Yamaha TMAX XP530-A 2017 Service Manual Download Page 212

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FRONT BRAKE

4-45

EAS30168

INTRODUCTION

WARNING

EWA14101

Disc brake components rarely require disas-

sembly. Therefore, always follow these pre-

ventive measures:

• Never disassemble brake components un-

less absolutely necessary.

• If any connection on the hydraulic brake

system is disconnected, the entire brake

system must be disassembled, drained,

cleaned, properly filled, and bled after reas-

sembly.

• Never use solvents on internal brake com-

ponents.

• Use only clean or new brake fluid for clean-

ing brake components.

• Brake fluid may damage painted surfaces

and plastic parts. Therefore, always clean

up any spilt brake 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 im-

mediate medical attention.

EAS30169

CHECKING THE FRONT BRAKE DISCS

The following procedure applies to both brake
discs.
1. Remove:

•

Front wheel
Refer to “FRONT WHEEL” on page 4-22.

2. Check:

•

Front brake disc
Damage/galling



Replace.

3. Measure:

•

Brake disc runout
Out of specification



Correct the brake disc

runout or replace the brake disc.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Place the vehicle on a maintenance stand so

that the front wheel is elevated.

b. Before measuring the brake disc runout, turn

the handlebar to the left or right to ensure that
the front wheel is stationary.

c. Remove the brake caliper.

d. Hold the dial gauge at a right angle against

the brake disc surface.

e. Measure the runout 1.5 mm (0.06 in) below

the edge of the brake disc.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4. Measure:

•

Brake disc thickness
Measure the brake disc thickness at a few dif-
ferent locations.
Out of specification



Replace.

5. Adjust:

•

Brake disc runout

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.

NOTICE

ECA19150

Replace the brake disc bolts with new ones.

TIP

Tighten the brake disc bolts in stages and in a
crisscross pattern.

Brake disc runout limit (as mea-

sured on wheel)

0.15 mm (0.0059 in)

Brake disc thickness limit

3.5 mm (0.14 in)

Front brake disc bolt

23 N·m (2.3 kgf·m, 17 lb·ft)

LOCTITE®

Summary of Contents for TMAX XP530-A 2017

Page 1: ...2017 SERVICE MANUAL XP530E A XP530 A XP530D A BV1 28197 E0 ...

Page 2: ......

Page 3: ...XP530 A XP530D A SERVICE MANUAL 2017 by Yamaha Motor Co Ltd First edition March 2017 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice EAS30001 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol I...

Page 5: ...eft Generator cover protector Water pump inlet pipe Water pump outlet pipe Water pump assembly Refer to WATER PUMP on page 6 9 Generator cover Generator rotor Starter clutch gear Refer to GENERATOR AND STARTER CLUTCH on page 5 44 1 y l b m e s s a p m u p l i O 1 1 n i a h c e v i r d p m u p l i O 2 2 t e k s a G 3 1 e p i p y r e v i l e d l i O 4 1 e p i p l i O 5 1 y l b m e s s a e v l a v f ...

Page 6: ...rviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one Silicone fluid G M BF B T R LS M S LT E New S ...

Page 7: ...GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 EAS10003 TABLE OF CONTENTS ...

Page 8: ......

Page 9: ...0D A 1 4 OUTLINE OF THE TCS Traction Control System 1 9 MULTI FUNCTION DISPLAY 1 12 IMPORTANT INFORMATION 1 22 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 22 REPLACEMENT PARTS 1 22 GASKETS OIL SEALS AND O RINGS 1 22 LOCK WASHERS PLATES AND COTTER PINS 1 22 BEARINGS AND OIL SEALS 1 22 CIRCLIPS 1 23 RUBBER PARTS 1 23 BASIC SERVICE INFORMATION 1 24 QUICK FASTENERS 1 24 ELECTRICAL SYSTEM 1 25 SPECIAL TO...

Page 10: ...EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAS30003 MODEL LABEL The model label 1 is affixed to the storage box This information will be needed to order spare parts 1 1 ...

Page 11: ...ible for the system to respond extremely quickly to the slightest adjustments made by the rider In par ticular optimized control of the throttle valve opening provides the optimum volume of intake air for easy to use torque even in a high revving engine Aims and advantages of using YCC T Increased engine power By shortening the air intake path higher engine speed is possible Increased engine power...

Page 12: ...em outline 5 6 7 8 3 2 1 4 1 Accelerator position sensor 2 Throttle servo motor 3 Throttle position sensor 4 ECU Engine Control Unit 5 Sensor input 6 Crankshaft position sensor 7 Rear wheel sensor 8 Coolant temperature sensor ...

Page 13: ... the throttle valves Because the system allows the rider to maintain a set cruising speed without operating the throttle the system reduces the burden of maintaining a constant speed during long distance touring In addition the cruise control system is equipped with a self diagnosis function 13 12 11 8 9 10 7 6 5 4 3 2 1 1 Meter assembly 2 ECU Engine Control Unit 3 Rear brake light switch 4 Cruise...

Page 14: ...ise control system Your current traveling speed will become the set cruising speed The cruise control setting indicator light SET will come on Adjusting the set cruising speed While the cruise control system is operating push the RES side of the cruise control setting switch to increase the set cruising speed or the SET side to decrease the set speed TIP Pushing the setting switch once will change...

Page 15: ...se control system The cruise control system is electronically controlled and linked with other control systems The cruise control system will automatically deactivate under the following conditions The cruise control system is not able to maintain the set cruising speed such as when going up a steep hill Wheel slip or wheel spin is detected If the traction control system is on traction control wil...

Page 16: ...ing light come on the vehicle should be checked as soon as possible in order to avoid engine damage A D d c b a a B C A Cruise control system is activated cruising speed is set B Cruise control system is turned off cruise control setting indicator light SET flashes C Cruise control system is turned off D Cruise control system is turned on cruising speed is not set a Condition for automatically dea...

Page 17: ...sing speed is set B Cruise control system is turned off engine trouble warning light comes on cruise control system is deactivated and cruise control system indicator light flashes C Cruise control system is turned off engine trouble warning light goes off cruise control system is deactivated and cruise control system indicator light flashes D Cruise control system is turned off E Cruise control s...

Page 18: ...using the signals from the front and rear wheel sen sors and detects rear wheel slipping according to the difference between the wheel speeds If the slip ping exceeds the preset value the ECU controls the slipping using integrated control of the ignition timing fuel cut off and throttle valve opening of the YCC T system The traction control system can be set to one of three operation modes or turn...

Page 19: ...g fuel cut off and throttle valve opening of the YCC T system so that the amount of slip is less than the preset value The traction control system indicator light in the meter assembly flashes when the traction control system has activated 1 A B D G E H F 4 C A 3 2 1 Front wheel sensor 2 Rear wheel sensor 3 ABS ECU 4 ECU A Signal conversion B Slip amount calculation C Exceeds preset value D Actuat...

Page 20: ... 1 16 TIP Turn the traction control system off to help free the rear wheel if the vehicle gets stuck in mud sand or other soft surfaces NOTICE ECA19650 Use only the specified tires Using different sized tires will prevent the traction control system from controlling tire rotation accurately Resetting the traction control system The traction control system will automatically disable under certain c...

Page 21: ...olant temperature varies with changes in the weather and engine load If the top segment starts flashing the information display automati cally changes to C TEMP and Hi flashes Stop the vehicle and let the engine cool TIP The information display cannot be changed while the engine is overheating NOTICE ECA10022 Do not continue to operate the engine if it is overheating Eco indicator This indicator c...

Page 22: ...00 mi thereafter to indicate that the en gine oil should be changed After changing the engine oil reset the oil change indicator To reset the oil change indica tor refer to Setting mode on page 1 16 If the engine oil is changed before the oil change indicator Oil flashes i e before the periodic oil change interval has been reached the indicator Oil must be reset after the oil change for the next p...

Page 23: ...he select switch To decrease the seat heater temperature push the side of the select switch NOTICE ECA23980 Be sure to wear protective clothing that covers your hip and legs when using the seat heater If the ambient temperature is 20 C 68 F or higher do not set the seat heater to the high setting If the seat becomes worn or damaged stop using the seat heater and replace the seat Information displa...

Page 24: ...hown Ambient temperature This display shows the ambient temperature from 9 C to 50 C in 1 C increments The tem perature displayed may vary from the actual am bient temperature TIP 9 C will be displayed even if the detected temperature is lower 50 C will be displayed even if the detected temperature is higher The accuracy of the temperature reading may be affected when riding under 20 km h 12 mi h ...

Page 25: ...will not appear Grip warmer settings 1 Use the select switch to highlight Grip Warmer 1 Setting mode display 1 Display Description Grip Warmer This function allows you to set the low middle and high set tings to 10 temperature levels Seat Heater This function allows you to set the low middle and high set tings to 10 temperature levels Traction Control This function allows you to switch the tractio...

Page 26: ...rn to the set ting mode menu Seat heater settings 1 Use the select switch to highlight Seat Heat er 2 Push the MENU switch The seat heater setting display will be shown and High will flash in the display 3 Push the MENU switch The temperature level for the high setting will start flashing Use the select switch to set the temperature level and then push the MENU switch High will start flashing 4 Us...

Page 27: ... changing the settings push the MENU switch to return to the set ting mode menu Resetting the maintenance counters 1 Use the select switch to highlight Mainte nance 2 Push the MENU switch and then use the select switch to select the item to reset 3 While the selected item is flashing push the select switch for one second 4 When you finished resetting use the select switch to highlight and then pus...

Page 28: ...the select switch to highlight Display Change 2 Push the MENU switch use the select switch to highlight the display to change and then push the MENU switch again 3 Use the select switch to highlight the item to change and then push the MENU switch TIP Display item order is as follows 4 Use the select switch to select the item to show and then push the MENU switch 5 When you finished changing the s...

Page 29: ...ing the clock TIP The clock uses a 12 hour time system 1 Use the select switch to highlight Clock 2 Push the MENU switch 3 When the hour digits start flashing use the select switch to set the hours 4 Push the MENU switch and the minute dig its start flashing 5 Use the select switch to set the minutes 6 Push the MENU switch to return to the set ting mode menu Resetting all of the display items 1 Us...

Page 30: ...maintenance counter item Oil and maintenance counter item V Belt will not be reset To exit the setting mode 1 Use the select switch to highlight Return 2 Push the MENU switch to exit the setting mode and return to the standard display mode ...

Page 31: ...m any source of fire EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS30008 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket surfac es oil seal lips and O rings m...

Page 32: ... CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EAS30012 RUBBER PARTS Check rubber parts for deterioration during in spection Some of the rubber parts are sensitive to gasoline ...

Page 33: ...stener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fasten...

Page 34: ...If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then...

Page 35: ...ly 5 seconds before pushing the ON start switch Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof coupl...

Page 36: ...erefore be sure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Connect Lead Coupler Connector TIP When connecting ...

Page 37: ...values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Intake air temperature sensor re sistance 5400 6600 a...

Page 38: ...r U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 1 28 1 28 5 32 8 227 8 228 8 228 8 229 8 233 8 239 8 240 8 241 8 241 8 242 8 242 8 243 8 244 8 244 8 245 8 246 8 246 8 248 8 248 8 249 8 249 8 250 8 250 Yam...

Page 39: ...Tension meter TEXA 90890 03258 3 22 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 24 4 98 Oil filter wrench 90890 01426 Oil filter wrench YU 38411 3 28 6 6 Oil pressure gauge set 90890 03120 3 29 Oil pressure adapter B 90890 03124 3 29 Tool name Tool No Illustration Reference pages YU 44456 ...

Page 40: ...pring compressor YM 01441 4 89 4 94 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 89 4 94 Damper rod holder ø27 90890 01423 Damping rod holder YM 01423 4 90 4 93 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 92 4 92 4 92 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 4 93 Tool name Tool No Illustration Reference pages YM A8...

Page 41: ...sion tester YU 33223 5 1 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 14 5 41 5 49 5 65 Valve spring compressor 90890 04019 Valve spring compressor YM 04019 5 19 5 24 Valve spring compressor attachment 90890 04114 Valve spring compressor adapter 19 5 mm YM 04114 5 19 5 24 Tool name Tool No Illustration Reference pages YM A8703 90890 03081 YU 33223 ...

Page 42: ... installer 4 0 mm YM 04112 5 21 Valve guide reamer ø4 90890 04113 Valve guide reamer 4 0 mm YM 04113 5 21 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 26 Sheave holder 90890 01481 5 38 5 38 5 41 5 42 5 42 Locknut wrench 90890 01348 Locknut wrench YM 01348 5 38 5 38 5 41 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 43: ...bracket YM 04135 5 38 5 41 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 47 5 47 5 48 5 49 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 47 Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 5 54 5 58 Clutch spring compressor 90890 01482 5 54 5 57 Tool name Tool No Illustration Reference pages ...

Page 44: ... 04139 5 69 5 73 Radiator cap tester 90890 01325 Mityvac cooling system tester kit YU 24460 A 6 3 6 3 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 3 6 3 Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A 6 12 Tool name Tool No Illustration Reference pages YU 24460 A YU 33984 ...

Page 45: ... pressure adapter 90890 03186 Fuel pressure adapter YM 03186 7 12 OBD GST Leadwire kit 90890 03249 8 62 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 242 Test harness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P YU 03209 8 242 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 8 249 Tool name Tool No Illustration R...

Page 46: ...SPECIAL TOOLS 1 37 ...

Page 47: ...TENING TORQUES 2 11 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 11 ENGINE TIGHTENING TORQUES 2 12 CHASSIS TIGHTENING TORQUES 2 12 LUBRICATION POINTS AND LUBRICANT TYPES 2 14 ENGINE 2 14 CHASSIS 2 15 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 17 ENGINE OIL LUBRICATION CHART 2 17 LUBRICATION DIAGRAMS 2 19 COOLING SYSTEM DIAGRAMS 2 27 CABLE ROUTING 2 31 ...

Page 48: ... mm 30 1 in Overall height 1420 1475 mm 55 9 58 1 in XP530 A XP530E A 1420 1555 mm 55 9 61 2 in XP530D A Wheelbase 1575 mm 62 0 in Ground clearance 125 mm 4 92 in Minimum turning radius 2 8 m 9 19 ft Weight Curb weight 213 kg 470 lb XP530 A XP530E A 216 kg 476 lb XP530D A Loading Maximum load 199 kg 439 lb XP530D A 202 kg 445 lb XP530 A XP530E A Riding capacity 2 person ...

Page 49: ...O standard MA Lubrication system Dry sump Engine oil quantity Oil change 2 60 L 2 75 US qt 2 29 Imp qt With oil filter removal 2 90 L 3 07 US qt 2 55 Imp qt Quantity disassembled 3 50 L 3 70 US qt 3 08 Imp qt Oil filter Oil filter type Cartridge Oil pump Oil pressure 120 0 kPa 1200 r min 1 20 kgf cm 1200 r min 17 4 psi 1200 r min Relief valve operating pressure 450 0 550 0 kPa 4 50 5 50 kgf cm 65 ...

Page 50: ... width intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve seat contact width exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve stem diameter intake 3 975 3 990 mm 0 1565 0 1571 in Limit 3 945 mm 0 1553 in Valve stem diameter exhaust 3 960 3 975 mm 0 1559 0 1565 in Limit 3 930 mm 0 1547 in Valve guide inside diameter intake 4 000 4 012 mm 0 1575 0 1580 in Valve guide ins...

Page 51: ...nd ring Ring type Taper End gap limit 0 85 mm 0 0335 in Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in Side clearance limit 0 115 mm 0 0045 in Connecting rod Oil clearance 0 036 0 060 mm 0 0014 0 0024 in Bearing color code Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green Crankshaft Runout limit 0 030 mm 0 0012 in Crankshaft journal diameter 54 984 55 000 mm 2 1647 2 1654 in Journal oil clea...

Page 52: ...Limit 31 4 mm 1 24 in Drivetrain Primary reduction ratio 1 000 Transmission type V belt automatic Transmission ratio 2 041 0 758 1 Weight outside diameter 25 0 mm 0 98 in Limit 24 5 mm 0 96 in Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Secondary shaft runout limit 0 12 mm 0 0047 in Secondary reduction ratio 6 034 52 32 x 36 22 x 59 26 Final drive Belt Air fi...

Page 53: ...F Intake vacuum 32 0 kPa 240 mmHg 9 4 inHg Difference in vacuum pressure between the cylinders 0 kPa 1 3 kPa 0 mmHg 10 mmHg 0 inHg 0 4 inHg CO 0 0 2 0 Fuel line pressure at idle 220 300 kPa 2 2 3 0 kgf cm 31 9 43 5 psi Throttle grip free play 1 0 3 0 mm 0 04 0 12 in ...

Page 54: ...ubeless Size 160 60R15M C 67H Manufacturer model BRIDGESTONE BATTLAXSCR XP530 A XP530E A DUNLOP ROADSMART3 XP530D A Tire air pressure measured on cold tires 1 person Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi 2 persons Front 225 kPa 2 25 kgf cm 33 psi Rear 280 kPa 2 80 kgf cm 41 psi Front brake Type Hydraulic dual disc brake Disc outside diameter thickness 267 0 4 0 mm 10 51 ...

Page 55: ... 46 in Inner tube bending limit 0 2 mm 0 01 in Recommended oil Yamaha Suspension Oil 01 Quantity left 447 0 cm 15 11 US oz 15 77 Imp oz Quantity right 437 0 cm 14 77 US oz 15 41 Imp oz Level left 114 mm 4 5 in Level right 118 mm 4 6 in Rear suspension Type Swingarm link suspension Spring Coil spring Shock absorber Gas hydraulic damper Wheel travel 117 mm 4 6 in Spring preload Adjusting system Mech...

Page 56: ...4 V Charging system Charging system AC magneto Standard output 14 0 V 25 0 A at 5000 r min Standard output 14 0 V 350 W at 5000 r min Stator coil resistance 0 224 0 336 Rectifier regulator Regulator type Three phase Regulated voltage DC 14 1 14 9 V Rectifier capacity DC 25 0 A Battery Model YTZ12S Voltage capacity 12 V 11 0 Ah 10 HR Bulb wattage Headlight LED Brake tail light LED Front turn signal...

Page 57: ... position sensor resistance 228 342 Intake air temperature sensor resistance 5400 6600 at 0 C 5400 6600 at 32 F Intake air temperature sensor resistance 289 391 at 80 C 289 391 at 176 F Coolant temperature sensor resistance 2512 2777 at 20 C 2512 2777 at 68 F Coolant temperature sensor resistance 210 220 at 100 C 210 220 at 212 F Fuse s Main fuse 40 0 A Headlight fuse 7 5 A Taillight fuse 7 5 A Br...

Page 58: ... To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques N m kgf m lb ft 10 mm 6 mm 6 0 ...

Page 59: ...M20 1 40 N m 4 0 kgf m 30 lb ft Coolant drain bolt M12 1 1 6 N m 0 16 kgf m 1 2 lb ft Engine oil drain bolt M14 1 43 N m 4 3 kgf m 32 lb ft Item Thread size Q ty Tightening torque Remarks Front wheel axle M14 1 91 N m 9 1 kgf m 67 lb ft Front wheel axle pinch bolt M8 4 21 N m 2 1 kgf m 15 lb ft See TIP Rear wheel pulley bolt M10 5 64 N m 6 4 kgf m 47 lb ft Rear wheel axle nut M24 1 160 N m 16 kgf ...

Page 60: ...ary manually push the front axle or lightly tap it with a soft hammer until its end is flush with the front fork However if the surface of the front axle end is not parallel to the surface of the front fork align a point on the outer edge of the axle with the fork making sure that the axle does not protrude past the fork 4 Tighten the pinch bolt 5 pinch bolt 4 and pinch bolt 5 to 21 N m 2 1 kgf m ...

Page 61: ... exhaust Valve stems and stem ends intake and exhaust Valve lifter outer surface intake and exhaust Water pump impeller shaft O ring coolant pipe or Oil pump shaft and rotors inner and outer Oil pump gaskets V belt case air filter case screw bushing Water or V belt case air filter case cover screw bushing Water or Crankshaft end access cover screw bushing Water or Generator cover protector screw b...

Page 62: ...amaha bond No 1215 Three bond No 1215 Crankshaft position sensor stator lead grommet Yamaha bond No 1215 Three bond No 1215 Lubrication point Lubricant Steering bearings upper and lower Upper bearing cover seal lip and lower bearing dust seal lip Tube guide throttle grip inner surface and throttle cables Moving parts of the grip warmer lead and the inside of the handlebar switch right for XP530D A...

Page 63: ...oving parts Sidestand hook and spring contact point Front wheel oil seal lip Rear wheel oil seal lip Front wheel axle bolt mating surface Brake caliper piston seal Master cylinder inside Brake caliper piston dust seal Rear brake caliper bolts Rear brake lock caliper caliper piston assembly shaft L piston adjusting bolt Rear brake lock caliper slide pin bolt sleeve Lubrication point Lubricant LS LS...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 17 EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART ...

Page 65: ...To piston 6 Starter clutch gear 7 Crankshaft 8 Balancer connecting rod 9 To balancer piston 10 Oil pipe 11 Check valve 12 Relief valve 13 Oil filter 14 Oil cooler 15 Oil tank 16 Oil strainer 17 Feed pump 18 Delivery pipe 19 Scavenge pump 20 Oil strainer 21 To starter idle gear 22 Clutch 23 Secondary shaft 24 To transmission ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 19 EAS30021 LUBRICATION DIAGRAMS ...

Page 67: ...CATION SYSTEM CHART AND DIAGRAMS 2 20 1 Exhaust camshaft 2 Intake camshaft 3 Delivery pipe 4 Oil pump assembly 5 Scavenge pump 6 Feed pump 7 Oil pipe 8 Oil cooler 9 Oil filter 10 Relief valve 11 Check valve ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 ...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 22 1 Crankshaft 2 Secondary shaft 3 Drive axle 4 Clutch 5 Generator cover ...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 ...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Oil strainer 2 Intake camshaft 3 Exhaust camshaft ...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ...

Page 73: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Generator cover 2 Oil strainer 3 Main gallery 4 Crankcase right A Forward ...

Page 74: ...COOLING SYSTEM DIAGRAMS 2 27 EAS20020 COOLING SYSTEM DIAGRAMS ...

Page 75: ...oolant reservoir hose 5 Coolant pipe 6 Oil cooler outlet hose 7 Thermostat 8 Oil cooler 9 Oil cooler inlet hose 10 Coolant hose 11 Water pump outlet pipe 12 Radiator outlet hose 13 Radiator bracket 14 Coolant reservoir 15 Coolant reservoir breather hose 16 Radiator 17 Water pump 18 Water pump inlet pipe ...

Page 76: ...COOLING SYSTEM DIAGRAMS 2 29 ...

Page 77: ...YSTEM DIAGRAMS 2 30 1 Thermostat 2 Cooling system air bleed hose 3 Coolant reservoir hose 4 Radiator cap 5 Radiator filler hose 6 Radiator 7 Radiator bracket 8 Coolant pipe 9 Oil cooler 10 Oil cooler outlet hose ...

Page 78: ...CABLE ROUTING 2 31 EAS20021 CABLE ROUTING Headlight stay front view ...

Page 79: ...ack han dlebar switch coupler 1 right white han dlebar switch coupler 2 right white handlebar switch coupler 3 left white rear brake light switch coupler white for XP530D A front brake light switch coupler black for XP530D A handlebar switch coupler 3 right black except for XP530D A handlebar switch coupler 4 left white except for XP530D A The order of arrangement of the coupler above does not mat...

Page 80: ...CABLE ROUTING 2 33 Front cowling assembly rear view ...

Page 81: ...the headlight sub wire harness going to the right turn signal light in front of the headlight assembly lead E Fully push in the blue tape section of the headlight sub wire harness all the way to the back of the rib section of the headlight assembly F Install the green tape section of the headlight sub wire harness to the rib section of the headlight assembly G Install the white tape section of the...

Page 82: ...CABLE ROUTING 2 35 Frame right side view ...

Page 83: ... hole in the radia tor bracket G Route the wire harness on the inside of the brake hose H Install the radiator fan motor coupler wire harness side into the hole in the stay I Route the horn lead on the outside of the brake hose and rear brake lock cable J Install the wire harness clamp into the hole in the stay K Install the clamp of the steering lock unit lead into the hole in the stay L Route th...

Page 84: ...CABLE ROUTING 2 37 Frame right side view ...

Page 85: ... optional D Install the clamp of the O2 sensor lead into the hole of the V belt case air filter case E To seat lock key cylinder F To seat heater for XP530D A G Fasten the lead with the clamp H It does not matter whether the storage box light leads are installed on the left or right of the storage box light I Install the clamp of the seat heater lead against the rib of the storage box J Rib of sto...

Page 86: ...CABLE ROUTING 2 39 Frame left side view ...

Page 87: ...of the throttle servo motor lead into the hole in the motor cover E Make sure the spark plug leads after this clamp are not twisted F Make sure there is no slack in the spark plug lead when installed within this range as shown in the illustration G Install the wire harness clamp into the hole on the battery box H The end of the cover must be above the relay steps Make sure the cover does not turn ...

Page 88: ...CABLE ROUTING 2 41 Rear frame left side view ...

Page 89: ... Install the clamp of the sidestand switch lead to the bracket H To the tracking system control unit except for XP530E A I Fasten the wire harness to the footboard with the plastic locking tie Position the plastic locking tie within the range shown in the illus tration Point the end of the plastic locking tie rearward and place it inside of the footboard J Install the wire harness clamp into the h...

Page 90: ...CABLE ROUTING 2 43 Frame left side view ...

