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Yamaha tmax XP500A Service Manual

Other manuals for tmax XP500A: Owner's Manual, Owner's Manual, Owner's Manual, Owner's Manual

Summary of tmax XP500A

  • Page 1

    2005 xp500 xp500a 5vu5-ae1 service manual.

  • Page 3

    Eas00000 xp500/xp500a 2005 service manual ©2004 by yamaha motor co., ltd. First edition, september 2004 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 4: Notice

    Eas00002 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on yama...

  • Page 5: How to Use This Manual

    Eas00007 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 the manual is di...

  • Page 6: Symbols

    Eas00008 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic checks and adjustments 4 chassis 5 engine 6 cooling system 7 fuel injection system 8 electrical system 9 troubleshooting sy...

  • Page 7: Table of Contents

    Eas00012 table of contents general information gen info 1 specifications spec 2 periodic checks and adjustments chk adj 3 chassis chas 4 engine eng 5 cooling system cool 6 fuel injection system fi 7 electrical system elec 8 troubleshooting trbl shtg 9 – +.

  • Page 9: Gen

    Gen info 1.

  • Page 10: Gen

    Gen info chapter 1 general information scooter identification .......................................................................... 1-1 vehicle identification number ..................................................... 1-1 model label...............................................................

  • Page 11: Gen

    Gen info.

  • Page 12: 1 - 1

    1 - 1 gen info eas00015 general information scooter identification eas00017 vehicle identification number the vehicle identification number 1 is stamped into the right side of the frame. Eas00018 model label the model label 2 is affixed to the storage box. This information will be needed to order sp...

  • Page 13: 1 - 2

    1 - 2 gen info features eas00019 features eas00896 outline of fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions. In a conventional carburetor system, the air-fuel ratio o...

  • Page 14: 1 - 3

    1 - 3 gen info features eas00897 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump) maintains the fuel pressure that is applied to the fuel injector at 240 ~ 260 kpa (2.40 ~ 2.60 kg/cm 2 , 34.1 ~ 37.0 psi) higher than the intake ...

  • Page 15: 1 - 4

    1 - 4 gen info features outline of anti-lock brake system (xp500a) yamaha abs features 1. The yamaha abs (anti-lock brake system) features a dual electronic control system, which acts on the front and rear brakes independently. 2. The abs features a compact and lightweight design to help maintain th...

  • Page 16: 1 - 5

    1 - 5 gen info features abs block diagram 1 rear brake master cylinder 2 hydraulic unit 3 hydraulic pump 4 abs motor 5 buffer chamber 6 hydraulic control valve 7 front brake master cylinder 8 rear brake caliper 9 front brake caliper 0 ecu (abs) a rear wheel sensor b front wheel sensor c abs warning ...

  • Page 17: 1 - 6

    1 - 6 gen info features eas00873 useful terms • wheel speed: the rotation speed of the front and rear wheels. • chassis speed: the speed of the chassis. When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel s...

  • Page 18: 1 - 7

    1 - 7 gen info features eas00874 brake force and vehicle stability when the brake pressure is increased, wheel speed is reduced. Slip occurs between the tire and the road surface and brake force is gener- ated. The limit of this brake force is determined by the friction force between the tire and th...

  • Page 19: 1 - 8

    1 - 8 gen info features eas00876 abs operation and vehicle control if the abs starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the limit of control. To make the rider aware of this condition, the abs has been designed to generate a reaction-force pulsat- ing...

  • Page 20: 1 - 9

    1 - 9 gen info features eas00878 abs component functions • wheel sensors and sensor rotors wheel sensors 1 detect the wheel rotation speed and transmit the wheel rotation signal to the ecu (abs). Each wheel sensor is composed of a perma- nent magnet and a coil. The wheel sensors are installed in the...

