut 1 Refer to REMOVING THE LOWER BRACKET and INSTALLING THE STEERING HEAD 4 Upper bracket 1 5 Lock washer 1 6 Upper ring nut 1 7 Rubber washer 1 8 Lower ring nut 1 ...

Page 283: ...g cover 1 10 Bearing outer race 1 Refer to INSTALLING THE STEERING HEAD 11 Upper bearing 1 12 Bearing inner race 1 13 Bearing outer race 1 14 Lower bearing 1 15 Bearing inner race 1 16 Oil seal 1 17 Lower bracket 1 For installation reverse the removal pro cedure ...

Page 284: ...lock washer 1 upper ring nut 2 rubber washer 3 lower ring nut 4 with the steering nut wrench WARNING Securely support the lower bracket so that there is no danger of it falling Steering nut wrench 90890 01403 YU 33975 Ring nut wrench 90890 01268 YU 01268 EAS00681 CHECKING THE STEERING HEAD 1 Wash bearings bearing races Recommended cleaning solvent Kerosine 2 Check bearings 1 bearing races 2 Damage...

Page 285: ...steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a set Whenever the steering head is disassem bled replace the rubber seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00684 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races Recommended lubricant Lithium soap based grease 2 I...

Page 286: ...RING HEAD 3 Install upper bracket 1 steering stem nut 2 4 Install front fork legs Refer to FRONT FORK NOTE Temporarily tighten the lower bracket pinch bolts 5 Tighten steering stem nut 2 T R 110 Nm 11 0 m kg 80 ft lb ...

Page 287: ...moving the rear shock absorber Remove the parts in the order listed Muffler Refer to MUFFLER ASSEMBLY in chapter 5 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 pro cedure ...

Page 288: ...gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damping performance will suffer EAS00689 DISPOSING OF A REAR SHOCK ABSORBER AND GAS ...

Page 289: ...orber bolts 1 hold the swingarm so that it does not drop down 3 Remove rear shock absorber assembly EAS00696 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 1 Check rear shock absorber rod Bends damage Replace the rear shock absorber assembly rear shock absorber Gas leaks oil leaks Replace the rear shock absorber assembly spring Damage wear Replace the rear shock absorber assembly gas c...

Page 290: ...hium soap based grease 2 Install rear shock absorber assembly 1 bolt rear side 2 nut 3 T R 53 Nm 5 3 m kg 38 ft lb 3 Install lock washer 1 bolt front side 2 NOTE When installing the bolt 1 hold the swing arm so that it does not drop down Bend the lock washer 2 tab along a flat side of the bolt 1 New T R 68 Nm 6 8 m kg 49 ft lb ...

Page 291: ...TEM XP500A EAS00882 ABS COMPONENTS 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 0 Front disc rotor 1 2 3 4 0 9 8 7 6 5 ...

Page 292: ...4 94 CHAS ANTI LOCK BRAKE SYSTEM XP500A ...

Page 293: ... B L BLACK B BLACK L B Br Y B Br Y Br Y Br L Br Y Br L L L BLUE L BLUE L B L BLUE L BLUE L L Br Y BLACK Y B BLACK Y R Br Y Br Y B Br L G L Lg Y L B W Dg Y Ch R G R W W R G Lg Br W G R G B B R B W B R L R W O L Y P W Y R W Y B Y Gy G Y L Y G L W Y B Y B L B W L W R R B Lg L W BLUE W R G W G Y B B B B B W W Sb B W B W G R W Y W Y W B G W W B P W Br W Lg W W R B W Gy W W B Gy W W B Br W R W W R W B P...

Page 294: ...use M Starting circuit cut off relay 2 N Starting circuit cut off relay 1 R Start switch S Engine stop switch U Front brake light switch W ECU engine d ABS test coupler e ECU ABS f Front wheel sensor g Rear wheel sensor h Fail safe relay i Hydraulic unit y Rear brake light switch Tail brake light Multi function display ABS warning light ...

Page 295: ...f the vehicle is maintained ABS function A brake system in which the hydraulic control has been performed by the ABS alerts a rider that the wheels had a tendency to lock by generating a reaction force pulsating action in the brake levers When the ABS is activated the grip between the road surface and tires is close to the limit The ABS cannot prevent wheel lock on slippery surfaces such as ice wh...

Page 296: ...ABS warning light flashes ABS operation is normal The brake switch is defective or improperly adjusted The rear wheel is racing The vehicle is continuously ridden on extremely uneven roads 2 Self diagnosis and service The ECU ABS has an ABS self diagnostic function By utilizing this function quick problem identification and service are possible The malfunction codes are stored in the memory of the...

Page 297: ...re troubleshooting A ABS malfunction check using the ABS warning light B Detailed ABS malfunction check The results of the self diagnosis by the ECU ABS are displayed using the multifunction display or a pocket tester C Determining the cause and location of the malfunction Determine the cause of the malfunction from the condition and place where the malfunction occurred D ABS maintenance Execute t...

Page 298: ...splay the malfunction code number and record it YES NO NO Check the fuse C 2 All indicator lights do not come on C 3 Warning light flashes continu ously C 5 Diagnose by malfunction codes C 4 ABS warning light flashes every 0 5 second Check the connectors and couplers Check the brake switch circuit Check the ECU ABS connector Check the wire harnesses ABS system s circuit C 1 Only ABS warn ing light...

Page 299: ...arning light flashes NOTE _ Check the battery voltage before proceeding Check the test coupler located in the front cowling Is the T C terminal grounded 1 Yes Disconnect the grounding lead from the T C terminal and install the protective cap onto the test coupler NOTE _ When the test coupler adaptor is connected to test coupler the T C terminal is grounded 2 No C 3 Function of the test coupler ter...

Page 300: ...4 C 5 If the ABS warning light flashes every 0 5 second the malfunction code of a past malfunction has not been stored in the memory of the ECU ABS If a malfunction code is displayed on the multi function display the ABS warning light flashes Make sure that the customer understands the possi ble conditions when the ABS warning light comes on CAUTION When checking for ABS malfunctions the odometer ...

Page 301: ...tester range to DC 20 V Connect the pocket tester negative probe to the T F termi nal light green of the test coupler adaptor and the pocket tester positive probe to the positive bat tery terminal Figure É Determine the malfunction code according to the movement of the pocket tester needle Figure Ê A tester reading with the digits of 10 and digits of 1 pattern is shown below 1 Test coupler 2 Lock ...

Page 302: ...S 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 3 Remove the ECU ABS coupler and check the ECU ABS coupler and test coupler adaptor ends of the white red lead for continuity If there is continuity the ECU ABS is defective Replace the ECU ABS Refer to D 1 Maintenance of the ECU ABS If there is no continuity the...

Page 303: ...s on 1 Warning light flashes The following are probable causes to explain why the ABS warning light flashed while riding and then stopped flashing or stopped flashing when the main switch was set to OFF then to ON 1 The rear wheel was rotated with the vehicle on the centerstand The system is normal 2 The rear wheel raced The system is normal 3 The vehicle was ridden on the rear wheel with the fron...

Page 304: ...front 13 or rear 14 wheel sensor 13 14 Wheel sensor installation Wheel sensor housings Wheel sensor rotors C 5 3 Mal function codes 13 front wheel and 14 rear wheel page 4 109 15 front 16 rear No continuity in the front or rear wheel sensor circuits 15 16 Continuity of sensor circuits Wire harness ABS system s circuit Connection of sensor coupler C 5 4 Mal function codes 15 front wheel sensor and ...

Page 305: ...signal is continuously transmitted from the ECU ABS to release the hydraulic state when the battery voltage is nor mal Brake dragging Hydraulic unit operation test 2 Refer to D 6 3 2 Rear wheel brake line C 5 11 Mal function code 42 page 4 113 51 Front wheel will not recover from the locking tendency even though the signal is continuously transmitted from the ECU ABS to release the hydraulic state...

Page 306: ...e components when installed for looseness distortion and bends C 5 2 Malfunction code 12 Rear wheel sensor signal is not received correctly Set the main switch to OFF then back to ON 1 ABS warning light remains on Defective connection in the rear wheel sensor circuit Rear wheel sensor coupler is disconnected D 4 Rear wheel sensor lead or coil is broken D 4 Rear wheel sensor circuit is disconnected...

Page 307: ...Broken front or rear wheel sensor circuit is detected Front or rear wheel sensor coupler is broken D 3 4 Front or rear wheel sensor or lead is broken D 3 4 Front or rear wheel sensor circuit is broken Refer to CIRCUIT DIAGRAM Wire harness ABS system circuit is disconnected from the ECU ABS coupler terminal D 1 NOTE _ Check that both the front and rear wheel sensor couplers are connected securely I...

Page 308: ...for continuity 4 Fail safe relay Check if the fail safe relay operates correctly D 2 5 Wire harness ABS system circuit Check for continuity between the red terminal of the fail safe relay coupler and the positive bat tery terminal Remove the ABS fuse and check for continuity between the brown white lead of the fail safe relay coupler and the ABS fuse See the illustration below C 5 7 Malfunction co...

Page 309: ...he fail safe relay from the wire harness ABS system circuit and then check for continuity between the white black lead terminals and the red white lead termi nals C 5 9 Malfunction code 34 ABS motor operation malfunction is detected ABS motor keeps rotating and does not stop Check the following 1 ABS motor Check if the ABS motor coupler located in the battery cover is connected properly Check the ...

Page 310: ...amination Check for air in the brake hose lines 4 Brake hose lines Check the brake hose lines for kinks and deterioration WARNING _ Only use genuine Yamaha parts Using other brake pipes hoses and union bolts may close the brake hose lines Check that the connections of the brake hose lines from the brake master cylinder to the hydrau lic unit and to the front brake caliper from the hydraulic unit a...

Page 311: ...the rear wheel Check that there is no brake drag on the rear wheel and make sure it rotates smoothly Check for brake disc distortion 2 Brake master cylinder and brake caliper Check that the brake fluid pressure is correctly transmitted to the brake disc when the brake lever is operated and that the pressure decreases when the lever is released 3 Brake fluid Visually check the brake fluid in the br...

Page 312: ...ithout pulsating when the final check in D 6 is performed If the front and rear brake hose connections are reversed on the hydraulic unit the pulsating action in the brake levers will be performed in the reverse order when the final check in D 6 is performed 5 Hydraulic unit solenoid coupler terminal Check if the front and rear hydraulic unit solenoid coupler terminals hydraulic unit and wire har ...

Page 313: ... 10 Malfunction code 41 6 Hydraulic unit Refer to C 5 10 Malfunction code 41 7 Battery voltage Measure the battery voltage C 5 13 Malfunction code 52 Rear wheel does not recover from the locking tendency even though the signal is continuously transmitted from the ECU ABS to release the hydraulic pressure when the battery voltage is low Check the following 1 Rotation of the rear wheel Refer to C 5 ...

Page 314: ...THE ECU ABS 1 Remove ECU ABS 2 Check ECU ABS terminals 1 Cracks damage Replace the ECU ABS ECU ABS coupler terminals 2 Defective connections contamination dis connections Repair or clean NOTE _ If the ECU ABS coupler terminals are clogged with mud or dirt clean with com pressed air ...