Page 91: ... as it is installed within this range D Install the plastic locking tie within this range E Install the wire harness clamp to the rounded end of the rib F Fasten the white tape section of the stator coil assembly lead and wire harness with the plastic locking tie The end of the plastic lock ing tie should be cut facing the outside G Fasten the tape portion of each lead with the clamp White tape Wi...

Page 92: ...CABLE ROUTING 2 45 Frame top view ...

Page 93: ...ottle servo motor lead A Route the coolant temperature sensor lead below the canister purge hose B Route the wire harness below the protruding portion of the fuel tank bracket C Install the clamp into the screw hole in the bracket except for XP530E A D Install the clamp so that it touches the cou pler side within the range shown in the illus tration E 0 10 mm 0 0 39 in F Install the coupler cover ...

Page 94: ...CABLE ROUTING 2 47 Frame top view ...

Page 95: ... XP530D A 9 Windshield drive unit relay down for XP530D A 10 Seat heater relay control for XP530D A 11 Seat heater relay power for XP530D A 12 Radiator fan motor relay 13 Turn signal hazard relay 14 Sidestand relay 15 Wire harness A To fuel pump B Route the lead along the edge of the filler cover C Make sure the seat lock cable does not get caught D Install the seat fuel lid lock solenoid lead to ...

Page 96: ...CABLE ROUTING 2 49 Handlebar top and left side view for XP530E A XP530 A ...

Page 97: ...lic unit 13 Brake hose holder 14 Rear brake lock lever A Route the rear brake lock cable through the hole in the handlebar cover B Route through the cable guide in the order of the throttle cable decelerator cable followed by throttle cable accelerator cable C Route the handlebar switch lead right on top of and at the back of the handlebar D Route the handlebar switch lead left on top of and at th...

Page 98: ...CABLE ROUTING 2 51 Handlebar front view for XP530E A XP530 A ...

Page 99: ...k on the metal part facing the front L Route the metal part of the rear brake hose between the guides of the brake master cylin der M Consolidate the leads around the handlebar and fasten them with the clamp See the clamp A fixed position details for more details N Face the end of the wire harness clamp toward the left O Clamp A fixed position details P Right side of the vehicle Q Left side of the...

Page 100: ...CABLE ROUTING 2 53 Handlebar top and left side view for XP530D A ...

Page 101: ...d right and front brake light switch lead on top of and behind the handlebar D Route the grip cancel switch lead between the lower handlebar holder and the upper bracket E Route the grip warmer lead left handlebar switch lead left and rear brake light switch lead on top of and behind the handlebar F Turn the rear brake lock lever up to the posi tion shown in the illustration before installing the ...

Page 102: ...CABLE ROUTING 2 55 Handlebar front view for XP530D A ...

Page 103: ...t brake hose should come into contact with the guide section of the brake master cylinder P Install the front brake hose with the white paint mark on the metal part facing the front Q Install the rear brake hose with the yellow paint mark on the metal part facing the front R Route the metal part of the rear brake hose between the guides of the brake master cylin der S Consolidate the leads around ...

Page 104: ...CABLE ROUTING 2 57 Front brake front left side and right side view ...

Page 105: ...gh the brake hose holder G Install the front brake hose with the paint mark on the outside H Install the brake hose holder with the rotation stopper in contact with the headlight stay When using the dimension B it is not nec essary to let the stopper touch the headlight stay I Fasten the white tape section of the front wheel sensor lead with the plastic locking tie The plastic locking tie should f...

Page 106: ...CABLE ROUTING 2 59 Frame right side view ...

Page 107: ... the protector part of the brake hose and rear wheel sensor lead D Route the rear brake lock cable in front of the section where the electrical components tray and frame are fastened E Route the rear brake hose along the guide of the electrical components tray F Make sure there is no slack in the rear wheel sensor lead within this interval G Arrange the rear wheel sensor lead either on top of belo...

Page 108: ...CABLE ROUTING 2 61 Rear brake right side view ...

Page 109: ...stopper in contact with the swingarm B Install the clamp with the clamp in contact with the protector end of the rear wheel sen sor lead C Install the rear brake hose with the rear brake hose in contact with the stopper of the rear brake caliper D Route the rear brake lock cable between the brackets E Route the rear brake hose through the guide portion of the stay F Fasten the rear brake hose and ...

Page 110: ...CABLE ROUTING 2 63 Fuel tank right side view ...

Page 111: ...ng downward and adjust the position so that the intersection of the rear brake hose and fuel tank breather hose is in contact with the clamp C Install the clamp into the hole in the stay of the coolant pipe Fasten the canister purge hose with the clamp D For the hoses to be installed to the canister install the fuel tank breather hose on the out side and the canister purge hose on the inside E Ins...

Page 112: ...CABLE ROUTING 2 65 Fuel tank left side view ...

Page 113: ... with the mark facing the outside B Route the fuel tank overflow hose between the sidestand bracket and the frame C Align the mark on the fuel tank with the mark on the fuel pump to install the fuel pump D Hold the fuel hose with its paint mark facing to the right and install the hose to the fuel tank After installing the fuel hose to the tank the paint mark should face downward ...

Page 114: ...CABLE ROUTING 2 67 Fuel tank top view ...

Page 115: ...ip at a distance of 3 mm 0 12 in or more from the hose end Make sure the clip does not ride on top of the bulge in the hose mounting area D Install the canister purge hose to the hose joint with the longer side facing the rear and the paint mark facing the right side E The end of the clip should face the rear Place the clip at a distance of 2 4 mm 0 08 0 16 in from the hose end F Install the canis...

Page 116: ...CABLE ROUTING 2 69 Air filter case and throttle body left side view ...

Page 117: ... assembly 6 Air filter case 7 Fuel rail 8 Intake air pressure sensor hose 9 Intake air pressure sensor A Place the clamp at a distance of 1 4 mm 0 04 0 16 in from the hose end The end of the clamp should face downward B Insert the intake air pressure sensor hose until it comes into contact with the throttle body ...

Page 118: ...CABLE ROUTING 2 71 Radiator right side view ...

Page 119: ...olant pipe N Insert the radiator filler hose until it comes into contact with the stay of the radiator filler pipe O Align the stay of the radiator filler pipe with the paint mark on the radiator filler hose P Install the coolant reservoir hose to the bot tom of the radiator filler hose Q The opening of the clamp should face the right R Insert the radiator inlet hose up to the end of the blue pain...

Page 120: ...CABLE ROUTING 2 73 Radiator left side view ...

Page 121: ...lamp so that the paint mark is visible H Install the clip with its end facing the left I Install the clamp so that the joint section is at a position relative to the screw head of the hose clamp as shown in the illustration when viewed from the rear of the vehicle J Example of bad clamp installing position K Make sure the clamp does not ride on top of the bulge in the hose installing area L 0 1 mm...

Page 122: ...CABLE ROUTING 2 75 Radiator top view ...

Page 123: ...facing the top and then put on the thermostat cover D Insert the coolant hose until it reaches the rounded end of the pipe E Install the clamp at a distance of at least 1 mm 0 04 in or more from the hose end Make sure the hose clamp does not ride on top of the bulge in the hose mounting area F Install the clip with its end facing the left G Insert the coolant reservoir hose until it comes into con...

Page 124: ...CABLE ROUTING 2 77 Hydraulic unit assembly top and front view ...

Page 125: ... hose 3 with the L shaped pin in contact with the side of the hydraulic unit The installation order of rear brake hose 1 and front brake hose 3 of rear brake hose 2 does not matter 2 Install front brake hose 4 with the protru sion in contact with the metal part of front brake hose 3 Install rear brake hose 2 with the protrusion in contact with the metal part of rear brake hose 1 The installation o...

Page 126: ...CABLE ROUTING 2 79 ...

Page 127: ... ADJUSTING THE FRONT DISC BRAKE 3 15 CHECKING THE FRONT BRAKE PADS 3 16 ADJUSTING THE REAR DISC BRAKE 3 16 CHECKING THE REAR BRAKE PADS 3 16 CHECKING THE FRONT BRAKE HOSES 3 16 CHECKING THE REAR BRAKE HOSE 3 17 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 17 ADJUSTING THE REAR BRAKE LOCK CABLE 3 18 CHECKING THE REAR BRAKE LOCK 3 19 CHECKING THE REAR BRAKE LOCK PADS 3 19 CHECKING THE WHEELS 3 19 CHECKING ...

Page 128: ... 27 MEASURING THE ENGINE OIL PRESSURE 3 29 CHECKING THE COOLANT LEVEL 3 30 CHECKING THE COOLING SYSTEM 3 30 CHANGING THE COOLANT 3 31 REPLACING THE V BELT 3 33 CHECKING THE BRAKE LIGHT SWITCHES 3 33 CHECKING AND LUBRICATING THE CABLES 3 33 CHECKING THE THROTTLE GRIP 3 33 CHECKING AND CHARGING THE BATTERY 3 34 CHECKING THE FUSES 3 34 ADJUSTING THE HEADLIGHT BEAMS 3 34 ...

Page 129: ...SION CONTROL SYSTEM EAS30615 GENERAL MAINTENANCE AND LUBRICATION CHART NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READINGS ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace 3 Valve clearance Check and adjust Every 40000 km...

Page 130: ...eafter 14 Drive pulley and drive axle Lubricate 15 Steering bearings Check bearing assemblies for looseness Moderately repack with lith ium soap based grease 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tight ened 17 Front and rear brake lever pivot shaft Lubricate with silicone grease 18 Sidestand center stand Check operation Lubricate with lithium soap based grease ...

Page 131: ... components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 25 Cooling system Check coolant level and vehi cle for coolant leakage Change Every 3 years 26 V belt Replace When the V belt replacement indicator flashes every 20000 km 12000 mi 27 Front and rear brake switches Check operation 28 Moving parts and ca...

Page 132: ...IP Use the Dynamic inspection function of the Yamaha diagnostic tool version 3 0 and after to perform the dynamic inspection For information about using the Yamaha diagnostic tool refer to the operation manual that is included with the tool 5 Install Battery cover Refer to GENERAL CHASSIS 1 on page 4 1 EAS30619 CHECKING THE FUEL LINE The following procedure applies to all of the fuel breather and ...

Page 133: ... 5 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug with a spark plug cleaner or wire brush 7 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 8 Install Spark plug TIP Before installing the spark plug clean the spark plug and gasket surface 9 Connect Spark plu...

Page 134: ...Refer to CAMSHAFTS on page 5 7 5 Remove Timing mark accessing plug 1 Crankshaft end access cover 2 6 Measure Valve clearance Out of specification Adjust a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the I mark a on the gen erator rotor with the mark b on the generator cover TIP TDC on the compression stroke can be found when the cylinder 1 camshaft lobe...

Page 135: ...cam shafts fasten the timing chain with a wire to re trieve it if it falls into the crankcase 8 Adjust Valve clearance a Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 TIP Cover the timing chain opening with a rag to 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 in stalled in the cor...

Page 136: ...5 mm 0 061 in 0 03 mm 0 001 in 1 58 mm 0 062 in The valve pad number is 158 e Round off the valve pad number according to the following table and then select the suit able valve pad TIP Refer to the following table for the available valve pads Example Valve pad number 158 Rounded value 160 New valve pad number 160 f Install the new valve pad 1 and the valve lift er 2 TIP Lubricate the valve pad wi...

Page 137: ...s 2 Check Engine idling speed Out of specification Go to next step 3 Check ISC Idle Speed Control learning value 00 or 01 Check the intake system 02 Clean the throttle bodies Refer to CHECKING AND CLEANING THE THROTTLE BODIES on page 7 9 a Connect the Yamaha diagnostic tool Use the diagnostic code number 67 Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE ECU on page 9 5 b Check the ISC...

Page 138: ...air screw in or out NOTICE ECA21300 Do not turn the bypass air screw white paint mark of the throttle body that is the stan dard Otherwise the engine may run roughly at idle and the throttle bodies may not oper ate properly TIP Turn the bypass air screw using the carburetor angle driver After each step rev the engine two or three times each time for less than a second and check the synchronization...

Page 139: ...page 4 11 2 Check Throttle body joints Cracks damage Replace 3 Install Center cover Refer to GENERAL CHASSIS 2 on page 4 11 EAS30625 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipes and gaskets 1 Remove Bottom side cowling Side panel Bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover right Footboard ...

Page 140: ...ake sure the cylinder head breather hose is routed correctly 3 Install All removed parts EAS30626 CHECKING THE CANISTER 1 Remove Bottom side cowling Side panel Bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 2 Check Canister Canister purge hose Fu...

Page 141: ...y areas 4 Install Air filter case cover NOTICE ECA20710 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect throttle body synchronization leading to poor engine per formance and possible overheating TIP When installing the air filter elem...

Page 142: ...elt case air filter case V belt case air filter case cover 7 Install V belt case air filter element left 8 Install Footboard Side cover Fuel tank cover assembly Center cover Refer to GENERAL CHASSIS 2 on page 4 11 Bottom center cowling Side panel Bottom side cowling Refer to GENERAL CHASSIS 1 on page 4 1 EAS30801 CHECKING THE BRAKE OPERATION 1 Check Brake operation Brake not working properly Check...

Page 143: ...int of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately TIP In order to ensure a correct reading of the brake fluid level make sure the top of the brake master cylinder reservoir is horizontal EAS30630 ADJUSTING THE FRONT DISC BRAKE 1 Adjust Brake lever position distance ...

Page 144: ...al with the arrow mark 2 on the brake lever hold er WARNING EWA13060 After adjusting the brake lever position make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the b...

Page 145: ... is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty TIP Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow When bleeding the ABS make sure that there is always enough brake fluid before applying the brake Ignoring this precaution could allow air to enter the ABS considerably len...

Page 146: ...e the vehicle on the centerstand 1 Measure Rear brake lock cable length a Out of specification Adjust TIP Measure while the rear brake lock lever is re leased 2 Adjust Rear brake lock cable length a Turn the rear brake lock cable adjusting nut 1 in direction b or c until the specified rear brake lock cable free play is obtained 3 Adjust Clearance between the brake pad and brake disc a Remove the c...

Page 147: ... indicator while ap plying the rear brake lock lever Passed the wear indicator groove 2 Ad just the rear brake lock cable length Refer to ADJUSTING THE REAR BRAKE LOCK CABLE on page 3 18 4 Check Rear brake lock caliper boot 3 Cracks damage Replace Refer to REAR BRAKE on page 4 53 EAS31427 CHECKING THE REAR BRAKE LOCK PADS The following procedure applies to all of the brake pads 1 Operate the rear ...

Page 148: ...nation other than one approved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done TIP For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the di rection of wheel rotati...

Page 149: ...d and lower guard Refer to REAR WHEEL on page 4 31 2 Check Drive belt External tooth cracks A Replace Missing teeth B Replace Hook wear C Replace Stone damage D Replace if damage is on the edge Internal tooth cracks hairline E OK to run but monitor condition Chipping not serious F OK to run but monitor condition Fuzzy edge cord G OK to run but moni tor condition Bevel wear outboard edge only H OK ...

Page 150: ...rive belt b Position the microphone part of the tension meter on the belt within 10 mm 0 39 in c Set the microphone part of the tension meter at the intermediate distance between the drive pulley and the rear wheel pulley d Tap with the suitable stick 2 to vibrate the belt e Repeat the measurement 3 times at different part and calculate the average of the read values Adjusting the drive belt tensi...

Page 151: ...uard Refer to REAR WHEEL on page 4 31 2 Remove Drive belt Refer to BELT DRIVE on page 4 100 3 Remove Drive pulley cover Refer to BELT DRIVE on page 4 100 Dust cover Refer to BELT DRIVE on page 4 100 Drive pulley assembly Refer to BELT DRIVE on page 4 100 4 Clean Drive axle Drive pulley assembly inner part 5 Lubricate Drive axle TIP Lubricate portion a of the drive axle with grease 6 Lubricate Driv...

Page 152: ... and right a couple of time to check that it moves smoothly c Loosen the lower ring nut completely then tighten it to specification WARNING EWA13140 Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING ...

Page 153: ...nterstand moves smoothly Rough movement Repair or replace EAS30857 LUBRICATING THE CENTERSTAND Lubricate the pivoting point metal to metal mov ing parts and spring contact point of the center stand EAS30652 CHECKING THE SIDESTAND SWITCH Refer to CHECKING THE SWITCHES on page 8 221 EAS30653 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle ...

Page 154: ...red position on the adjusting ring with the stopper 3 Rebound damping NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a Turn the adjusting screw 1 in direction a or b TIP To obtain a precise adjustment it is advisable to check the actual total number of turns of the damping force adjusting mechanism This ad justment range may not exactly match t...

Page 155: ...ould cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD or higher and do not use oils labeled ENERGY CONSERVING II Do not allow foreign materials to enter the crankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine o...

Page 156: ...lithium soap based grease 7 Fill Crankcase with the specified amount of the recom mended engine oil 8 Install Engine oil filler cap along with the O ring 9 Start the engine warm it up for several min utes and then turn it off 10 Check Engine for engine oil leaks 11 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 27 12 Check Engine oil pressure a Remove the bottom side cowli...

Page 157: ...d then turn it off NOTICE ECA13410 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 3 Remove Engine oil pressure check point plug 1 Bottom of the crankcase WARNING EWA12980 The engine muffler and engine oil are ex tremely hot 4 Install Oil pressure gauge 1...

Page 158: ...ion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several min utes and then turn it off 4 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles EAS30812 CHECKING THE COOLING SYSTEM 1 Remove Bottom side cowling Side panel Bottom center cowling Refer to GENERAL CHAS...

Page 159: ...ain Coolant from the coolant reservoir 4 Remove Radiator cap 1 WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator ca...

Page 160: ...ilable soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 10 Install Radiator cap 11 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 12 Install Coolant reservoir cap 13 Start the engine warm it up for several min utes and then stop it 14 Check Coolant level Refer to C...

Page 161: ...ulty Refer to CHECKING THE SWITCHES on page 8 221 EAS31147 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough move...

Page 162: ...ADLIGHT BEAMS 1 Adjust Headlight beam vertically a Turn the adjusting screw 1 in direction a or b TIP Other than the socket wrench the adjusting screws can be turned with a screwdriver Phillips No 2 2 as shown in the illustration 2 Adjust Headlight beam horizontally a Turn the adjusting screw 1 in direction a or b TIP Other than the socket wrench the adjusting screws can be turned with a screwdriv...

Page 163: ...PERIODIC MAINTENANCE 3 35 Right headlight Direction a Headlight beam moves to the left Direction b Headlight beam moves to the right a b 1 1 2 2 1 a b b a ...

Page 164: ...PERIODIC MAINTENANCE 3 36 ...

Page 165: ... WHEEL 4 25 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR 4 26 ADJUSTING THE FRONT WHEEL STATIC BALANCE 4 27 INSTALLING THE FRONT WHEEL DISC BRAKE 4 28 REAR WHEEL 4 31 REMOVING THE REAR WHEEL 4 34 DISASSEMBLING THE REAR WHEEL 4 34 CHECKING THE REAR WHEEL 4 35 CHECKING THE REAR WHEEL DRIVE HUB 4 35 CHECKING AND REPLACING THE REAR WHEEL PULLEY 4 35 ASSEMBLING THE REAR WHEEL 4 35 MAINTENANCE...

Page 166: ...E REAR BRAKE LOCK PADS 4 67 REPLACING THE REAR BRAKE LOCK CABLE 4 68 REMOVING THE REAR BRAKE LOCK CALIPER 4 68 CHECKING THE REAR BRAKE LOCK CALIPER 4 69 ASSEMBLING THE REAR BRAKE LOCK CALIPER 4 69 INSTALLING THE REAR BRAKE LOCK CALIPER 4 70 ABS Anti lock Brake System 4 71 ABS COMPONENTS CHART 4 72 REMOVING THE HYDRAULIC UNIT ASSEMBLY 4 73 CHECKING THE HYDRAULIC UNIT ASSEMBLY 4 73 INSTALLING THE HY...

Page 167: ...ABSORBER 4 103 DISPOSING OF A REAR SHOCK ABSORBER 4 103 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 103 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 104 CHECKING THE CONNECTING ARM AND RELAY ARM 4 104 ASSEMBLING THE CONNECTING ARM 4 104 INSTALLING THE RELAY ARM 4 104 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 105 SWINGARM 4 106 REMOVING THE SWINGARM 4 108 CHECKING THE SWINGARM 4 108 INSTALLING T...

Page 168: ... cover 1 5 Windshield inner panel 1 6 Meter assembly coupler 1 Disconnect 7 Meter panel assembly 1 8 Meter assembly 1 9 Rearview mirror 2 3 1 1 2 3 4 5 6 7 8 9 9 1 6 N m 0 16 kgf m 1 2 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m ...

Page 169: ...panel 1 5 Meter assembly coupler 1 Disconnect 6 Meter panel assembly 1 7 Meter assembly 1 8 Rearview mirror 2 3 1 1 2 3 4 5 6 7 8 8 1 6 N m 0 16 kgf m 1 2 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 170: ...ect 2 Front turn signal light 2 3 Headlight assembly coupler 2 Disconnect 4 Front cowling assembly 1 5 Side cowling 2 6 Front turn signal light bracket 2 7 Headlight under panel 1 8 Headlight sub wire harness 1 9 Headlight 1 10 Plate 2 11 Rearview mirror adaptor 2 1 2 1 2 3 4 5 5 6 6 7 8 9 10 11 10 11 1 5 N m 0 15 kgf m 1 1 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 ...

Page 171: ...arts to remove Q ty Remarks 1 Footboard mat 4 2 Bottom side cowling 2 3 Side panel 2 4 Radiator cover 1 5 Bottom center cowling 1 3 1 1 1 2 3 2 3 4 5 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 7 N m 0 7 kgf m 5 2 lb ft ...

Page 172: ...1 1 Battery cover 1 2 Negative battery lead 1 Disconnect 3 Positive battery lead 1 Disconnect 4 Battery band 1 5 Battery 1 6 Storage compartment lid lock solenoid coupler 1 Disconnect for XP530 A XP530D A 7 Remote control unit coupler 1 Disconnect 8 Auxiliary DC jack coupler 1 Disconnect 9 Inner panel 2 10 Leg shield assembly 1 11 Band 1 12 Remote control unit 1 FWD FWD 1 2 3 4 5 6 7 8 9 9 10 11 1...

Page 173: ... 13 Auxiliary DC jack 1 14 Storage box 1 15 Protector 1 16 Storage compartment lid lock solenoid 1 17 Cover 1 FWD FWD 13 14 15 16 17 1 5 N m 0 15 kgf m 1 1 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 4 3 N m 0 43 kgf m 3 2 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 2 8 N m 0 28 kgf m 2 1 lb ft ...

Page 174: ...Install the windshield to the desired position by installing the screws 3 d Tighten the screws to the specified torque e Place the windshield covers 1 and then in stall the quick fasteners EAS31398 REMOVING THE FRONT COVER 1 Remove Front cover 1 a Remove the front cover bolts 2 b Remove the front cover bolt 3 c Remove the front cover 1 by sliding it for ward Windshield screw 10 N m 1 0 kgf m 7 4 l...

Page 175: ... Remove Bottom side cowling 2 Remove Side panel 1 a Remove the side panel screws 2 b Remove the quick fasteners 3 and the side panel bolt 4 c Remove the side panel 1 TIP Remove the side panel by removing the lower part a and upper part b EAS30822 INSTALLING THE SIDE PANEL The following procedure applies to both of the side panels 1 Install Side panel 1 1 a b 1 2 4 3 1 b a 1 ...

Page 176: ...m side cowling EAS30819 REMOVING THE INNER PANEL The following procedure applies to both of the in ner panels 1 Remove Inner panel 1 a Remove the part a of the inner panel and slide the inner panel 1 to the upper side TIP When removing the part a of the inner panel use a commercially available cover removal tool b Side panel bolt 1 5 N m 0 15 kgf m 1 1 lb ft Side panel screw 1 5 N m 0 15 kgf m 1 1...

Page 177: ...1 by moving it in the arrow direction EAS31677 REMOVING THE BATTERY COVER 1 Remove Battery cover 1 a Remove the battery cover screw 2 b Remove the part a of the battery cover c Remove the battery cover 1 by sliding it to the upper side b a 1 1 2 1 a ...

Page 178: ... 2 Fuel tank cover assembly 1 3 Seat fuel lid lock solenoid coupler 1 Disconnect 4 Seat lock cable 1 Disconnect 5 Side cover 2 6 Footboard 4 7 Cover 1 8 Seat fuel lid lock solenoid 1 9 Cover 2 10 Fuel tank cover 1 FWD FWD 1 3 4 2 5 6 5 6 7 8 9 9 10 4 0 N m 0 40 kgf m 3 0 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N ...

Page 179: ...over assembly Side cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 1 Cover 1 2 Rear cover 1 3 Grab bar 2 4 Rear cowling 2 5 Rear turn signal light coupler 2 Disconnect 6 License plate light connector 2 Disconnect 7 Mudguard assembly 1 1 7 2 3 4 5 5 4 3 6 22 N m 2 2 kgf m 16 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 10 N m 1 0 kgf m 7 4 lb ft 22 N m 2 2 kgf m 16 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft ...

Page 180: ... assembly Refer to GENERAL CHASSIS 2 on page 4 11 1 Rear cowling assembly 1 2 Seat lock cable 1 Disconnect 3 Tail brake light coupler 2 Disconnect 4 Seat heater coupler 1 Disconnect for XP530D A 5 Seat assembly 1 6 Tail brake light 2 7 Lid 1 8 Seat lock key cylinder 1 9 Tail brake light cover 1 5 6 6 1 9 7 8 4 3 3 2 7 N m 0 7 kgf m 5 2 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 4 0 N m 0 40 kgf m 3 0 lb f...

