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. Throttle cable guide (accelerator cable)
10. Handlebar cover
11. Cable holder
12. Grip warmer lead (right)
13. Handlebar switch (right)
14. Rear brake master cylinder
15. Bracket
16. Wire harness
17. Grip warmer lead (right)
18. Handlebar switch lead (right)
19. Front brake light switch lead
20. Rear brake light switch lead
21. Handlebar switch lead (left)
22. Grip warmer 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 grip cancel switch lead between
the accelerator position sensor coupler
and the wire harness.
G. Route the rear brake hose on top of the
front brake hose.
H. Arrange the grip cancel switch coupler in
front of the rear brake hose and leads
around the handlebar.
I. Route the front brake hose behind the
throttle cables.
J. Route the throttle cables thorough the right
side opening in the handlebar cover as
shown in the illustration.
K. Pass the grip warmer lead through the side
of the throttle cable guide (accelerator
cable) to the front of the vehicle.
L. Pass the grip warmer lead through the
inside of the handlebar cover.
M. Face the flat part of the cable holder
towards the handlebar switch (right) to
assemble it.
N. The metal part of the front brake hose
should come into contact with the guide
section of the front brake master cylinder.
O. Install the front brake hose with the white
paint mark on the metal part facing the
front.
P. Route the metal part of the rear brake hose
between the guides of the rear brake mas-
ter cylinder.
Q. Install the rear brake hose with the yellow
paint mark on the metal part facing the
front.
R. Consolidate the leads around the handle-
bar and fasten them with the clamp. Refer
to “T. Clamp A fixed position details”.
S. Face the end of the wire harness clamp
toward the left.
T. Clamp A fixed position details
U. Right side of the vehicle
V. Left side of the vehicle
W. Fasten the grip warmer lead (left), grip
warmer lead (right), handlebar switch lead
(left), handlebar switch lead (right), front
brake light switch lead, and rear brake light
switch lead with the clamp. The positions
of the wires are arbitrary.
X. The end of the clamps should face the right
without being cut.
Y. 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.
Z. 305–315 mm (12.01–12.40 in): Grommet
end face
AA.285–295 mm (11.22–11.61 in): Case end
face
AB.255–265 mm (10.04–10.43 in): Case end
face
AC.165–175 mm (6.50–6.89 in): Clamp point
AD.Reference point
AE.330–340 mm (12.99–13.39 in): Collar end
face
AF. 245–255 mm (9.65–10.04 in): Case end
face
AG.215–225 mm (8.46–8.86 in): Case end
face
AH.Make sure there is no slack, break, entan-
gling, etc., within this interval for each har-
ness.
AI. Interval between the clamp A end and the
clamp B end: 275–285 mm (10.83–11.22 in)
AJ. 205–215 mm (8.07–8.46 in)
AK.Wrap the white tape around twice.
AL. 10 mm (0.39 in): Tape width