Page 315: ...probe Terminal 8 Tester reading is Replace the fail safe relay Connect the positive battery terminal to ter minal 7 and the negative battery terminal to terminal 8 and then check for continuity between terminals 4 and 5 of the solenoid relay Positive tester probe Terminal 4 Negative tester probe Terminal 5 Tester reading is Replace the fail safe relay CAUTION _ When connecting the solenoid relay a...

Page 316: ...ontinuity between terminals 2 and 5 of the ABS motor relay Positive tester probe Terminal 2 Negative tester probe Terminal 5 Tester reading is Replace the fail safe relay CAUTION _ Be sure to connect the pocket tester posi tive and negative probes correctly If the pocket tester probes are connected in reverse the diode of the fail safe relay will be broken When connecting the battery and the ABS m...

Page 317: ...hen check the hydraulic unit solenoid relay and ABS motor do not remove the brake hoses 1 Measure resistance of the solenoid valve front Connect a pocket tester Ω 1 to the termi nals of the solenoid valve front Positive tester probe Terminal 1 Negative tester probe Terminal 2 Out of specification Replace the hydrau lic unit 2 Measure resistance of the solenoid valve rear Connect the pocket tester ...

Page 318: ...ck the wheel sensors for proper installa tion 3 Perform hydraulic unit operation test 1 or 2 4 Delete the malfunction codes 5 Perform a trial run D 6 1 Checking the brake fluid level of the brake master cylinder reservoirs 1 Check brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 D 6 2 Checking the wheel sensors for proper installation 1 Check if the front wheel sensor housing...

Page 319: ...vehicle is stopped The hydraulic unit operation can be tested by the following two methods Hydraulic unit operation test 1 this test gen erates the same reaction force pulsating action that is generated in the brake levers when the ABS is activated Hydraulic unit operation test 2 this test checks the function of the ABS after the system was disassembled adjusted or ser viced D 6 3 1 Hydraulic unit...

Page 320: ...n 10 V the ABS warning light comes on and the ABS does not operate Battery voltage Higher than 12 8 V 5 Connect the test coupler adaptor 1 to the test coupler 2 Test coupler adaptor 90890 03149 2 1 6 Set the engine stop switch 1 to 7 Set the main switch to ON NOTE After setting the main switch to ON wait approximately 2 seconds until the ABS warn ing light goes off 8 Push the start switch 2 for at...

Page 321: ...ontinues for approximately 1 second NOTE Be sure to continue to operate the brake levers even after the pulsating action has stopped 11 After the pulsating action has stopped in the rear brake lever it is generated in the front brake lever 0 5 second after and con tinues for approximately 1 second CAUTION _ Check that the pulsating action is felt in the front brake lever rear brake lever and again...

Page 322: ...cle on the centerstand 2 Set the main switch to OFF 3 Remove front cowling battery Refer to FUEL TANK in chapter 3 4 Check battery voltage Lower than 12 8 V Charge or replace the battery NOTE _ If the battery voltage is lower than 12 8 V charge the battery and perform hydraulic unit operation test 2 If the battery voltage is lower than 10 V the ABS warning light comes on and the ABS does not opera...

Page 323: ...eck that the front brake lever returns to its home position before the rear brake lever 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 hy...

Page 324: ...omes on for 2 seconds goes off for 3 seconds then starts flashing to confirm that all malfunction codes are deleted 8 Set the main switch to OFF 9 Disconnect the test coupler adaptor from the test coupler and install the protective cap onto the test coupler NOTE _ Do not forget to install the protective cap onto the test coupler CAUTION _ Since the malfunction codes remain in the memory of the ECU...

Page 325: ...art switch lead continuity Connect the pocket tester Ω 1 to the ECU ABS coupler and start switch cou pler Positive tester probe green white 1 ECU Negative tester probe green white 2 start switch No continuity Replace or repair the wire harness Battery voltage Higher than 12 8 V 7 Check ECU ABS voltage Connect the pocket tester DC 20 V to the ECU ABS coupler Positive tester probe green white 1 Nega...

Page 326: ......

Page 327: ...ENG 5 ...

Page 328: ...LINDER HEAD 5 18 INSTALLING THE CYLINDER HEAD 5 19 VALVES AND VALVE SPRINGS 5 20 REMOVING THE VALVES 5 21 CHECKING THE VALVES AND VALVE GUIDES 5 22 CHECKING THE VALVE SEATS 5 24 CHECKING THE VALVE SPRINGS 5 26 CHECKING THE VALVE LIFTERS 5 27 INSTALLING THE VALVES 5 27 CYLINDER AND PISTON 5 30 REMOVING THE CYLINDERS AND PISTONS 5 31 CHECKING THE CYLINDERS AND PISTONS 5 32 CHECKING THE PISTON RINGS ...

Page 329: ... ASSEMBLY SECONDARY SHEAVE ASSEMBLY AND V BELT 5 62 DISASSEMBLING THE PRIMARY SHEAVE 5 63 DISASSEMBLING THE SECONDARY SHEAVE 5 63 CHECKING THE V BELT 5 63 CHECKING THE V BELT CASE AIR DUCT 5 64 CHECKING THE PRIMARY SHEAVE 5 64 CHECKING THE WEIGHTS 5 64 CHECKING THE SLIDERS 5 64 CHECKING THE SECONDARY SHEAVE 5 65 ASSEMBLING THE PRIMARY SHEAVE 5 65 ASSEMBLING THE SECONDARY SHEAVE 5 66 INSTALLING THE...

Page 330: ... TRANSMISSION 5 85 CHECKING THE TRANSMISSION 5 85 ASSEMBLING THE CRANKCASE 5 86 CHAIN DRIVE 5 87 CHECKING THE SWINGARM 5 91 CHECKING THE CHAIN DRIVE ASSEMBLY 5 91 ASSEMBLING THE CHAIN DRIVE ASSEMBLY 5 91 INSTALLING THE CHAIN DRIVE 5 92 ...

Page 331: ...ENG ...

Page 332: ...r assembly Remove the parts in the order listed Right rear side cover inner fender Refer to COVER AND PANEL in chap ter 3 1 O2 sensor coupler 1 Disconnect 2 Protector 1 1 3 O2 sensor 1 4 Protector 2 1 5 Muffler assembly 1 6 Gasket 2 For installation reverse the removal pro cedure ENGINE REMOVAL ...

Page 333: ...he order listed Leg shield footrest board Refer to COVER AND PANEL in chap ter 3 Storage box fuel tank Refer to FUEL TANK in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Chain drive oil Drain Refer to CHANGING THE CHAIN DRIVE OIL in chapter 3 Thermostat outlet hose coolant pipe oil filter cartridge Refer to RADIAT...

Page 334: ...let pipe Refer to WATER PUMP in chapter 6 Throttle body injector Refer to THROTTLE BODY in chapter 7 Muffler assembly Refer to ENGINE REMOVAL Rear shock absorber Refer to REAR SHOCK ABSORBER in chapter 4 Chain drive assembly Refer to CHAIN DRIVE 1 Spark plug cap 2 Disconnect 2 Starter motor lead 1 Disconnect 3 Battery negative lead 1 Disconnect 4 Coolant temperature sensor coupler 1 Disconnect 5 A...

Page 335: ... R 23 Nm 2 3 m kg 17 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib 6 4 5 5 2 1 1 3 7 Order Job Part Q ty Remarks 6 Intake air pressure sensor hose 1 Disconnect 7 Right passenger footrest 1 For installation reverse the removal pro cedure ENGINE REMOVAL ...

Page 336: ...Ib 1 1 5 3 4 4 3 1 1 2 Order Job Part Q ty Remarks Removing the engine Remove the parts in the order listed 1 Front lower mounting bolt washer 4 4 Refer to INSTALLING THE ENGINE 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 pro cedure ...

Page 337: ...per mounting bolt nut 2 washers 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 4 1 2 4 3 2 1 4 T R 87 Nm 8 7 m kg 63 ft lb T R 87 Nm 8 7 m kg 63 ft lb T R 48 Nm 4 8 m kg 35 ft lb ...

Page 338: ...oving the cylinder head cover Remove the parts in the order listed Engine Refer to ENGINE REMOVAL Intake manifold Refer to THROTTLE BODY in chapter 7 1 Spark plug 2 2 Cylinder head cover 1 3 Cylinder head cover gasket 1 4 Dowel pin 2 For installation reverse the removal pro cedure ...

Page 339: ...moving the camshafts Remove the parts in the order listed 1 Timing chain tensioner 1 Refer to REMOV ING THE CAM SHAFTS and INSTALLING THE CAMSHAFTS 2 Timing chain tensioner gasket 1 3 Camshaft cap 2 4 Dowel pin 4 NOTE During removal the dowel pins may still be con nected to the camshaft cap 5 Intake camshaft 1 6 Exhaust camshaft 1 For installation reverse the removal pro cedure ...

Page 340: ...the stationary pointer b on the A C magneto rotor cover NOTE TDC on the compression stroke can be found when the camshaft lobes are turned away from each other In order to be sure that the piston is at TDC the alignment mark c on the intake cam shaft sprocket and the alignment mark d on the exhaust camshaft sprocket must align with the cylinder head mating surface as shown in the illustration 3 Lo...

Page 341: ... camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 1 2 6 Remove intake camshaft 1 exhaust camshaft 2 NOTE To prevent the timing chain from falling into the crankcase faster it with a wire 3 7 Remove timing chain guide exhaust side 1 2 3 EAS00204 CHECKING THE CAMSHAFTS 1 Check camshaft lobes Blue discoloration pitting scratch...

Page 342: ...252 33 352 mm 1 3091 1 3131 in Limit 33 152 mm 1 3052 in b 24 956 25 056 mm 0 9825 0 9865 in Limit 24 856 mm 0 9786 in Camshaft runout limit 0 03 mm 0 0012 in 4 Measure camshaft journal to camshaft cap clear ance Out of specification Measure the cam shaft journal diameter a Install the camshaft into the cylinder head without the dowel pins and camshaft caps b Position a strip of Plastigauge 1 onto...

Page 343: ...bolt 10 Nm 1 0 m kg 7 2 ft lb 5 Measure camshaft journal diameter a Out of specification Replace the cam shaft Within specification Replace the cylinder head and the camshaft caps as a set CHECKING THE CAMSHAFT SPROCKETS AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides 1 Check camshaft sprocket More than 1 4 tooth wear a Replace the c...

Page 344: ... chain tensioner rod into the timing chain tensioner housing by hand NOTE While pressing the timing chain tensioner rod wind it clockwise with a thin screwdriver 1 until it stops b Remove the screwdriver and slowly release the timing chain tensioner rod c Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the t...

Page 345: ... alignment mark c on the intake camshaft sprocket and the align ment mark d on the exhaust camshaft sprocket align with the cylinder head mating surface as shown in the illustration CAUTION _ 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 The camshaft cap ...

Page 346: ...r bolts 3 to the specified torque WARNING Always use a new gasket d Remove the screwdriver make sure that the timing chain tensioner rod releases and tighten the timing chain tensioner cap bolt to the specified torque 4 Turn crankshaft several turns counterclockwise 5 Check I mark a Make sure that the I mark is aligned with the stationary pointer b camshaft sprocket alignment marks c Make sure tha...

Page 347: ...fication Adjust Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3 7 Install cylinder head cover gasket cylinder head cover NOTE Tighten the cylinder head cover bolts in stages and in a crisscross pattern New T R 10 Nm 1 0 m kg 7 2 ft lb CAMSHAFTS ...