Page 181: ...o GENERAL CHASSIS 2 on page 4 11 1 Storage box inner mat 1 2 Storage box light switch coupler 1 Disconnect 3 Storage box light connector 2 Disconnect 4 Wire harness 1 5 Storage box 1 6 Rear panel 2 7 Bracket 1 8 Seat hinge assembly 1 9 Storage box light switch 1 10 Stopper 2 11 Storage box light 1 12 Seat lock assembly 1 2 9 8 3 4 6 10 10 11 12 6 1 5 7 0 7 N m 0 07 kgf m 0 52 lb ft 16 N m 1 6 kgf ...

Page 182: ...n the side cover from grommets b EAS31523 REMOVING THE FOOTBOARD The following procedure applies to both of the footboards 1 Remove Bottom side cowling Side panel Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Side cover 2 Remove Footboard 1 a Remove the footboard bolt screw and quick fastener b Remove the footboard 1 by sliding it to the upper side EAS31193 REMOVING THE REAR COVER 1 Remove C...

Page 183: ...EMOVING THE REAR COWLING The following procedure applies to both of the rear cowlings 1 Remove Side cover Refer to GENERAL CHASSIS 2 on page 4 11 Cover Rear cover Grab bar 2 Remove Rear cowling 1 a Remove the rear cowling screw bolt and quick fastener b Remove the rear cowling 1 by sliding it rear ward 1 1 2 2 1 1 ...

Page 184: ...n page 4 1 Center cover Fuel tank cover assembly Side cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 1 Ignition coil connector 2 Disconnect 2 Ignition coil 1 3 Buzzer coupler 1 Disconnect 4 Intake air temperature sensor coupler 1 Disconnect 5 ECU coupler 2 Disconnect 6 Wire harness 1 7 Battery box 1 8 Battery band 1 9 ECU Engine Control Unit 1 10 Buzzer 1 11 Intake air temperature sensor ...

Page 185: ...ERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 1 Handlebar switch coupler 2 2 Rectifier regulator coupler 1 Disconnect 3 Wire harness 1 4 Rear brake hose 1 5 Rectifier regulator 1 6 Electrical components tray 1 7 Meter bracket 1 8 Windshield bracket 2 7 8 5 2 3 4 6 1 8 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ...

Page 186: ...ide cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Brake hose holder Refer to HANDLEBAR on page 4 79 1 Handlebar switch coupler 2 2 Rectifier regulator coupler 1 Disconnect 3 Windshield drive unit coupler 1 Disconnect 4 Wire harness 1 5 Rear brake hose 1 6 Rectifier regulator 1 7 Meter bracket 1 8 Windshield drive unit 1 9 Electrical components tray 1 7 8 6 2 4 3 5 9 1 10 N m 1 0 kgf m 7 ...

Page 187: ...er to GENERAL CHASSIS 2 on page 4 11 Battery box Electrical components tray Meter bracket Windshield bracket XP530E A XP530 A Windshield drive unit XP530D A Refer to GENERAL CHASSIS 3 on page 4 17 Hydraulic unit Refer to ABS Anti lock Brake System on page 4 71 1 Brake hose holder 1 2 Wire harness 1 3 Clamp 2 4 Cover 2 5 Plate 1 6 Headlight stay 1 1 7 Wire harness bracket 1 8 Headlight stay 2 1 9 D...

Page 188: ...ght stay check the operation of the drive unit a Install the windshield drive unit 1 and then connect the windshield drive unit coupler to the wire harness b Operate the windshield drive unit and check that the windshield drive unit arms can be moved fully up and down within the specified operation time Specified operation time time re quired to move up or down 1 9 3 8 seconds 1 1 ...

Page 189: ...wheel axle bolt 1 8 Front wheel axle 1 9 Front wheel 1 10 Collar 1 Length 22 mm 0 87 in 11 Collar 1 Length 18 mm 0 71 in 12 Front brake disc 2 LT LT 1 2 3 3 3 3 4 5 5 6 6 7 8 9 10 11 12 12 1 2 2 5 N m 0 25 kgf m 1 8 lb ft 9 N m 0 9 kgf m 6 6 lb ft 21 N m 2 1 kgf m 15 lb ft 35 N m 3 5 kgf m 26 lb ft 35 N m 3 5 kgf m 26 lb ft 7 N m 0 7 kgf m 5 2 lb ft 23 N m 2 3 kgf m 17 lb ft 23 N m 2 3 kgf m 17 lb...

Page 190: ...ing the front wheel Order Job Parts to remove Q ty Remarks 1 Front wheel sensor rotor 1 2 Oil seal 2 3 Wheel bearing 2 4 Collar 1 LT 8 N m 0 8 kgf m 5 9 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft 1 2 3 4 2 3 ...

Page 191: ...the sensor housing 3 Elevate Front wheel TIP Place the vehicle on a maintenance stand so that the front wheel is elevated 4 Loosen Wheel axle pinch bolt 5 Remove Front wheel axle bolt Front wheel axle Front wheel EAS30146 DISASSEMBLING THE FRONT WHEEL NOTICE ECA21340 Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1...

Page 192: ... sensor ro tor wipe it off immediately 1 Install Wheel bearings Oil seals a Install the new wheel bearing right side NOTICE ECA18110 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 TIP Use a socket 4 that matches the diameter of the wheel bearing outer race b Install the spacer c Install the new wheel bearing left side TIP Place a suitable...

Page 193: ... sensor rotor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 EAS30155 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR NOTICE ECA21070 Handle the ABS components with care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The front wheel sensor cannot be disas sembled Do not attempt to disassemble it If faulty re...

Page 194: ... rotor a Hold the dial gauge at a right angle against the wheel sensor rotor surface b Measure the wheel sensor rotor runout c If the runout is above specification remove the sensor rotor from the wheel rotate it by two or three bolt holes and then install it NOTICE ECA17200 Replace the wheel sensor rotor bolts with new ones d If the runout is still above specification re place the wheel sensor ro...

Page 195: ...ctly opposite the heavy spot X TIP 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 weight d Repeat steps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel doe...

Page 196: ...lts to 21 N m 2 1 kgf m 15 lb ft in the order of pinch bolt 5 pinch bolt 4 pinch bolt 5 6 Install Front wheel sensor NOTICE ECA21020 Make sure there are no foreign materials in the front wheel sensor rotor and front wheel sensor Foreign materials cause damage to the front wheel sensor rotor and front wheel sensor TIP When installing the front wheel sensor check the front wheel sensor lead for twis...

Page 197: ...the front wheel sensor 8 Install Front brake calipers Front brake hose holder WARNING EWA13500 Make sure the brake hose is routed properly Distance a between the front wheel sensor rotor and front wheel sensor 0 3 1 1 mm 0 01 0 04 in Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 Front brake caliper bolt 35 N m 3 5 kgf m 26 lb ft Front brake hose holder bolt left 9 N m 0 9 kgf m 6 6 lb ft...

Page 198: ...wer guard 1 5 Locknut 2 Loosen 6 Adjusting bolt 2 Loosen 7 Rear wheel axle nut 1 8 Washer 1 9 Rear wheel axle 1 10 Adjusting block left 1 11 Adjusting block right 1 12 Brake caliper bracket 1 13 Rear wheel sensor housing 1 14 Rear wheel 1 15 Collar right 1 16 Collar left 1 1 2 3 4 7 8 5 6 9 10 11 12 13 14 15 16 6 5 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 16 N m 1 6 kgf m 12 lb ft 16 N...

Page 199: ...rder Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sensor rotor 1 3 Drive belt guide 1 4 Rear wheel pulley 1 5 Rear wheel 1 1 2 3 4 5 LT LT LT LT 8 N m 0 8 kgf m 5 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 64 N m 6 4 kgf m 47 lb ft ...

Page 200: ...REAR WHEEL 4 33 Disassembling the rear wheel assembly Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing left 1 3 Collar 1 4 Wheel bearing right 1 1 4 3 2 1 ...

Page 201: ...ontact the sensor electrode to any metal part when removing the rear wheel sensor from the rear brake caliper bracket 3 Loosen Locknuts 1 Adjusting bolts 2 left side and right side 4 Remove Wheel axle nut 1 Washer Rear wheel axle 2 Rear wheel Rear brake caliper bracket Rear wheel sensor housing Collars NOTICE ECA21400 Be sure to remove the rear wheel sensor be fore removing the brake caliper brack...

Page 202: ...he drive belt guide 2 Replace Rear wheel pulley a Remove the drive belt guide bolts and the drive belt guide b Remove the rear wheel pulley bolts and the rear wheel pulley c Clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the pulley d Install the new rear wheel pulley and drive belt guide TIP Tighten the rear wheel pulley bolts in stages and in a crisscross p...

Page 203: ...NSOR ROTOR on page 4 26 3 Measure Wheel sensor rotor runout Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 EAS30164 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel pulley installed Adjust Rear wheel static balance ...

Page 204: ...nstalling the rear brake caliper bracket and the rear wheel sensor housing align the projection c on the rear brake caliper bracket with the slot d of the rear wheel sensor hous ing After installing the rear wheel to the vehicle make sure that the projection e on the brake caliper bracket and the projection f on the rear wheel sensor housing are aligned Install the left adjusting block so that pro...

Page 205: ...en the rear wheel sensor rotor 1 and rear wheel sensor 2 Out of specification Check the wheel bear ing for looseness and the rear wheel sensor and sensor rotor installation conditions warpage caused by overtorque wrong in stallation direction rotor decentering LOC TITE on the mounting surface of the rotor deformation caused by an impact during ser vice and caught foreign materials If there is any ...

Page 206: ...HEEL 4 39 sor rotor and the rear wheel sensor 11 Adjust Rear brake lock cable length Refer to ADJUSTING THE REAR BRAKE LOCK CABLE on page 3 18 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 2 1 1 2 a ...

Page 207: ...Brake pad 2 5 Front brake hose holder bolt 1 The tightening torque of the front brake hose holder bolt on the right side is 7 N m 0 7 kgf m 5 2 lb ft 6 Front brake hose holder 1 7 Front reflector 1 8 Front brake caliper 1 9 Bleed screw 1 Left brake caliper side 10 Bleed screw 1 Right brake caliper side FWD FWD 10 9 6 7 2 8 3 4 1 5 5 N m 0 5 kgf m 3 7 lb ft 35 N m 3 5 kgf m 26 lb ft 35 N m 3 5 kgf ...

Page 208: ...aphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake lever 1 5 Front brake light switch connector 2 Disconnect For XP530E A XP530 A 6 Brake hose union bolt 1 7 Brake hose gasket 2 8 Front brake hose 1 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 11 Front brake light switch 1 For XP530E A XP530 A 12 Front brake light switch 1 For XP530D A FWD FWD S...

Page 209: ...FRONT BRAKE 4 42 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 ...

Page 210: ... brake hose holder bolt 1 The tightening torque of the front brake hose holder bolt on the right side is 7 N m 0 7 kgf m 5 2 lb ft 2 Front brake hose holder 1 3 Front reflector 1 4 Brake hose union bolt 1 5 Brake hose gasket 1 Left side only 6 Front brake hose 1 Left side only 7 Brake hose gasket 2 8 Brake hose 1 9 Front brake caliper 1 FWD FWD 1 4 5 7 9 3 8 6 2 35 N m 3 5 kgf m 26 lb ft 30 N m 3 ...

Page 211: ...alipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Front brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 Left brake caliper side 9 Bleed screw 1 Right brake caliper side BF BF BF BF FWD FWD 2 1 5 8 9 3 4 6 6 6 5 7 6 7 5 N m 0 5 kgf m 3 7 lb ft 5 N m 0 5 kgf m 3 7 lb ft ...

Page 212: ...Remove Front wheel Refer to FRONT WHEEL on page 4 22 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc a Place the vehicle on a maintenance stand so that the front wheel is elevated b Before measuring the brake disc runout turn the handlebar to the left or right to ensure that the front wheel is ...

Page 213: ... to disconnect the brake hose or disassem ble the brake caliper 1 Remove Brake pad clips 1 Brake pad pin 2 Brake pad spring 2 Remove Brake pads 1 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Remove Brake caliper bolts 5 Install Brake pads Brake pad spring TIP Always install new brake pads and new brake pad spring as a set a Connect a clear plastic hose 1 ...

Page 214: ...ke lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 EAS30724 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolts 1 Brake hose gaskets 2 Brake hoses 3 TIP Put the e...

Page 215: ... the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13611 Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS3...

Page 216: ...d WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reserv...

Page 217: ...very passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir cap 1 Brake master cylinder reservoir 2 Brake master cylinder reservoir diaphragm holder 3 Cracks damage Replace Brake master cylinder reservoir diaphragm 4 Damage wear Replace 4 Check Brake hoses Cracks damage wea...

Page 218: ...ARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake 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...

Page 219: ...FRONT BRAKE 4 52 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 a LOWER ...

Page 220: ... the rear brake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad support 2 5 Bleed screw 1 S 3 4 3 4 2 5 1 1 FWD FWD 27 N m 2 7 kgf m 20 lb ft 6 N m 0 6 kgf m 4 4 lb ft ...

Page 221: ...oir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake lever 1 5 Rear brake light switch connector 2 Disconnect For XP530E A XP530 A 6 Brake hose union bolt 1 7 Brake hose gasket 2 8 Rear brake hose 1 9 Rear brake master cylinder holder 1 10 Rear brake master cylinder 1 11 Rear brake light switch 1 For XP530E A XP530 A 12 Rear brake light switch 1 For XP530D A S S 11 12 ...

Page 222: ...REAR BRAKE 4 55 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 S BF ...

Page 223: ...LEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Rear brake hose 1 4 Rear brake caliper bolt 2 5 Rear brake caliper 1 6 Rear brake pad 2 7 Brake pad support 2 8 Caliper bolt boot 2 1 3 4 4 5 8 6 6 7 2 7 S S S FWD FWD 27 N m 2 7 kgf m 20 lb ft 30 N m 3 0 kgf m 22 lb ft ...

Page 224: ...rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 5 Brake caliper body 1 6 N m 0 6 kgf m 4 4 lb ft S BF 5 4 3 2 1 FWD FWD ...

Page 225: ...rear brake lock pads Order Job Parts to remove Q ty Remarks 1 Rear brake lock cable adjusting nut 1 2 Pin 1 3 Rear brake lock spring 1 4 Rear brake lock caliper 1 5 Rear brake lock pad 2 5 3 2 1 4 FWD FWD 23 N m 2 3 kgf m 17 lb ft ...

Page 226: ...emoving the rear brake lock caliper Order Job Parts to remove Q ty Remarks 1 Rear brake lock cable adjusting nut 1 2 Pin 1 3 Rear brake lock spring 1 4 Rear brake lock caliper 1 3 2 1 4 FWD FWD 23 N m 2 3 kgf m 17 lb ft ...

Page 227: ...4 Boot 1 5 Rear brake lock pad 2 6 Caliper piston assembly 1 7 Rear brake lock caliper bracket bolt 1 8 Rear brake lock caliper bracket 1 9 Sleeve 1 10 Boot 2 11 Boot 1 12 Slide pin bolt 1 13 Rear brake lock caliper 1 S S S S LT 1 2 3 4 5 6 7 8 9 10 10 11 12 13 22 N m 2 2 kgf m 16 lb ft 15 N m 1 5 kgf m 11 lb ft 17 N m 1 7 kgf m 13 lb ft 22 N m 2 2 kgf m 16 lb ft FWD FWD ...

Page 228: ...fer to REAR WHEEL on page 4 31 2 Check Rear brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 45 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DIS...

Page 229: ...ake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 15 8 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 EAS30186 REMOVING THE REAR BRAKE CALIPER TIP Before removing the brake caliper drain the brake fluid from the entir...

Page 230: ...k Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13601 Whenever a brake caliper is disassembled replace the brake caliper pis...

Page 231: ...stall Brake pad supports Rear brake pads Rear brake caliper Rear brake caliper bolt Refer to REPLACING THE REAR BRAKE PADS on page 4 61 4 Fill Brake master cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with t...

Page 232: ...uid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir cap Brake master cylinder reservoir Brake master cylinder reservoir diaphragm holder Cracks damage Replace 4 Check Brake hose Cracks damage wear Replace EAS30195 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WA...

Page 233: ... 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 brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13...

Page 234: ...olts 1 Rear brake lock caliper 2 3 Remove Rear brake lock pad left side 1 TIP Push on the back of the pad using a rod with a round end 4 Remove Rear brake lock pad right side 1 a Remove the bolt 2 and then slide the rear brake lock caliper bracket 3 b Insert a flathead screwdriver in between the piston adjusting bolt and rear brake lock pad and then remove the rear brake lock pad NOTICE ECA22110 A...

Page 235: ...e 3 18 EAS31418 REPLACING THE REAR BRAKE LOCK CABLE 1 Remove Rear brake lock cable 2 Check Rear brake lock cable Cracks damage wear Replace the rear brake lock cable 3 Install Rear brake lock cable WARNING EWA13490 Make sure the brake cable is routed properly 4 Adjust Rear brake lock cable length a Adjust the clearance for the rear brake lock pad Refer to ADJUSTING THE REAR BRAKE LOCK CABLE on pag...

Page 236: ...ASSEMBLING THE REAR BRAKE LOCK CALIPER 1 Install Slide pin bolt 1 to the rear brake lock caliper bracket 2 Install Rear brake lock caliper bracket 3 Install Boots 1 Sleeve 2 4 Install Boot 1 5 Install Shaft L 1 Piston adjusting bolt 2 Locknut 3 Rear brake lock caliper slide pin bolt 17 N m 1 7 kgf m 13 lb ft Recommended lubricant Silicone grease 4 3 4 2 1 5 2 1 3 4 5 6 7 8 8 8 8 T R Rear brake loc...

Page 237: ...Rear brake lock adjusting nut Cap 9 Install Rear brake lock pads NOTICE ECA22120 After installing the rear brake lock pad to the caliper check that the pad rotates smoothly EAS31422 INSTALLING THE REAR BRAKE LOCK CALIPER 1 Install Rear brake lock caliper 1 Rear brake lock caliper bolts 2 Rear brake lock spring 3 Pin 4 Rear brake lock cable adjusting nut 5 2 Adjust Rear brake lock cable length Refe...

Page 238: ...YSTEM on page 3 17 1 ABS ECU coupler 1 Disconnect 2 Brake hose union bolt 4 3 Brake hose gasket 8 4 Rear brake hose rear brake master cylinder to hydraulic unit 1 Disconnect 5 Front brake hose hydraulic unit to front brake caliper 1 Disconnect 6 Front brake hose front brake master cylinder to hydraulic unit 1 Disconnect 7 Rear brake hose hydraulic unit to rear brake caliper 1 Disconnect 8 Hydrauli...

Page 239: ...draulic unit assembly 5 Front wheel sensor rotor 6 Front wheel sensor 7 Front brake caliper 8 Rear brake caliper 9 Rear wheel sensor 10 Rear wheel sensor rotor 11 Front brake hose front brake master cylinder to hydraulic unit 12 Front brake hose hydraulic unit to front brake caliper 13 Rear brake hose hydraulic unit to rear brake caliper 14 Rear brake hose rear brake master cylinder to hydraulic u...

Page 240: ...emoved be sure to tighten them to the specified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP While pushing the portion a of the ABS ECU coupler pull the lock lever up to release the lock NOTICE ECA20080 Do not use a tool to disconnect the ABS ECU coupler 2 Remove Brake hoses TIP Do not operate the front brake lever and rear brake lever while removing the brake hoses NOTICE ...

Page 241: ...S ECU coupler and then push the lock lever of the coupler in the direction of the arrow shown 5 Fill Brake master cylinder reservoir Brake fluid reservoir with the specified amount of the specified brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brak...

Page 242: ...line routing confir mation make sure that no malfunctions have been detected in the ABS ECU and that the wheels are not rotating 1 Place the vehicle on a maintenance stand 2 Push the OFF LOCK switch 3 Remove Battery cover Refer to GENERAL CHASSIS 1 on page 4 1 4 Check Battery voltage Lower than 12 8 V Charge or replace the battery TIP If the battery voltage is lower than 12 8 V charge the battery ...

Page 243: ...If the operation of the hydraulic unit is normal delete all of the fault codes ABS reaction force confirmation WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP For the ABS reaction force confirmation use the diagnosis of function of the Yamaha diag nostic tool For more information refer to the operation manual of the Yamaha diagnostic tool Before perf...

Page 244: ...tion force pulsating action is generated in the front brake lever 1 and continues for a few seconds TIP The reaction force pulsating action consists of quick pulses Be sure to continue operating the front brake lever and rear brake lever even after the pul sating action has stopped ON and OFF on the tool screen indicate when the brakes are being applied and re leased respectively 10 After the puls...

Page 245: ...unit assembly If the pulse is hardly felt in either the front brake lever or rear brake lever check that the brake hoses and brake pipes are con nected correctly to the hydraulic unit as sembly 12 Push the OFF LOCK switch 13 Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler and then in stall the protective cap 14 Push the ON start switch 15 Set the engine stop switch to 16 ...

Page 246: ...ver front 1 3 Parking Unlock switch coupler 1 Disconnect 4 OFF LOCK switch coupler 1 Disconnect 5 Lower handlebar cover 1 6 Accelerator position sensor coupler 1 Disconnect 7 Handlebar cover rear 1 8 Parking Unlock switch 1 9 OFF LOCK switch 1 FWD FWD 1 2 3 4 5 6 7 8 9 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 k...

Page 247: ... to GENERAL CHASSIS 2 on page 4 11 Handlebar cover Refer to HANDLEBAR on page 4 79 1 Front brake light switch connector 2 Disconnect for XP530E A XP530 A 2 Front brake master cylinder holder 1 3 Front brake master cylinder assembly 1 4 Handlebar switch right 1 5 Throttle cable 2 Disconnect 6 Throttle cable throttle grip side 2 Disconnect 7 Grip end 2 8 Throttle grip 1 FWD FWD 1 1 2 3 4 5 6 7 7 8 3...

Page 248: ...ock lever 1 13 Rear brake lock cable 1 Disconnect 14 Rear brake master cylinder assembly 1 15 Handlebar switch left 1 16 Handlebar switch holder 2 17 Handlebar grip 1 FWD FWD 10 9 11 12 13 14 15 17 16 16 3 5 N m 0 35 kgf m 2 6 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 26 N m 2 6 kgf m 19 lb f...

Page 249: ...to GENERAL CHASSIS 2 on page 4 11 Handlebar cover Brake master cylinder Handle bar switch Refer to HANDLEBAR on page 4 79 1 Clamp 2 2 Bracket 1 3 Upper handlebar holder 2 4 Handlebar 1 5 Lower handlebar holder 1 6 Brake hose holder 1 7 Brake hose bracket 1 8 Throttle cable pulley 1 9 Grip cancel switch 1 10 Accelerator position sensor 1 FWD FWD 1 2 3 3 4 5 6 7 8 9 10 3 5 N m 0 35 kgf m 2 6 lb ft 2...

Page 250: ...n it EAS30205 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Brake hose bracket Lower handlebar holder Handlebar 1 Upper handlebar holders 2 Bracket 3 NOTICE ECA19130 First tighten the bolts on the front side of the upper handlebar holder and then on the rear side Turn the handleb...

Page 251: ...INDER on page 4 50 5 Install Handlebar switch holder Handlebar switch left TIP Align the projection a on the handlebar switch left with the hole b in the handlebar 6 Lubricate Rear brake lock cable to cable end 7 Connect Rear brake lock cable to rear brake lock lever TIP Rotate the lever to the position a and then in stall the rear brake lock cable 8 Install Rear brake master cylinder assembly Ref...

Page 252: ...1 Check Accelerator position sensor Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 12 2 Adjust Accelerator position sensor angle a Temporary tighten the accelerator position sensor screws b Check that the throttle valves are fully closed c Connect the accelerator position sensor to the wire harness d Connect the throttle cables to the throttle ca ble pulley e Remove the protective cap 1...

Page 253: ...Yamaha diagnostic tool screen value is not 9 23 adjust the accelerator posi tion sensor angle o Turn the throttle grip to the fully open position p Check the Yamaha diagnostic tool screen value If the Yamaha diagnostic tool screen value is not 93 109 adjust the accelerator position sensor angle q Repeat steps f to p until the Yamaha diag nostic tool screen values are within the spec ified ranges r...

Page 254: ...ly Rearview mirror Bottom side cowling Side panel Front cowling assembly Refer to GENERAL CHASSIS 1 on page 4 1 Front wheel Refer to FRONT WHEEL on page 4 22 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Cap bolt 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 1 2 4 3 5 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 23 N m 2 3 kgf m 17 lb ft 23 N m 2 3 kgf m 17 lb f...

Page 255: ... Damper rod locknut 1 4 Spacer 1 5 Fork spring 1 6 Damper rod assembly bolt 1 7 Copper washer 1 8 Damper rod assembly 1 9 Dust seal 1 10 Oil seal clip 1 11 Outer tube 1 12 Oil seal 1 13 Washer 1 14 Outer tube bushing 1 15 Inner tube bushing 1 16 Inner tube 1 1 2 3 4 5 7 6 9 10 15 16 8 12 14 13 11 LT 15 N m 1 5 kgf m 11 lb ft 23 N m 2 3 kgf m 17 lb ft 23 N m 2 3 kgf m 17 lb ft ...