  • Page 21: 1 - 10

    1 - 10 gen info features • electronic control unit (ecu) the ecu (abs) 1 controls the abs and is located on the right side of the vehicle near the top of the front fork. To protect the ecu (abs) from water damage, it is protected by a cover. 1 • abs control operation the abs control operation perfor...

  • Page 22: 1 - 11

    1 - 11 gen info features composition and operation the fail-safe relay is composed of the solenoid relay 1 and abs motor relay 2 . The solenoid relay is activated (continuous) by signals transmitted from the ecu (abs). As a result, the solenoid valve 3 can be operated. If a malfunction occurs in the...

  • Page 23: 1 - 12

    1 - 12 gen info features abs operation the abs hydraulic circuit consists of two systems: the front wheel and rear wheel. The following describes the front system only. • normal braking (abs not activated) when the abs is not activated port d a of the solenoid valve is closed because a control signa...

  • Page 24: 1 - 13

    1 - 13 gen info features • emergency braking (abs activated) 1) depressurized state when the front wheel is about to lockup, port d a of the solenoid valve is opened by the “depres- surization” signal transmitted from the ecu (abs). When this occurs, the spool of the flow control valve compresses th...

  • Page 25: 1 - 14

    1 - 14 gen info features 2) pressurized state port d a is closed by the “pressurization” signal transmitted from the ecu (abs). Before this occurs, the spool of the flow control valve has compressed the return spring to close port b 9 . Brake fluid that has entered through port a 7 is further restri...

  • Page 26: 1 - 15

    1 - 15 gen info features instrument function multi-function display warning be sure to stop the vehicle before making any setting changes to the multi-function display. The multi-function display is equipped with the following: • a fuel meter 1 • a coolant temperature meter 2 • an odometer (which sh...

  • Page 27: 1 - 16

    1 - 16 gen info features when approximately 2.8 l (0.62 imp gal, 0.74 us gal) of fuel remains in the fuel tank, the bottom segment of the fuel meter and fuel level warning symbol will start flashing, and the display will automatically change to the fuel reserve tripmeter mode “trip f” and start coun...

  • Page 28: 1 - 17

    1 - 17 gen info features oil change indicator “oil” this indicator flashes at the initial 1,000 km (600 mi), then at 5,000 km (3,000 mi) and every 5,000 km (3,000 mi) thereafter to indi- cate that the engine oil should be changed. After changing the engine oil, reset the oil change indicator. Refer ...

  • Page 29: 1 - 18

    1 - 18 gen info features v-belt replacement indicator “v-belt” this indicator flashes every 20,000 km (12,000 mi) when the v-belt needs to be replaced. The electrical circuit of the indicator can be checked according to the following pro- cedure. 1. Turn the key to “on” and make sure that the engine...

  • Page 30: 1 - 19

    1 - 19 gen info important information eas00020 important information preparation for removal and disassembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “special tools”. 3. When disassembling, a...

  • Page 31: 1 - 20

    1 - 20 gen info important information eas00023 lock washers/plates and cotter pins after removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. Eas00024 bearings and oil seals install ...

  • Page 32: 1 - 21

    1 - 21 gen info checking the connections eas00026 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and discon...

  • Page 33: 1 - 22

    1 - 22 gen info special tools eas00027 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, p...

  • Page 34: 1 - 23

    1 - 23 gen info special tools 90890-01362 yu-33270-b flywheel puller this tool is used to remove the a.C. Mag- neto rotor. Fork seal driver weight 90890-01367 ym-a5142-4 fork seal driver attachment 90890-01381 ym-a5142-2 fork seal driver weight fork seal driver attachment (41 mm) these tools are use...

  • Page 35: 1 - 24

    1 - 24 gen info special tools 90890-03079 ym-34483 thickness gauge this tool is used to measure the valve clearance. Compression gauge 90890-03081 yu-33223 extension 90890-04082 compression gauge extension these tools are used to measure engine compression. Vacuum gauge 90890-03094 yu-44456 vacuum g...