Page 348: ...he cylinder head Remove the parts in the order listed Intake and exhaust camshafts Refer to CAMSHAFTS 1 Cylinder head 1 Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal pro cedure ...

Page 349: ...ark plug bore threads valve seats 2 Check cylinder head Damage scratches Replace cylinder head water jacket Mineral deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limited is exceeded resurface the cyl inder head as follows d Place a 400...

Page 350: ...ming chain cavity 3 Tighten cylinder head nuts 1 cylinder head nuts 2 cylinder head bolts 3 NOTE 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 New T R 35 Nm 3 5 m kg 25 ft lb T R 46 Nm 4 6 m kg 33 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 351: ...ts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Valve lifter 8 Refer to REMOVING THE VALVES and INSTALLING THE VALVES 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 pro cedure ...

Page 352: ...ey can be reinstalled in their original place 2 Check valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS 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 ...

Page 353: ...valves and valve guides 1 Measure valve stem to valve guide clearance Out of specification Replace the valve guide Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0031 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in 2 Replace valve guide NOTE To e...

Page 354: ...the valve guide reface the valve seat Valve guide remover 4 mm 90890 04111 YM 04111 Valve guide installer 4 mm 90890 04112 YM 04112 Valve guide reamer 4 mm 90890 04113 YM 04113 3 Eliminate carbon deposits from the valve face and valve seat 4 Check valve face Pitting wear Grind the valve face valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve 5 Measur...

Page 355: ...ECKING THE 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 onto the valve face Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in ...

Page 356: ...or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound a to the valve face CAUTION Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly pol...

Page 357: ... again If the valve seat width is out of specification reface and lap the valve seat EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure valve spring free length a Out of specification Replace the valve spring 2 Measure compressed spring force a Out of specification Replace the valve spring b Installed length Valve spring free length intake and...

Page 358: ...ALVE LIFTERS The following procedure applies to all of the valve lifters 1 Check valve lifter Damage scratches Replace the valve lift ers and cylinder head EAS00245 INSTALLING THE VALVES The 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 Recommended lubricant...

Page 359: ...ng up b Smaller pitch New 4 Install valve cotters 1 NOTE Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and valve spring compressor attachment 3 Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment 90890 04114 YM 04114 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION...

Page 360: ...ON CAUTION After making sure that the valve pads are fully inserted install the valve lifter taking care so that the pads do not fall NOTE The valve lifter must move smoothly when rotated with a finger Each valve lifter and valve pad must be rein stalled in its original position Recommended lubricant Molybdenum disulfide oil ...

Page 361: ...e order listed Cylinder head Refer to CYLINDER HEAD 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 4 Refer to REMOVING THE CYLINDERS AND PISTONS and INSTALLING THE PISTONS AND CYLINDERS 6 Piston pin 2 7 Piston 2 8 Piston ring set 2 For installation reverse the removal pro cedure ...

Page 362: ...th a clean rag to pre vent the piston pin clip from falling into the crankcase Before removing the piston pin deburr the piston pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller 4 Piston pin puller set 90890 01304 YU 01304 2 Remove top ring 2nd ring oil ring NOTE When removing a piston ri...

Page 363: ...ure cylinder bore C with the cylinder bore gauge NOTE _ Measure cylinder bore C by taking side to side and front to back measurements of the cylinder Then find the average of the mea surements b If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set Cylinder bore C 66 00 66 01 mm 2 5984 2 5988 in Taper limit T 0 05 mm 0 0020 in Out of round R 0 05 m...

Page 364: ...iston ring side clearance Out of specification Replace the piston and piston rings as a set NOTE Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Micrometers 50 75 mm 90890 03008 YU 03008 Piston size P Standard 65 965 65 980 mm 2 5970 2 5976 in Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to ...

Page 365: ...ap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top ring 0 15 0 25 mm 0 0059 0 0098 in Limit 0 50 mm 0 0197 in 2nd ring 0 40 0 50 mm 0 0157 0 0197 in Limit 0 75 mm 0 0295 in Oil ring 0 10 0 35 mm 0 0039 0 0138 in EAS00266 CHECKING THE PISTON PINS The following procedure applies to all of the piston pins 1 Check piston pin Blue disco...

Page 366: ...43 mm 0 5922 in 4 Calculate piston pin to piston pin bore clearance Out of specification Replace the piston pin EAS00271 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pistons and cylinders 1 Install top ring 2nd ring oil ring NOTE Be sure to install the top and 2nd rings so that the manufacturer s marks or numbers face up Piston pin to piston pin bore clearance...

Page 367: ...e vent the clip from falling into the crankcase 3 Install gasket 1 dowel pins 4 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil New New 5 Offset top ring 2nd ring oil ring Offset the piston ring end gaps as shown a Top ring end b Upper oil ring rail end c Oil ring expander end d Lower oil ring rail end e 2nd ring end f 20 mm 0 79 in 6 Install ...

Page 368: ...anel lower side cover mould ing footrest board Refer to COVER AND PANEL in chap ter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Water pump assembly Refer to WATER PUMP in chapter 6 1 Starter coil assembly coupler 2 Disconnect 2 A C magneto cover 1 Refer to INSTALLING THE A C MAG NETO ROTOR 3 A C magneto cover gasket 1 4 ...

Page 369: ...l assembly 1 10 A C magneto rotor nut 1 Refer to REMOVING THE A C MAG NETO ROTOR and INSTALLING THE A C MAGNETO ROTOR 11 Spacer 1 12 A C magneto rotor 1 13 Starter clutch 1 14 Woodruff key 1 15 Starter clutch idler gear shaft 1 16 Starter clutch idler gear 1 17 Starter clutch gear 1 18 Washer 1 For installation reverse the removal pro cedure ...

Page 370: ...r to touch the projection on the A C magneto rotor 3 Remove A C magneto rotor 1 with the flywheel puller set 2 woodruff key NOTE Remove the A C magneto rotor 1 using the flywheel puller Center the flywheel puller over the A C mag neto rotor Make sure after installing the holding bolts that the clearance between the flywheel puller and the A C magneto rotor is the same everywhere If necessary one h...

Page 371: ...arter clutch and the starter clutch drive gear should engage If the starter clutch drive gear and starter clutch do not engage the starter clutch is faulty and must be replaced c When turning the starter clutch drive gear clockwise È it should turn freely If the starter clutch drive gear does not turn freely the starter clutch is faulty and must be replaced INSTALLING THE A C MAGNETO ROTOR 1 Insta...

Page 372: ...rotor nut be sure to use an F type torque wrench After tightening the A C magneto rotor nut to the specified torque turn the A C magneto rotor nut another 120 Sheave holder 90890 01701 YS 01880 A T R 60 Nm 6 0 m kg 43 ft lb 120 3 Apply sealant onto the stator coil assembly lead grom met 4 Install A C magneto rotor cover NOTE Tighten the A C magneto rotor cover bolts in stages and in a crisscross p...

Page 373: ...r mould ing footrest board Refer to COVER AND PANEL in chap ter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 A C magneto cover Starter clutch gear Refer to STARTER CLUTCH AND A C MAGNETO ROTOR 1 Oil pump assembly 1 2 Oil pump drive chain 1 3 O ring 2 4 Oil delivery pipe 1 ...

Page 374: ...5 43 ENG OIL PUMP Order Job Part Q ty Remarks 5 Oil delivery pipe 1 6 Relief valve assembly 1 For installation reverse the removal pro cedure ...

Page 375: ...e parts in the order listed 1 Oil pump housing 1 2 Oil pump outer rotor 2 3 Oil pump inner rotor 2 Refer to ASSEMBLING THE OIL PUMP 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 assembly reverse the disassembly procedure ...

Page 376: ...ce b oil pump housing to inner and outer rotor clearanace c Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 04 0 12 mm 0 0016 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 045 0 085 mm 0 0018 0 0033 in Limit 0 15 mm 0 0059 in Oil pump housing to inner and outer rotor clearance 0 11 0...

Page 377: ...very pipe 1 Damage Replace Obstruction Wash and blow out with compressed air EAS00368 CHECKING THE OIL STRAINER 1 Check oil strainer Damage Replace Contaminants Clean with engine oil 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 ASSEMBLING THE OIL PUMP 1 Lubricate inner rotor outer rotor oil pu...

Page 378: ...L PUMP 2 Install pins inner rotors NOTE When installing the inner rotor align the pin 1 in the oil pump shaft with the groove a on the inner rotor 3 Check oil pump operation Refer to CHECKING THE OIL PUMP 1 a 1 a ...

Page 379: ...g the clutch Remove the parts in the order listed A C magneto cover Refer to STARTER CLUTCH AND A C MAGNETO ROTOR 1 Clutch assembly nut 1 Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH 2 Clutch assembly 1 For installation reverse the removal pro cedure ...

Page 380: ...rclip 1 Refer to DISASSEMBLING THE CLUTCH and ASSEMBLING THE CLUTCH 2 Spring stopper plate 1 3 Clutch damper spring 2 1 4 Pressure plate 1 5 Clutch plate 2 2 6 Clutch damper spring 1 6 7 Friction plate 5 8 Clutch plate 1 4 9 Clutch spring 6 0 Thrust plate 1 A Clutch boss nut 1 B Primary drive gear 1 C Bearing 1 ...

Page 381: ...5 50 ENG CLUTCH Order Job Part Q ty Remarks D Circlip 1 E Bearing 1 F Clutch boss 1 G Collar 1 H Weight 12 I Clutch housing 1 For assembly reverse the disassembly procedure ...

Page 382: ...ing compressor 2 onto the clutch assembly as shown Then com press the spring and remove the circlip 2 Remove spring stopper plate 1 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 spr...

Page 383: ...late thickness Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places Friction plate thickness 2 75 3 05 mm 0 108 0 120 in Limit 2 65 mm 0 104 in EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check clutch plate Damage Replace the clutch plates as a set 2 Measure clutch plate warpage with a surface...

Page 384: ...4 mm 1 00 in 3 Measure clutch damper spring 1 b Out of specification Replace the clutch damper spring 1 Clutch damper spring 1 limit 2 90 mm 0 11 in 4 Measure clutch damper spring 2 c Out of specification Replace the clutch damper spring 2 Clutch damper spring 2 limit 4 40 mm 0 17 in EAS00284 CHECKING THE CLUTCH HOUSING 1 Check clutch housing dogs Damage pitting wear Deburr the clutch housing dogs...

Page 385: ...AS00286 CHECKING THE PRESSURE PLATE AND THRUST PLATE 1 Check pressure plate thrust plate Cracks damage Replace CHECKING THE WEIGHT 1 Check weight Cracks wear scaling chipping Replace Out of specification Replace Weight outside diameter 16 0 mm 0 63 in Limit 15 5 mm 0 61 in ASSEMBLING THE CLUTCH 1 Lubricate friction plates clutch plates with the recommended lubricant Recommended lubricant Engine oi...

Page 386: ...boss nut NOTE While holding the clutch boss 2 with the clutch holding tool 3 tighten the clutch boss nut Clutch holding tool 90890 04086 YM 91042 1 2 3 T R 90 Nm 9 0 m kg 65 ft lb 4 Install clutch damper spring 1 1 clutch plate 2 2 friction plate 3 clutch plate 1 4 È Engine side CLUTCH ...