Page 256: ...th of the front fork legs NOTICE ECA22020 Because the left and right damper rod as semblies are different be sure to install them in the correct positions 1 Remove Cap bolt 1 Spacer 2 Damper rod locknut 3 a Press down on the spacer with the fork spring compressor 4 b Install the rod holder 5 between the damper rod locknut 3 and the spacer 2 TIP Use the side of the rod holder that is marked B c Hol...

Page 257: ...E ECA14180 Do not scratch the inner tube 5 Remove Outer tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the outer tube from the inner tube by pulling the outer tube forcefully but careful ly NOTICE ECA19880 Excessive force will damage the bushings Damaged bushings must be replaced EAS30208 CHECKING THE FRONT FORK LEGS The f...

Page 258: ... stability TIP When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushing Oil seal Dust seal Oil seal clip O ring Copper washer Before assembling the front fork leg make sure all of the components are clean 1 Lubricate Inner tube outer surface 2 Install Dust seal 1 Oil seal clip 2 Oil seal 3 Washer 4 Outer tube bushing 5 Inner tube bushing 6 NOT...

Page 259: ...e 7 Install Dust seal 1 with the fork seal driver 2 8 Install Damper rod assembly 1 to inner tube 2 Copper washer Damper rod assembly bolt NOTICE ECA17401 For the damper rod assembly the right side Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 6 New 5 New 1 New 2 New 3 New 1 3 2 Fork seal driv...

Page 260: ...sembly bolt 10 Install Rod puller 1 Rod puller attachment M10 2 onto the damper rod 3 11 Fill Front fork leg with the specified amount of the recom mended fork oil NOTICE ECA14230 Be sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance A Compression side B Rebound side Damper rod assembly bolt 23 N m 2 3 kgf m 17 lb ft LOCTITE Damper rod holder ø27 9...

Page 261: ...outer tube fully compressed and without the fork spring Out of specification Correct 15 Install Damper rod locknut 1 Fork spring 2 Spacer 3 Cap bolt 4 along with the O ring WARNING EWA12850 Always use a new O ring a Remove the rod puller and rod puller attach ment b Install the damper rod locknut c Install the fork spring and spacer TIP Install the spring with the smaller diameter a facing up A d ...

Page 262: ...pressor EAS30210 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts TIP Make sure the outer tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 Cap bolt 2 Upper bracket pinch bolt 3 Damper rod locknut 15 N m 1 5 kgf m 11 lb ft 3 1 6 5 1 1...

Page 263: ...embly Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Handlebar cover Handlebar Lower handlebar holder Refer to HANDLEBAR on page 4 79 Front wheel Refer to FRONT WHEEL on page 4 22 1 Stay 2 2 Steering stem nut 1 3 Upper bracket 1 4 Lock washer 1 5 Upper ring nut 1 6 Rubber washer 1 7 Lower ring nut 1 FWD LT L...

Page 264: ... remove Q ty Remarks 8 Lower bracket 1 9 Upper bearing cover 1 10 Upper bearing 1 11 Lower bearing 1 12 Dust seal 1 13 Steering lock unit coupler 1 Disconnect 14 Steering lock unit 1 15 Stay 1 FWD LT LT LT 8 9 10 11 12 13 14 15 7 N m 0 7 kgf m 5 2 lb ft 130 N m 13 kgf m 96 lb ft 1st 2nd 52 N m 5 2 kgf m 38 lb ft 16 N m 1 6 kgf m 12 lb ft ...

Page 265: ...ash Bearings Bearing races 2 Check Bearings 1 Bearing races 2 Damage pitting Replace 3 Replace Bearings Bearing races a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Install a new rubber seal and new bearing races NOTICE ECA14270 If the bearing race is not installed properly...

Page 266: ...r ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 24 3 Install Upper bracket Washer Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 87 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Recommended lubricant Lithium soap based grease Steering stem nu...

Page 267: ...s Rear brake caliper Rear brake lock caliper Refer to REAR BRAKE on page 4 53 Rear wheel Refer to REAR WHEEL on page 4 31 1 Drive pulley cover 1 2 Dust cover 1 3 Holder 1 4 Circlip 1 5 Bearing 1 6 Oil seal 1 7 Drive pulley 1 8 Collar 2 9 Drive belt 1 FWD FWD 1 2 3 4 5 6 7 8 9 10 N m 1 0 kgf m 7 4 lb ft 48 N m 4 8 kgf m 35 lb ft 48 N m 4 8 kgf m 35 lb ft ...

Page 268: ...n page 3 21 3 Check Drive pulley 1 Rear wheel pulley 2 Bent teeth Replace the drive belt and pul leys as a set 4 Check Holder 1 Cracks damage Replace EAS32443 INSTALLING THE DRIVE PULLEY ASSEMBLY 1 Install Drive pulley assembly Drive pulley assembly bolt 2 Tighten Drive pulley assembly bolt TIP Tighten the drive pulley assembly bolts in the fol lowing order bolt 1 bolts 2 and bolts 3 EAS31423 INST...

Page 269: ...bly lower nut Rear shock absorber assembly lower bolt 1 1 3 Collar 1 4 Collar 1 5 Rear shock absorber assembly upper nut Washer Rear shock absorber assembly upper bolt 1 2 1 6 Rear shock absorber assembly 1 7 Connecting arm bolt Connecting arm nut 1 1 8 Connecting arm 2 9 Relay arm 1 10 Collar Oil seal Bearing 1 2 1 11 Collar Oil seal Bearing 1 2 1 12 Collar Oil seal Bearing 1 2 2 13 Oil seal Bear...

Page 270: ...RBER 1 Gas pressure must be released before dis posing of a rear shock absorber To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips TIP Drill a hole at a point 50 mm 1 97 in from the center of the installation hole EAS30219 REMOVING THE REAR SHOCK ABSORBER A...

Page 271: ...hes Replace EAS32420 ASSEMBLING THE CONNECTING ARM 1 Lubricate Collars Oil seals 2 Install Bearings 1 Oil seals 2 TIP When installing the oil seals 2 to the connect ing arms 3 face the character stamp of the oil seals outside Install the bearing to the connecting arm by pressing the character stamped side EAS30222 INSTALLING THE RELAY ARM 1 Lubricate Collars Oil seals 2 Install Bearings 1 to the r...

Page 272: ...s facing downward Install the rear shock absorber assembly so that the rebound damping adjusting screw b is facing downward for XP530D A EAS30225 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Install Rear shock absorber assembly TIP Install the rear shock absorber assembly lower bolt and relay arm bolt from the right Install the rear shock absorber assembly with the swingarm down 2 Tighten Rear sh...

Page 273: ...R ASSEMBLY on page 4 102 Drive belt Refer to BELT DRIVE on page 4 100 1 Holder 1 2 Holder 1 3 Drive belt inner guard 1 4 Swingarm left 1 5 Swingarm right 1 6 Dowel pin 2 7 Pivot shaft 1 8 Oil seal 1 9 Oil seal 1 10 Outer race 1 FWD FWD LT 1 2 3 4 5 6 7 8 9 10 6 7 N m 0 7 kgf m 5 2 lb ft 6 N m 0 6 kgf m 4 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 40 N m...

Page 274: ... housing 1 13 O ring 1 14 Collar 1 15 Oil seal 1 16 Bearing 1 FWD FWD LT 11 12 13 14 15 16 7 N m 0 7 kgf m 5 2 lb ft 6 N m 0 6 kgf m 4 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 40 N m 4 0 kgf m 30 lb ft 40 N m 4 0 kgf m 30 lb ft 100 N m 10 kgf m 74 lb ft ...

Page 275: ... is binding check the bearings 3 Remove Drive belt Refer to BELT DRIVE on page 4 100 4 Remove Drive pulley assembly bolt Swingarm bolt Pivot shaft nut EAS30227 CHECKING THE SWINGARM 1 Check Swingarm left 1 Swingarm right 2 Bends cracks damage Replace 2 Check Drive pulley assembly bolts Swingarm bolts Damage wear Replace EAS30228 INSTALLING THE SWINGARM 1 Lubricate Taper roller bearing TIP Lubricat...

Page 276: ...our fingers screw in the pivot shaft until it touches the collar and then tighten the piv ot shaft to the specified torque b Tighten the pivot shaft nut to the specified torque Swingarm bolt 40 N m 4 0 kgf m 30 lb ft Drive pulley assembly bolt 48 N m 4 8 kgf m 35 lb ft Pivot shaft 6 N m 0 6 kgf m 4 4 lb ft Pivot shaft nut 100 N m 10 kgf m 74 lb ft T R T R ...

Page 277: ... VALVES AND VALVE GUIDES 5 19 CHECKING THE VALVE SEATS 5 21 CHECKING THE VALVE SPRINGS 5 22 CHECKING THE VALVE LIFTERS 5 23 INSTALLING THE VALVES 5 23 CYLINDER AND PISTONS 5 25 REMOVING THE PISTON 5 26 CHECKING THE CYLINDERS AND PISTONS 5 26 CHECKING THE PISTON RINGS 5 27 CHECKING THE PISTON PINS 5 28 INSTALLING THE PISTON AND CYLINDER 5 28 ELECTRIC STARTER 5 30 CHECKING THE STARTER MOTOR 5 32 ASS...

Page 278: ...CH PLATES 5 55 CHECKING THE CLUTCH DAMPER SPRINGS 5 55 CHECKING THE CLUTCH SPRING PLATE 5 55 CHECKING THE CLUTCH SPRINGS 5 56 CHECKING THE CLUTCH HOUSING 5 56 CHECKING THE CLUTCH BOSS 5 56 CHECKING THE PRESSURE PLATE AND THRUST PLATE 5 56 ASSEMBLING THE CLUTCH 5 56 INSTALLING THE CLUTCH 5 58 OIL PUMP 5 59 CHECKING THE OIL PUMP 5 61 CHECKING THE RELIEF VALVE 5 61 CHECKING THE OIL PIPES 5 61 CHECKIN...

Page 279: ...INSTALLING THE CONNECTING RODS 5 73 INSTALLING THE CRANKSHAFT ASSEMBLY 5 75 TRANSMISSION 5 77 CHECKING THE TRANSMISSION 5 78 ...

Page 280: ...ank the engine until the reading on the compression gauge stabilizes TIP The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 kgf cm 14 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the min imum specific...

Page 281: ... page 4 1 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Exhaust assembly 1 4 Gasket 2 5 Front muffler protector 1 6 Muffler protector 1 7 Muffler end 1 8 Muffler end bracket 1 FWD FWD 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 8 N m 0 8 kgf m 5 9 lb ft 8 N m 0 8 kgf m 5 9 lb ft 20 N m 2 0 kgf m 15 lb ft 25 N m 2 5 kgf m 18 lb ft 31 N m 3 1 kgf m 23 lb ft 1 3 4 5 6 7 8 LT 2 LT LT LT ...

Page 282: ...at assem bly Storage box Refer to GENERAL CHASSIS 2 on page 4 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 27 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 Exhaust assembly Refer to ENGINE REMOVAL on page 5 2 Fuel tank Rollover valve Refer to FUEL TANK on page 7 1 Front wheel Refer to FRONT WHEEL on page 4 22 Front fender Refer to FRONT FORK on page 4 87 Rear wheel Ref...

Page 283: ...ge 5 34 Oil cooler outlet hose Refer to OIL COOLER on page 6 5 Cooling system air bleed hose Thermostat out let hose Refer to THERMOSTAT on page 6 7 1 Spark plug cap 2 Disconnect 2 Sidestand switch coupler 1 Disconnect 3 Centerstand lock solenoid coupler 1 Disconnect 4 Stator coil coupler 1 Disconnect 5 Crankshaft position sensor coupler 1 Disconnect 6 Starter motor lead 1 Disconnect 7 Coolant tem...

Page 284: ...r side 1 5 Rear frame 2 6 Engine mounting bolt front left lower side 2 7 Sidestand 1 8 Engine mounting bolt front right lower side 1 9 Engine mounting bolt front upper side 2 10 Engine 1 FWD FWD 77 N m 7 7 kgf m 57 lb ft 78 N m 7 8 kgf m 58 lb ft 70 N m 7 0 kgf m 52 lb ft 83 N m 8 3 kgf m 61 lb ft 105 N m 10 5 kgf m 77 lb ft 1 2 2 3 4 5 6 6 7 8 9 9 10 LT LT LT LT LT LT ...

Page 285: ...nut rear side 4 Rear frame bolts 5 TIP When tightening the engine mounting nuts and engine mounting bolts do not apply an upward load to the frame such as supporting the area around steering head of the frame upwards Al so do not apply an upward or downward load on the rear frame such as supporting the rear end of the rear frame upwards or pushing it down wards Engine mounting bolt front up per si...

Page 286: ...CHANGING THE ENGINE OIL on page 3 27 Air filter case Refer to THROTTLE BODY on page 7 5 1 Spark plug cap 2 Disconnect 2 Spark plug 2 3 Cylinder head breather hose 1 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Dowel pin 2 7 Gasket 2 8 Timing chain guide upper side 1 10 N m 1 0 kgf m 7 4 lb ft 13 N m 1 3 kgf m 9 6 lb ft ...

Page 287: ...AFTS on page 5 7 1 Timing mark accessing plug 1 2 Timing chain tensioner rod accessing plug 1 3 Timing chain tensioner 1 4 Timing chain tensioner gasket 1 5 Intake camshaft cap 1 6 Exhaust camshaft cap 1 7 Dowel pin 4 TIP During removal the dowel pins may still be connected to the camshaft caps 8 Intake camshaft 1 9 Exhaust camshaft 1 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 ...

Page 288: ...he piston is at TDC the alignment marks c on the intake camshaft sprocket and the alignment marks d on the exhaust camshaft sprocket must align with the cylinder head mating surface as shown in the illustration 2 Remove Timing chain tensioner 1 Timing chain tensioner gasket 3 Remove Intake camshaft cap 1 Exhaust camshaft cap 2 Dowel pins NOTICE ECA13720 To prevent damage to the cylinder head camsh...

Page 289: ...ap tempo rarily to lower the entire cap while paying at tention not to twist the dowel pins and camshaft journal After the camshaft cap touches the cyl inder head tighten the two bolts in the middle to the specified torque and then the remaining four bolts to the specified torque To prevent the camshaft cap from cracking tighten the camshaft cap carefully by tapping the camshaft using a soft face ...

Page 290: ... a set EAS30265 CHECKING THE TIMING CHAIN GUIDES 1 Check Timing chain guide intake side 1 Timing chain guide exhaust side 2 Timing chain guide upper side 3 Damage wear Replace the defective part s EAS30266 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage Replace a Push the timing chain tensioner rod 1 into the timing chain tensioner housing by hand TIP While pushing...

Page 291: ...on the compres sion stroke align the I mark a on the gen erator rotor with the stationary pointer b on the generator cover c Install the timing chain onto both camshaft sprockets and then install the camshafts onto the cylinder head TIP Lubricate the camshaft journal with the molyb denum disulfide oil When installing the timing chain start with the exhaust camshaft and be sure to keep the tim ing ...

Page 292: ...t to twist the dowel pins and camshaft journal After the camshaft cap touches the cyl inder head tighten the two bolts in the middle to the specified torque and then the remaining four bolts to the specified torque To prevent the camshaft cap from cracking tighten the camshaft cap carefully by tapping the camshaft using a soft face hammer both for temporary and final tightening 4 Install Timing ch...

Page 293: ...head mating surface Out of alignment Correct Refer to the installation steps above 7 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 8 Install Timing chain guide upper side Gaskets to the cylinder head cover TIP Apply Yamaha bond No 1215 1 onto the mat ing surfaces of the cylinder head cover and gas kets 9 Install Cylinder head cover gasket C...

Page 294: ...to ENGINE REMOVAL on page 5 2 Thermostat Refer to THERMOSTAT on page 6 7 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Gasket 1 4 Cylinder head 1 5 Cylinder head gasket 1 6 Dowel pin 2 10 N m 1 0 kgf m 7 4 lb ft 1st 3rd 2nd 10 N m 1 0 kgf m 7 4 lb ft 20 N m 2 0 kgf m 15 lb ft Specified angle 120 1 2 3 4 5 6 6 15 N m 1 5 kgf m 11 lb ft ...

Page 295: ...inate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern TIP To ensure an even su...

Page 296: ... nuts cylinder head bolts and cylinder bolt when the cylinder head and cylinder are cold Use three steps to tighten the cylinder head nuts 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 12 Cylinder head nut 1st 10 N m 1 0 kgf m 7 4 lb ft 2nd 20 N m 2 0 kgf m 15 lb ft 3rd 120 Cylinder head bolt 10 N m 1 0 kgf m 7 4 lb ft Cylinder bolt 10 N m 1 0 kgf m 7 4 lb ...

Page 297: ...springs Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 15 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve spring retainer 8 5 Valve spring 8 6 Intake valve 4 7 Exhaust valve 4 8 Valve stem seal 8 9 Valve spring seat 8 10 Valve guide 8 S M E M E M M ...

Page 298: ...e intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Identify the position ...

Page 299: ...lve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear an...

Page 300: ...ylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width TIP Where the valve seat and valve face contacted one another the blue layout fluid will have b...

Page 301: ... forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply blue layout fluid b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres ...

Page 302: ...ocedure 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 3 Install Valve spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 into the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitc...

Page 303: ...Lubricate Valve lifter with the recommended lubricant 8 Install Valve pad Valve lifter NOTICE ECA22150 After making sure that the valve pads are ful ly inserted install the valve lifter taking care so that the pads do not fall TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position b Smaller pitch Valve sprin...

Page 304: ... Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 15 1 Coolant hose 1 Disconnect 2 Timing chain guide exhaust side 1 3 Cylinder 1 4 Cylinder gasket 1 5 Dowel pin 2 6 Piston pin clip 4 7 Piston pin 2 8 Piston 2 9 Top ring 2 10 2nd ring 2 11 Oil ring 2 10 N m 1 0 kgf m 7 4 lb ft 1 2 3 4 5 5 6 6 7 8 9 10 11 ...

Page 305: ...h the piston pin puller set 4 2 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS30291 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder piston and piston ring...

Page 306: ...level the piston ring near the bottom of the cylinder where the cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring set TIP The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings b 9 0 mm 0 35 in from the bottom edge of the piston Piston Diameter 67 975 67 990 mm 2 6762 2 6768 ...

Page 307: ...lowing procedure applies to all of the pis tons and cylinders 1 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 into the piston TIP Be sure to install the top and 2nd rings so that the manufacturer marks or numbers a face up 2 Install Piston 1 Piston pin 2 Piston pin clips 3 TIP Apply engine oil onto the piston pin a Bottom of cylinder b Upper of cylin...

Page 308: ...e piston as shown in the illustration 3 Install Dowel pins Cylinder gasket 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant 5 Offset Piston ring end gaps 6 Install Cylinder Cylinder bolt TIP While compressing the piston rings install the cylinder Pass the timing chain and timing chain guide intake side through the timing chain cavity 7 Tighten Cylinder bolt Recommended lubri...

Page 309: ...ide panel Bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 FWD FWD 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 2 ...

Page 310: ...ter motor yoke insulator and starter motor rear cover replace the starter motor assembly Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Armature assembly 1 3 Starter motor yoke 1 4 O ring 2 5 Brush holder set 1 6 Insulator 1 7 Starter motor rear cover 1 11 N m 1 1 kgf m 8 1 lb ft 5 N m 0 5 kgf m 3 7 lb ft ...

Page 311: ...easure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor assembly 4 Measure Brush length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of specification Replace the brush holder set Mica undercut depth 0 70 mm 0 03 in Digital circuit tester CD732 90890 03243 Model 88 Multime...

Page 312: ...2 Install Starter motor yoke 1 Starter motor rear cover 2 Starter motor front cover 3 TIP Align the match mark a on the starter motor rear cover with the match mark b on the start er motor yoke Align the match mark c on the starter motor yoke with the match mark d on the starter mo tor front cover EAS30327 INSTALLING THE STARTER MOTOR 1 Install Starter motor 1 Starter motor lead 2 TIP Connect the ...

Page 313: ...GENERAL CHASSIS 2 on page 4 11 1 Crankshaft end access cover 1 2 Damper 1 3 V belt case air filter case cover 1 4 O2 sensor lead 1 5 V belt case air filter case 1 6 V belt case air filter element right 1 7 Outer V belt case 1 8 Outer V belt case gasket 1 9 Bearing retainer 1 10 Bearing 1 11 Circlip 1 12 Oil seal 1 13 Bearing 1 FWD FWD S S LT S 3 2 4 6 3 1 2 3 4 5 6 7 8 9 10 11 12 13 7 N m 0 7 kgf ...

Page 314: ...ly 1 5 Secondary sheave nut 1 6 Secondary sheave assembly 1 7 V belt 1 8 Primary fixed sheave 1 9 V belt case air duct joint clamp 1 Loosen 10 V belt case air duct 1 11 Inner V belt case plate 1 12 Inner V belt case 1 13 Dowel pin 2 14 Plate 1 15 Inner V belt case seal 1 FWD FWD 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 13 18 N m 1 8 kgf m 13 lb ft 24 N m 2 4 kgf m 18 lb ft 90 N m 9 0 kgf m 66 lb ft 1...

Page 315: ...heave 1 Apply YAMAHA GREASE H Polyurea Grease 2 When replacing the primary sliding sheave or collar replace them as a set Order Job Parts to remove Q ty Remarks 1 Cam 1 2 Slider 8 3 Primary sheave weight 8 4 Primary sliding sheave 1 5 Collar 1 6 Oil seal 2 FWD FWD ...

Page 316: ...ase Order Job Parts to remove Q ty Remarks 1 Secondary sheave spring seat nut 1 2 Upper spring seat 1 3 Secondary sheave compression spring 1 4 Spring seat 1 5 Guide pin 6 6 Secondary sliding sheave 1 7 O ring 2 8 Oil seal 2 9 Secondary fixed sheave 1 1 2 3 4 5 6 7 8 8 9 90 N m 9 0 kgf m 66 lb ft FWD FWD ...

Page 317: ... with the sheave holder 3 loosen the second ary sheave spring seat nut with the locknut wrench 4 Do not loosen the secondary sheave spring seat nut 1 more than 1 4 turn 2 Remove Secondary sheave spring seat nut 1 TIP Install the sheave spring compressor 2 and sheave fixed block 3 onto the secondary sheave assembly as shown Then compress the spring and remove the secondary sheave spring seat nut wi...

Page 318: ...o all of the pri mary sheave weights 1 Check Primary sheave weight Cracks damage wear Replace 2 Measure Primary sheave weight outside diameter Out of specification Replace EAS30318 CHECKING THE SLIDERS The following procedure applies to all of the slid ers 1 Check Slider Cracks damage wear Replace EAS30319 CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixed sheave Secondary sliding sheave Cracks...

Page 319: ...eave inner surface 2 Oil seals with the recommended lubricant 2 Install Guide pins TIP Before installing the guide pin align the position where fixed sheave rivet head a and guide pin hole b are in alignment with each other with alignment mark c of the sliding sheave Install the guide pin Then make sure that the sliding sheave slides to the LOW side without an inter ference of rivet head d 3 Lubri...

Page 320: ...ave 2 with the sheave holder 3 tighten the second ary sheave spring seat nut 1 with the locknut wrench 4 EAS31437 INSTALLING THE PRIMARY SHEAVE ASSEMBLY SECONDARY SHEAVE ASSEMBLY AND V BELT 1 Apply Sealant onto the inner V belt case seal 2 Install V belt case air duct joint clamp 1 V belt case air duct 2 Sheave spring compressor 90890 04134 Sheave spring compressor YM 04134 Sheave fixed block 9089...

Page 321: ...bly then pass the V belt the primary sheave side Align the a and b during reassembly 4 Tighten Secondary sheave nut 1 TIP While holding the secondary sheave with the sheave holder 2 tighten the secondary sheave nut 5 Tighten Primary sheave nut 1 NOTICE ECA22200 Before tightening the nut to remount the primary sheave make sure that the serra tions of the cam are fitted firmly into the serrations of...

Page 322: ...h 10 g 0 35 oz or more of lithium soap based grease 3 Install Bearing retainer 1 TIP Install the bearing retainer 1 with its mark a facing outward Apply locking agent LOCTITE to the threads of the bearing retainer screw Installed depth of oil seal a 4 0 4 3 mm 0 16 0 17 in V belt case bearing retainer screw 11 N m 1 1 kgf m 8 1 lb ft LOCTITE 1 2 New 1 a b T R 1 a ...

Page 323: ...page 4 1 Center cover Fuel tank cover assembly Side cover left Footboard left Refer to GENERAL CHASSIS 2 on page 4 11 V belt case air filter element left Generator cover protector Water pump inlet pipe Water pump outlet pipe Water pump assembly Refer to WATER PUMP on page 6 9 1 Centerstand lock solenoid coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Stator coil coupler 1 ...

Page 324: ... pin 2 7 Starter clutch idle gear shaft 1 8 Starter clutch idle gear 1 9 Generator rotor nut 1 10 Spacer 1 11 Generator rotor 1 12 Woodruff key 1 13 Washer 1 14 Starter clutch gear 1 15 Starter clutch 1 E E E 13 15 5 6 7 8 6 11 12 10 9 3 17 14 E LT E 32 N m 3 2 kgf m 24 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1st 2nd 65 N m 6 5 kgf m 48 lb ft Specified angle 120 ...

Page 325: ...hem as a set Order Job Parts to remove Q ty Remarks 1 Oil tank 1 2 Oil tank gasket 1 3 Dowel pin 2 4 Oil strainer 1 5 Crankshaft position sensor 1 6 Stator coil 1 7 Bearing cover 1 8 Oil seal 1 9 Bearing 1 10 Bearing 1 LT LT 7 2 3 3 5 10 6 3 8 9 4 7 E 3 1 2 LT E 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft ...

