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Yamaha TMAX XP530E-A 2017, Service Manual


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VALVES AND VALVE SPRINGS

5-24

4. Install:

•

Valve cotters

TIP

Install the valve cotters by compressing the
valve spring with the valve spring compressor
“1” and the valve spring compressor attachment
“2”.

5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.

NOTICE

ECA13800

Hitting the valve tip with excessive force

could damage the valve.

6. Lubricate:

•

Valve pad
(with the recommended lubricant)

7. 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 spring compressor

90890-04019

Valve spring compressor

YM-04019

Valve spring compressor attach-

ment

90890-04114

Valve spring compressor adapter 

19.5 mm

YM-04114

Recommended lubricant

Molybdenum disulfide oil

Recommended lubricant

Engine oil

Summary of Contents for TMAX XP530E-A 2017

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

Page 2: ......

Page 3: ...P530 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 ex...

Page 4: ...ificant 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...

Page 5: ...ft 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...

Page 6: ...viceable 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 Mo...

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: ...D 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...

Page 10: ...AS30002 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 informat...

Page 11: ...ble 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...

Page 12: ...m 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 Co...

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 distan...

Page 14: ...se 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...

Page 15: ...e 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...

Page 16: ...ng 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...

Page 17: ...ing 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 sys...

Page 18: ...sing 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...

Page 19: ...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...

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 size...

Page 21: ...lant 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...

Page 22: ...0 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...

Page 23: ...e 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...

Page 24: ...own 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...

Page 25: ...ill 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 se...

Page 26: ...n 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 displ...

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...

Page 28: ...he 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 th...

Page 29: ...ng 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 P...

Page 30: ...aintenance 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 a...

Page 31: ...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 func...

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 c...

Page 33: ...tener 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 fast...

Page 34: ...f 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 R...

Page 35: ...y 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...

Page 36: ...refore 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 an...

Page 37: ...alues 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...

Page 38: ...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 Mo...

Page 39: ...ension 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...

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 27 90890 01423 Damping rod holder YM 01423 4 90 4 93 Fork seal driver 908...

Page 41: ...ion 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 at...

Page 42: ...installer 4 0 mm YM 04112 5 21 Valve guide reamer 4 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...

Page 43: ...racket 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 Un...

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 in...

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...

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

Page 47: ...ENING 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 LUB...

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 W...

Page 49: ...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...

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 1...

Page 51: ...d 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...

Page 52: ...imit 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 axl...

Page 53: ...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...

Page 54: ...beless 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 Re...

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 m...

Page 56: ...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 ty...

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 tempera...

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 specif...

Page 59: ...20 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 a...

Page 60: ...ry 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...

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 g...

Page 62: ...maha 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 c...

Page 63: ...ving 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...

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

Page 65: ...o 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 pu...

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

Page 67: ...ATION 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...

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: ...olant 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...

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

Page 77: ...STEM 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 o...

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

Page 79: ...ck 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 cou...

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

Page 81: ...he 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 ba...

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...

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...

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

Page 87: ...f 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 w...

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...

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 co...

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

Page 93: ...ttle 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...

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 Si...

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

Page 97: ...ic 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 decel...

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

Page 99: ...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...

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

Page 101: ...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 le...

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

Page 103: ...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...

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

Page 105: ...h 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 di...

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 b...

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

Page 109: ...topper 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 contac...

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

Page 111: ...g 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...

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 pu...

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

Page 115: ...p 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 lo...

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 shou...

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

Page 119: ...lant 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 fille...

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

Page 121: ...amp 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 sho...

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

Page 123: ...acing 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 ho...

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 brak...

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...

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 CH...

Page 129: ...ION 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 m...

Page 130: ...after 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 nut...

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 f...

Page 132: ...P 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 operatio...

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...

Page 134: ...efer 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...

Page 135: ...am 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 th...

Page 136: ...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 fo...

Page 137: ...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 CLEA...

Page 138: ...ir 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...

Page 139: ...age 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 o...

Page 140: ...ke 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 CH...

Page 141: ...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...

Page 142: ...lt 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...

Page 143: ...nt 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 e...

Page 144: ...l 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...

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 cyli...