Page 387: ...ch assembly 1 clutch assembly nut 2 NOTE Align the a and b during reassembly While holding the clutch assembly with the rotor holding tool 3 tighten the clutch assembly nut Rotor holding tool 90890 01235 YU 01235 T R 65 Nm 6 5 m kg 47 ft lb CLUTCH ...

Page 388: ...arts in the order listed Muffler Refer to ENGINE REMOVAL 1 V belt case cover 1 1 2 V belt case cover 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 pro cedure ...

Page 389: ... case air filter element left Refer to WATER PUMP in chapter 6 1 Primary sheave nut 1 Refer to REMOVING THE PRIMARY SHEAVE ASSEMBLY SECONDARY SHEAVE ASSEMBLY AND V BELT and INSTALLING THE PRIMARY SHEAVE ASSEMBLY SECONDARY SHEAVE ASSEMBLY AND V BELT 2 Spacer 1 3 O ring 2 4 Primary sheave assembly 1 5 Primary fixed sheave 1 6 Secondary sheave nut 1 7 Secondary sheave assembly 1 8 Collar 1 9 O ring 1...

Page 390: ...ube Order Job Part Q ty Remarks 12 V belt case air duct joint clamp 1 Loosen Refer to INSTALLING THE PRIMARY SHEAVE ASSEMBLY SECOND ARY SHEAVE ASSEM BLY AND V BELT 13 V belt case air duct 1 14 Plate 1 15 V belt case air duct seal 1 For installation reverse the removal pro cedure ...

Page 391: ...t Q ty Remarks Disassembling the primary sheave Remove the parts in the order listed 1 Cam 1 Refer to DISASSEMBLING THE PRI MARY SHEAVE and ASSEMBLING THE PRIMARY SHEAVE 2 Slider 4 3 Weight 8 4 Primary sliding sheave 1 5 Collar 1 For assembly reverse the disassembly procedure ...

Page 392: ...1 Secondary sheave spring seat nut 1 Refer to DISASSEMBLING THE SEC ONDARY SHEAVE and ASSEMBLING THE SECONDARY SHEAVE 2 Upper spring seat 1 Refer to ASSEMBLING THE SECOND ARY SHEAVE 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 procedure ...

Page 393: ...890 01481 1 2 2 Install bolts 1 NOTE Insert M6 bolts more than 45 mm 1 77 in into the holes of the secondary sheave assem bly and then tighten the bolts to open the sec ondary sheave assembly 1 3 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 she...

Page 394: ...ave as shown Then com press the spring and remove the secondary sheave spring seat nut 1 with locknut wrench 3 Sheave spring compressor 2 90890 04134 YM 04134 Locknut wrench 3 90890 01348 YM 01348 Sheave fixed block 4 90890 04135 YM 04135 CHECKING THE V BELT 1 Check V belt 1 Cracks damage wear Replace Grease oil Check the primary and sec ondary pulleys 2 Measure V belt width 2 Out of specification...

Page 395: ...age wear Replace the pri mary sliding sheave and primary fixed sheave as a set CHECKING THE WEIGHTS The following procedure applies to all of the weights 1 Check weights 1 Cracks wear scaling chipping Replace Out of specification Replace Weight outside diameter 25 0 mm 0 98 in Limit 24 5 mm 0 96 in CHECKING THE SLIDERS The following procedure applies to all of the sliders 1 Check sliders 1 Cracks ...

Page 396: ...as a set 2 Check torque cam groove 1 Damage wear Replace the secondary fixed and sliding sheaves as a set 3 Check guide pin 2 Damage wear Replace the secondary fixed and sliding sheaves as a set 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 1 ...

Page 397: ... outer and inner surfaces 2 grease nipple groove oil seals with the recommended lubricant Recommended lubricant BEL RAY assembly lube New 2 Install secondary sliding sheave 1 3 Install guide pin 2 4 Lubricate guide pin groove 3 O ring with the recommended lubricant Recommended lubricant BEL RAY assembly lube New 5 Install spring seat 1 compression spring 2 upper spring seat 3 ...

Page 398: ... 04134 Locknut wrench 3 90890 01348 YM 01348 Sheave fixed block 4 90890 04135 YM 04135 T R 90 Nm 9 0 m kg 65 ft lb INSTALLING THE PRIMARY SHEAVE ASSEMBLY SECONDARY SHEAVE ASSEMBLY AND V BELT 1 Install V belt case air duct joint clamp 1 V belt case air duct 2 NOTE Align the projection a in the V belt case air duct 2 with the slot b on the V belt case air duct joint clamp 1 Align the projection c in...

Page 399: ...n install the belt Make sure the belt pullout direction is correct Install the V belt and secondary sheave assembly onto the primary sheave side Align the a and b during reassembly 3 Tighten secondary sheave nut 1 NOTE While holding the secondary sheave with the sheave holder 2 tighten the secondary sheave nut 1 Sheave holder 90890 01481 1 2 T R 90 Nm 9 0 m kg 65 ft lb 4 Install primary sliding sh...

Page 400: ...to 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 Recommended lubricant Shell BT grease 3 Sheave holder 90890 01481 1 2 T R 160 Nm 16 0 m kg 115 ft lb V BELT AUTOMATIC TRANSMISSION ...

Page 401: ...d Refer to CYLINDER HEAD Cylinder piston Refer to CYLINDER AND PISTON Starter clutch A C magneto rotor Refer to STARTER CLUTCH AND A C MAGNETO ROTOR Clutch Refer to CLUTCH Oil pump Refer to OIL PUMP Right crankcase cover Refer to V BELT AUTOMATIC TRANS MISSION 1 Centerstand assembly 1 2 Timing chain 1 3 Timing chain guide intake side 1 4 Left crankcase 1 Refer to DISASSEMBLING THE CRANKCASE and AS...

Page 402: ...Refer to INSTALLING THE CRANK SHAFT 7 Balancer cylinder 1 8 Right crankcase 1 9 Oil strainer 1 10 Dowel pin 2 11 Crankshaft main journal bearing 2 Refer to REMOVING THE CRANK SHAFT MAIN JOURNAL BEARINGS and INSTALLING THE CRANKSHAFT MAIN JOURNAL BEARINGS For installation reverse the removal pro cedure ...

Page 403: ...move the parts in the order listed 1 Connecting rod 2 Refer to REMOVING THE CONNECT ING RODS and INSTALLING THE CONNECTING RODS 2 Connecting rod balancer 1 3 Connecting rod cap 3 4 Big end bearing 6 5 Circlip 2 6 Piston pin 1 7 Balancer piston 1 8 Crankshaft 1 For installation reverse the removal pro cedure ...

Page 404: ...only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure that the crank case halves separate evenly 3 Remove dowel pins EAS00387 REMOVING THE CRANKSHAFT MAIN JOURNAL BEARINGS 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...

Page 405: ...oughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check crankcase Cracks damage Replace oil delivery passages Obstruction Blow out with compressed air EAS00207 CHECKING THE TIMING CHAIN 1 Check timing chain Damage stiffness Replace the timing chain and camshaft sprockets as a set CHECKING THE CRANKSHAFT AND CONNECTING RODS...

Page 406: ...rrect crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their orig inal positions a Clean the big end bearings crankshaft pins and the inside of the connecting rod halves b Install the big end upper bearing into the connecting rod and the big end lower bear ing into the connecting rod cap NOTE Align the projections a on the big end bea...

Page 407: ...ecting rod and connecting rod cap are aligned e Tighten the connecting rod nuts CAUTION When tightening the connecting rod nuts be sure to use an F type torque wrench After tightening the connecting rod nut to the specified torque turn the connecting rod nut another 90 Refer to INSTALLING THE CONNECTING RODS f Remove the connecting rod and big end bearings Refer to REMOVING THE CONNECTING RODS g M...

Page 408: ...en the bearing size for P1 is Bearing size for P1 P1 connecting rod P1 crankshaft web 4 1 3 brown BEARING COLOR CODE 1 blue 2 black 3 brown 4 green P3 P2 P1 5 Measure crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings The following procedure applies to all of the journal bearing CAUTION On the journal the larger value is used as...

Page 409: ...t c Measure the outside diameter a of each main journal at two places If it is out of specification replace the crankshaft d Measure the inside diameter b of each journal bearing at two places e 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 select a replacement bearing...

Page 410: ...ed to determine the replacement crankshaft journal bearing size J1 J2 refer to the bearings shown in the crankshaft illustration For example if the crankcase J1 and the crankshaft web J1 numbers are 4 and 2 respectively then the bearing size for J1 is Bearing size for J1 J1 crankcase J1 crankshaft web 4 2 2 black BEARING COLOR CODE 1 blue 2 black 3 brown 4 green J2 J1 ...

Page 411: ...an iron 3 plate beneath the crankcase and press fit until the end of the plain bearing installer touches the iron plate INSTALLING THE CONNECTING RODS 1 Install big end bearings 1 NOTE Align the projection a of the big end bear ings with the notches b in the connecting rod cap Install each big end bearing in its original place Plane bearing installer 90890 04139 2 Install connecting rods NOTE The ...

Page 412: ...Clean the connecting rod bolts and nuts c Tighten the connecting rod nuts with speci fied torque d Put a mark 1 on the corner of the connect ing rod nut 2 and the connecting rod 3 e Tighten the nut further to reach the speci fied angle 90 WARNING When the nut is tightened more than the specified angle do not loosen the nut and then retighten it Replace the bolt with a new one and per form the proc...

Page 413: ...reached If the tightening is inter rupted 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 T R 60 Nm 6 0 m kg 43 ft lb INSTALLING THE CRANKSHAFT 1 Install crankshaft assembly 1 balancer piston cylinder 2 CAUTION To avoid scratching the crankshaft and to ease the installation procedure apply grease onto the oil seal lips and apply engine oil onto...

Page 414: ...AFT 2 Apply sealant onto the crankcase mating surfaces NOTE Do not allow any sealant to come into contact with the oil gallery 3 Install dowel pins left crankcase Yamaha bond No 1215 90890 85505 Sealant Quick Gasket ACC 11001 05 01 ...

Page 415: ...ve the parts in the order listed Left crankcase Refer to CRANKCASE AND CRANK SHAFT 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 pro cedure ...

Page 416: ...ain axle runout with a centering device and dial gauge Out of specification Replace the main axle Maximum main axle runout 0 08 mm 0 0031 in 2 Measure drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle Maximum drive axle runout 0 08 mm 0 0031 in 3 Measure secondary shaft runout with a centering device and dial gauge Out of specification Replace the...

Page 417: ...ue discoloration pitting wear Replace the defective gear s 5 Check transmission gear movement Rough movement Replace the defective part s 6 Check circlips Damage bends looseness Replace EAS00418 ASSEMBLING THE CRANKCASE Refer to CRANKCASE AND CRANKSHAFT ...

Page 418: ... Refer to CHANGING THE CHAIN DRIVE OIL in chapter 3 Rear shock absorber Refer to REAR SHOCK ABSORBER in chapter 4 Rear brake caliper rear wheel Refer to REAR WHEEL AND BRAKE DISC in chapter 4 1 Rear brake hose rear brake lock lever cable holder 1 2 Cover 1 3 Nut 1 Refer to INSTALLING THE CHAIN DRIVE 4 Washer 1 5 Swingarm 1 6 Dowel pin 2 7 Pivot shaft 1 ...

Page 419: ...N DRIVE Order Job Part Q ty Remarks 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 14 O ring 1 For installation reverse the removal pro cedure ...