Page 326: ...r rotor 1 with the flywheel puller 2 Woodruff key TIP Make sure the flywheel puller is centered over the generator rotor EAS30868 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Starter clutch TIP While holding the generator rotor 2 with the sheave holder 3 remove the starter clutch bolts Do not allow the sheave holder to touch the projection on the generator rotor EAS30869 CHECKING TH...

Page 327: ... When turning the starter clutch gear clock wise B it should turn freely otherwise the starter clutch is faulty and must be replaced EAS31439 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with solvent EAS31440 ASSEMBLING THE OIL TANK 1 Install Bearing TIP Seal a is adhered only on one side of the bear ing Note the press in orientation EAS30871 INSTALLING THE STAR...

Page 328: ...tor rotor 2 with the sheave holder 3 tighten the generator rotor nut Do not allow the sheave holder to touch the projection on the generator rotor TIP When tightening the generator rotor nut be sure to use a beam type torque wrench Tighten the nut until it is at the specified angle 3 Apply Sealant onto the crankshaft position sensor stator lead grommet 4 Install Generator cover Generator rotor nut...

Page 329: ...GENERATOR AND STARTER CLUTCH 5 50 TIP Tighten the generator cover bolts in stages and in a crisscross pattern ...

Page 330: ...NERAL CHASSIS 2 on page 4 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 27 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 V belt case air filter element left Generator cover protector Water pump inlet pipe Water pump outlet pipe Water pump assembly Refer to WATER PUMP on page 6 9 Generator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 44 1 Clutch assembly nut 1 2...

Page 331: ...late 1 4 Pressure plate 1 5 Clutch plate 2 2 6 Clutch damper spring 7 7 Friction plate 6 8 Clutch plate 1 5 9 Clutch spring 6 10 Thrust plate 1 11 Clutch boss nut 1 12 Primary drive gear 1 13 Bearing 2 14 Clutch boss 1 15 Collar 1 1 2 3 4 5 5 6 6 6 6 6 6 6 7 7 7 7 7 7 8 9 6 10 11 12 13 14 15 E 8 8 8 8 130 N m 13 kgf m 96 lb ft ...

Page 332: ...CLUTCH 5 53 Disassembling the clutch Order Job Parts to remove Q ty Remarks 16 Thrust plate 1 17 Clutch weight 12 18 Clutch housing 1 130 N m 13 kgf m 96 lb ft 16 17 12 18 E ...

Page 333: ...r plate 1 TIP To ensure proper balance of the clutch assem bly one to three holes a or no hole at all may have been drilled in the spring stopper plate Be fore removing the spring stopper plate make alignment marks on both the plate and the clutch housing so that the plate can be reinstalled in its original position 3 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal...

Page 334: ...tch plates as a set EAS31442 CHECKING THE CLUTCH DAMPER SPRINGS The following procedure applies to all of the clutch damper springs 1 Check Clutch damper spring Damage Replace 2 Measure Clutch damper spring free height a Out of specification Replace the clutch damper springs as a set EAS30350 CHECKING THE CLUTCH SPRING PLATE 1 Check Clutch spring plate Damage Replace 2 Measure Clutch spring plate ...

Page 335: ...using dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation EAS30353 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAS31443 CHECKING THE PRESSURE PLATE AND THRUST PLATE 1 Check Pressure plate 1 Thrust plate 2 Cracks ...

Page 336: ...s 1 5 Pressure plate 6 Clutch spring plate 7 TIP Clutch damper spring a installed at the end must be installed backwards The pressure plate 6 and thrust plate 1 can be identified by punch mark b on the pressure plate 4 Install Clip 1 TIP While compressing the clutch springs with the clutch spring compressor 2 install the clip Clutch boss nut 130 N m 13 kgf m 96 lb ft Universal clutch holder 90890 ...

Page 337: ...bly nut 2 TIP Align the a and b during reassembly While holding the clutch assembly with the ro tor holding tool 3 tighten the clutch assembly nut Clutch assembly nut 65 N m 6 5 kgf m 48 lb ft Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 T R 2 1 a b 1 3 2 ...

Page 338: ...RAL CHASSIS 2 on page 4 11 V belt case air filter element left Generator cover protector Water pump inlet pipe Water pump outlet pipe Water pump assembly Refer to WATER PUMP on page 6 9 Generator cover Generator rotor Starter clutch gear Refer to GENERATOR AND STARTER CLUTCH on page 5 44 1 Oil pump assembly 1 2 Oil pump drive chain 1 3 Gasket 2 4 Oil delivery pipe 1 5 Oil pipe 1 6 Relief valve ass...

Page 339: ...rks 1 Oil pump housing 1 1 2 Dowel pin 2 3 Oil pump outer rotor 1 1 4 Oil pump inner rotor 1 1 5 Pin 1 6 Washer 1 7 Oil pump housing center 1 8 Oil pump outer rotor 2 1 9 Oil pump inner rotor 2 1 10 Pin 1 11 Oil pump driven gear 1 12 Oil pump housing 2 1 1 2 3 4 5 6 7 8 9 10 11 12 E E E FWD FWD 6 N m 0 6 kgf m 4 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft ...

Page 340: ...CHECKING THE OIL PUMP DRIVE CHAIN 1 Check Oil pump drive chain Cracks stiffness Replace the oil pump chain and oil pump assembly as a set EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Inner rotors TIP When installing the inner rotor align the pins 1 in the oil pump shaft with the grooves a in the inner rotor 3 Check Oil...

Page 341: ...age 6 9 Generator cover Generator rotor Starter clutch gear Refer to GENERATOR AND STARTER CLUTCH on page 5 44 Clutch assembly Refer to CLUTCH on page 5 51 Oil pump assembly Refer to OIL PUMP on page 5 59 Outer V belt case Primary sheave assem bly Secondary sheave assembly Inner V belt case Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 34 Bearing housing Refer to SWINGARM on page 4 106 4 4 6 6...

Page 342: ...ake side 1 4 Crankcase left 1 5 Dowel pin 2 6 Oil strainer 1 7 Crankcase right 1 8 Centerstand lock solenoid cover 1 9 Centerstand lock solenoid 1 4 4 6 6 8 5 2 1 2 3 4 5 6 7 8 9 LT 5 LT LT 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 24 N m 2 4 kgf m 18 lb ft 43 N m 4 3 kgf m 32 lb ft 55 N m 5 5 kgf m 41 lb ft ...

Page 343: ...e oil seals and bearings Order Job Parts to remove Q ty Remarks Crankshaft assembly Refer to CRANKSHAFT on page 5 67 Transmission Refer to TRANSMISSION on page 5 77 1 Bearing retainer 2 2 Oil seal 2 3 Bearing 5 1 2 2 3 3 3 3 E E ...

Page 344: ...ean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS31445 CHECKING THE TIMING CHAIN 1 Check Timing chain Damage stiffness Replace the timing chain camshafts and crankshaft assembly as a set EAS30397 ASSEMBLING THE CRANKCASE 1 Install Cylinder stud bolts 1 TIP For the cylinder stud bolt e...

Page 345: ...g es and in a crisscross pattern M8 120 mm 4 72 in bolts 1 M8 110 mm 4 33 in bolts 2 M6 50 mm 1 97 in bolts 3 M6 35 mm 1 38 in bolts 4 6 Check Crankshaft and transmission operation Rough movement Repair Crankcase bolt M8 10 N m 1 0 kgf m 7 4 lb ft Crankcase bolt M6 24 N m 2 4 kgf m 18 lb ft T R 4 4 3 3 3 3 2 2 2 2 1 ...

Page 346: ... Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 62 1 Dowel pin 2 2 Balancer cylinder 1 3 Crankshaft assembly 1 4 Oil seal 1 5 Crankshaft journal bearing 2 1 2 3 4 4 5 5 E E E E E LT 1st 2nd 16 N m 1 6 kgf m 12 lb ft 58 N m 5 8 kgf m 43 lb ft ...

Page 347: ...pin clip 2 6 Balancer piston pin 1 7 Balancer piston 1 8 Balancer connecting rod cap 1 9 Balancer big end lower bearing 1 10 Balancer connecting rod 1 11 Balancer big end upper bearing 1 M M M M E E E E E E E E M M M M M E 60 N m 6 0 kgf m 44 lb ft 1st 2nd 16 N m 1 6 kgf m 12 lb ft Specified angle 90 1st 2nd 16 N m 1 6 kgf m 12 lb ft Specified angle 90 1 1 2 2 3 3 4 4 5 5 6 7 8 9 10 11 ...

Page 348: ... Remove Crankshaft assembly Crankshaft journal bearing 1 TIP Remove the crankshaft journal bearing using the plane bearing installer 2 TIP Identify the position of each crankshaft journal bearing so that it can be reinstalled in its original place EAS30423 CHECKING THE CRANKSHAFT AND CONNECTING RODS 1 Measure Crankshaft runout Out of specification Replace the crank shaft 2 Check Crankshaft journal...

Page 349: ... a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves TIP Do not move the connecting rod or crankshaft until the clearance measurement has been completed Lubricate the bolts threads and nut seats with molybdenum disulfide grease Make sure the Y mark c on the connecting rod faces towards the left side of the crank shaft Make sure the characters d on both the con nect...

Page 350: ...f the crankshaft journal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original positions a Clean the crankshaft journal bearings crank shaft journals and bearing portions of the crankcase b Check the b...

Page 351: ... into the crank shaft web the number B on the left crank case and the number C on the right crankcase The numbers A B and C are used to de termine the replacement crankshaft journal bearing size J1 J2 refer to the bearings shown in the crank shaft illustration For example if the crankcase J1 and the crankshaft web J1 numbers are 4 and 2 re spectively then the bearing size for J1 is Crankshaft jour...

Page 352: ...reads Nut seats with the recommended lubricant 2 Lubricate Crankshaft pins Big end bearings inner surface Balancer big end bearings inner surface with the recommended lubricant 3 Install Big end bearings Connecting rods Connecting rod caps onto the crankshaft pins TIP Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reins...

Page 353: ...with a new one and perform the procedure again NOTICE ECA19930 Do not use a torque wrench to tighten the connecting rod nut to the specified angle Tighten the nut until it is at the specified an gle TIP On a hexagonal nut note that the angle from one corner to another is 60 5 Install Balancer big end bearings Balancer connecting rod Balancer connecting rod cap onto the crankshaft pin TIP Align the...

Page 354: ...alancer piston pin Piston pin clip 2 TIP Apply engine oil onto the balancer piston pin Make sure that the clip ends a are positioned away from the cutout b in the balancer piston as shown in the illustration EAS30428 INSTALLING THE CRANKSHAFT ASSEMBLY 1 Install Crankshaft assembly 1 Balancer cylinder 2 Balancer cylinder bolt NOTICE ECA13970 To avoid scratching the crankshaft and to ease the instal...

Page 355: ...CRANKSHAFT 5 76 2 1 2 4 3 ...

Page 356: ... the transmission Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 62 1 Secondary shaft 1 2 Collar 1 3 Primary driven gear 1 4 Main axle 1 5 1st pinion gear 1 6 Drive axle 1 7 1st wheel gear 1 8 Circlip 1 E 3 4 5 ...

Page 357: ...ve part s 3 Check Main axle Cracks damage wear Replace the main axle 4 Measure Drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle 5 Measure Secondary shaft runout with a centering device and dial gauge Out of specification Replace the second ary shaft Drive axle runout limit 0 08 mm 0 0032 in Secondary shaft runout limit 0 12 mm 0 0047 in ...

Page 358: ...TRANSMISSION 5 79 ...

Page 359: ...6 3 OIL COOLER 6 5 CHECKING THE OIL COOLER 6 6 INSTALLING THE OIL COOLER 6 6 THERMOSTAT 6 7 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT ASSEMBLY 6 8 WATER PUMP 6 9 DISASSEMBLING THE WATER PUMP 6 11 CHECKING THE WATER PUMP 6 11 ASSEMBLING THE WATER PUMP 6 11 INSTALLING THE WATER PUMP 6 12 ...

Page 360: ...AL CHASSIS 2 on page 4 11 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 1 Coolant reservoir hose 1 2 Coolant reservoir 1 3 Coolant reservoir cap 1 4 Coolant reservoir breather hose 1 5 Radiator cap 1 TIP Remove Install it with the radiator filler pipe held 6 Cooling system air bleed hose 1 Disconnect FWD FWD LT 1 1 2 3 4 5 6 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 13 N m 1 3...

Page 361: ... Disconnect 10 Radiator inlet hose 1 11 Radiator fan motor coupler 1 Disconnect 12 Radiator 1 13 Radiator fan 1 14 Radiator bracket 1 FWD FWD LT 7 8 9 10 11 12 13 14 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 13 N m 1 3 kgf m 9 6 lb ft 13 N m 1 3 kgf m 9 6 lb ft 8 N m 0 8 kgf m 5 9 lb ft 9 N m 0 9 kgf m 6 6 lb ft 13 N m 1 3 kgf m 9 6 lb ft ...

Page 362: ...lace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 47 EAS30440 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 31 2 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator b Apply 137 3 kPa 1 37 kgf cm...

Page 363: ...RADIATOR 6 4 pressure c Measure the indicated pressure with the gauge ...

Page 364: ... Fuel tank cover assembly Side cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 27 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 1 Oil filter cartridge 1 2 Oil cooler inlet hose 1 3 Oil cooler outlet hose 1 4 Oil filter cartridge union bolt 1 5 Oil cooler 1 6 Gasket 1 1 2 3 5 6 FWD FWD 4 17 N m 1 7 kgf m 13 lb ft 40 N m ...

Page 365: ... cartridge Refer to CHANGING THE ENGINE OIL on page 3 27 4 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 31 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 27 5 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 3 6 M...

Page 366: ... cover assembly Side cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 1 Cooling system air bleed hose 1 Disconnect 2 Thermostat outlet hose 1 Disconnect 3 Thermostat cover 1 4 Thermostat 1 5 Radiator fan motor coupler 1 6 Coolant pipe 1 10 N m 1 0 kgf m 7 4 lb ft 7 N m 0 7 kgf m 5 2 lb ft 1 2 3...

Page 367: ... cause serious overheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat TIP Install the thermostat with its breather hole a facing forward 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 31 3 Check Cooling system Leaks Repair or replace any faulty pa...

Page 368: ...t Drain Refer to CHANGING THE COOLANT on page 3 31 1 V belt case air filter element joint clamp 1 Loosen 2 V belt case air filter element left 1 3 Oil filler cap 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 10 Water pump assembly 1 7 5 3 M S 4 9 10 6 8 2 1 3 ...

Page 369: ...g the water pump Order Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 Circlip 1 3 Impeller shaft 1 4 Mechanical seal 1 5 Bearing 1 6 Oil seal 1 7 Water pump housing 1 1 2 2 3 4 5 6 7 M E 10 N m 1 0 kgf m 7 4 lb ft ...

Page 370: ...HE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 2 Impeller shaft 3 Cracks damage wear Replace 2 Check Water pump inlet pipe Water pump outlet pipe Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the water pump housing TIP Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a...

Page 371: ...eal impeller side that contacts the mechanical seal housing side is dirty clean it EAS30449 INSTALLING THE WATER PUMP 1 Install O ring Water pump assembly TIP Align the slit a on the impeller shaft with the projection b on the oil pump shaft Lubricate the O ring with a thin coat of lithium soap based grease 2 Fill Cooling system with the specified amount of the recom mended coolant Mechanical seal...

Page 372: ...3 31 3 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 3 4 Measure Radiator cap valve opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 373: ...HE FUEL TANK 7 4 THROTTLE BODY 7 5 CHECKING THE INJECTORS BEFORE REMOVING 7 9 REMOVING THE FUEL HOSE FUEL RAIL SIDE 7 9 REMOVING THE INJECTORS 7 9 CHECKING THE INJECTORS 7 9 CHECKING AND CLEANING THE THROTTLE BODIES 7 9 REPLACING THE THROTTLE BODIES 7 11 INSTALLING THE INJECTORS 7 11 CHECKING THE INJECTOR PRESSURE 7 11 CHECKING THE FUEL PRESSURE 7 12 INSTALLING THE FUEL HOSE FUEL RAIL SIDE 7 13 AD...

Page 374: ...er Footboard Refer to GENERAL CHASSIS 2 on page 4 11 1 Fuel tank overflow hose 1 2 Fuel tank breather hose 1 Disconnect 3 Fuel pump coupler 1 Disconnect 4 Fuel hose connector 1 Disconnect 5 Fuel tank 1 6 Fuel pump bracket 1 7 Fuel pump 1 8 Fuel pump gasket 1 9 Fuel tank cap 1 10 Filler cover 1 FWD FWD 1 2 3 4 5 6 7 8 9 10 4 0 N m 0 40 kgf m 3 0 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4...

Page 375: ...ssembly Side cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 1 Canister breather hose 1 2 Canister purge hose hose joint to canister 1 3 Fuel tank breather hose rollover valve to canis ter 1 4 Rollover valve 1 5 Fuel tank breather hose fuel tank to rollover valve 1 6 Canister bracket 1 7 Canister holder 1 8 Canister 1 FWD FWD 7 N m 0 7 kgf m 5 2 lb ...

Page 376: ... of the connector and then remove the hose Before removing the hose place a few rags in the area under where it will be removed It is prohibited to wear the cotton work gloves or equivalent coverings 4 Remove Fuel tank TIP Do not set the fuel tank down so that the instal lation surface of the fuel pump is directly under the tank Be sure to lean the fuel tank in an up right position EAS30451 REMOVI...

Page 377: ...ing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel pump until a distinct click is heard To install the fuel hose onto the fuel pump slide the fuel hose connector cover 1 on the end of the hose in the direct...

Page 378: ...ly Side cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 Throttle body assembly Refer to THROTTLE BODY on page 7 5 Front wheel Refer to FRONT WHEEL on page 4 22 Front fender Refer to FRONT FORK on page 4 87 1 Plate 1 2 Cylinder head breather hose 1 3 Air filter case joint clamp 2 Loosen 4 Air filter case cover 1 5 Air filter element 1 6 Air filter ca...

Page 379: ...el tank Refer to FUEL TANK on page 7 1 Air filter case Disconnect Refer to THROTTLE BODY on page 7 5 1 Throttle servo motor coupler 1 Disconnect 2 Throttle position sensor coupler 1 Disconnect 3 Throttle body joint clamp screw 4 Loosen 4 Throttle body assembly 1 5 Throttle body joint 2 6 Intake air pressure sensor coupler 1 Disconnect 7 Injector coupler 2 Disconnect 8 Intake air pressure sensor ho...

Page 380: ...er Job Parts to remove Q ty Remarks 10 Intake manifold 1 11 Gasket 2 12 Fuel hose 1 13 Fuel rail 1 14 Injector 2 FWD FWD 12 10 11 13 14 4 3 5 N m 0 35 kgf m 2 6 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft 14 N m 1 4 kgf m 10 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft ...

Page 381: ...THROTTLE BODY 7 8 Disassembling the throttle body assembly Order Job Parts to remove Q ty Remarks 1 Throttle position sensor 1 2 Canister purge hose 2 3 Hose joint 1 3 5 N m 0 35 kgf m 2 6 lb ft 1 2 3 ...

Page 382: ...well ventilated area free of combustible materials Make sure that there is no smoking or use of electric tools in the vicinity of the injectors Be careful when disconnecting the fuel hose Any remaining pressure in the fuel hose may cause the fuel to spray out Place a container or rag under the hose to catch any fuel that spills Always clean up any spilt fuel immediately Push the OFF LOCK switch an...

Page 383: ... fittings a c Hold the throttle valves in the open position WARNING EWA15940 When cleaning the throttle bodies be careful not to injure yourself on the throttle valves or other components of the throttle bodies NOTICE ECA20380 Do not open the throttle valves by supply ing electrical power to the throttle bodies Do not use tools to open the throttle valves or to keep them in the open position Do no...

Page 384: ...TLE BODIES on page 3 9 5 Place the vehicle on a maintenance stand so that the rear wheel is elevated 6 Check Engine idling speed Start the engine warm it up and then mea sure the engine idling speed EAS30480 INSTALLING THE INJECTORS NOTICE ECA21550 Always use new O rings When installing the injectors do not allow any foreign material to enter or adhere to the injectors fuel rails or O rings Be car...

Page 385: ...ove the bottom side cowling side panel and bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 b Remove the center cover fuel tank cover as sembly side cover and footboard Refer to GENERAL CHASSIS 2 on page 4 11 c Remove the fuel tank bolt and hold up the fuel tank d Disconnect the fuel hose 1 from the fuel pump Refer to REMOVING THE FUEL TANK on page 7 3 WARNING EWA17320 Cover fuel hose ...

Page 386: ...ensor to strong shocks If the throttle position sensor is dropped replace it 1 Check Throttle position sensor Refer to CHECKING THE THROTTLE PO SITION SENSOR on page 8 246 2 Adjust Throttle position sensor angle TIP Before adjusting the throttle position sensor the throttle bodies must be removed a Temporary tighten the throttle position sensor screws b Check that the throttle valves are fully clo...

Page 387: ...THROTTLE BODY 7 14 2 2 ...

Page 388: ...THROTTLE BODY 7 15 ...

Page 389: ...TROUBLESHOOTING 8 53 FUEL INJECTION SYSTEM 8 55 CIRCUIT DIAGRAM 8 55 ECU SELF DIAGNOSTIC FUNCTION 8 61 TROUBLESHOOTING METHOD 8 61 YAMAHA DIAGNOSTIC TOOL 8 62 TROUBLESHOOTING DETAILS FAULT CODE 8 63 CRUISE CONTROL SYSTEM for XP530D A 8 117 CIRCUIT DIAGRAM 8 117 CRUISE CONTROL CIRCUIT OPERATION 8 119 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 8 121 BASIC PROCESS FOR TROUBLESHOOTING 8 122 A CHECKING THE...

Page 390: ... 170 A 1 ONLY THE ABS WARNING LIGHT FAILS TO COME ON 8 170 A 2 ALL INDICATOR LIGHTS FAIL TO COME ON 8 170 A 3 THE ABS WARNING LIGHT COMES ON 8 170 A 4 ONLY THE ABS ECU FAILS TO COMMUNICATE The select unit screen does not appear 8 171 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE 8 171 B 1 MALFUNCTION ARE CURRENTLY DETECTED 8 171 B 2 DIAGNOSIS USING THE FAULT CODES 8 171 B 3 DELETING THE FAULT CODES 8...

Page 391: ...CHECKING THE FUEL SENDER 8 244 CHECKING THE FUEL METER FUEL LEVEL WARNING INDICATOR 8 244 CHECKING THE RADIATOR FAN MOTOR 8 245 CHECKING THE COOLANT TEMPERATURE SENSOR 8 245 CHECKING THE THROTTLE POSITION SENSOR 8 246 CHECKING THE ACCELERATOR POSITION SENSOR 8 246 CHECKING THE THROTTLE SERVO MOTOR 8 247 CHECKING THE WINDSHIELD DRIVE UNIT for XP530D A 8 247 CHECKING THE GRIP WARMERS for XP530D A 8 ...

Page 392: ...IGNITION SYSTEM 8 1 EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM XP530E A ...

Page 393: ...ry 17 Main fuse 19 Engine ground 21 Ignition fuse 45 Diode 1 46 Sidestand relay 47 Diode 2 49 Starting circuit cut off relay 50 Sidestand switch 51 Handlebar switch right 52 Engine stop switch 89 ECU Engine Control Unit 90 Ignition coil 91 Spark plug 98 Lean angle sensor A Wire harness B Negative battery sub wire harness ...

Page 394: ...IGNITION SYSTEM 8 3 XP530 A ...

Page 395: ...ry 17 Main fuse 19 Engine ground 21 Ignition fuse 45 Diode 1 46 Sidestand relay 47 Diode 2 49 Starting circuit cut off relay 50 Sidestand switch 51 Handlebar switch right 52 Engine stop switch 94 ECU Engine Control Unit 95 Ignition coil 96 Spark plug 103 Lean angle sensor A Wire harness B Negative battery sub wire harness ...

Page 396: ...IGNITION SYSTEM 8 5 XP530D A ...

Page 397: ...nition fuse 26 Diode fuse box 40 Headlight relay dimmer 46 Diode 1 47 Sidestand relay 48 Diode 2 50 Starting circuit cut off relay 51 Sidestand switch 52 Handlebar switch right 53 Engine stop switch 57 Brake light relay 85 Tracking system control unit 106 ECU Engine Control Unit 107 Ignition coil 108 Spark plug 115 Lean angle sensor A Wire harness B Negative battery sub wire harness ...

Page 398: ...ry OK 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 5 NG Re gap or replace the spark plugs OK 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 241 OK Ignition system is OK NG 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 240 NG Replace the spark plug caps OK 6 Check the ignition coil Refer to CHECKING THE IGNI TI...

Page 399: ... Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 221 NG The engine stop switch is faulty Replace the handlebar switch right OK 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 242 NG Replace the lean angle sensor OK 14 Check the crankshaft position sen sor Refer to CHECKING THE CRANK SHAFT POSITION SENSOR on page 8 242 NG Replace the stator coi...

Page 400: ...ELECTRIC STARTING SYSTEM 8 9 EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM XP530E A ...

Page 401: ... 20 Signaling system fuse 21 Ignition fuse 26 Diode fuse box 40 Headlight relay dimmer 46 Sidestand relay 47 Diode 2 49 Starting circuit cut off relay 50 Sidestand switch 51 Handlebar switch right 52 Engine stop switch 53 ON start switch 55 Front brake light switch 56 Handlebar switch left 62 Rear brake light switch A Wire harness B Negative battery sub wire harness ...