Page 146: ...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 Tu...

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 b...

Page 148: ...ation 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...

Page 149: ...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 Interna...

Page 150: ...ive 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 t...

Page 151: ...ard 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 Dr...

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 st...

Page 153: ...terstand 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 EAS...

Page 154: ...ed 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 i...

Page 155: ...uld 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...

Page 156: ...ithium 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 u...

Page 157: ...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 a...

Page 158: ...on 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 l...

Page 159: ...in 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...

Page 160: ...lable 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 rese...

Page 161: ...lty 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...

Page 162: ...DLIGHT 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...

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...

Page 166: ...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 INST...

Page 167: ...BSORBER 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 A...

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...

Page 169: ...anel 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 1...

Page 170: ...ct 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...

Page 171: ...rts 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...

Page 172: ...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 XP530...

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...

Page 174: ...nstall 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 REM...

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 removi...

Page 176: ...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 t...

Page 177: ...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...

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...

Page 179: ...ver 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 con...

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...

Page 181: ...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 B...

Page 182: ...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...

Page 183: ...MOVING 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 Rem...

Page 184: ...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 In...

Page 185: ...RAL 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 W...

Page 186: ...de 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...

Page 187: ...r 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 Hydr...

Page 188: ...ht 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...

Page 189: ...heel 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...

Page 190: ...ng 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...

Page 191: ...he 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...

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 sho...

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...

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 whee...

Page 195: ...tly 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 h...

Page 196: ...ts 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 r...

Page 197: ...he 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 whee...

Page 198: ...er 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 w...

Page 199: ...der 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...

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: ...ntact 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...

Page 202: ...e 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...

Page 203: ...SOR 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 repla...

Page 204: ...stalling 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 th...

Page 205: ...n 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...

Page 206: ...EEL 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...

Page 207: ...rake 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 F...

Page 208: ...phragm 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...

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 bol...

Page 211: ...lipers 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 brak...

Page 212: ...emove 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...

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 R...

Page 214: ...e 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...

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 passage...

Page 216: ...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 t...

Page 217: ...ery 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 mas...

Page 218: ...RNING 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...

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...

Page 221: ...ir 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 ga...

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: ...EEDING 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 sup...

Page 224: ...ear 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...

Page 225: ...ear 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...

Page 226: ...moving 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...

Page 227: ...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 brak...

Page 228: ...er 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 CHECK...

Page 229: ...ke 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 feelin...

Page 230: ...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 b...

Page 231: ...tall 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...

Page 232: ...id 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 Bra...

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 performanc...

Page 234: ...lts 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...

Page 235: ...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 WAR...

Page 236: ...SSEMBLING 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...

Page 237: ...ear 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...

Page 238: ...STEM 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 hydrauli...

Page 239: ...raulic 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 cy...

Page 240: ...moved 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...

Page 241: ...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 bra...

Page 242: ...ine 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...

Page 243: ...f 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 ove...

Page 244: ...ion 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 fr...

Page 245: ...nit 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...

Page 246: ...er 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 P...

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...

Page 248: ...ck 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...

Page 249: ...o 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 handleba...

Page 250: ...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 Lo...

Page 251: ...NDER 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...

Page 252: ...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...

Page 253: ...amaha 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...

Page 254: ...y 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...

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 Out...

Page 256: ...h 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 locknu...

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 t...

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 th...

Page 259: ...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 For...

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 r...

Page 261: ...uter 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...

Page 262: ...ressor 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 M...

Page 263: ...mbly 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...

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 L...

Page 265: ...sh 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 hamm...

Page 266: ...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...

Page 267: ...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...

Page 268: ...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 Ins...

Page 269: ...ly 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 assem...

Page 270: ...BER 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 We...

Page 271: ...es 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...

Page 272: ...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 R...

Page 273: ...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...

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...

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 le...

Page 276: ...ur 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...

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...

Page 278: ...H 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...

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

Page 280: ...nk 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 pressur...

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...

Page 282: ...t 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...

Page 283: ...e 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 cou...

Page 284: ...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...

Page 285: ...ut 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 th...

Page 286: ...HANGING 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 h...

Page 287: ...FTS 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...