Page 420: ...emove the parts in the order listed 1 Chain drive case outer 1 2 Secondary 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 0 Oil seal 4 A Collar 1 B Chain drive case inner 1 ...

Page 421: ...5 90 ENG Order Job Part Q ty Remarks C Retainer 1 For assembly reverse the disassembly procedure CHAIN DRIVE ...

Page 422: ...its respective gears as a set 2 Check primary drive gear 3 primary 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 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...

Page 423: ...d then tighten the pivot shaft to the tightening torque Tighten the nut to the tightening torque Install the shock absorber and rear wheel after the swingarm is installed 4 Fill chain drive oil Refer to CHANGING THE CHAIN DRIVE OIL in chapter 3 5 Check chain drive oil level Refer to CHECKING THE CHAIN DRIVE OIL LEVEL in chapter 3 T R 40 Nm 4 0 m kg 29 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb T R 100 Nm 1...

Page 424: ...COOL 6 ...

Page 425: ... CHECKING THE OIL COOLER 6 4 INSTALLING THE OIL COOLER AND RADIATOR 6 4 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 7 INSTALLING THE THERMOSTAT 6 7 WATER PUMP 6 9 DISASSEMBLING THE WATER PUMP 6 12 CHECKING THE WATER PUMP 6 13 ASSEMBLING THE WATER PUMP 6 13 INSTALLING THE WATER PUMP 6 15 ...

Page 426: ...COOL ...

Page 427: ...ield inner fender Refer to COVER AND PANEL in chap ter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Coolant 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 RADIATOR AND OIL COOLER ...

Page 428: ...t hose 1 Disconnect 10 Radiator fan motor coupler 1 Disconnect 11 Radiator filler neck 1 12 Radiator filler hose 1 13 Stay 1 14 Radiator 1 15 Radiator fan 1 16 Oil filter cartridge 1 17 Oil cooler inlet hose 1 Disconnect 18 Oil cooler 1 Refer to INSTALLING THE OIL COOLER AND RADIATOR For installation reverse the removal pro cedure ...

Page 429: ...ecified pressure Replace the radiator cap a Install the radiator cap tester 1 and radiator cap tester adapter 2 onto the radiator cap 3 b Apply the specified pressure for ten sec onds and make sure that there is no drop in pressure 4 Check radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 8 Radiator cap opening pressure 107 9 137 3 kPa 1 08 1 37 kg cm2 15 ...

Page 430: ... cooler bolt 2 oil filter cartridge NOTE Before installing the oil cooler lubricate the oil cooler bolt with engine oil Make sure that the O ring is positioned prop erly Align the projection a on the oil cooler with the slot b in the crankcase 3 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 crankcase with the specified amount o...

Page 431: ...to the radi ator 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 RADIATOR Radiator cap tester 90890 01325 YU 24460 01 Radiator cap tester adapter 90890 01352 YU 33984 1 ...

Page 432: ...r listed Center cover side cover Refer to COVER AND PANEL in chap ter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 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 Refer to INSTALLING THE THERMO STAT For installation reverse the removal pro cedure ...

Page 433: ...stat 2 Thermometer 3 Water 4 Container È Fully closed É Fully opens NOTE If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check thermostat cover thermostat housing cylinder head Cracks damage Replace EAS00467 INSTALLING THE THERMOSTAT 1 Install thermostat thermostat cover NOTE NOTE Install the thermostat with its breathe...

Page 434: ...mount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 4 Check cooling system Leaks Repair or replace any faulty part 5 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 435: ... PANEL in chap ter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 V belt case air filter element clamp joint 1 Loosen 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 Disconnect 6 Coolant hose 1 Disconnect 7 Radiator outlet hose 1 Disconnect 8 Water pump inlet pipe 1 9 Water pump outlet pipe 1 ...

Page 436: ...6 10 COOL Order Job Part Q ty Remarks 10 Water pump assembly 1 Refer to INSTALLING THE WATER PUMP For installation reverse the removal pro cedure WATER PUMP ...

Page 437: ...emove the impeller 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 Refer to DISASSEMBLING THE WATER PUMP and ASSEMBLING THE WATER PUMP 5 Water pump seal 1 6 Bearing 1 7 Oil seal 1 8 Water pump housing 1 For assembly reverse the disassembly procedure ...

Page 438: ...er pump housing 2 Remove oil seal 1 with a thin flat head screwdriver NOTE NOTE Remove the oil seal from the outside of the water pump housing 3 Remove bearing 1 NOTE NOTE Remove the bearing from inside of the water pump housing 4 Remove rubber damper holder 1 rubber damper 2 from the impeller with a thin flat head screwdriver NOTE NOTE Do not scratch the impeller shaft ...

Page 439: ...der Cracks damage wear Replace 2 Check bearing Rough movement Replace EAS00475 ASSEMBLING THE WATER PUMP 1 Install oil seal 1 to the water pump housing NOTE NOTE Install the oil seal with a socket that matches its outside diameter Before installing the oil seal apply tap water or coolant onto its outer surface Installed depth of oil seal a 11 5 mm 0 45 in New 1 a New 2 Install bearing 1 ...

Page 440: ...pply Yamaha bond No 1215 or Sealant Quick Gasket 2 to the water pump housing 3 È Push down Mechanical seal installer 90890 04078 YM 33221 A 4 Middle driven shaft bearing driver 90890 04058 YM 04058 5 Yamaha bond No 1215 90890 85505 Sealant Quick Gasket ACC 11001 05 01 New 4 Install rubber damper 1 rubber damper holder 2 NOTE NOTE Before installing the rubber damper apply tap water or coolant onto ...

Page 441: ... WATER PUMP 1 Install water pump assembly NOTE NOTE Align the projection a at the oil pump shaft and water pump shaft groove b 2 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 3 Check cooling system Leaks Repair or replace any faulty part 4 Measure radiator cap opening pressure Below the specified pressure Replace the radiator c...

Page 442: ......

Page 443: ...FI 7 ...

Page 444: ...INSTRUCTIONS OPERATION CONTROL FAIL SAFE ACTION 7 4 FAIL SAFE ACTION TABLE 7 4 TROUBLESHOOTING CHART 7 6 DIAGNOSTIC MODE 7 7 TROUBLESHOOTING DETAILS 7 12 THROTTLE BODY 7 23 CHECKING THE FUEL INJECTORS 7 27 CHECKING THE THROTTLE BODY 7 27 CHECKING THE FUEL PUMP OPERATION 7 27 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 7 29 ...

Page 445: ...FI ...

Page 446: ...ection system relay 5 Lean angle cut off switch 6 Engine trouble warning light 7 ECU engine 8 Intake air pressure sensor 9 Throttle position sensor 0 Fuel injector A Fuel tank B Fuel delivery hose C Fuel pump D Battery E Catalyst F O2 sensor G Crankshaft position sensor H Coolant temperature sensor I Spark plug 1 2 3 4 5 6 7 8 9 0 A B C D F E G H I ...

Page 447: ... Y BLACK Y B BLACK Y R Br Y Br Y B Br L G L Lg Y L B W Dg Y Ch R G R W G Lg Br W G R G B B R B W Y R L R W O L Y P W Y R W B Y Gy G Y L Y G L W Y B Y B L B W L G Y R B Lg G Y BLUE 5 1 2 3 4 6 7 E 9 0 A B C D ß ç å z z y x w s u u v t l m p o n q k j j i O P Q R N S F J I G H L K M Y Z U V W X a h g e f c b d d 8 r Y R W Y Y G Lg W R W B W L W Br G Br G Br G Br G Ch Dg B Y G Y G Y G B L R L R L R B...

Page 448: ... rider of the detected mal function by illuminating the engine trouble warning light After the engine has been stopped the lowest fault code number appears on the clock LCD Once a fault code has been displayed it remains stored in the memory of the ECU engine until it is deleted EAS00900 Engine trouble warning light indication and FI system operation The warning light flashes when any one of the c...

Page 449: ...table below EAS00903 FAIL SAFE ACTION TABLE Fault code No Item Symptom Fail safe action Engine start ability Vehicle drive ability 12 Crankshaft position sensor No normal signals are received from the crankshaft position sensor Unable Unable 13 14 Intake air pressure sensor open or short circuit pipe system Intake air pressure sensor open or short circuit detected Faulty intake air pressure sen so...

Page 450: ... not normal Able Able 50 ECU engine internal malfunction memory check error Faulty ECU engine memory When this malfunction is detected the code number might not appear on the meter Unable Unable Fault code No Item Symptom Fail safe action Engine start ability Vehicle drive ability Er 1 ECU engine internal malfunction output sig nal error No signals are received from the ECU engine Unable Unable Er...

Page 451: ...t method in TROUBLE SHOOTING DETAILS Turn the main switch to OFF turn the main switch back to ON and then check if the fault code number is still displayed Repairs completed Not fault code number displayed Erasing the malfunction history The malfunction history is stored even if the main switch is turned OFF The malfunction history must be erased in the diagnostic mode Refer to Diagnostic mode tab...

Page 452: ...stic mode dIAG 5 After selecting dIAG simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selection 6 Set the engine stop switch to 7 Select the diagnostic code number that applies to the item that was verified with the fault code number by pressing the SELECT and RESET buttons NOTE The diagnostic code number appears on the tripmeter LCD 01 70 To decrease the sel...

Page 453: ... The data representing the operating condi tions of the sensor appears on the trip LCD Actuator operation Set the engine stop switch to to oper ate the actuator NOTE If the engine stop switch is set to set it to and then set it to again 9 Turn the main switch to OFF to cancel the diagnostic mode ...

Page 454: ...U engine 20 21 Coolant temperature sensor open or short circuit detected Open or short circuit in wiring harness Defective coolant temperature sensor Malfunction in ECU engine Improperly installed sensor 06 22 Intake air temperature sensor open or short circuit detected Open or short circuit in wiring harness Defective intake air temperature sensor Malfunction in ECU engine Improperly installed se...

Page 455: ...3 Data from the ECU engine cannot be received correctly Improper connection in wiring sub lead Malfunction in meter Malfunction in ECU engine Er 4 Non registered data has been received from the meter Improper connection in wiring sub lead Malfunction in meter Malfunction in ECU engine Diagnostic code Item Description of action Data displayed on meter reference value 01 Throttle angle Displays the ...

Page 456: ...s off If the engine stop switch is turn it once and then turn it back Check the fuel injection system relay operating sound 5 times with the engine stop switch 51 Radiator fan motor relay After 1 second has elapsed from the time the engine stop switch has been turned from to it actuates the radiator fan motor relay five times every 5 seconds and illuminates the engine trouble warn ing light ON 2 s...

Page 457: ...TIC MODE 61 Malfunction history code display Displays the codes of the history of the self diag nosis malfunctions i e a code of a malfunction that occurred once and which has been corrected If multiple malfunctions have been detected differ ent codes are displayed at 2 second intervals and this process is repeated 12 50 00 Displays when there is no mal function 62 Malfunction history code erasure...

Page 458: ...n sensor coupler as shown 3 Measure the crankshaft position sensor resis tance 4 Is the crankshaft position sensor OK 3 Open or short circuit in wiring har ness Repair or replace if there is an open or short circuit between the main wiring harnesses Between sensor coupler and ECU engine coupler black yellow black yellow black blue black blue 4 Connected condition of connector Inspect the coupler f...