Page 402: ...ELECTRIC STARTING SYSTEM 8 11 XP530 A ...

Page 403: ... 20 Signaling system fuse 21 Ignition fuse 26 Diode fuse box 40 Headlight relay dimmer 46 Sidestand relay 47 Diode 2 49 Starting circuit cut off relay 50 Sidestand switch 51 Handlebar switch right 52 Engine stop switch 53 ON start switch 56 Front brake light switch 57 Handlebar switch left 63 Rear brake light switch A Wire harness B Negative battery sub wire harness ...

Page 404: ...ELECTRIC STARTING SYSTEM 8 13 XP530D A ...

Page 405: ...e 21 Ignition fuse 26 Diode fuse box 40 Headlight relay dimmer 47 Sidestand relay 48 Diode 2 50 Starting circuit cut off relay 51 Sidestand switch 52 Handlebar switch right 53 Engine stop switch 54 ON start switch 57 Brake light relay 75 Brake light fuse 76 Front brake light switch 77 Rear brake light switch 85 Tracking system control unit A Wire harness B Negative battery sub wire harness ...

Page 406: ...sed The rear brake lever is pulled to the handlebar the rear brake light switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the abov...

Page 407: ...rake light switch 8 Rear brake light switch 9 Diode fuse box 10 Starting circuit cut off relay 11 ON start switch 12 ECU Engine Control Unit 13 Fuel injection system relay 14 Diode 3 15 Engine stop switch 16 Fuel injection system fuse 17 Spark plug 18 Ignition coil 19 Diode 1 20 Sidestand switch 21 Sidestand relay 22 Starter relay 23 Starter motor ...

Page 408: ... START ER MOTOR OPERATION on page 8 243 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 NG 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 32 NG Repair or replace the starter motor OK 5 Check the ignition system relay Refer to CHECKING THE RE LAYS on page 8 233 NG Replace the ignition system relay OK 6 Check the diodes Diode...

Page 409: ...ge 8 221 NG Replace the front brake light switch OK 13 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 221 NG Replace the rear brake light switch OK 14 Check the ON start switch Refer to CHECKING THE SWITCHES on page 8 221 NG The ON start switch is faulty Replace the handlebar switch right OK 15 Check the start diodes Diode 1 and 3 and diode fuse box for XP530D A Refer t...

Page 410: ...CHARGING SYSTEM 8 19 EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM XP530E A ...

Page 411: ...CHARGING SYSTEM 8 20 4 Joint coupler 12 AC magneto 13 Rectifier regulator 15 Battery 17 Main fuse 19 Engine ground A Wire harness B Negative battery sub wire harness ...

Page 412: ...CHARGING SYSTEM 8 21 XP530 A ...

Page 413: ...CHARGING SYSTEM 8 22 4 Joint coupler 12 AC magneto 13 Rectifier regulator 15 Battery 17 Main fuse 19 Engine ground A Wire harness B Negative battery sub wire harness ...

Page 414: ...CHARGING SYSTEM 8 23 XP530D A ...

Page 415: ...CHARGING SYSTEM 8 24 4 Joint coupler 12 AC magneto 13 Rectifier regulator 15 Battery 17 Main fuse 19 Engine ground A Wire harness B Negative battery sub wire harness ...

Page 416: ...r to CHECKING AND CHARGING THE BATTERY on page 8 230 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 243 NG Replace the stator coil OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 243 NG Replace the rectifier regulator OK 5 Check the entire charging system s wiring Refer t...

Page 417: ...CHARGING SYSTEM 8 26 ...

Page 418: ...LIGHTING SYSTEM 8 27 EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM XP530E A ...

Page 419: ... 41 Headlight control unit 42 Headlight low 43 Headlight high 44 Auxiliary light 56 Handlebar switch left 57 Dimmer pass switch 67 License plate light 68 Tail brake light left 69 Tail brake light right 72 Smart key system relay unlock 75 Meter assembly 77 Meter light 84 High beam indicator light 86 Yamaha diagnostic tool coupler 89 ECU Engine Control Unit A Wire harness B Negative battery sub wire...

Page 420: ...LIGHTING SYSTEM 8 29 XP530 A ...

Page 421: ... 41 Headlight control unit 42 Headlight low 43 Headlight high 44 Auxiliary light 57 Handlebar switch left 58 Dimmer pass switch 68 License plate light 69 Tail brake light left 70 Tail brake light right 73 Smart key system relay unlock 77 Meter assembly 79 Meter light 86 High beam indicator light 91 Yamaha diagnostic tool coupler 94 ECU Engine Control Unit A Wire harness B Negative battery sub wire...

Page 422: ...LIGHTING SYSTEM 8 31 XP530D A ...

Page 423: ...42 Headlight control unit 43 Headlight low 44 Headlight high 45 Auxiliary light 58 Handlebar switch left 61 Dimmer pass switch 70 License plate light 71 Tail brake light left 72 Tail brake light right 79 Smart key system relay unlock 87 Meter assembly 89 Meter light 98 High beam indicator light 103 Yamaha diagnostic tool coupler 106 ECU Engine Control Unit A Wire harness B Negative battery sub wir...

Page 424: ...lace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 230 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the ignition system relay Refer to CHECKING THE RE LAYS on page 8 233 NG Replace the ignition system relay OK 5 Check the diode Diode 3 Refer to CHECKING THE DI ODES on page 8 239 NG Replace the diode OK 6 Check the dimmer switch ...

Page 425: ...HE SWITCHES on page 8 221 NG Replace the storage box light switch OK 10 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 8 27 NG Properly connect or replace the wire har ness OK Replace the ECU headlight assem bly remote control unit or meter as sembly ...

Page 426: ...SIGNALING SYSTEM 8 35 EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM XP530E A ...

Page 427: ...ht switch 63 Front turn signal light left 64 Front turn signal light right 65 Rear turn signal light left 66 Rear turn signal light right 68 Tail brake light left 69 Tail brake light right 70 Diode 5 71 Horn 75 Meter assembly 78 Tachometer 79 Engine trouble warning light 80 Traction control system indicator light 81 Turn signal indicator light left 82 Turn signal indicator light right 85 Multi fun...

Page 428: ...SIGNALING SYSTEM 8 37 XP530 A ...

Page 429: ...t switch 64 Front turn signal light left 65 Front turn signal light right 66 Rear turn signal light left 67 Rear turn signal light right 69 Tail brake light left 70 Tail brake light right 71 Diode 5 72 Horn 77 Meter assembly 80 Tachometer 81 Engine trouble warning light 82 Traction control system indicator light 83 Turn signal indicator light left 84 Turn signal indicator light right 87 Multi func...

Page 430: ...SIGNALING SYSTEM 8 39 XP530D A ...

Page 431: ...ht right 68 Rear turn signal light left 69 Rear turn signal light right 71 Tail brake light left 72 Tail brake light right 73 Diode 5 74 Horn 75 Brake light fuse 76 Front brake light switch 77 Rear brake light switch 85 Tracking system control unit 87 Meter assembly 90 Tachometer 91 Engine trouble warning light 92 Traction control system indicator light 93 Turn signal indicator light left 94 Turn ...

Page 432: ...x 3 Fuel tank 4 Footboards 5 Rear cowling right 1 Check the fuses Main signaling system ABS mo tor ABS solenoid ABS ECU and backup Refer to CHECKING THE FUSES on page 8 229 NG Replace the fuse s OK 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 230 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the ignition system relay Refer to CHECKING THE RE ...

Page 433: ...21 NG Replace the front brake light switch OK 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 221 NG Replace the rear brake light switch OK 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 35 NG Properly connect or replace the wire har ness OK Replace the tail brake light assembly or remote control unit 1 Check the turn signal switch Refe...

Page 434: ...e 8 35 NG Properly connect or replace the wire har ness OK Replace the meter assembly 1 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 245 NG Replace the coolant temperature sensor OK 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 35 NG Properly connect or replace the wire har ness OK Replace the ECU or meter assembl...

Page 435: ...o CHECKING THE CRANK SHAFT POSITION SENSOR on page 8 242 NG Replace the stator coil OK 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 35 NG Properly connect or replace the wire har ness OK Replace the ECU or meter assembly 1 Check the air temperature sensor Refer to CHECKING THE INTAKE AIR TEMPERATURE SENSOR on page 8 249 NG Replace the intake air temperature sen sor...

Page 436: ...RAM on page 8 35 NG Properly connect or replace the wire har ness OK Replace the meter assembly 1 Check the buzzer Refer to CHECKING THE BUZZ ER on page 8 250 NG Replace the buzzer OK 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 35 NG Properly connect or replace the wire har ness OK Replace the remote control unit or ECU ...

Page 437: ...SIGNALING SYSTEM 8 46 ...

Page 438: ...COOLING SYSTEM 8 47 EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM XP530E A ...

Page 439: ...9 Engine ground 21 Ignition fuse 23 Radiator fan motor fuse 25 Backup fuse 75 Meter assembly 85 Multi function display 86 Yamaha diagnostic tool coupler 87 Radiator fan motor 88 Radiator fan motor relay 89 ECU Engine Control Unit 95 Coolant temperature sensor A Wire harness B Negative battery sub wire harness ...

Page 440: ...COOLING SYSTEM 8 49 XP530 A ...

Page 441: ... Engine ground 21 Ignition fuse 23 Radiator fan motor fuse 25 Backup fuse 77 Meter assembly 87 Multi function display 91 Yamaha diagnostic tool coupler 92 Radiator fan motor 93 Radiator fan motor relay 94 ECU Engine Control Unit 100 Coolant temperature sensor A Wire harness B Negative battery sub wire harness ...

Page 442: ...COOLING SYSTEM 8 51 XP530D A ...

Page 443: ...ngine ground 21 Ignition fuse 23 Radiator fan motor fuse 25 Backup fuse 87 Meter assembly 99 Multi function display 103 Yamaha diagnostic tool coupler 104 Radiator fan motor 105 Radiator fan motor relay 106 ECU Engine Control Unit 112 Coolant temperature sensor A Wire harness B Negative battery sub wire harness ...

Page 444: ...he ignition system relay Refer to CHECKING THE RE LAYS on page 8 233 NG Replace the ignition system relay OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 245 NG Replace the radiator fan motor OK 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 233 NG Replace the radiator fan motor relay OK 6 Check the coolant temperature sen sor Ref...

Page 445: ...COOLING SYSTEM 8 54 ...

Page 446: ...FUEL INJECTION SYSTEM 8 55 EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM XP530E A ...

Page 447: ...g light 84 High beam indicator light 85 Multi function display 86 Yamaha diagnostic tool coupler 87 Radiator fan motor 88 Radiator fan motor relay 89 ECU Engine Control Unit 90 Ignition coil 91 Spark plug 92 Grip warmer connector 93 Grip warmer left OPTION 94 Grip warmer right OPTION 95 Coolant temperature sensor 96 Intake air temperature sensor 97 Intake air pressure sensor 98 Lean angle sensor 9...

Page 448: ...FUEL INJECTION SYSTEM 8 57 XP530 A ...

Page 449: ...light 86 High beam indicator light 87 Multi function display 91 Yamaha diagnostic tool coupler 92 Radiator fan motor 93 Radiator fan motor relay 94 ECU Engine Control Unit 95 Ignition coil 96 Spark plug 97 Grip warmer connector 98 Grip warmer left OPTION 99 Grip warmer right OPTION 100 Coolant temperature sensor 101 Intake air temperature sensor 102 Intake air pressure sensor 103 Lean angle sensor...

Page 450: ...FUEL INJECTION SYSTEM 8 59 XP530D A ...

Page 451: ...r assembly 91 Engine trouble warning light 98 High beam indicator light 99 Multi function display 103 Yamaha diagnostic tool coupler 104 Radiator fan motor 105 Radiator fan motor relay 106 ECU Engine Control Unit 107 Ignition coil 108 Spark plug 109 Grip warmer connector 110 Grip warmer left 111 Grip warmer right 112 Coolant temperature sensor 113 Intake air temperature sensor 114 Intake air press...

Page 452: ...gine to continue operating or stop operating depending on the conditions EAS30506 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on 1 Check Fault code number a Check the fault code numbers that have a condition of Detected using the Yamaha diagnostic tool b Identify the faulty system with the fault code number c Identify the probable cause of t...

Page 453: ...tions of the Yamaha diagnostic tool 01 Throttle position sensor signal 1 throttle angle 13 Throttle position sensor signal 2 throttle angle 14 Accelerator position sensor signal 1 throttle angle 15 Accelerator position sensor signal 2 throttle angle 30 Ignition coil 36 Injector 1 37 Injector 2 Yamaha diagnostic tool USB 90890 03256 Yamaha diagnostic tool A I 90890 03254 OBD GST Leadwire kit 90890 ...

Page 454: ...the diagnostic mode is operated Refer to SELF DIAGNOS TIC FUNCTION AND DIAGNOSTIC CODE TABLE ECU on page 9 5 Parts connected to the ECU The following parts are connected to the ECU When checking for a power short circuit the couplers must be disconnected from all of the following parts beforehand Logging Records and saves the sensor output value in actual driving conditions CO adjustment Adjust th...

Page 455: ...ke the actions specified for fault code number P2135 first Fault code No P0030 Item O2 sensor heater defective heater controller detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of O2 sensor cou pler Check the locking condition...

Page 456: ...y red blue red blue Push the ON start switch and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Start the engine and then check the condition of the fault code Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 4 TIP For this...

Page 457: ...of the pins Improperly connected Con nect the coupler securely or replace the wire harness Push the ON start switch and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the ...

Page 458: ... wire harness 3 4 For P0108 Open circuit Between intake air pressure sensor coupler and ECU coupler blue blue If there is no continuity replace the wire harness A XP530E A B XP530 A C XP530D A Fault code No P0107 P0108 Item P0107 Intake air pressure sensor ground short circuit detected P0108 Intake air pressure sensor open or power short circuit detected B L L B L P W P W L 5V 5V 1 2 3 4 5 B L P W...

Page 459: ...pressure sensor ground short circuit detected P0108 Intake air pressure sensor open or power short circuit detected B L P W L B L P W L B L P W L Lg L G R W W B Y O W R L Y R Lg W Br W B R G L R G L W Lg L L P W Lg L W G B W B L Y G Gy G W Y W G Y L Lg B B L B L Lg L G R W W B Y R L Y R Lg W Br W B R L W Lg L L P W W G B W B L Y G Gy G W Y W G Y L B L B L Lg L G R W W B Y R L Y R Lg W Br W B R L W...

Page 460: ...tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 Fault code No P0107 P0108 Item P0107 Intake air pressure sensor ground short circuit detected P0108 Intake air pressure sensor open or power short circuit detected Lg L G R W W B Y O W R L Y R Lg W Br W B R G L R G L W Lg L L ...

Page 461: ...anking Check the intake air pressure sensor Replace if defective Refer to REPLACING THE ECU Engine Control Unit on page 8 230 Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE...

Page 462: ...urely or replace the wire harness Push the ON start switch and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and l...

Page 463: ...r coupler and ECU coupler brown white brown white If there is no continuity replace the wire harness A XP530E A B XP530 A C XP530D A Fault code No P0112 P0113 Item P0112 Intake air temperature sensor ground short circuit detected P0113 Intake air temperature sensor open or power short circuit detected Br W B L Br W B L 5V 1 2 3 4 B L Br W B L Br W B L Br W B L Br W Lg L G R W W B Y O W R L Y R Lg ...

Page 464: ...f the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 Fault code No P0112 P0113 Item P0112 Intake air temperature sensor ground short circuit detected P0113 Intake air temperature sensor open or power short circuit detected B L Br W B L Br W B L Br W Lg L G R W W B Y O W R L Y R Lg W B...

Page 465: ...117 P0118 Item P0117 Coolant temperature sensor ground short circuit detected P0118 Coolant temperature sensor open or power short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 06 Tool display When engine is cold Displays temperature closer to air temperature When engine is hot Displays current coolant temperature Procedure Compare the actually mea...

Page 466: ...the ON start switch and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 4 3 1 1 Coolant temperature sensor 2 ECU 3 Sensor output lead 4 Sensor ground lead 3 2 Disconnect the ECU coupler from the ECU Disconnect the coolant temperature sensor coupler from th...

Page 467: ...perature sensor ground short circuit detected P0118 Coolant temperature sensor open or power short circuit detected B L G R B L G R B L G R Lg L G R W W B Y O W R L Y R Lg W Br W B R G L R G L W Lg L L P W Lg L W G B W B L Y G Gy G W Y W G Y L Lg B B L B L Lg L G R W W B Y R L Y R Lg W Br W B R L W Lg L L P W W G B W B L Y G Gy G W Y W G Y L B L B L Lg L G R W W B Y R L Y R Lg W Br W B R L W Lg L ...

Page 468: ...efective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 245 Push the ON start switch and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 230 Service...

Page 469: ...firmation of service com pletion 1 Connection of throttle position sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Push the ON start switch and then check the condition of the fault code using the malfunction m...

Page 470: ...een throttle position sensor coupler and ground white ground If there is continuity replace the wire harness Fault code No P0122 P0123 P0222 P0223 P2135 Item P0122 Throttle position sensor ground short circuit detected P0123 Throttle position sensor open or power short circuit detected P0222 Throttle position sensor ground short circuit detected P0223 Throttle position sensor open or power short c...

Page 471: ...ttle position sensor open or power short circuit detected P0222 Throttle position sensor ground short circuit detected P0223 Throttle position sensor open or power short circuit detected P2135 Throttle position sensor output voltage deviation error Lg L G R W W B Y O W R L Y R Lg W Br W B R G L R G L W Lg L L P W Lg L W G B W B L Y G Gy G W Y W G Y L Lg B B L B L Lg L G R W W B Y R L Y R Lg W Br W...

Page 472: ...e position sensor open or power short circuit detected P0222 Throttle position sensor ground short circuit detected P0223 Throttle position sensor open or power short circuit detected P2135 Throttle position sensor output voltage deviation error Lg L G R W W B Y O W R L Y R Lg W Br W B R G L R G L W Lg L L P W Lg L W G B W B L Y G Gy G W Y W G Y L Lg B B L B L Lg L G R W W B Y R L Y R Lg W Br W B ...

Page 473: ...finish the service Condition is Detected Go to item 5 Fault code No P0122 P0123 P0222 P0223 P2135 Item P0122 Throttle position sensor ground short circuit detected P0123 Throttle position sensor open or power short circuit detected P0222 Throttle position sensor ground short circuit detected P0223 Throttle position sensor open or power short circuit detected P2135 Throttle position sensor output v...

Page 474: ...re fully open A value of 92 108 is indicated An indicated value is out of the specified range Replace the throttle position sensor Push the ON start switch and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 7 7 Malfunction in ECU Replace the ECU Refer to ...

Page 475: ...e condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the ...

Page 476: ...ers Diagnostic code No 36 Actuation Actuates fuel injector 1 five times at one second intervals The check indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated Procedure Disconnect the fuel pump coupler Check that fuel injector 1 is actuated five times by listening for the operating sound Item Probable cause of malfunc tion and check Maintenance job Confir...

Page 477: ...has a condition of Recovered using the malfunction mode of the Yamaha diagnostic tool and then delete the fault code Fault code No P0202 Item Fuel injector 2 malfunction in fuel injector 2 Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No 37 Actuation Actuates fuel injector 2 five t...

Page 478: ...een black Between fuel injector coupler and starting circuit cut off relay coupler red blue red blue Execute the diagnostic mode Code No 37 Operating sound Go to item 6 No operating sound Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 230 6 Delete the fault code and check that the engine trouble warning light goes off Start the engine and...

Page 479: ...gine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 4 4 Installed condition of crankshaft position sensor Check for looseness or pinch ing Check the gap between the crankshaft position sensor and the generator rotor Improperly installed sensor Reinsta...

Page 480: ...Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode o...

Page 481: ...lse 0 999 Procedure Check that the number increases when the rear wheel is rotated The number is cumulative and does not reset each time the wheel is stopped Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of rear wheel sen sor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken t...

Page 482: ...nd and check that the indicated value increases Value increases Go to item 7 Value does not increase Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 230 Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indicated value increases Value increases Go to item 7 Value does not increase Go to item 6 6 Malfun...

Page 483: ...let it idle for approximately 5 minutes Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 4 and finish the service Condition is Detected Go to item 2 2 ISC learning overcompensated Check the intake system and clean the throttle body Refer to CHECKING AND CLEANING THE THROTTLE BODIES on page 7 9 Execute the diagnostic mo...

Page 484: ...n mode of the Yamaha diagnostic tool Condition is Recovered Go to item 2 and finish the service Condition is Detected Repeat item 1 2 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No P0601 P0606 Item Internal malfunction in ECU When th...

Page 485: ...item 4 2 01 is indicated in diagnostic mode Code No 60 EEPROM data error for adjust ment of CO concentration of cyl inder 1 Change the CO concentration of cylinder 1 and rewrite in EEPROM Refer to ADJUSTING THE EXHAUST GAS VOLUME on page 3 12 After this adjustment is made push the OFF LOCK switch Push the ON start switch and then check the condition of the fault code using the malfunction mode of ...

Page 486: ...stem Able Unable to start engine Able Unable to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of throttle servo motor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperl...

Page 487: ...he throttle servo motor Replace the throttle bodies if defective Refer to CHECKING THE THROTTLE SERVO MOTOR on page 8 247 Push the ON start switch and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 6 6 Defective throttle bodies Check the throttle bodies R...

Page 488: ...e job Confirmation of service com pletion 1 Connection of fuel injection sys tem relay coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition o...

Page 489: ...stem relay Execute the diagnostic mode Code No 50 No operating sound Replace the fuel injection system relay and ignition system relay Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective fue...

Page 490: ...and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Push the ON start switch and then extend and retract the side stand Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Connection of sidestand swit...

Page 491: ...c code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Installed condition of battery leads Check the installed condition of the battery and battery leads loose bolts Improperly installed battery or battery leads Reinstall or replace the battery leads Push the ON start switch and then check the condition of the fault cod...

Page 492: ...ush the ON start switch and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condit...

Page 493: ...replace the wire harness Push the ON start switch then to OFF and then back to ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Push the ON start switch then to OFF and then back to ON...

Page 494: ...nuity replace the wire harness A XP530E A B XP530 A C XP530D A Fault code No P1604 P1605 Item P1604 Lean angle sensor ground short circuit detected P1605 Lean angle sensor open or power short circuit O B R B G Y W Y R R L R R W Y W B G B B Y R L Y G L B W O B R B G Y W Y R R L R R W Y W B G B B Y R L Y G L B W O B R B G Y W Y R R L R R W Y W B G B B Y R L Y G L B W Lg L G R W W B Y O W R L Y R Lg ...

Page 495: ...gnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 230 Service is finished Fault code No P1604 P1605 Item P1604 Lean angle sensor ground short circuit detected P1605 Lean angle sensor open or power short circuit Lg L G R W W B Y O W R L Y R Lg W Br W...

Page 496: ... position 93 109 fully open position Procedure Check with throttle grip in fully closed position Check with throttle grip in fully open position Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of accelerator posi tion sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken term...

Page 497: ...ead 1 5 Sensor output lead 2 6 Sensor ground lead 3 2 Disconnect the ECU coupler from the ECU Disconnect the accelerator position sensor coupler from the accelerator position sensor Fault code No P2122 P2123 P2127 P2128 P2138 Item P2122 Accelerator position sensor open or ground short circuit detected P2123 Accelerator position sensor power short circuit detected P2127 Accelerator position sensor ...

Page 498: ...harness Fault code No P2122 P2123 P2127 P2128 P2138 Item P2122 Accelerator position sensor open or ground short circuit detected P2123 Accelerator position sensor power short circuit detected P2127 Accelerator position sensor ground short circuit detected P2128 Accelerator position sensor open or power short circuit detected P2138 Accelerator position sensor output voltage deviation error R R R R ...

Page 499: ...sition sensor ground short circuit detected P2128 Accelerator position sensor open or power short circuit detected P2138 Accelerator position sensor output voltage deviation error R R R Lg L G R W W B Y O W R L Y R Lg W Br W B R G L R G L W Lg L L P W Lg L W G B W B L Y G Gy G W Y W G Y L Lg B B L B L Lg L G R W W B Y R L Y R Lg W Br W B R L W Lg L L P W W G B W B L Y G Gy G W Y W G Y L B L B L Lg...

Page 500: ...ected P2123 Accelerator position sensor power short circuit detected P2127 Accelerator position sensor ground short circuit detected P2128 Accelerator position sensor open or power short circuit detected P2138 Accelerator position sensor output voltage deviation error R R R Lg L G R W W B Y O W R L Y R Lg W Br W B R G L R G L W Lg L L P W Lg L W G B W B L Y G Gy G W Y W G Y L Lg B B L B L Lg L G R...

Page 501: ...2 Execute the diagnostic mode Code No 15 When the throttle grip is fully closed A value of 9 23 is indicated When the throttle grip is fully open A value of 93 109 is indicated An indicated value is out of the specified range Replace the accelerator position sensor Push the ON start switch and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condi...

Page 502: ...r broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Execute the diagnostic mode Code No 16 Rotate the front wheel by hand and check that the indicated value increases Value increases Go to item 7 and finish the service Value does not increase Go to item 2 2 Connection of ABS ECU cou pler Check the locking condition of ...

Page 503: ...s Value increases Go to item 7 and finish the service Value does not increase Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 230 Execute the diagnostic mode Code No 16 Rotate the front wheel by hand and check that the indicated value increases Value increases Go to item 7 and finish the service Value does not increase Go to item 6 6 Malfu...