Page 288: ...e 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 ill...

Page 289: ...p 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...

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 EAS3...

Page 291: ...n 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 c...

Page 292: ...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 spe...

Page 293: ...ead 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 Ti...

Page 294: ...o 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 ga...

Page 295: ...nate 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...

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...

Page 297: ...prings 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 val...

Page 298: ...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 w...

Page 299: ...ve 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 guid...

Page 300: ...cylinder 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 t...

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 f...

Page 302: ...cedure 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 se...

Page 303: ...ubricate 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...

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 Pist...

Page 305: ...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 C...

Page 306: ...evel 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...

Page 307: ...owing 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...

Page 308: ...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 Cylin...

Page 309: ...de 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 310: ...er 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...

Page 311: ...asure 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 Re...

Page 312: ...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 t...

Page 313: ...ENERAL 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...

Page 314: ...y 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 Inn...

Page 315: ...eave 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 weig...

Page 316: ...se 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...

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...

Page 318: ...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...

Page 319: ...ave 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 ali...

Page 320: ...ve 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 Sea...

Page 321: ...ly 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 seconda...

Page 322: ...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 bear...

Page 323: ...age 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...

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...

Page 325: ...em 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 Beari...

Page 326: ...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 clu...

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 Repla...

Page 328: ...or 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...

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

Page 330: ...ERAL 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...

Page 331: ...ate 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...

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: ...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 al...

Page 334: ...ch 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 s...

Page 335: ...sing 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 Re...

Page 336: ...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...

Page 337: ...ly 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 ho...

Page 338: ...AL 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...

Page 339: ...ks 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 Pi...

Page 340: ...HECKING 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...

Page 341: ...ge 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...

Page 342: ...ke 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 k...

Page 343: ...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...

Page 344: ...an 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 Che...

Page 345: ...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 Repai...

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...

Page 347: ...in 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...

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 th...

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 b...

Page 350: ...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...

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...

Page 352: ...eads 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 bearin...

Page 353: ...ith 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 TI...

Page 354: ...lancer 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 illust...

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 Dr...

Page 357: ...e 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 s...

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

Page 359: ...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 PUM...

Page 360: ...L 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 Radia...

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...

Page 362: ...ace 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...

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...

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 specif...

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...

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 ho...

Page 368: ...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 c...

Page 369: ...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...

Page 370: ...E 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 EAS3044...

Page 371: ...al 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 wit...

Page 372: ...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 r...

Page 373: ...E 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 T...

Page 374: ...r 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...

Page 375: ...sembly 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 breat...

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...

Page 377: ...ng 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 I...

Page 378: ...y 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 pa...

Page 379: ...l 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 Thrott...

Page 380: ...r 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...

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: ...ell 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...

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 thrott...

Page 384: ...LE 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 EA...

Page 385: ...ve 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 CHA...

Page 386: ...nsor 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 se...

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

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

Page 389: ...ROUBLESHOOTING 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 CR...

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 u...

Page 391: ...HECKING 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 POSIT...

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

Page 393: ...y 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 E...

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

Page 395: ...y 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 E...

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

Page 397: ...ition 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...

Page 398: ...y 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 24...

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...

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 E...

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 E...

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

Page 405: ...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...

Page 406: ...ed 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...

Page 407: ...ake 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 swi...

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 MOTO...

Page 409: ...e 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 swi...

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: ...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 Replac...

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...

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...

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

Page 423: ...2 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...

Page 424: ...ace 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...

Page 425: ...E 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...

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

Page 427: ...t 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 7...

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

Page 429: ...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...

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

Page 431: ...t 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 bra...

Page 432: ...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 C...

Page 433: ...1 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 sys...

Page 434: ...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...

Page 435: ...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 th...

Page 436: ...AM 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 entir...

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

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

Page 439: ...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 rela...

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...

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

Page 443: ...gine 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 rela...

Page 444: ...e 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 Re...

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

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

Page 447: ...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 p...

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

Page 449: ...ight 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 plu...

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

Page 451: ...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 C...

Page 452: ...ine 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 c...

Page 453: ...ions 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 Acc...

Page 454: ...he 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...