Page 459: ...ir pressure sensor OK Reinstated by turn ing the main switch ON 2 Open or short circuit in wiring har ness and or sub lead Repair or replace if there is an open or short circuit Between sensor coupler and ECU engine coupler black blue black blue pink white pink white blue blue 3 Connected condition of connector Inspect the coupler for any pins that may have pulled out Check the locking condition o...

Page 460: ...in switch ON 2 Open or short circuit in wiring har ness 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 3 Installed condition of throttle posi tion sensor Check the installed area for looseness or pinching Check that it is installed in the specified position Refer to THROTTLE BODY 4 Connected conditi...

Page 461: ...circuit is detected from the coolant temperature sensor Used diagnostic code No 06 coolant temperature sensor Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Installed condition of sensor Check the installed area for looseness or pinching Reinstated by turn ing the main switch ON 2 Defective coolant temperature sen sor Replace if defectiv...

Page 462: ...perature sensor resis tance WARNING Handle the intake air temperature sensor with special care Never subject the intake air temperature sen sor to strong shocks If the intake air temper ature sensor is dropped replace it 4 Is the intake air temperature sensor OK 3 Open or short circuit in wiring har ness Repair or replace if there is an open or short circuit Between sensor coupler and ECU engine c...

Page 463: ... 000 r min until the warning light goes off When the warning light goes off the reset oper ation is finished 2 Connected state of connector O2 sensor coupler Main wiring 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 wiring har ness R...

Page 464: ...ion of the coupler If there is a malfunction repair it and connect it securely Lean angle cut off switch coupler Main wiring harness ECU engine coupler Fault code No 33 Symptom Malfunction detected in the primary lead of the ignition coil Used diagnostic code No 30 ignition coil Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Defective ig...

Page 465: ...it detected in the lean angle cut off switch Used diagnostic code No 08 lean angle cut off switch Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Defective lean angle cut off switch Replace if defective Refer to Fault code No 30 Reinstated by turn ing the main switch ON 2 Open or short circuit in wiring har ness Repair or replace if there...

Page 466: ...blue red blue 3 Malfunction or open circuit in fuel injection system relay Replace if defective 1 Disconnect the fuel injection system relay from the wire harness 2 Connect the pocket tester Ω 1 and battery 12 V to the fuel injection system relay terminals as shown 3 Does the fuel injection system relay have conti nuity between red blue and red blue 4 Connected condition of connector Inspect the c...

Page 467: ...measure Reinstatement method 1 Faulty battery Replace or change the battery Refer to CHECKING AND CHARGING THE BAT TERY in chapter 3 Reinstated by starting the engine and operating it at idle 2 Open or short circuit in wiring har ness Repair or replace if there is an open circuit Between battery and main switch red red Between main switch and fuse ignition brown blue brown blue Between fuse igniti...

Page 468: ... Remove the parts in the order listed Footrest board Refer to COVER AND PANEL in chapter 3 Leg shield Inner fender 1 Air vent hose 1 2 Crankcase breather hose 1 Disconnect 3 Silencer joint clamp 2 Loosen 4 Throttle body joint clamp 2 Loosen 5 Silencer 1 6 Throttle cable 2 Disconnect 7 Fast idle inlet hose 1 Disconnect 8 Fast idle outlet hose 1 Disconnect 9 Throttle position sensor coupler 1 Discon...

Page 469: ...ake air pressure sensor coupler 1 Disconnect 13 Intake air pressure sensor 1 14 Fuel injector with fuel hose 2 CAUTION Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses since there may be fuel remaining in it Do not disconnect the fuel hose except the fuel hose connector of the fuel pump feeding side NOTE Before removing the hoses place a few rags in the...

Page 470: ...5 6 10 13 14 14 15 15 7 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 15 Intake manifold 2 For installation reverse the removal pro cedure THROTTLE BODY ...

Page 471: ...d NOTE Before disassembling the throttle body make sure to note the number of times the air screw is turned out from the seated position to its set position 1 Throttle position sensor 1 2 Fast idle plunger 1 3 Idle adjust screw 1 4 Air screw 2 For assembly reverse the disassembly procedure THROTTLE BODY ...

Page 472: ...dy Cracks damage Replace the throttle body 2 Check fuel passages Obstructions Clean a Wash the throttle body in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages with com pressed air EAS00915 CHECKING THE FUEL PUMP OPERATION 1 Check fuel pump operation a Remove the seat fuel tank cover and fuel hose connector cover Refer to SEAT and FUEL T...

Page 473: ... main switch to ON and the engine stop switch to e Start the engine f Measure the fuel pressure Out of specification Check the fuel hose connection or replace the fuel pump 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 ...

Page 474: ...en sor resistance Out of specification Replace the throttle position sensor e Connect the pocket tester Ω 1k to the terminals of the throttle position sensor f While slowly opening the throttle check that the throttle position sensor resistance is within the specified range Resistance does not change or it changes abruptly Replace the throttle position sensor The slot is worn or broken Replace the...

Page 475: ... position sensor coupler to the wire harness b Connect the digital circuit tester to the throt tle position sensor c Measure the throttle position sensor volt age d Adjust the throttle position sensor angle so that the voltage is within the specified range e After adjusting the throttle position sensor angle tighten the throttle position sensor screws 3 Positive tester probe yellow terminal 1 Nega...

Page 476: ...ELEC 8 ...

Page 477: ...XP500 8 15 CIRCUIT DIAGRAM XP500A 8 16 STARTING CIRCUIT CUT OFF SYSTEM OPERATION XP500 8 17 STARTING CIRCUIT CUT OFF SYSTEM OPERATION XP500A 8 18 TROUBLESHOOTING 8 19 STARTER MOTOR 8 23 CHECKING THE STARTER MOTOR 8 25 ASSEMBLING THE STARTER MOTOR 8 27 CHARGING SYSTEM 8 28 CIRCUIT DIAGRAM 8 28 TROUBLESHOOTING 8 29 LIGHTING SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 TROUBLESHOOTING 8 33 CHECKING THE LIGHTING ...

Page 478: ...EM DIAGRAM 8 54 CIRCUIT DIAGRAM 8 55 GENERAL INFORMATION 8 56 KEY CODE REGISTRATION 8 57 SELF DIAGNOSIS MALFUNCTION CODES 8 59 TROUBLESHOOTING 8 61 CHECKING THE IMMOBILIZER SYSTEM 8 62 PART REPLACEMENT KEY REGISTRATION REQUIREMENTS 8 65 ...

Page 479: ...Turn signal hazard relay 4 Starting circuit cut off relay 1 5 Starting circuit cut off relay 2 XP500A 6 Battery 7 Fuse box 8 Starter relay 9 Main fuse 0 Rectifier regulator A Sidestand switch B Crankshaft position sensor C Stator coil D Radiator fan 1 2 3 4 5 6 7 8 9 0 A B C D E H F G J K L I ELECTRICAL COMPONENTS ...

Page 480: ...PONENTS E Speed sensor XP500 F Throttle position sensor G Ignition coil H Horn I Lean angle cut off switch J Fuel injection system relay K Headlight relay L Radiator fan motor relay 1 2 3 4 5 6 7 8 9 0 A B C D E H F G J K L I ...

Page 481: ...r 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 0 Hydraulic unit XP500A A Front wheel sensor XP500A B Intake air temperature sensor C ECU engine 3 1 2 4 5 6 7 8 9 0 A B C ELECTRICAL COMPONENTS ...

Page 482: ...ng for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration 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 betw...

Page 483: ...ce the switch R W Br R B B G Y L W BROWN Ch Br W L Y Dg Br L BLACK PASS Y R Y Y G L B P B NR N NL Dg Br W Ch L W B OFF ON P Br R Br L R R WR B Ch DgL YBr L Br W R L G 6 R Br L Br R 1 3 4 7 5 2 8 9 0 A B C B Y L Y G Y Br L Y G Ch B Y Y Dg B P R Y Br W L B BLUE B B BLUE 1 Pass switch 2 Dimmer switch 3 Turn signal switch 4 Horn switch 5 Rear brake light switch 6 Sidestand switch 7 Storage box light s...

Page 484: ...BS The bulbs used on this scooter are shown in the illustration on the left Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise Bulbs C is used for turn signal and tail brake lights and can be removed from the socket by...

Page 485: ...wise 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 2 Check bulb for continuity with the pocket tester No continuity Replace NOTE _ Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive test...

Page 486: ...continuity Replace NOTE _ Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester 90890 03112 Y...

Page 487: ...B W Y R G R W G Lg Br W G R G B B R B W Y R L R W O L Y P W Y R W B Y Gy G Y L Y G L W Y B Y B L B W L G Y R B Lg G Y BLUE 5 1 2 3 4 E 9 0 A B C D ß ç å l m p o n q k j j i O P Q R N S F J I G H L K M Y Z U V W X a h g e f c b d d 8 r Y R W Y Y G Lg W R W B W L W Ch Dg Y G Y G R Br Br R R L L R R W R Y Br L B Y B L W W W W W W R R B R G G L R W B Y L B W Br L L R R R G L R B W Lg G L G Lg L Y Dg C...

Page 488: ... spark Ignition checker 90890 06754 YM 34487 Pocket tester 90890 03112 YU 03112 C 1 Main and ignition fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at...

Page 489: ...witch and gradually increase the spark gap until a misfire occurs Minimum ignition spark gap 6 mm 0 24 in Is there a spark and is the spark gap within specification The ignition system is OK 5 Spark plug cap resistance The following procedure applies to all of the spark plug caps Remove the spark plug cap from the spark plug lead Connect the pocket tester Ω 1k to the spark plug cap as shown Measur...

Page 490: ...y coil resistance Secondary coil resistance 12 18 kΩ at 20 C 68 F Is the ignition coil OK Replace the ignition coil 7 Crankshaft position sensor resistance Disconnect the crankshaft position sensor coupler from the wire harness Connect the pocket tester Ω 100 to the crankshaft position sensor terminal as shown Positive tester probe gray 1 Negative tester probe black 2 Measure the crankshaft positi...

Page 491: ...tarting circuit cut off relay 1 Remove the starting circuit cut off relay 1 Connect the pocket tester Ω 1 to the starting circuit cut off relay 1 terminals as shown Check the starting circuit cut off relay 1 for continuity Positive tester probe light green 1 Negative tester probe red black 2 Continuity Positive tester probe red black 2 Negative tester probe light green 1 No conti nuity NOTE _ When...

Page 492: ...ive tester probe yellow green 2 Lean angle cut off switch voltage Less than 45 a Approximately 1 V More than 45 b Approximately 4 V Is the lean angle cut off switch OK Replace the lean angle cut off switch 13 Wiring Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly connected and without defects Replace the ECU engine Properly connect or rep...

Page 493: ...R W O L Y P W Y R W B Y Gy G Y L Y G L W Y B Y B L B W L G Y R B Lg G Y BLUE 5 1 2 3 4 6 7 E 9 0 A B C D ß ç å l m p o n q k j j i O P Q R N S F J I G H L K M Y Z U V W X h g e f c d d 8 r Y R W Y Y G Lg W R W B W L W Ch Dg Y G Y G R Br Br R R L L R R W R Y Br L B Y B L W W W W W W R R B R G G L R W B Y L B W Br L L R R G B L G L G R R G L R B B B B B B W Lg G L G Lg L Y Dg Ch B W R G R W Y L D C ...