Page 504: ...on of O2 sensor cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Start the engine and let it idle for approximately 10 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic ...

Page 505: ...he engine and let it idle for approximately 10 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 6 Also delete this fault code which has a condition of Detected 6 Defective O2 sensor Check the O2 sensor Replace if defective Refer to ENGINE REMOVAL on page...

Page 506: ...Push the ON start switch and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between meter assembly cou pler and joint coupler light green blue light green blue light green white li...

Page 507: ...FUEL INJECTION SYSTEM 8 116 ...

Page 508: ...CRUISE CONTROL SYSTEM for XP530D A 8 117 EAS20087 CRUISE CONTROL SYSTEM for XP530D A EAS30544 CIRCUIT DIAGRAM ...

Page 509: ...se control power switch 60 Cruise control setting switch 63 Menu switch 64 Select switch 75 Brake light fuse 76 Front brake light switch 77 Rear brake light switch 78 Grip cancel switch 85 Tracking system control unit 87 Meter assembly 95 Cruise control system indicator light 96 Cruise control setting indicator light 99 Multi function display 103 Yamaha diagnostic tool coupler 106 ECU Engine Contr...

Page 510: ...CRUISE CONTROL SYSTEM for XP530D A 8 119 EAS30666 CRUISE CONTROL CIRCUIT OPERATION 20 19 18 17 15 14 13 12 11 10 7 6 3 2 1 9 8 5 4 16 ...

Page 511: ...e 8 Ignition fuse 9 Cruise control system fuse 10 Cruise control power switch 11 Cruise control setting switch 12 Front brake light switch 13 Rear brake light switch 14 Grip cancel switch 15 Brake light relay 16 Fuel injection system relay 17 ECU Engine Control Unit 18 Multi function meter 19 Cruise control system indicator light 20 Cruise control setting indicator light ...

Page 512: ...Use sufficiently charged regular batteries only A Malfunction check using the cruise control system indicator light B Use the Yamaha diagnostic tool to determine the cause of the malfunction for the stored fault code from the condition and place where the malfunction occurred TIP For information about using the Yamaha diagnostic tool refer to YAMAHA DIAGNOSTIC TOOL on page 8 62 C Servicing the cru...

Page 513: ...there automatic deactivation history for the cruise control system Check the malfunction history using the malfunction mode of the Yamaha diagnostic tool Is there any malfunction history Diagnosis using the fault codes Yes Yes OK The cruise control power switch is defective The cruise control system fuse is blown The ECU is defective Delete the fault codes Final check Return to A Return to A If th...

Page 514: ... light come on B 2 EAS30670 B 1 DIAGNOSIS USING THE FAULT CODES 1 Information for the fault codes from the cruise control system is contained in the following table Re fer to this table for troubleshooting Fault code table Fault code No P056C Fault code No Symptom Check point P056C No normal signals from the switch are received by the ECU Wire harness ECU coupler and front or rear brake light swit...

Page 515: ... then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item A 10 and finish the ser vice Condition is Detected Go to item A 4 A 4 Connection of ignition system relay coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improp...

Page 516: ...brake light relay cou pler and battery black black Push the ON start switch Operate the front brake lever and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item A 10 and finish the ser vice Condition is Detected Go to item A 8 A 8 Defective front brake light switch Replace the front brake light switch Push the ON s...

Page 517: ...h Operate the rear brake lever and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item B 10 and finish the ser vice Condition is Detected Go to item B 3 B 3 Connection of brake light relay coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and lockin...

Page 518: ... Between ignition system relay coupler and fuse box brown blue brown blue Between fuse box and rear brake light switch brown green yellow Between rear brake light switch coupler and brake light relay coupler light green black light green black Between brake light relay cou pler and ECU coupler light green black light green black Between brake light relay cou pler and battery black black Push the O...

Page 519: ...ntrol setting switch RES is pushed ON When the cruise control setting switch is released OFF Malfunction Go to item A 2 Execute the diagnostic mode Code No 81 When the cruise control setting switch SET is pushed ON When the cruise control setting switch is released OFF Malfunction Go to item B 2 for the cruise control setting switch SET A 2 Connection of handlebar switch coupler left Check the loc...

Page 520: ... Recovered Go to item A 9 and finish the ser vice Condition is Detected Go to item A 5 A 5 Check the fuse ignition fuse cruise control system fuse Abnormality Replace the fuse ignition fuse cruise con trol system fuse Push the ON start switch Push and release the RES side of the cruise control setting switch and then check the con dition of the fault code using the malfunction mode of the Yamaha d...

Page 521: ...rcuit is detected B Cruise control setting switch SET open or short circuit is detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 80 81 Tool display ON when the switch is pushed OFF when the switch is released Procedure Push the SET side of the cruise control setting switch Item Probable cause of malfunc tion and check Maintenance job Confirmation of service co...

Page 522: ...ha diagnostic tool Condition is Recovered Go to item B 9 and finish the ser vice Condition is Detected Go to item B 4 B 4 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Push the ON start switch Push...

Page 523: ...ctive cruise control setting switch Replace the handlebar switch left Push the ON start switch Push the RES side and SET side of the cruise control setting switch and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item B 9 and finish the ser vice Condition is Detected Go to item B 8 B 8 Malfunction in ECU Replace the...

Page 524: ... explain the automatic deactivation function of the cruise control system to the customer and explain that this is not a malfunction EAS30674 C 1 DELETING THE FAULT CODES 1 Delete the fault code using the malfunction of the Yamaha diagnostic tool and check that the engine trouble warning light goes off EAS30675 C 2 FINAL CHECK 1 Check the front brake lever and rear brake lever operation 2 Check th...

Page 525: ...CRUISE CONTROL SYSTEM for XP530D A 8 134 ...

Page 526: ...FUEL PUMP SYSTEM 8 135 EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM XP530E A ...

Page 527: ... relay 15 Battery 17 Main fuse 19 Engine ground 21 Ignition fuse 24 Fuel injection system fuse 25 Backup fuse 48 Fuel injection system relay 51 Handlebar switch right 52 Engine stop switch 89 ECU Engine Control Unit 106 Fuel pump A Wire harness B Negative battery sub wire harness ...

Page 528: ...FUEL PUMP SYSTEM 8 137 XP530 A ...

Page 529: ... relay 15 Battery 17 Main fuse 19 Engine ground 21 Ignition fuse 24 Fuel injection system fuse 25 Backup fuse 48 Fuel injection system relay 51 Handlebar switch right 52 Engine stop switch 94 ECU Engine Control Unit 111 Fuel pump A Wire harness B Negative battery sub wire harness ...

Page 530: ...FUEL PUMP SYSTEM 8 139 XP530D A ...

Page 531: ...17 Main fuse 19 Engine ground 21 Ignition fuse 24 Fuel injection system fuse 25 Backup fuse 49 Fuel injection system relay 52 Handlebar switch right 53 Engine stop switch 103 Yamaha diagnostic tool coupler 106 ECU Engine Control Unit 123 Fuel pump A Wire harness B Negative battery sub wire harness ...

Page 532: ... engine stop switch Refer to CHECKING THE SWITCHES on page 8 221 NG The engine stop switch is faulty Replace the handlebar switch right OK 4 Check the ignition system relay Refer to CHECKING THE RE LAYS on page 8 233 NG Replace the ignition system relay OK 5 Check the fuel injection system re lay Refer to CHECKING THE RE LAYS on page 8 233 NG Replace the fuel injection system relay OK 6 Check the ...

Page 533: ...FUEL PUMP SYSTEM 8 142 ...

Page 534: ...WINDSHIELD DRIVE SYSTEM for XP530D A 8 143 EAS20083 WINDSHIELD DRIVE SYSTEM for XP530D A EAS30517 CIRCUIT DIAGRAM ...

Page 535: ...relay 15 Battery 17 Main fuse 19 Engine ground 21 Ignition fuse 25 Backup fuse 58 Handlebar switch left 63 Menu switch 64 Select switch 82 Windshield drive unit 83 Windshield drive unit relay down 84 Windshield drive unit relay up 87 Meter assembly 99 Multi function display A Wire harness B Negative battery sub wire harness ...

Page 536: ...ECKING THE FUSES on page 8 229 NG Replace the fuse s OK 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 230 NG Clean the battery terminals Recharge or replace the battery OK 5 Check the ignition system relay Refer to CHECKING THE SWITCHES on page 8 221 NG Replace the ignition system relay OK 6 Check the menu switch Refer to CHECKING THE SWITCHES on page 8 221 NG The menu s...

Page 537: ...indshield drive unit relay down OK 10 Check the windshield drive motor Refer to CHECKING THE WIND SHIELD DRIVE UNIT for XP530D A on page 8 247 NG Replace the windshield drive unit OK 11 Check the entire windshield drive system wiring Refer to CIRCUIT DIAGRAM on page 8 143 NG Properly connect or replace the wire har ness OK Replace the meter assembly ...

Page 538: ...GRIP WARMER SYSTEM for XP530D A 8 147 EAS20167 GRIP WARMER SYSTEM for XP530D A EAS31007 CIRCUIT DIAGRAM ...

Page 539: ...Engine ground 21 Ignition fuse 25 Backup fuse 58 Handlebar switch left 63 Menu switch 64 Select switch 87 Meter assembly 99 Multi function display 103 Yamaha diagnostic tool coupler 106 ECU Engine Control Unit 109 Grip warmer connector 110 Grip warmer left 111 Grip warmer right A Wire harness B Negative battery sub wire harness ...

Page 540: ... of the grip warmer settings OK 3 Check the fuses Main ignition and backup Refer to CHECKING THE FUSES on page 8 229 NG Replace the fuse s OK 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 230 NG Clean the battery terminals Recharge or replace the battery OK 5 Check the ignition system relay Refer to CHECKING THE RE LAYS on page 8 233 NG Replace the ignition system relay ...

Page 541: ...he temperature level of the high grip warmer setting is set to highest temperature NG Adjust the temperature levels of the grip warmer settings OK 2 Check that the engine trouble warn ing light is on and that fault code No P0500 is displayed in the Yamaha diagnostic tool display NG Perform the troubleshooting for fault code No P0500 Refer to TROUBLESHOOT ING DETAILS FAULT CODE on page 8 63 OK Repl...

Page 542: ...SEAT HEATER SYSTEM for XP530D A 8 151 EAS20312 SEAT HEATER SYSTEM for XP530D A EAS32438 CIRCUIT DIAGRAM ...

Page 543: ...in fuse 19 Engine ground 20 Signaling system fuse 25 Backup fuse 58 Handlebar switch left 63 Menu switch 64 Select switch 87 Meter assembly 99 Multi function display 100 Seat heater relay power 101 Seat heater relay control 102 Seat heater 106 ECU Engine Control Unit A Wire harness B Negative battery sub wire harness ...

Page 544: ...ine is started NG Start the engine OK 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 230 NG Clean the battery terminals Recharge or replace the battery OK 5 Check the ignition system relay Refer to CHECKING THE RE LAYS on page 8 233 NG Replace the ignition system relay OK 6 Check the seat heater relay power Refer to CHECKING THE RE LAYS on page 8 233 NG Replace the seat h...

Page 545: ...AYS on page 8 233 NG Replace the seat heater relay power OK 3 Check the seat heater Refer to CHECKING THE SEAT HEATER for XP530D A on page 8 248 NG Replace the seat assembly OK Replace the meter assembly 1 Check that the temperature level of the high seat heater setting is set to highest temperature NG Adjust the temperature levels of the seat heater settings OK 2 Check the seat heater relay power...

Page 546: ... 221 NG The menu switch is faulty Replace the handlebar switch left OK 2 Check the select switch Refer to CHECKING THE SWITCHES on page 8 221 NG The select switch is faulty Replace the handlebar switch left OK 3 Check the wire harness between the handlebar switch left and the meter assembly NG Properly connect or replace the wiring har ness OK Replace the meter assembly ...

Page 547: ...SEAT HEATER SYSTEM for XP530D A 8 156 ...

Page 548: ...ABS Anti lock Brake System 8 157 EAS20085 ABS Anti lock Brake System EAS30843 CIRCUIT DIAGRAM XP530E A ...

Page 549: ...fuse 40 Headlight relay dimmer 51 Handlebar switch right 55 Front brake light switch 56 Handlebar switch left 62 Rear brake light switch 68 Tail brake light left 69 Tail brake light right 75 Meter assembly 83 ABS warning light 85 Multi function display 86 Yamaha diagnostic tool coupler 89 ECU Engine Control Unit 107 ABS ECU Electronic Control Unit 108 Front wheel sensor 109 Rear wheel sensor A Wir...

Page 550: ...ABS Anti lock Brake System 8 159 XP530 A ...

Page 551: ...fuse 40 Headlight relay dimmer 51 Handlebar switch right 56 Front brake light switch 57 Handlebar switch left 63 Rear brake light switch 69 Tail brake light left 70 Tail brake light right 77 Meter assembly 85 ABS warning light 87 Multi function display 91 Yamaha diagnostic tool coupler 94 ECU Engine Control Unit 112 ABS ECU Electronic Control Unit 113 Front wheel sensor 114 Rear wheel sensor A Wir...

Page 552: ...ABS Anti lock Brake System 8 161 XP530D A ...

Page 553: ...ECU fuse 40 Headlight relay dimmer 57 Brake light relay 71 Tail brake light left 72 Tail brake light right 75 Brake light fuse 76 Front brake light switch 77 Rear brake light switch 87 Meter assembly 97 ABS warning light 99 Multi function display 103 Yamaha diagnostic tool coupler 106 ECU Engine Control Unit 124 ABS ECU Electronic Control Unit 125 Front wheel sensor 126 Rear wheel sensor A Wire ha...

Page 554: ...ABS Anti lock Brake System 8 163 EAS30525 ABS COMPONENTS CHART 5 6 7 2 8 10 9 1 4 4 3 ...

Page 555: ...nostic tool coupler 2 ABS warning light 3 Fuse box ABS motor fuse ABS solenoid fuse and ABS ECU fuse 4 ABS ECU 5 Front wheel sensor rotor 6 Front wheel sensor 7 Front brake caliper 8 Rear brake caliper 9 Rear wheel sensor 10 Rear wheel sensor rotor ...

Page 556: ... 3 4 5 R W R L G Y Br W Dg G B Lg L Lg W R G B W P W P B P W P B B W Br Y L R L R Br Y Ch Dg R G R W Ch Dg Ch G R G L G W G W R W L Y B W Lg WLg L B W R G R G Dg P W P B Br Y Ch Dg R G R W Ch Dg Ch G R G L G W G W R W L Y B W Lg WLg L B W R G R G Dg G B P W P B B W Br Y Br Y Ch Dg R G R W Ch Dg Ch G R G L G W G W R W L Y B W Lg WLg L B W R G R G ...

Page 557: ... 8 166 1 Rear wheel sensor coupler 2 Meter assembly coupler for XP530E A 3 Meter assembly coupler for XP530 A 4 Meter assembly coupler for XP530D A 5 Yamaha diagnostic tool coupler 6 Front wheel sensor coupler 7 ABS ECU coupler ...

Page 558: ...c tool For information about using the Yamaha diagnostic tool refer to B 2 DIAG NOSIS USING THE FAULT CODES on page 8 171 For troubleshooting items other than the following items follow the normal service method WARNING EWA16710 When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle to the customer TIP To final...

Page 559: ...ubjecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the fault codes when the ser vice is finished This is because the past fault codes will be displayed again if another malfunction occurs E...

Page 560: ...al checks Were all of the final checks completed normally Finished Yes No A Push the ON start switch and check the ABS warning light Fails to come on Comes on The ABS ECU fuse is blown The ABS ECU coupler is disconnected The wire harness is defective The hydraulic unit assembly is defective The connection with the Yamaha diagnostic tool is defective The wire harness is defective Cannot communicate...

Page 561: ...meter assembly If the ABS warning light comes on the ABS ECU is defective Replace the hydraulic unit assembly EAS30964 A 2 ALL INDICATOR LIGHTS FAIL TO COME ON 1 ON start switch Check the ON start switch for continuity Refer to CHECKING THE SWITCHES on page 8 221 If there is no continuity replace the handlebar switch right 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING...

Page 562: ...agnostic tool coupler CANH Check for continuity between blue black terminal of the ABS ECU coupler and blue black terminal of the Yamaha diagnostic tool coupler CANL 4 ABS ECU malfunction Replace the hydraulic unit assembly EAS31164 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE 1 Yamaha diagnostic tool Check that the Yamaha diagnostic tool is properly connected 2 Wire harness Open circuit in the wire...

Page 563: ...is traveling Foreign material adhered around the front wheel sen sor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrect installation of the sensor 12 Rear wheel sensor intermit tent pulses or no pulses Rear wheel sensor signal is not received properly Pulses are not received or are received intermittent...

Page 564: ...r short circuit in the wire harness between the rear wheel sensor and the hydraulic unit assembly Defective rear wheel sen sor or hydraulic unit assembly 17 45 Front wheel sensor missing pulses Front wheel sensor signal is not received properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the front wheel sen sor Incorrect installation of...

Page 565: ... supply circuit Short circuit is detected in the solenoid power supply circuit in the hydraulic unit assembly Defective hydraulic unit assembly 33 Hydraulic unit assembly abnormal ABS motor power supply Power is not supplied to the motor circuit in the hydraulic unit assembly Blown ABS motor fuse Defective coupler between the battery and the hydrau lic unit assembly Open or short circuit in the wi...

Page 566: ...sensor rotor or incorrect installation of the rotor Defective rear wheel sen sor or incorrect installation of the sensor 51 52 Vehicle system power sup ply voltage of ABS ECU power supply is high for fault code No 51 Vehicle system power sup ply voltage of wheel sen sor power supply is high for fault code No 52 Power voltage supplied to the ABS ECU in the hydraulic unit assembly is too high for fa...

Page 567: ...nsor and the hydraulic unit assembly Defective rear wheel sen sor Defective hydraulic unit assembly Fault code No 11 25 Item Front wheel sensor intermittent pulses or no pulses Symptom Front wheel sensor signal is not received properly Pulses are not received or are received intermittently while the vehicle is traveling Order Item components and probable cause Check or maintenance job 1 Foreign ma...

Page 568: ... for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 36 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on ...

Page 569: ...el sensor Check the surface of the sensor rotor and wheel sensor for foreign material such as metal particles Clean the sensor rotor and wheel sensor if necessary 2 Incorrect installation of the rear wheel Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 35 3 Defective sensor rotor or incorrect instal lation of the rotor Check the surface of the se...

Page 570: ... 2 and the black terminal 5 If there is no continuity the wire harness is defective Replace the wire harness Check that there is no short circuit between the white terminal 1 and the black terminal 2 and between the white terminal 4 and the black terminal 5 If there is short circuit the wire harness is defective Replace the wire harness Check that there is no short circuit between the black termin...

Page 571: ... 2 and the black terminal 5 If there is no continuity the wire harness is defective Replace the wire harness Check that there is no short circuit between the white terminal 1 and the black terminal 2 and between the white terminal 4 and the black terminal 5 If there is short circuit the wire harness is defective Replace the wire harness Check that there is no short circuit between the black termin...

Page 572: ...sor rotor and wheel sensor if necessary 2 Incorrect installation of the front wheel Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 24 3 Defective sensor rotor or incorrect instal lation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR ...

Page 573: ...ear brake light switch circuit Order Item components and probable cause Check or maintenance job 1 Defective signaling system tail brake light or brake light switch Check the brake light switches Refer to CHECKING THE SWITCHES on page 8 221 2 Defective coupler between the signaling system tail brake light or brake light switch and the hydraulic unit assembly Check the coupler for any pins that may...

Page 574: ...the hydraulic unit assembly Replace if there is an open or short circuit Between ABS ECU coupler and ABS solenoid fuse Red White Red White 4 Defective hydraulic unit assembly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 71 Fault code No 32 Item Hydraulic unit assembly short circuit in ABS solenoid...

Page 575: ...robable cause Check or maintenance job 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 71 Fault code No 41 Item Front wheel ABS intermittent wheel speed pulses or incorrect depressurization Symptom Pulses from the front wheel sensor are received intermittently while the vehicle is traveling Front wheel will not recover from the ...

Page 576: ...ar wheel sensor for fault code No 42 Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 35 2 Incorrect rotation of the rear wheel Check that there is no brake disc drag on the wheel and make sure that it rotates smoothly Refer to CHECKING THE REAR WHEEL on page 4 35 3 Rear brake dragging Check that the brake fluid pressure is correctly transmit ted t...

Page 577: ...of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 Fault code No 44 Item Rear wheel sensor missing pulses Symptom Rear wheel sensor signal is not received properly Missing pulses are detected in the signal while the vehicle is traveling Order Item components and probable cause Check or maintenance job 1 Foreign...

Page 578: ... if necessary 3 Defective charging system Check the charging system Refer to CHARGING SYSTEM on page 8 19 Fault code No 53 Item Vehicle system power supply voltage of ABS ECU power supply is low Symptom Power voltage supplied to the ABS ECU in the hydraulic unit assem bly is too low Order Item components and probable cause Check or maintenance job 1 Defective battery Recharge or replace the batter...

Page 579: ...re is an open or short circuit Between ABS ECU coupler and ABS motor fuse Red Blue Red Blue Between ABS ECU coupler and ABS solenoid fuse Red White Red White 4 Defective charging system Check the charging system Refer to CHARGING SYSTEM on page 8 19 5 Defective hydraulic unit assembly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS ...

Page 580: ...ort circuit between the black terminal 3 and the white terminal 1 If there is a short circuit the wire harness is defective Replace the wire harness 4 ABS ECU 5 Front wheel sensor 2 Defective front wheel sensor Check that there is no short circuit between the gray terminal 1 and the white terminal 2 If there is a short circuit the wheel sensor is defective Repair or replace the wheel sensor 3 ABS ...

Page 581: ...ort circuit between the black terminal 3 and the white terminal 1 If there is a short circuit the wire harness is defective Replace the wire harness 4 ABS ECU 5 Rear wheel sensor 2 Defective rear wheel sensor Check that there is no short circuit between the gray terminal 1 and the white terminal 2 If there is a short circuit the wheel sensor is defective Repair or replace the wheel sensor 3 ABS EC...

Page 582: ...proper installation Refer to INSTALLING THE FRONT WHEEL DISC BRAKE on page 4 28 and INSTALLING THE REAR WHEEL DISC BRAKE on page 4 36 3 Perform brake line routing confirmation Refer to HYDRAULIC UNIT OPERATION TEST on page 4 75 If it does not have reaction force properly the brake hose is not properly routed or connected 4 Delete the fault codes Refer to B 3 DELETING THE FAULT CODES on page 8 191 ...

Page 583: ...ABS Anti lock Brake System 8 192 ...

Page 584: ...SMART KEY SYSTEM 8 193 EAS20201 SMART KEY SYSTEM EAS31452 CIRCUIT DIAGRAM XP530E A ...

Page 585: ...off relay 51 Handlebar switch right 53 ON start switch 54 Hazard switch 56 Handlebar switch left 61 Turn signal switch 63 Front turn signal light left 64 Front turn signal light right 65 Rear turn signal light left 66 Rear turn signal light right 72 Smart key system relay unlock 73 Seat fuel lid lock solenoid 74 Smart key system relay lock 75 Meter assembly 76 Smart key system indicator light 81 T...

Page 586: ...SMART KEY SYSTEM 8 195 XP530 A ...

Page 587: ...t 53 ON start switch 54 Hazard switch 57 Handlebar switch left 62 Turn signal switch 63 Rear brake light switch 64 Front turn signal light left 65 Front turn signal light right 66 Rear turn signal light left 67 Rear turn signal light right 73 Smart key system relay unlock 74 Storage compartment lid lock solenoid 75 Seat fuel lid lock solenoid 76 Smart key system relay lock 77 Meter assembly 78 Sma...

Page 588: ...SMART KEY SYSTEM 8 197 XP530D A ...

Page 589: ...h right 54 ON start switch 55 Hazard switch 57 Brake light relay 58 Handlebar switch left 65 Turn signal switch 66 Front turn signal light left 67 Front turn signal light right 68 Rear turn signal light left 69 Rear turn signal light right 79 Smart key system relay unlock 80 Storage compartment lid lock solenoid 81 Seat fuel lid lock solenoid 86 Smart key system relay lock 87 Meter assembly 88 Sma...

Page 590: ... KEY BATTERY on page 8 250 NG Replace the button cell battery of the smart key Standard battery CR2025 OK 2 Check the fuses Main backup and ignition Refer to CHECKING THE FUSES on page 8 229 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 230 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the ON start switch Refer to CHEC...

Page 591: ...Replace the smart key or remote control unit The vehicle cannot be turned on in the emergency mode but the storage box light comes on when the seat is opened Replace the remote control unit The storage box light does not come on when the seat is opened Replace the seat or storage box light NO 3 The smart key system indicator light flashes The indicator light flashes once ev ery 2 seconds and then ...

Page 592: ...g lock unit NO The smart key system indicator light does not flash There are sources of strong electro magnetic waves in the vicinity Move the vehicle Smart key malfunction Register and use a different smart key Remote control unit malfunction Replace the remote control unit 1 When the vehicle power is turned on the smart key system indicator light flashes Refer to SMART KEY SYSTEM SELF DIAGNOSIS ...

Page 593: ... 0 3 second goes off for 1 0 second and this pattern con tinues for 20 seconds Refer to SMART KEY SYSTEM SELF DIAGNOSIS on page 8 205 YES Communication between the remote con trol unit and meter is not possible Check the wire harness Light green Green Light green White and or replace the remote control unit and or me ter NO The seat fuel lid cannot be opened Check the mechanical components of the ...

