Yamaha XP560D, Service Manual

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CABLE ROUTING
1. Front brake master cylinder
2. Front brake hose (front brake master cylin-
der to hydraulic unit)
3. OFF/LOCK switch coupler
4. Parking/Unlock switch coupler
5. Clamp A
6. Clamp B
7. Throttle cable (decelerator cable)
8. Throttle cable (accelerator cable)
9. Wire harness
10. Handlebar cover
11. Rear brake master cylinder
12. Bracket
13. Handlebar switch lead (right)
14. Handlebar switch lead (left)
A. Route the throttle cable (accelerator cable)
in front of the throttle cable (decelerator
cable).
B. Connect the OFF/LOCK switch coupler to
the coupler (black) on the wire harness.
C. Connect the Parking/Unlock switch coupler
to the coupler (white) on the wire harness.
D. Route the rear brake hose behind the
leads around the handlebar and throttle
cables.
E. Route the wire harness in front of the leads
around the handlebar.
F. Route the rear brake hose on top of the
front brake hose.
G. Route the front brake hose behind the
throttle cables.
H. Route the throttle cables thorough the right
side opening in the handlebar cover as
shown in the illustration.
I. Connect the front brake light switch con-
nector from inside the vehicle.
J. The metal part of the front brake hose
should come into contact with the guide
section of the front brake master cylinder.
K. Attach the front brake hose with the white
paint mark on the metal part facing the
front.
L. Route the metal part of the rear brake hose
between the guides of the rear brake mas-
ter cylinder.
M. Attach the rear brake hose with the yellow
paint mark on the metal part facing the
front.
N. Consolidate the leads around the handle-
bar and fasten them with the clamp. Refer
to “P. Clamp A fixed position details”.
O. Face the end of the wire harness clamp
toward the left.
P. Clamp A fixed position details
Q. Right side of the vehicle
R. Left side of the vehicle
S. Fasten the handlebar switch lead (left) and
handlebar switch lead (right) with the
clamp. The positions of the wires are arbi-
trary.
T. The end of the clamp should face the right
without being cut.
U. Clamp installing procedure
1. Mark the reference point on the lead of
each component.
2. Align the marking of each lead and fas-
ten with the clamp A.
3. Fasten the wire harness with the clamp
B at a position that is located 275–285 mm
(10.83–11.22 in) from the end of clamp A.
4. Wrap the positioning tape at a position
205–215 mm (8.07–8.46 in) from the edge
of clamp B.
V. 285–295 mm (11.22–11.61 in): Case end
face
W. Reference point
X. 245–255 mm (9.65–10.04 in): Case end
face
Y. Make sure there is no slack, break, entan-
gling, etc., within this interval for each har-
ness.
Z. Interval between the clamp A end and the
clamp B end: 275–285 mm (10.83–11.22
in)
AA.205–215 mm (8.07–8.46 in)
AB.10 mm (0.39 in): Tape width
AC.Wrap the white tape around twice.