  • Page 36: 1 - 25

    1 - 25 gen info special tools 90890-03174 digital circuit tester this tool is used to check electrical sys- tem. 90890-03181 fuel pressure adapter this tool is used to measure fuel pres- sure. Valve spring compres- sor 90890-04019 ym-04019 valve spring compres- sor attachment 90890-04114 ym-04114 va...

  • Page 37: 1 - 26

    1 - 26 gen info special tools 90890-04112 ym-04112 valve guide installer (4 mm) this tool is used to install the valve guides. 90890-04113 ym-04113 valve guide reamer (4 mm) this tool is used to rebore the new valve guides. Sheave spring com- pressor 90890-04134 ym-04134 sheave fixed block 90890-041...

  • Page 38: Spec

    Spec 2.

  • Page 39: Spec

    Spec chapter 2 specifications general specifications ........................................................................ 2-1 engine specifications ............................................................................ 2-2 chassis specifications ...............................................

  • Page 40: Spec

    Spec.

  • Page 41: 2 - 1

    2 - 1 spec specifications general specifications item standard limit model code xp500: 5vu6 xp500a: 5vu5 ---- ---- dimensions overall length 2,235 mm (88.0 in) ---- overall width 775 mm (30.5 in) ---- overall height 1,410 mm (55.5 in) ---- seat height 795 mm (31.3 in) ---- wheelbase 1,575 mm (62.0 i...

  • Page 42: 2 - 2

    2 - 2 spec engine specifications engine specifications item standard limit engine engine type liquid-cooled 4-stroke, dohc ---- displacement 499 cm 3 (30.45 cu.In) ---- cylinder arrangement forward inclined parallel 2-cylinder ---- bore × stroke 66 × 73 mm (2.60 × 2.87 in) ---- compression ratio 11....

  • Page 43: 2 - 3

    2 - 3 spec engine specifications oil filter oil filter type cartridge (paper) ---- bypass valve opening pressure 80 ~ 120 kpa (0.8 ~ 1.2 kg/cm 2 , 11.6 ~ 17.4 psi) ---- oil pump oil pump type trochoid ---- inner-rotor-to-outer-rotor-tip clear- ance 0.04 ~ 0.12 mm (0.0016 ~ 0.0047 in) 0.20 mm (0.0079...

  • Page 44: 2 - 4

    2 - 4 spec engine specifications camshafts drive system chain drive (left) ---- camshaft cap inside diameter 23.000 ~ 23.021 mm (0.9055 ~ 0.9063 in) ---- camshaft journal diameter 22.967 ~ 22.980 mm (0.9042 ~ 0.9047 in) ---- camshaft-journal-to-camshaft cap clearance 0.020 ~ 0.054 mm (0.0008 ~ 0.002...

  • Page 45: 2 - 5

    2 - 5 spec engine specifications valves, valve seats, valve guides valve clearance (cold) intake 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in) ---- exhaust 0.25 ~ 0.30 mm (0.0098 ~ 0.0118 in) ---- valve dimensions valve head diameter a intake 24.9 ~ 25.1 mm (0.9803 ~ 0.9882 in) ---- exhaust 21.9 ~ 22.1 mm (0....

  • Page 46: 2 - 6

    2 - 6 spec engine specifications valve stem runout ---- 0.04 mm (0.0016 in) valve seat width intake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.06 in) exhaust 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.06 in) valve springs free length intake 35.59 mm (1.40 in) 33.81 mm (1.33 in) exhaust 35.59 mm (1...

  • Page 47: 2 - 7

    2 - 7 spec engine specifications winding direction (top view) intake clockwise ---- exhaust clockwise ---- valve lifter valve lifter outside diameter intake 24.476 ~ 24.500 mm (0.9636 ~ 0.9646 in) 24.451 mm (0.9626 in) exhaust 24.476 ~ 24.500 mm (0.9636 ~ 0.9646 in) 24.451 mm (0.9626 in) cylinders b...