Page 594: ...the remote control unit and or me ter NO The storage compartment cannot be opened Check the mechanical components of the lock for malfunctions Repair or replace any defective parts Check the storage compartment lid solenoid for XP530 A XP530D A Refer to CHECKING THE STOR AGE COMPARTMENT LID LOCK SOLENOID for XP530 A XP530D A on page 8 251 Replace the remote control unit and or meter 1 Check the tu...

Page 595: ...ion between the remote con trol unit and centerstand lock unit is not possible Check the wire harness Light green Green Light green White and or replace the remote control unit and or cen terstand lock unit NO The centerstand cannot be un locked Check the mechanical components of the lock for malfunctions Repair or replace any defective parts Replace the remote control unit and or centerstand lock...

Page 596: ...cognized Check that there are no sources of strong elec tromagnetic waves in the vicinity the smart key is not lost and the battery is not dis charged Running detection error a LED on b LED off Flashes continuously until the error is resolved The smart key cannot be recognized Check that there are no sources of strong elec tromagnetic waves in the vicinity the smart key is not lost and the battery...

Page 597: ... b LED off Flashes continuously until the error is resolved flashes 4 times in a repeating cycle Check the wire harness Check the ECU Check the remote con trol unit Steering lock abnormal or centerstand lock abnormal end position contact a LED on b LED off 10 seconds Check whether the steering lock is stuck Steering lock abnormal or centerstand lock abnormal others a LED on b LED off 20 seconds fl...

Page 598: ...by inserting the mechanical key into the lock located right side of body and turn it counter clockwise 3 Open the seat and check that the trunk light comes on 4 Push the ON start switch once 5 Without completely shutting the seat raise and lower it three times within 10 seconds TIP Use the rear storage compartment light as a guide when raising and lowering the seat The smart key system indicator l...

Page 599: ...light will flash for 10 seconds if the correct identification number was entered TIP Emergency mode will be terminated when either one of the following situations apply In this case start over again from step 4 When there are no Parking Unlock switch operations for 10 seconds during the identification number input process When the smart key system indicator light is allowed to flash 10 or more tim...

Page 600: ... on page 8 207 3 While the smart key system indicator light is on for 10 seconds push the Parking Unlock switch 1 and OFF LOCK switch 2 alternately 3 times total of 6 times TIP Either switch can be pushed first 4 The smart key indicator light red 1 on the new smart key comes on for 10 seconds TIP While the smart key indicator light on the smart key is on the smart key system indicator light flash ...

Page 601: ...vehicle or lock the com munication 2 Perform steps 1 to 7 in SMART KEY SYSTEM EMERGENCY MODE on page 8 207 3 While the smart key system indicator light is on for 10 seconds perform the following procedure a While pushing the OFF LOCK switch 1 push the Parking Unlock switch 2 3 times Then release both switches 4 Check that the smart key system indicator light goes off the smart key disable mode is ...

Page 602: ...e remote control unit identification number and smart key identification number to the remote control unit and overwrite the smart identification number on the smart key with the new number EAS31556 REPLACING THE STEERING LOCK UNIT 1 Replace the steering lock unit and then place the previously used smart key within 80 cm 31 5 in of the remote control unit 2 Push the ON start switch 3 Push the OFF ...

Page 603: ...ion number in the emergency mode Remote control unit When the vehicle system is turned on the smart key identifi cation number is automatically registered to the remote control unit Steering lock unit When the vehicle system is turned on the smart key identifi cation number is automatically registered to the steering lock unit ECU When the vehicle system is turned on the smart key identifi cation ...

Page 604: ...and ECU as a set Smart key Remote control unit Steering lock unit Replace the smart key remote control unit steering lock unit and ECU as a set Smart key Remote control unit ECU Replace the smart key remote control unit steering lock unit and ECU as a set Smart key Steering lock unit ECU Register the smart key identifica tion number in the emergency mode When the vehicle system is turned on the sm...

Page 605: ...SMART KEY SYSTEM 8 214 ...

Page 606: ...ELECTRICAL COMPONENTS 8 215 EAS20089 ELECTRICAL COMPONENTS 17 1 20 6 3 2 4 5 7 8 9 18 19 10 11 16 15 13 12 14 ...

Page 607: ...jector 11 Coolant temperature sensor 12 Spark plug 13 Spark plug cap 14 Radiator fan motor 15 Throttle servo motor 16 Throttle position sensor 17 Front wheel sensor 18 Diode 1 19 Ignition coil 20 Smart key system relay unlock Smart key system relay lock Headlight relay dimmer Brake light relay for XP530D A Fuel injec tion system relay Steering lock relay Starting circuit cut off relay Ignition sys...

Page 608: ...ELECTRICAL COMPONENTS 8 217 1 2 3 4 5 6 7 8 9 10 11 13 12 ...

Page 609: ...hazard relay Radiator fan motor relay Seat heater relay power for XP530D A Seat heater relay control for XP530D A Windshield drive unit relay down for XP530D A Wind shield drive unit relay up for XP530D A 6 Diode 2 7 Rear wheel sensor 8 Centerstand lock solenoid 9 Starter motor 10 O2 sensor 11 Stator coil 12 Crankshaft position sensor 13 Sidestand switch ...

Page 610: ...ELECTRICAL COMPONENTS 8 219 22 3 4 6 5 7 8 9 10 11 12 13 14 15 16 17 20 21 19 2 18 1 ...

Page 611: ...Rear brake light switch for XP530D A 8 Starter relay 9 Fuse box 4 Brake light fuse for XP530D A Fuse box 5 Cruise control fuse for XP530D A 10 Fuse box 1 11 Fuse box 2 12 Fuse box 3 13 Diode fuse box 2 14 Remote control unit 15 Auxiliary DC jack 16 Windshield drive unit 17 Horn 18 Rectifier regulator 19 Intake air pressure sensor 20 Lean angle sensor 21 Storage compartment lid lock solenoid for XP...

Page 612: ...530E A G Y Br G Y Br Ch N Br WDg W LB W FREE PUSH W R B W W G UP Neutral DOWN Br P B L B B PASS R B R W Br WBr Y L W B B R B B Br W R W G L B B P Br G Y Dg Ch Br W W L B W L B L B L B L B Br Y R W Br W R B Br G Y L W B L G R R L G 1 2 3 4 5 6 11 7 12 13 8 9 10 14 ...

Page 613: ...switch 3 Menu switch 4 Select switch 5 Turn signal switch 6 Rear brake light switch 7 Sidestand switch 8 Engine stop switch 9 ON start switch 10 Hazard switch 11 Front brake light switch 12 OFF LOCK switch 13 Parking Unlock switch 14 Storage box light switch ...

Page 614: ...g W LB W FREE PUSH W R B W W G UP Neutral DOWN Br P B L B B PASS R B R W Br WBr Y B W W G FREE PUSH L W B B B B B Br W R W G L B B P Br G Y Dg Ch Br W W L B W L B L B L B L B Br Y R W Br W R B L W W G B W B Br G Y L G R R L G 1 2 3 4 5 6 12 7 13 14 8 9 10 11 15 ...

Page 615: ... Menu switch 4 Select switch 5 Turn signal switch 6 Rear brake light switch 7 Sidestand switch 8 Engine stop switch 9 ON start switch 10 Hazard switch 11 Mode switch 12 Front brake light switch 13 OFF LOCK switch 14 Parking Unlock switch 15 Storage box light switch ...

Page 616: ... B B R R L G Br W R W G L B B P Dg Ch Y B O W Br W Br L G L W L B W B Y B O W PUSH FREE G W G Y Y B Y W OFF ON G W G Y Y W Y W OFF ON Br P R B R W Br WBr Y R GY B G L RES FREE SET Ch N Br WDg W LB W FREE PUSH B W W G FREE PUSH W R B W W G UP Neutral DOWN B L B B PASS L W B B R B B 1 2 3 4 5 6 7 8 9 10 11 12 15 16 18 13 14 17 ...

Page 617: ...tch 4 Horn switch 5 Menu switch 6 Select switch 7 Turn signal switch 8 Sidestand switch 9 Front brake light switch 10 Rear brake light switch 11 Engine stop switch 12 ON start switch 13 Hazard switch 14 Mode switch 15 OFF LOCK switch 16 Parking Unlock switch 17 Grip cancel switch 18 Storage box light switch ...

Page 618: ...o the range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the ON start switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given swi...

Page 619: ... re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 ...

Page 620: ...rational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Front cover Refer to GENERAL C...

Page 621: ... large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion NOTICE ECA13661 This is a VRLA Valve Regulated Lead Acid battery Never remove the sealing caps be cause the balance between cells will not be maintained and battery performance will deteriorate Charging time charging amperage and charging voltage for a VRLA Valve Regu lat...

Page 622: ...e removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during...

Page 623: ...d using a constant voltage charger a Measure the open circuit voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standard charging current written on the...

Page 624: ...it tester and bat tery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starting circuit cut off relay Starter relay Recommended lubricant Dielectric grease Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 1 2 G Y B Sb L W A 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative test...

Page 625: ...ttery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result Continuity between 3 and 5 No continuity between 3 and 4 Y W Y Y B Br L B 2 1 3 1 2 3 5 4 Y W Y Y B Br L B 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Pos...

Page 626: ...e battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 G R G Y L Y Lg R G Br W R G Br 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester prob...

Page 627: ...ester probe 2 Negative tester probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 Br G Y Lg B B Br B Br P W 1 3 2 Br R 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continuity between 3 and 4 Continuity between 3 and 5 1 Positive tester probe 2 Negative tester probe...

Page 628: ...ontinuity between 3 and 4 Continuity between 3 and 5 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 2 3 5 4 R B Br P B Br R 1 2 3 4 B W Y R Br 1 Positive tester probe 2 Negative tester probe Result Continuity between 1 and 2 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 ...

Page 629: ...R B R G Br R P W 1 2 3 R B Br R R G P W 1 2 3 Br R B Br R R G P W 3 4 2 1 5 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe A XP530E A B XP530 A C XP530D A Result No continuity between 3 and 4 Continuity between 3 and 5 1 Positive tester probe 2 Negative tester probe 3 Negative tester probe Br R R B R G Br R P W 3 4 2 ...

Page 630: ... 1 Negative tester probe Red Green 2 No continuity Positive tester probe Red Green 2 Negative tester probe Green Red Blue White 1 Diode 2 Continuity Positive tester probe Red Black 3 Negative tester probe Blue Yellow 4 No continuity Positive tester probe Blue Yellow 4 Negative tester probe Red Black 3 Diode 3 Continuity Positive tester probe Black White 5 Negative tester probe Red White 6 No conti...

Page 631: ...reversed EAS30557 CHECKING THE SPARK PLUG CAPS The following procedure applies to all of the spark plug caps 1 Check Spark plug cap resistance Out of specification Replace a Remove the spark plug cap from the spark plug lead b Connect the digital circuit tester to the spark plug cap as shown R G L W G R 1 2 L Y R B 3 4 R W B W 5 6 P B P 7 8 A Diode 1 B Diode 2 C Diode 3 D Diode 5 E Diode fuse box ...

Page 632: ...ON SPARK GAP 1 Check Ignition spark gap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 8 7 TIP If the ignition spark gap is within specification the ignition system circuit is operating normally a Disconnect the spark plug cap from the spark plug b Connect the ignition checker 1 as shown Primary coil resistance 1 87 2 53 Digit...

Page 633: ...ngle sensor output voltage Out of specification Replace a Connect the test harness lean angle sensor 6P 1 to the lean angle sensor and wire harness as shown b Connect the digital circuit tester DC V to the test harness lean angle sensor 6P Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 2 Spark plug cap Crankshaft position sensor resis tance 228 342 Digital circuit tester CD732...

Page 634: ...e gas or fluid is in the vicinity b Check the starter motor operation EAS30566 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the digital circuit tester to the sta tor coil coupler as shown b Measure the stator coil resistance EAS30680 CHECKING THE RECTIFIER REGULATOR 1 Check Batt...

Page 635: ...AS31557 CHECKING THE FUEL METER FUEL LEVEL WARNING INDICATOR This model is equipped with a self diagnosis de vice for the fuel level detection circuit 1 Check Fuel meter fuel level warning indicator 1 Push the ON start switch Fuel meter fuel level warning indicator comes on for a few seconds then goes off Fuel meter fuel level warning indicator is OK Fuel meter fuel level warning indicator does no...

Page 636: ...emper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the digital circuit tester to the coolant temperature sensor terminals as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure the coolant temperature sensor ter minals do not get wet c Place a thermometer 3 in the coolant d He...

Page 637: ... ACCELERATOR POSITION SENSOR 1 Remove Accelerator position sensor from the throttle bodies WARNING EWA16700 Handle the accelerator position sensor with special care Never subject the accelerator position sen sor to strong shocks If the accelerator po sition sensor is dropped replace it 2 Check Accelerator position sensor maximum resis tance Out of specification Replace the accelera tor position se...

Page 638: ...motor TIP Do not use old batteries to operate the throttle servo motor EAS32448 CHECKING THE WINDSHIELD DRIVE UNIT for XP530D A 1 Check Windshield drive unit operation Faulty rough movement Replace a Disconnect the windshield drive unit coupler from the wire harness b Connect the battery DC V to the windshield drive unit terminals 1 as shown A Check that the throttle valves 2 fully close B Check t...

Page 639: ...SSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the test harness S pressure sensor 1 to the intake air pressure sensor and wire harness as shown NOTICE ECA20040 Pay attention to the installing direction of the test harness S pressure sensor 3P coupler a b Connect the digital circuit tester to the test harness S pressure sensor 3P Grip warmer re...

Page 640: ...rminals do not get wet c Place a thermometer 3 in the water d Heat the water or let it cool down to the spec ified temperatures e Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor EAS30681 CHECKING THE FUEL INJECTOR 1 Check Fuel injector resistance Out of specification Replace the fuel injec tor Digital circuit tester CD732 90890 03243 Model 88 Multimeter...

Page 641: ...ct the buzzer coupler from the wire harness b Connect the battery 12 V to the buzzer cou pler as shown c Check that the buzzer sounds EAS32440 CHECKING THE SEAT FUEL LID LOCK SOLENOID 1 Check Seat fuel lid lock solenoid Faulty rough movement Replace a Disconnect the seat fuel lid lock solenoid Resistance 12 0 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Po...

Page 642: ...XP530D A 1 Check Storage compartment lid lock solenoid Faulty rough movement Replace a Disconnect the storage compartment lid lock solenoid from the wire harness b Connect the battery DC 12 V as shown c Check the storage compartment lid lock sole noid movement Positive battery terminal Brown 1 Negative battery terminal Red 2 Positive battery terminal Brown 1 Negative battery terminal Black 2 R Br ...

Page 643: ...FORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 3 TROUBLESHOOTING AT THE ABS WARNING LIGHT 9 4 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE ECU 9 5 SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM 9 5 COMMUNICATION ERROR WITH THE METER 9 12 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 12 DIAGNOSTIC CODE ACTUATOR OPERATION TABLE 9 15 EVE...

Page 644: ...em relay Damaged vacuum hose Improperly routed hose 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty sp...

Page 645: ...sion gear Clutch slips 1 Clutch Improperly assembled clutch Fatigued clutch spring Worn clutch weight Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil 3 Primary sliding sheave Seized primary sliding sheave Poor starting performance 1 V belt V belt slips Oil or grease on the V belt 2 Primary sliding sheave Faulty operation Worn pin ...

Page 646: ...damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS30611 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race 3 Front fork leg s Uneven oil levels both...

Page 647: ...r incorrect fuse Turn signal blinks slowly Faulty turn signal hazard relay Faulty remote control unit Faulty turn signal switch Incorrect turn signal bulb Turn signal remains lit Faulty turn signal hazard relay Burnt out turn signal bulb Turn signal blinks quickly Incorrect turn signal bulb Faulty turn signal hazard relay Burnt out turn signal bulb Horn does not sound Improperly adjusted horn Dama...

Page 648: ...ctive coupler between intake air pressure sensor and ECU Open or short cir cuit in wire harness between intake air pressure sensor and ECU Defective intake air pressure sensor Malfunction in ECU Engine idling speed is unstable Engine response is poor Loss of engine power Increased exhaust emissions N is fixed Fuel is not cut off due to the intake air pres sure difference Intake air pressure is fix...

Page 649: ...222 Throttle posi tion sensor ground short circuit detected P0223 Throttle posi tion sensor open or power short circuit detected P2135 Throttle posi tion sensor output voltage deviation error P0122 P0222 Low voltage of the throttle position sensor circuit 0 25 V or less P0123 P0223 High voltage of the throttle position sensor circuit 4 75 V or more P2135 Difference in output voltage 1 and output v...

Page 650: ...ISC learning is not carried out Cruise control system cannot be operated P0335 Crankshaft position sensor no normal signals are received from the crankshaft position sensor Defective coupler between crankshaft position sensor and ECU Open or short cir cuit in wire harness between crankshaft position sensor and ECU Improperly installed crankshaft position sensor Malfunction in gen erator rotor Defe...

Page 651: ...s not carried out Traction control does not work Cruise control system cannot be operated P0507 Engine idling speed is too high Malfunction when writing the ISC learning values Air leak in the intake passage Defective throttle valve Malfunction in ECU Engine idling speed is too high O2 feedback is not carried out ISC learning is not carried out P0560 Rectifier regulator malfunction detected Chargi...

Page 652: ... P062F EEPROM fault code number an error is detected while read ing or writing on EEPROM CO adjustment value is not properly written ISC learning value is not properly written OBD memory value is not properly writ ten Malfunction in ECU Increased exhaust emissions Engine cannot be started or is difficult to start Engine idling speed is unstable OBD memory value is not correct CO adjustment value f...

Page 653: ...function in ECU Engine cannot be started Engine is forcefully stopped the injector output is stopped P1602 Malfunction in ECU internal circuit mal function of ECU power cut off function Open or short cir cuit in wire harness between ECU and battery Open or short cir cuit in wire harness between ECU and ignition system relay Blown backup fuse Malfunction in ECU Engine idling speed is unstable Engin...

Page 654: ...r opening is fixed to 0 O2 feedback is not carried out YCC T evacuation is activated Fuel cut is prohibited by accelerator open ing Output is restricted ISC feedback is not carried out ISC learning is not carried out Cruise control system cannot be operated P2158 Front wheel sensor no normal signals are received from the front wheel sensor Open or short cir cuit in wire harness between front wheel...

Page 655: ...tle position sensor sig nal 1 Fully closed position 11 20 Check with throttle valves fully closed Fully open position 95 106 Check with throttle valves fully open 03 Intake air pressure Displays the intake air pres sure Operate the throttle while pushing the ON start switch If the display value changes the performance is OK 05 Air temperature Displays the air temperature Compare the actually mea s...

Page 656: ...signal 1 Fully closed position 11 20 Check with throttle grip fully closed position Fully open position 95 106 Check with throttle grip fully open position 15 Accelerator position sensor signal 2 Fully closed position 9 23 Check with throttle grip fully closed position Fully open position 93 109 Check with throttle grip fully open position 16 Front wheel vehicle speed pulses Front wheel speed puls...

Page 657: ...e Speed Control learning condition display ISC Idle Speed Control learning data erasure 00 ISC Idle Speed Control learning data has been erased 01 It is not necessary to erase the ISC Idle Speed Control learning data 02 It is necessary to erase the ISC Idle Speed Control learning data To erase the ISC Idle Speed Control learning data set the engine stop switch from to 3 times in 5 sec onds 70 Cont...

Page 658: ...eleased OFF 87 O2 feedback learning data erasure 00 O2 feedback learning data has been erased 01 O2 feedback learning data has not been erased To erase the O2 feedback learning data set the engine stop switch from to 3 times in 5 seconds Diagnostic code No Item Actuation Procedure 30 Ignition coil Actuates the ignition coil five times at one second inter vals The check indicator on the Yamaha diag...

Page 659: ...elay is actuated five times by listening for the operating sound 51 Radiator fan motor relay Actuates the radiator fan motor relay five times at five second intervals The check indicator on the Yamaha diagnostic tool screen come on each time the relay is actuated Check that the radiator fan motor relay is actuated five times by listening for the operating sound 52 Headlight relay dimmer Actuates t...

Page 660: ...umber P0112 and P0113 Perform the inspection items listed for fault code number P0112 and P0113 203 Lean angle sen sor Brief abnormality detected in the lean angle sensor Same as for fault code number P1604 and P1605 Perform the checks and maintenance jobs for fault code number P1604 and P1605 207 Accelerator posi tion sensor Brief abnormality detected in the accel erator position sensor Same as f...

Page 661: ...tioning properly 244 Poor start ing inability to start Poor starting inability to start detected No gasoline Malfunction in the fuel injection system Dirty or worn spark plug Malfunction in the bat tery Malfunction in ECU If a fault code is occurring respond to that first Rarely Code 244 occurs even when the system is functioning properly 245 Engine stop Engine stop detected No gasoline Poorly adj...

Page 662: ...e on Service is finished Engine trouble warning light comes on Go to item 2 2 Installed condition of lean angle sensor Check the installed direction and condition of the sensor Push the ON start switch then push the OFF LOCK switch and then push the ON start switch Engine trouble warning light does not come on Service is finished Engine trouble warning light comes on Go to item 3 3 Defective lean ...

Page 663: ...r a long period of time Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Allow to idle for a long period of time Push the OFF LOCK switch Check whether it is possible to start the engine Able to start the engine Ser vice is finished Unable to start the engine Go to item 2 2 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU on page 8 21...

Page 664: ...EVENT CODE TABLE 9 21 ...

Page 665: ...8 Horn switch 59 Menu switch 60 Select switch 61 Turn signal switch 62 Rear brake light switch 63 Front turn signal light left 64 Front turn signal light right 65 Rear turn signal light left 66 Rear turn signal light right 67 License plate light 68 Tail brake light left 69 Tail brake light right 70 Diode 5 71 Horn 72 Smart key system relay un lock 73 Seat fuel lid lock solenoid 74 Smart key system...

Page 666: ...ch 64 Front turn signal light left 65 Front turn signal light right 66 Rear turn signal light left 67 Rear turn signal light right 68 License plate light 69 Tail brake light left 70 Tail brake light right 71 Diode 5 72 Horn 73 Smart key system relay un lock 74 Storage compartment lid lock solenoid 75 Seat fuel lid lock solenoid 76 Smart key system relay lock 77 Meter assembly 78 Smart key system i...

Page 667: ...left 69 Rear turn signal light right 70 License plate light 71 Tail brake light left 72 Tail brake light right 73 Diode 5 74 Horn 75 Brake light fuse 76 Front brake light switch 77 Rear brake light switch 78 Grip cancel switch 79 Smart key system relay un lock 80 Storage compartment lid lock solenoid 81 Seat fuel lid lock solenoid 82 Windshield drive unit 83 Windshield drive unit relay down 84 Win...

Page 668: ...ow G B Green Black G L Green Blue G R Green Red G W Green White G Y Green Yellow Gy G Gray Green L B Blue Black L G Blue Green L R Blue Red L W Blue White L Y Blue Yellow Lg B Light green Black Lg L Light green Blue Lg W Light green White O W Orange White P B Pink Black P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow W G White Green W L White Blue W R White Red...

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Page 671: ...XP530E A 2017 WIRING DIAGRAM XP530E A 2017 SCHÉMA DE CÂBLAGE XP530E A 2017 SCHALTPLAN XP530E A 2017 SCHEMA ELETTRICO XP530E A 2017 DIAGRAMA ELÉCTRICO BV1 28197 E0_W D indd 1 2017 04 04 14 44 50 ...

Page 672: ...XP530E A 2017 WIRING DIAGRAM XP530E A 2017 SCHÉMA DE CÂBLAGE XP530E A 2017 SCHALTPLAN XP530E A 2017 SCHEMA ELETTRICO XP530E A 2017 DIAGRAMA ELÉCTRICO BV1 28197 E0_W D indd 2 2017 04 04 14 44 50 ...

Page 673: ...XP530 A 2017 WIRING DIAGRAM XP530 A 2017 SCHÉMA DE CÂBLAGE XP530 A 2017 SCHALTPLAN XP530 A 2017 SCHEMA ELETTRICO XP530 A 2017 DIAGRAMA ELÉCTRICO BV1 28197 E0_W D indd 3 2017 04 04 14 44 51 ...

Page 674: ...XP530 A 2017 WIRING DIAGRAM XP530 A 2017 SCHÉMA DE CÂBLAGE XP530 A 2017 SCHALTPLAN XP530 A 2017 SCHEMA ELETTRICO XP530 A 2017 DIAGRAMA ELÉCTRICO BV1 28197 E0_W D indd 4 2017 04 04 14 44 51 ...

Page 675: ...XP530D A 2017 WIRING DIAGRAM XP530D A 2017 SCHÉMA DE CÂBLAGE XP530D A 2017 SCHALTPLAN XP530D A 2017 SCHEMA ELETTRICO XP530D A 2017 DIAGRAMA ELÉCTRICO BV1 28197 E0_W D indd 5 2017 04 04 14 44 52 ...

Page 676: ...XP530D A 2017 WIRING DIAGRAM XP530D A 2017 SCHÉMA DE CÂBLAGE XP530D A 2017 SCHALTPLAN XP530D A 2017 SCHEMA ELETTRICO XP530D A 2017 DIAGRAMA ELÉCTRICO BV1 28197 E0_W D indd 6 2017 04 04 14 44 52 ...

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Summary of Contents for TMAX XP530-A 2017

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Yamaha TMAX XP530-A 2017, Service Manual, Page: 212 / 676

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Summary of Contents for TMAX XP530-A 2017

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