Yamaha TMAX XP530E-A 2017 страница 279 Скачать руководство пользователя

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INSTALLING THE CONNECTING RODS................................................5-73
INSTALLING THE CRANKSHAFT ASSEMBLY.......................................5-75

TRANSMISSION

.............................................................................................5-77

CHECKING THE TRANSMISSION ..........................................................5-78

Содержание TMAX XP530E-A 2017

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 46: ...SPECIAL TOOLS 1 37...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

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

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

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

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

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 126: ...CABLE ROUTING 2 79...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 164: ...PERIODIC MAINTENANCE 3 36...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 358: ...TRANSMISSION 5 79...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 388: ...THROTTLE BODY 7 15...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 417: ...CHARGING SYSTEM 8 26...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 437: ...SIGNALING SYSTEM 8 46...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 445: ...COOLING SYSTEM 8 54...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 669: ......

Страница 670: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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