  • Page 48: 2 - 8

    2 - 8 spec engine specifications piston rings top ring ring type barrel ---- dimensions (b × t) 0.80 × 2.45 mm (0.03 × 0.10 in) ---- end gap (installed) 0.15 ~ 0.25 mm (0.0059 ~ 0.0098 in) 0.50 mm (0.0197 in) ring side clearance 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) 0.10 mm (0.0039 in) 2nd ring ring...

  • Page 49: 2 - 9

    2 - 9 spec engine specifications crankshaft width a 50.00 ~ 50.60 mm (1.969 ~ 1.992 in) ---- width b 118.55 ~ 118.60 mm (4.667 ~ 4.669 in) ---- maximum runout c ---- 0.03 mm (0.0012 in) big end side clearance d 0.160 ~ 0.262 mm (0.0063 ~ 0.0103 in) ---- big end radial clearance e 0.026 ~ 0.050 mm (0...

  • Page 50: 2 - 10

    2 - 10 spec engine specifications clutch damper springs 1 height 3.30 mm (0.13 in) 2.90 mm (0.11 in) spring quantity 6 ---- clutch damper spring 2 height 4.70 mm (0.19 in) 4.40 mm (0.17 in) spring quantity 1 ---- v-belt v-belt width 32.0 mm (1.26 in) 30.5 mm (1.20 in) transmission transmission type ...

  • Page 51: 2 - 11

    2 - 11 spec chassis specifications chassis specifications item standard limit frame frame type diamond ---- caster angle 28° ---- trail 95 mm (3.74 in) ---- front wheel wheel type cast wheel ---- rim size 14m/c × mt3.50 ---- material aluminum ---- wheel travel 120 mm (4.72 in) ---- wheel runout maxi...

  • Page 52: 2 - 12

    2 - 12 spec chassis specifications rear tire tire type tubeless ---- size 160/60r15 m/c 67h ---- model/manufacturer th01r/bridgestone d252/dunlop ---- ---- tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lbs) 250 kpa (2.50 kgf/cm 2 , 36 psi) ---- 90 kg (198 lbs) ~ maximum load 280 kpa (2.80 kgf/cm 2 , 41 ps...

  • Page 53: 2 - 13

    2 - 13 spec chassis specifications front suspension type telescopic fork ---- front fork type coil spring/oil damper ---- front fork travel 120.0 mm (4.72 in) ---- fork spring free length 405.0 mm (15.94 in) 400.0 mm (15.75 in) installed length 400.0 mm (15.75 in) ---- collar length 145.0 mm (5.71 i...

  • Page 54: 2 - 14

    2 - 14 spec chassis specifications swingarm free play (at the end of the swing- arm) radial ---- 1.0 mm (0.04 in) axial ---- 1.0 mm (0.04 in) secondary drive chain model/manufacturer 23rh303.5-82asm/borg warner ---- link quantity 82 ---- primary drive chain model/manufacturer 89hv302.5rcf-66/borg wa...

  • Page 55: 2 - 15

    2 - 15 spec electrical specifications electrical specifications item standard limit system voltage 12 v ---- ignition system ignition system type transistorized coil ignition (digital) ---- ignition timing 10° btdc at 1,200 r/min ---- advancer type digital ---- crankshaft position sensor resis- tanc...

  • Page 56: 2 - 16

    2 - 16 spec electrical specifications bulbs (voltage, wattage × quantity) headlight 12 v, 60 w/55 w + 12 v, 55 w ---- auxiliary light 12 v, 5 w × 2 ---- tail/brake light 12 v, 5 w/21 w × 2 ---- front turn signal light 12 v, 21 w × 2 ---- rear turn signal light 12 v, 21 w × 2 ---- licence plate light...