Page 494: ... Y B Y B L B W L W R R B Lg L W BLUE W R G W G Y B B B B B W Lg W R Sb B 5 1 2 3 4 6 7 F 0 9 A B C D E µ º æ ø ß t u x w v y s r r q R S T U Q V G L K I J O N P b X Y Z c p o m n k j 8 M H d Y R W B Y G Lg W Y R W B W R Br Br R Br W R L L R R W R Y Br L B Y B L W W W W W W R R B R G G L R W B Y L B W Br L L R R G B L G L G R G L R B B B B B Õ B W Lg G L G Lg L Y Dg Ch W R R G R W Y L G Y B P R Y L...

Page 495: ...tions are met A brake lever is pulled to the handlebar the brake light switch is closed and the side stand is up the sidestand switch is closed 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Starting circuit cut off relay 1 7 Sidestand switch 8 Signaling system fuse 9 Front brake light switch 0 Rear brake light switch A Start switch B Starter relay C Starter motor ELECT...

Page 496: ...ulled to the handlebar the brake light switch is closed and the side stand is up the sidestand switch is closed 1 Battery 2 Main fuse 3 Main switch 4 Signaling system fuse 5 Ignition fuse 6 Engine stop switch 7 Starting circuit cut off relay 1 8 Front brake light switch 9 Rear brake light switch 0 Sidestand switch A Starting circuit cut off relay 2 B Start switch C Starter relay D Starter motor M ...

Page 497: ...in ignition and signaling system fuses Check the main ignition and signaling sys tem fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and signaling sys tem fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean...

Page 498: ...s the starting circuit cut off relay 1 have continuity between green yellow and green yellow Replace the starting circuit cut off relay 1 XP500 XP500A 5 Starting circuit cut off relay 2 XP500A Remove the starting circuit cut off relay 2 Connect the pocket tester Ω 1 and bat tery 12 V to the starting circuit cut off relay 2 terminals as shown Check the starting circuit cut off relay 2 for continuit...

Page 499: ... continuity between red and black Replace the starter relay 7 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch immobilizer unit 8 Engine stop switch Check the engine stop switch for continu ity Refer to CHECKING THE SWITCHES Is the engine stop switch OK Replace the right handlebar switch 9 Sidestand switch Check the sides...

Page 500: ...THE SWITCHES Is the start switch OK Replace the right handlebar switch 12 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM XP500 or CIRCUIT DIAGRAM XP500A Is the starting system s wiring properly connected and without defects The starting system circuit is OK Properly connect or repair the starting system s wiring ...

Page 501: ...art Q ty Remarks Removing the starter motor Remove the parts in the order listed Fuel tank Refer to FUEL TANK in chapter 3 1 Negative battery lead 1 Disconnect 2 Starter motor lead 1 Disconnect 3 Starter motor 1 For installation reverse the removal pro cedure ...

Page 502: ...or Remove the parts in the order listed 1 Front bracket 1 2 O ring 2 3 Shims 4 Lock washer 1 5 Oil seal 1 6 Bearing 1 7 Rear bracket 1 8 Shims 9 Brush holder set 1 0 Armature assembly 1 A Starter motor yoke 1 For assembly reverse the disassembly procedure STARTER MOTOR ...

Page 503: ...undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator NOTE _ The mica of the commutator must be undercut to ensure proper operation of the commutator Mica undercut 0 7 mm 0 03 in 4 Measure armature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armatur...

Page 504: ...ance 2 Above 1 MΩ at 20 C 68 F 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 springs as a set 7 Check gear teeth Damage wear Replace the gear Brush length wear limit 4 0 mm 0 16 in Brush spring force 7 65 10 01 N 780 1 021 gf 27 53 36 04 oz 8 Check bearing 1 oil seal 2 bushing 3 Damage wear Replace the...

Page 505: ...R MOTOR EAS00772 ASSEMBLING THE STARTER MOTOR 1 Install starter motor yoke 1 front bracket 2 rear bracket 3 NOTE _ Align the match marks a on the starter motor yoke with the match marks b on the front and rear bracket ...

Page 506: ...r L R W R Y L R L R Br R R R R G R L R R R L R G R W Br R B G Y L W B G Y G Y Br R W L W R B Ch Dg Br W Br L L Y Dg Ch Br W BROWN BROWN BLACK BLACK B BLACK B B R L 5 1 2 3 4 6 7 E 9 0 A B C D O P Q N F J I G H 8 R Br Br R R L L R R W R Y Br L B Y B L W W W W W W R R B R G G L R W B Y L B W Br L L R R G B L G L G R R G L R R W L W R B G Y Dg Ch L W B R R B B R R B B L W B 2 A C magneto 3 Rectifier ...

Page 507: ...oubleshoot with the following special tool s EAS00738 YES NO EAS00739 YES NO The battery is not being charged Pocket tester 90890 03112 YU 03112 C 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSES in chapter 3 Is the main fuse OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit volt...

Page 508: ...rcuit is OK 4 Stator coil resistance Remove the generator cover Connect the pocket tester Ω 1 to the stator coils as shown Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe white 3 Measure the stator coil resistances Stator coil resistance 0 22 0 26 Ω at 20 C 68 F between white and white Is the stator coil OK Replace the crank shaft pos...

Page 509: ...K BLACK G B R L R L O B GREEN GREEN L Y B L W L B B Gy GB L R L B BLACK BLACK B L P W L BLACK GREEN Br W B L G R GREEN B L W R B L W B L L Y G B L BLACK Br R L R W Y R B L BLACK B BLACK L B Br Y B Br Y Br Y Br L Br Y Br L L L BLUE L BLUE L B L BLUE L BLUE L L Br Y BLACK Y B BLACK Y R Br Y Br Y B Br L G L Lg Y L B W Dg Y Ch R G R W G Lg Br W G R G B B R B W Y R L R W O L Y P W Y R W B Y Gy G Y L Y ...

Page 510: ...immobilizer unit and meter assembly A Signaling system fuse B Headlight fuse E Lighting system fuse F Battery G Main fuse T ECU engine k Headlight relay m Pass switch n Dimmer switch u Tail brake light v Licence plate light z Auxiliary light Headlight high beam Headlight low beam Meter light ß High beam indicator light ...

Page 511: ...t tester 90890 03112 YU 03112 C 1 Main headlight signaling system lighting system and backup fuses Check the main headlight signaling sys tem lighting system and backup fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main headlight signaling system lighting system and backup fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGIN...

Page 512: ... relay Connect the pocket tester Ω 1 and bat tery 12 V to the headlight relay terminals as shown Check the headlight relay for continuity Positive battery terminal red yellow 1 Negative battery terminal white yellow 2 Positive tester probe red yellow 3 Negative tester probe blue black 4 Does the headlight relay have continuity between red yellow and blue black Replace the head light relay 8 Wiring...

Page 513: ...onnect the pocket tester DC 20 V to the headlights and meter assembly couplers as shown È When the dimmer switch is set to É When the dimmer switch is set to Headlight Positive tester probe yellow 1 or green 3 Negative tester probe black 2 Headlight coupler wire harness side High beam indicator light Positive tester probe yellow 4 Negative tester probe black white 5 Meter assembly coupler wire har...

Page 514: ...ltage within specification This circuit is OK The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be repaired 1 Tail brake light bulb and socket Check the tail brake light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the tail brake light bulb and socket OK Replace the tail brake light bulb socket or both 2 Voltage Connect the...

Page 515: ...Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the auxiliary light coupler is faulty and must be repaired 1 License plate light bulb and socket Check the license plate light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the license plate light bulb and socket OK Replace the license plate light bulb socket or both ...

Page 516: ...rage box light bulb socket or both 2 Voltage Connect the pocket tester DC 20 V to the storage box light connectors wire harness side as shown Positive tester probe blue green 1 Negative tester probe black 2 Set the main switch to ON Measure the voltage DC 12 V of blue green 1 on the storage box light connec tor wire harness side Is the voltage within specification This circuit is OK The wiring cir...

Page 517: ...CK BLACK G B R L R L O B GREEN GREEN L Y B L W L B B Gy GB L R L B BLACK BLACK B L P W L BLACK GREEN Br W B L G R GREEN B L W R B L W B L L Y G B L BLACK Br R L R W Y R B L BLACK B BLACK L B Br Y B Br Y Br Y Br L Br Y Br L L L BLUE L BLUE L B L BLUE L BLUE L L Br Y BLACK Y B BLACK Y R Br Y Br Y B Br L G L Lg Y L B W Dg Y Ch R G R W G Lg Br W G R G B B R B W Y R L R W O L Y P W Y R W B Y Gy G Y L Y...

Page 518: ...nal hazard relay j Horn o Horn switch p Turn signal switch q Rear brake light switch s Rear turn signal light right t Rear turn signal light left u Tail brake light w Front turn signal light right x Front turn signal light left V belt replacement reset coupler ç Multi function display Speedometer Tachometer Engine oil change indicator light V belt replacement indicator light Engine trouble warning...

Page 519: ...lighting system and backup fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main signaling system lighting system and backup fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace th...

Page 520: ...the main switch to ON Measure the voltage DC 12 V of brown at the horn coupler Is the voltage within specification The wiring circuit from the main switch to the horn coupler is faulty and must be repaired 3 Horn Disconnect the horn coupler at the horn Connect a jumper lead 1 to the brown ter minal in the horn coupler and the horn ter minal Connect a jumper lead 2 to the horn ter minal and ground ...

Page 521: ...y Refer to CHECKING THE SWITCHES Is the brake light switch OK Replace the brake light switch es 3 Voltage Connect the pocket tester DC 20 V to the tail brake light assembly coupler wire har ness side as shown Positive tester probe green yellow 1 Negative tester probe black 2 Set the main switch to ON Pull in the brake levers Measure the voltage DC 12 V of green yellow 1 on the tail brake light ass...

Page 522: ...ace the turn sig nal indicator light bulb socket or both 3 Turn signal switch Check the turn signal switch for continuity Refer to CHECKING THE SWITCHES Is the turn signal switch OK Replace the left han dlebar switch 4 Hazard switch Check the hazard switch for continuity Refer to CHECKING THE SWITCHES Is the hazard switch OK Replace the right handlebar switch 5 Voltage Connect the pocket tester DC...

Page 523: ...ly left É Front turn signal light assembly right Ê Tail brake light assembly Ë Meter assembly turn signal indicator light Left turn signal light Positive tester probe chocolate 1 or brown green 2 Negative tester probe ground Right turn signal light Positive tester probe dark green 3 or brown green 4 Negative tester probe ground Set the main switch to ON Set the turn signal switch to or Measure the...

Page 524: ...cement indicator reset coupler for continuity Positive tester probe black 1 Negative tester probe black 2 Is the V belt replacement indicator reset coupler OK Replace the V belt replacement indica tor reset coupler 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Positive tester probe light green 1 Negative tester probe ground Set the main switch...

Page 525: ...e trouble warning light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the engine trouble warning light bulb and socket OK Replace the meter assembly Replace the engine trouble warning light bulb socket or both 1 Fuel sender Drain the fuel from the fuel tank and then remove the fuel pump fuel sender from the fuel tank Connect the fuel pump coupler to the fuel pump ...

Page 526: ...t the main switch to ON Measure the voltage DC 12 V of green 1 on the meter assembly coupler wire har ness side Is the voltage within specification Check the wiring connections of the entire signaling sys tem 3 Fuel meter Set the main switch to ON Move the float up 1 or down 2 Check that the fuel meter appear to E or F Does the fuel meter appear appropriately This circuit is OK Replace the meter a...