Page 455: ...e 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 Dia...

Page 456: ...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 s...

Page 457: ...f 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 Yama...

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 co...

Page 459: ...ressure 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...

Page 460: ...ion 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 I...

Page 461: ...nking 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 m...

Page 462: ...rely 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 an...

Page 463: ...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 g...

Page 464: ...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 P0...

Page 465: ...17 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 v...

Page 466: ...he 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 Detec...

Page 467: ...erature 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...

Page 468: ...fective 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...

Page 469: ...irmation 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 locki...

Page 470: ...en 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...

Page 471: ...tle 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...

Page 472: ...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 po...

Page 473: ...inish 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 o...

Page 474: ...e 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 cod...

Page 475: ...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...

Page 476: ...rs 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...

Page 477: ...as 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 sy...

Page 478: ...en 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...

Page 479: ...ine 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...

Page 480: ...etected 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 Imprope...

Page 481: ...se 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 che...

Page 482: ...d 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 483: ...et 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 Conditi...

Page 484: ...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 lig...

Page 485: ...tem 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 ADJU...

Page 486: ...tem 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...

Page 487: ...e 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 t...

Page 488: ...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 termin...

Page 489: ...tem 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...

Page 490: ...nd 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...

Page 491: ...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 o...

Page 492: ...sh 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 D...

Page 493: ...eplace 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 G...

Page 494: ...uity 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...

Page 495: ...nostic 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...

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 Maintenanc...

Page 497: ...ad 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...

Page 498: ...arness 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 Acc...

Page 499: ...ition 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...

Page 500: ...cted 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 detect...

Page 501: ...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 ou...

Page 502: ...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...

Page 503: ...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...

Page 504: ...n 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 th...

Page 505: ...e 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...

Page 506: ...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 6 and finish the service Condition is...

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: ...e 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 sys...

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: ...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 ligh...

Page 512: ...se 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 st...

Page 513: ...here 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 usin...

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 troubleshoo...

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...

Page 516: ...rake 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 diagno...

Page 517: ...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 Co...

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 c...

Page 519: ...trol 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...

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...

Page 521: ...cuit 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 swi...

Page 522: ...a 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...

Page 523: ...tive 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 fa...

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...

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 Engin...

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 Engin...

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

Page 531: ...7 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 cou...

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 LAY...

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: ...elay 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 W...

Page 536: ...CKING 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...

Page 537: ...ndshield 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 entir...

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

Page 539: ...ngine 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 Cont...

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 BATT...

Page 541: ...e 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 a...

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

Page 543: ...n 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 Sea...

Page 544: ...ne 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...

Page 545: ...YS 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 assemb...

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...

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: ...use 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 asse...

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

Page 551: ...use 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 asse...

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

Page 553: ...CU 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 9...

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: ...ostic 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...

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...

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...

Page 558: ...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 serv...

Page 559: ...bjecting 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 malfu...

Page 560: ...l 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 coup...

Page 561: ...eter 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 swit...

Page 562: ...gnostic 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 h...

Page 563: ...s 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 so...

Page 564: ...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 w...

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 suppl...

Page 566: ...ensor 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 f...

Page 567: ...sor 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 sens...

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 th...

Page 569: ...l 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 w...

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 a...

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 a...

Page 572: ...or 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 se...

Page 573: ...ar 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...

Page 574: ...he 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 pe...

Page 575: ...obable 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 int...

Page 576: ...r 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...

Page 577: ...f 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...

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 Sympto...

Page 579: ...e 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 charg...

Page 580: ...rt 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 whe...

Page 581: ...rt 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...

Page 582: ...roper 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 O...

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: ...ff 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 sign...

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

Page 587: ...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 ligh...

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

Page 589: ...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 ligh...

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...

Page 591: ...eplace 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...

Page 592: ...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...

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...

Page 594: ...he 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 co...

Page 595: ...on 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...

Page 596: ...ognized 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...

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 centerstan...

Page 598: ...y 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...

Page 599: ...ight 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 fr...

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 pus...

Page 601: ...ehicle 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 proced...

Page 602: ...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 RE...

Page 603: ...on 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...

Page 604: ...nd 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 r...