  • Page 57: 2 - 17

    2 - 17 spec electrical specifications fuel pump assembly (fuel sender) model/manufacturer 5vu/aisan ---- sender unit resistance-full 19 ~ 21 Ω ---- sender unit resistance-empty 137 ~ 143 Ω ---- coolant temperature sensor model/manufacturer 5ps/denso ---- resistance at 20 °c (68 °f) 2.32 ~ 2.59 k Ω -...

  • Page 58: 2 - 18

    2 - 18 spec conversion table/ general tightening torque specifications eas00028 conversion table all specification data in this manual are listed in si and metric units. Use this table to convert metric unit data to imperial unit data. Conversion table eas00030 general tightening torque specificatio...

  • Page 59: 2 - 19

    2 - 19 spec tightening torques tightening torques engine tightening torques item part name thread size q’ty tightening torque remarks nm m · kg ft · lb spark plug — m10 2 13 1.3 9.4 cylinder head cover bolt m6 10 10 1.0 7.2 camshaft cap bolt m6 12 10 1.0 7.2 cylinder head and cylinder body nut m9 4 ...

  • Page 60: 2 - 20

    2 - 20 spec tightening torques note: *1:after tightening to 16 nm (1.6 m · kg, 11 ft · lb), tighten another 90°. *2:after tightening to 60 nm (6.0 m · kg, 43 ft · lb), tighten another 120°. Timing plug plug m16 1 8 0.8 5.8 a.C. Magneto cover bolt m6 19 10 1.0 7.2 v-belt case bolt m6 4 10 1.0 7.2 v-b...

  • Page 61: 2 - 21

    2 - 21 spec tightening torques crankcase tightening sequence: cylinder head tightening sequence: 1 ~ 8 m8 bolt 9 ~ 21 m6 bolt.

  • Page 62: 2 - 22

    2 - 22 spec tightening torques chassis tightening torques item thread size tightening torque remarks nm m · kg ft · lb upper bracket pinch bolt m8 30 3.0 22 steering stem nut m22 110 11.0 80 lower ring nut m25 20 2.0 14 see note. Front fork cap bolt m38 24 2.4 17 lower bracket pinch bolt m8 23 2.3 1...

  • Page 63: 2 - 23

    2 - 23 spec tightening torques note: 1. First, tighten the lower ring nut to approximately 52 nm (5.2 m · kg, 37 ft · lb) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 20 nm (2.0 m · kg, 14 ft · lb) with a torque wrench. Headlight unit and front ...

  • Page 64: 2 - 24

    2 - 24 spec lubrication points and lubricant types lubrication points and lubricant types engine lubrication points and lubricant types lubrication point lubricant oil seal lips ls o-rings ls bearing and bushes e crankshaft pins e piston surfaces e piston pins and connecting rod small end e balancer...

  • Page 65: 2 - 25

    2 - 25 spec lubrication points and lubricant types secondary sheave nut bel-ray assembly lube ® primary sheave bel-ray assembly lube ® secondary sheave bel-ray assembly lube ® swingarm pivot shaft bearing ls crankcase mating surface yamaha bond no. 1215 a.C. Magneto lead yamaha bond no. 1215 cylinde...

  • Page 66: 2 - 26

    2 - 26 spec lubrication points and lubricant types eas00032 chassis lubrication points and lubricant types lubrication point symbol front wheel oil seal lip ls steering bearings and oil seal lip ls throttle grip inner surface and throttle cables ls brake lever pivoting point and metal-to-metal movin...

  • Page 67: 2 - 27

    2 - 27 spec oil flow diagrams oil flow diagrams 1 oil pump 2 oil tank 3 oil strainer 4 relief valve 5 oil cooler 6 oil filter cartridge 7 exhaust camshaft 8 intake camshaft 9 oil pipe 0 oil delivery pipe.

  • Page 68: 2 - 28

    2 - 28 spec oil flow diagrams 1 oil strainer 2 crankshaft.