Page 527: ...f white and black blue With each full rotation of the front wheel the voltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V Does the voltage reading cycle correctly Replace the speed sensor 2 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Positive tester probe yellow blue 1 Negative tester probe black white 2 Set the main switch to O...

Page 528: ...N Br W B L G R GREEN B L W R B L W B L L Y G B L BLACK Br R L R W Y R B L BLACK B BLACK L B Br Y B Br Y Br Y Br L Br Y Br L L L BLUE L BLUE L B L BLUE L BLUE L L Br Y BLACK Y B BLACK Y R Br Y Br Y B Br L G L Lg Y L B W Dg Y Ch R G R W G Lg Br W G R G B B R B W Y R L R W O L Y P W Y R W B Y Gy G Y L Y G L W Y B Y B L B W L G Y R B Lg G Y BLUE 5 1 2 3 4 6 7 E 9 0 A B C D ß ç å z z y x w s u u v t l ...

Page 529: ...s to turn The coolant temperature meter meter assembly fails to indicate Pocket tester 90890 03112 YU 03112 C 1 Main ignition radiator fan motor fuses Check the main ignition radiator fan motor fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition radiator fan motor fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING...

Page 530: ...nd must be replaced 5 Radiator fan motor relay Remove the radiator fan motor relay from the wire harness Connect the pocket tester Ω 1 and bat tery 12 V to the radiator fan motor relay terminal as shown Check the radiator fan motor relay of conti nuity Positive battery lead yellow red 1 Negative battery lead red white 2 Positive tester probe brown red 3 Negative tester probe blue 4 Does the radiat...

Page 531: ...continuity at the temperatures indicated in the table Test step Coolant temperature Resistance 1 20 C 68 F 2 32 2 59 kΩ 2 80 C 176 F 0 310 0 326 kΩ 3 110 C 230 F 0 140 0 144 kΩ WARNING _ Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it T R Coolant temperature sensor 18 Nm 1 ...

Page 532: ...unit 2 ECU engine 3 Immobilizer system indicator light Main switch Ignition fuse Immobilizer unit Backup fuse Anti theft alarm option Meter assembly Immobilizer system indi cator light Main fuse Battery R Red Br L Brown Blue G L Green Blue R G Red Green R W Red White Y L Yellow Blue ECU engine ...

Page 533: ...Y R L R W O L Y P W Y R W B Y Gy G Y L Y G L W Y B Y B L B W L G Y R B Lg G Y BLUE 5 1 2 3 4 6 7 E 9 0 A B C D ß ç å l m p o n q k j j i O P Q R N S F J I G H L K M Y Z U V W X h g e f c d d 8 r Y R W Y Y G Lg W R W B W L W Ch Dg Y G Y G R Br Br R R L L R R W R Y Br L B Y B L W W W W W W R R B R G G L R W B Y L B W Br L L R R G B L G L G R R G L R B B B B B B W Lg G L G Lg L Y Dg Ch B W R G R W Y ...

Page 534: ...registering the keys at purchase is not necessary 1 Code re registering key red bow 2 Standard keys black bow CAUTION DO NOT LOSE THE CODE RE REGISTERING KEY If the code re registering key is lost reg istering new codes in the standard keys is impossible The standard keys can still be used to start the scooter however if code re registering is required i e if a new standard key is made or all keys...

Page 535: ...n A standard key should be registered or the other standard key should be re registered when a reg istered standard key has been lost The standard keys must be re registered when the immobilizer unit or ECU engine has been replaced and the code re registering key has been re registered NOTE Do not start the engine with a standard key that has not been registered If the main switch is turned to ON ...

Page 536: ...is complete 6 Check that the engine can be started with the two registered standard keys Voiding a standard key code If a registered standard key has been lost and you want to disable its use register a new standard key or re register the other standard key For registration of a standard key refer to Standard key registration Standard key registration erases the stored standard key codes from memo...

Page 537: ...bilizer unit Noise interference or discon nected lead cable 1 Interference due to radio wave noise 2 Disconnected communication harness 3 Immobilizer unit malfunction 4 ECU engine malfunction 1 Check the wire harness and connector 2 Replace the main switch immobilizer unit 3 Replace the ECU engine 54 Immobilizer unit Codes transmitted between ECU engine and immobi lizer unit do not match Noise int...

Page 538: ...ystem indicator light malfunction code indication Units of 10 on for 1 second and off for 1 5 seconds Units of 1 on for 0 5 second and off for 0 5 second Light on Light off Example malfunction code 52 1 1 5 1 1 1 1 0 5 0 5 0 5 3 1 5 1 5 1 5 1 5 ...

Page 539: ...r continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and backup fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery 3 Main switch Check the main switch for continuit...

Page 540: ...e immobilizer unit coupler wire harness side Is the voltage within specification The wiring circuit from the main switch to the immobilizer unit coupler is faulty and must be repaired 2 Wiring Disconnect the meter assembly coupler and immobilizer unit coupler Check the immobilizer system indicator light lead green blue continuity meter assembly coupler immobilizer unit coupler Is the immobilizer s...

Page 541: ...oupler as shown LCD display Positive tester probe red white 1 or red green 2 Negative tester probe black white 3 Turn the main switch to ON Measure the voltage DC 12 V at the meter assembly coupler wire harness side Is the voltage within specification Replace the meter assembly The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be repaired ...

Page 542: ... Correct Turn the main switch to ON with the code re registering key and check the immobilizer system indicator light Malfunction Second standard key transpon der is defective Correct Re register the stan dard key Malfunc tion Replace the standard key Check if a malfunction code is dis played Displayed Read the malfunction code and check the corresponding part Refer to SELF DIAGNOSIS MAL FUNCTION ...

Page 543: ...th the new unit s Parts to be replaced Required key registration Main switch Standard key ECU engine Accessory lock 2 and key Immobilizer unit Standard key is lost New standard key All keys have been lost including code re reg istering key 1 Code re registering key and standard keys ECU engine is defec tive Code re registering key and standard keys Immobilizer unit is defective Code re registering...

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Page 545: ...TRBL SHTG 9 ...

Page 546: ...SPEED PERFORMANCE 9 2 ENGINE 9 2 FUEL SYSTEM 9 2 FAULTY CLUTCH 9 2 ENGINE OPERATES BUT SCOOTER WILL NOT MOVE 9 2 CLUTCH SLIPS 9 2 POOR STARTING PERFORMANCE 9 2 POOR SPEED PERFORMANCE 9 3 OVERHEATING 9 3 ENGINE 9 3 COOLING SYSTEM 9 3 FUEL SYSTEM 9 3 CHASSIS 9 3 ELECTRICAL SYSTEMS 9 3 OVERCOOLING 9 3 COOLING SYSTEM 9 3 POOR BRAKING PERFORMANCE 9 4 FAULTY FRONT FORK LEGS 9 4 LEAKING OIL 9 4 MALFUNCTI...

Page 547: ... NOT COME ON 9 5 HEADLIGHT BULB BURNT OUT 9 5 TAIL BRAKE LIGHT DOES NOT COME ON 9 5 TAIL BRAKE LIGHT BULB BURNT OUT 9 5 TURN SIGNAL DOES NOT COME ON 9 5 TURN SIGNAL BLINKS SLOWLY 9 5 TURN SIGNAL REMAINS LIT 9 5 TURN SIGNAL BLINKS QUICKLY 9 5 HORN DOES NOT SOUND 9 5 ...

Page 548: ...rankshaft FUEL SYSTEM Fuel tank Empty fuel tank Clogged fuel tank cap breather hole Deteriorated or contaminated fuel Clogged or damaged fuel hose Fuel pump Faulty fuel pump Faulty fuel pump relay Throttle body Deteriorated or contaminated fuel Sucked in air ELECTRICAL SYSTEMS Battery Discharged battery Faulty battery Fuse s Blown damaged or incorrect fuse Improperly installed fuse Spark plug s In...

Page 549: ...plug lead Ignition system Faulty ECU engine Faulty crankshaft position sensor EAS00849 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING FAILURE HARD STARTING ENGINE Air filter Clogged air filter element Air intake system Clogged or leaking air duct FUEL SYSTEM Fuel pump Faulty fuel pump EAS00853 FAULTY CLUTCH ENGINE OPERATES BUT SCOOTER WILL NOT MOVE V belt Bent damaged or worn V belt Slip...

Page 550: ...evel Incorrect oil viscosity Inferior oil quality COOLING SYSTEM Coolant Low coolant level Radiator Damaged or leaking radiator Faulty radiator cap Bent or damaged radiator fin Water pump Damaged or faulty water pump Thermostat Thermostat stays closed Oil cooler Clogged or damaged oil cooler Hose s and pipe s Damaged hose Improperly connected hose Damaged pipe Improperly connected pipe FUEL SYSTEM...

Page 551: ...r damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS00862 UNSTABLE HANDLING Handlebar Bent or improperly installed handlebar Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race Front fork leg s Uneven oil levels both fro...

Page 552: ...Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired TURN SIGNAL DOES NOT COME ON Faulty turn signal switch Faulty turn signal hazard relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY Faulty tur...

Page 553: ......

Page 554: ...itch m Pass switch n Dimmer switch o Horn switch p Turn signal switch q Rear brake light switch r Tail brake light assembly s Rear turn signal light right t Rear turn signal light left u Tail brake light v Licence plate light w Front turn signal light right x Front turn signal light left y Headlight assembly z Auxiliary light Headlight high beam Headlight low beam V belt replacement indicator rese...

Page 555: ...lay r Horn s Headlight relay t Left handlebar switch u Pass switch v Dimmer switch w Horn switch x Turn signal switch y Rear brake light switch z Tail brake light assembly Rear turn signal light right Rear turn signal light left Tail brake light Licence plate light å Front turn signal light right ç Front turn signal light left Headlight assembly Auxiliary light Headlight high beam Headlight low be...

Page 556: ......

Page 557: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 558: ...L R L O B GREEN GREEN L Y B L W L B B Gy GB L R L B BLACK BLACK B L P W L BLACK GREEN Br W B L G R GREEN B L W R B L W B L L Y G B L BLACK Br R L R W Y R B L BLACK B BLACK L B Br Y B Br Y Br Y Br L Br Y Br L L L BLUE L BLUE L B L BLUE L BLUE L L Br Y BLACK Y B BLACK Y R Br Y Br Y B Br L G L Lg Y L B W Dg Y Ch R G R W G Lg Br W G R G B B R B W Y R L R W O L Y P W Y R W B Y Gy G Y L Y G L W Y B Y B ...

Page 559: ...LACK L B Br Y B Br Y Br Y Br L Br Y Br L L L BLUE L BLUE L B L BLUE L BLUE L L Br Y BLACK Y B BLACK Y R Br Y Br Y B Br L G L Lg Y L B W Dg Y Ch R G R W W R G Lg Br W G R G B B R B W B R L R W O L Y P W Y R W Y B Y Gy G Y L Y G L W Y B Y B L B W L W R R B Lg L W BLUE W R G W G Y B B B B B W Gy W W B Gy W W B Br W R W W R W B P W R B R G W R R W G R R R W B B W R W B W Y W B G W W B P W Br W Lg W W ...

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Yamaha tmax XP500A, Service Manual

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