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: ...ector 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...

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

Page 609: ...azard 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 XP530...

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: ...ear 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...

Page 612: ...30E 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...

Page 613: ...witch 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 sw...

Page 614: ...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...

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...

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 FR...

Page 617: ...ch 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 1...

Page 618: ...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...

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 transpare...

Page 620: ...ational 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 wro...

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 re...

Page 622: ...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 t...

Page 623: ...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...

Page 624: ...t 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 Di...

Page 625: ...tery 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...

Page 626: ...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 ba...

Page 627: ...ster 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 b...

Page 628: ...ntinuity 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...

Page 629: ...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 pro...

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 pr...

Page 631: ...eversed 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 f...

Page 632: ...N 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 withi...

Page 633: ...gle 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...

Page 634: ...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 spec...

Page 635: ...S31557 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...

Page 636: ...mper 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 s...

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 positi...

Page 638: ...otor 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 D...

Page 639: ...SURE 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 NO...

Page 640: ...minals 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 a...

Page 641: ...t 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...

Page 642: ...P530D 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...

Page 643: ...ORMANCE 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...

Page 644: ...m 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 dama...

Page 645: ...ion 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...

Page 646: ...amaged 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 component...

Page 647: ...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 haz...

Page 648: ...tive 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...

Page 649: ...22 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 P02...

Page 650: ...SC 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 cr...

Page 651: ...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 p...

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 p...

Page 653: ...unction 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 c...

Page 654: ...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...

Page 655: ...le 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 in...

Page 656: ...ignal 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...

Page 657: ...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 Contro...

Page 658: ...leased 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...

Page 659: ...lay 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...

Page 660: ...mber 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...

Page 661: ...ioning 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 ter...

Page 662: ...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...

Page 663: ...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 whethe...

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

Page 665: ...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 tu...

Page 666: ...h 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 ri...

Page 667: ...eft 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 swi...

Page 668: ...w 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 Li...

Page 669: ......

Page 670: ......

Page 671: ...XP530E A 2017 WIRING DIAGRAM XP530E A 2017 SCH MA DE C BLAGE XP530E A 2017 SCHALTPLAN XP530E A 2017 SCHEMA ELETTRICO XP530E A 2017 DIAGRAMA EL CTRICO BV1 28197 E0_W D indd 1 2017 04 04 14 44 50...

Page 672: ...XP530E A 2017 WIRING DIAGRAM XP530E A 2017 SCH MA DE C BLAGE XP530E A 2017 SCHALTPLAN XP530E A 2017 SCHEMA ELETTRICO XP530E A 2017 DIAGRAMA EL CTRICO BV1 28197 E0_W D indd 2 2017 04 04 14 44 50...

Page 673: ...XP530 A 2017 WIRING DIAGRAM XP530 A 2017 SCH MA DE C BLAGE XP530 A 2017 SCHALTPLAN XP530 A 2017 SCHEMA ELETTRICO XP530 A 2017 DIAGRAMA EL CTRICO BV1 28197 E0_W D indd 3 2017 04 04 14 44 51...

Page 674: ...XP530 A 2017 WIRING DIAGRAM XP530 A 2017 SCH MA DE C BLAGE XP530 A 2017 SCHALTPLAN XP530 A 2017 SCHEMA ELETTRICO XP530 A 2017 DIAGRAMA EL CTRICO BV1 28197 E0_W D indd 4 2017 04 04 14 44 51...

Page 675: ...XP530D A 2017 WIRING DIAGRAM XP530D A 2017 SCH MA DE C BLAGE XP530D A 2017 SCHALTPLAN XP530D A 2017 SCHEMA ELETTRICO XP530D A 2017 DIAGRAMA EL CTRICO BV1 28197 E0_W D indd 5 2017 04 04 14 44 52...

Page 676: ...XP530D A 2017 WIRING DIAGRAM XP530D A 2017 SCH MA DE C BLAGE XP530D A 2017 SCHALTPLAN XP530D A 2017 SCHEMA ELETTRICO XP530D A 2017 DIAGRAMA EL CTRICO BV1 28197 E0_W D indd 6 2017 04 04 14 44 52...

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