  • Page 69: 2 - 29

    2 - 29 spec oil flow diagrams 1 clutch 2 right main journal bearing 3 main gallery plug.

  • Page 70: 2 - 30

    2 - 30 spec oil flow diagrams exhaust camshaft intake camshaft piston cooler crankshaft oil tank oil filter cartridge oil cooler relief valve check valve flush oil pump suction oil pump strainer strainer oil pan.

  • Page 71: 2 - 31

    2 - 31 spec coolant flow diagrams eas00035 coolant flow diagrams 1 coolant reservoir 2 thermostat 3 radiator 4 water pump 5 radiator fan 6 radiator cap 7 fast idle plunger 1 2 3 5 6 2 3 6 4 7.

  • Page 72: 2 - 32

    2 - 32 spec cable routing eas00035 cable routing 1 headlight sub-wire harness 2 horn 3 horn (h mark on the back of the horn) È securely fasten the wire strap to the front cowl- ing hook to prevent it from being pulled out by the headlight assembly. (left and right) É connect the headlight sub-wire h...

  • Page 73: 2 - 33

    2 - 33 spec cable routing Ë fasten the headlight sub-wire harness using a lead holder. (left and right) Ì connect the turn signal light. (left and right) Í route the horn lead through the wire guide. Î after passing the horn lead through the lead holder, crimp the lead holder. Ï install a wire harne...

  • Page 74: 2 - 34

    2 - 34 spec cable routing Õ fasten the right handlebar switch leads to the handlebar with a plastic band. Ö route the rear brake hose and left handlebar switch leads over the wire harness..

  • Page 75: 2 - 35

    2 - 35 spec cable routing 1 rear brake hose 2 front brake hose 3 rear brake lock lever cable 4 left handlebar switch È route the rear brake lock lever cable in front of the handlebar, then down through the space between the handlebar and the upper bracket. É fasten the wire harness by sliding the pl...

  • Page 76: 2 - 36

    2 - 36 spec cable routing 1 grommet 2 fuel over flow hose 3 fuel tank 4 fuel overflow tray 5 fuel tank cap 6 upper side cover moulding (left) 7 hose guide 8 grommet 9 footrest board 0 hose clamp a fuel tank breather hose b rear footrest assembly c fuel tank breather hose d hose holder e hose holder ...

  • Page 77: 2 - 37

    2 - 37 spec cable routing È do not protrude from the upper side cover moul- ding (left). É fix the fuel overflow hose with the white paint mark as shown. Ê pass the fuel tank breather hose to the hose guide of frame (both right and left). Ë pass the fuel tank breather hose to the hose guide of rear ...

  • Page 78: 2 - 38

    2 - 38 spec cable routing Ô align the projection on the fuel pump with the projection on the fuel tank when installing the fuel pump. Õ tighten the fuel pump bolts in the proper tighten- ing sequence as shown. Ö pass the fuel hose to the hose guide. × pass the fuel hose to the inside of the frame gu...

  • Page 79: 2 - 39

    2 - 39 spec cable routing xp500 1 main switch/immobilizer unit 2 throttle cable 3 brake hose 4 meter assembly 5 cooling system air bleed hose 6 horn lead 7 radiator filer hose 8 ignition coil 9 coolant reservoir hose 0 radiator fan motor lead a throttle position sensor coupler b starter motor lead c...

  • Page 80: 2 - 40

    2 - 40 spec cable routing k rear brake lock lever cable l negative battery lead m seat lock cable (left) n frame o wire harness p storage box q v-belt replacement indicator reset coupler lead r o 2 sensor lead s fuel hose È after adjusting the adjustment nut, attach the front and rear parts of the b...

  • Page 81: 2 - 41

    2 - 41 spec cable routing Í after connecting the wire harness and meter assembly lead, use a plastic holder to connect them to stay 1. Î after connecting the left headlight sub-wire har- ness and wire harness (by matching the coupler colors), fold back the lead facing to the right and insert it into...

  • Page 82: 2 - 42

    2 - 42 spec cable routing Õ insert the tail/brake light coupler between the wire harness and the seat lock cable (left). Ö to the tail/brake light × to the starter relay Ø route the wire harness and rectifier/regulator lead through the frame wire holder. Place the rectifier/regulator lead under the ...

  • Page 83: 2 - 43

    2 - 43 spec cable routing Þ fasten the starter motor lead and negative bat- tery lead to the frame with a plastic band. Posi- tion the band clasp on the bottom of the frame and face the band end to the outside. ß install the clamshell cover around the v-belt replacement indicator reset coupler and o...

  • Page 84: 2 - 44

    2 - 44 spec cable routing pass the wire harness to the frame wire har- ness holder. After making the connections, push the cou- plers into the space inside the frame above the mudguard. Install the band’s fastened part between frame and storage box. Route the seat lock cable through the frame bracke...

  • Page 85: 2 - 45

    2 - 45 spec cable routing 1 rear brake lock lever cable 2 throttle cable (decelerator cable, double lock- nut) 3 fast idle inlet hose 4 rear brake hose 5 a.C. Magneto lead 6 fuel tank breather hose 7 coolant hose 8 sidestand switch 9 fast idle outlet hose 0 radiator outlet hose a crankcase breather ...

  • Page 86: 2 - 46

    2 - 46 spec cable routing Ê pass the fuel tank breather hose by the outside of the wire harness. Ë pass the wire harness by the outside of the rear footrest mounting boss. (when installing the rear footrest, do not catch or pinch the a.C. Magneto lead in the bracket.) Ì fasten the wire harness to th...

  • Page 87: 2 - 47

    2 - 47 spec cable routing 1 rear brake lock lever cable 2 coolant system air bleed hose 3 thermostat outlet hose 4 fuel tank breather hose 5 fuel hose 6 negative battery lead 7 starter motor lead 8 turn signal/hazard relay 9 starting circuit cut-off relay 1 0 rectifier/regulator a seat lock b batter...

  • Page 88: 2 - 48

    2 - 48 spec cable routing È route the wire harness against the stay 1 wire guide. É fasten the lean angle cut-off switch lead to the stay 1 with a plastic band. Face the band end to the downward. Ê route the lean angle cut-off switch lead through the back of the mirror stay (cross pipe). Ë fasten th...

  • Page 89: 2 - 49

    2 - 49 spec cable routing Ï pass the wire harness and seat lock cable through the guide. Ð fasten the negative battery lead and the starter motor lead to the frame with a plastic holder. Ñ fasten the fuel tank breather hose to the frame with a plastic holder. Ò pass the seat lock cable (black) betwe...

  • Page 90: 2 - 50

    2 - 50 spec cable routing Ø fasten the wire harness and seat lock cable to the frame with a plastic holder. Ù pass the wire harness, lead and cable the out- side of the frame bracket. Ú install the starter relay to the mad guard. Û fasten the wire harness, positive battery lead and seat lock cable t...

  • Page 91: 2 - 51

    2 - 51 spec cable routing to the storage box light switch on the seat hinge. Fasten the fuel injector lead (#1/#2), intake air pressure sensor lead to the frame with a plas- tic holder. Route the intake air pressure sensor lead over the fuel hose. Bundle the fuel injector lead (#2) to the frame with...

  • Page 92: 2 - 52

    2 - 52 spec cable routing 1 cooling system air bleed hose 2 storage box light switch lead 3 coolant reservoir hose 4 spark plug lead #2 5 radiator fan motor lead 6 sidestand switch lead 7 spark plug lead #1 8 rear brake lock lever cable 9 rear brake hose 0 speed sensor lead È pass the rear brake loc...

  • Page 93: 2 - 53

    2 - 53 spec cable routing Î fasten the sidestand switch lead to the frame with a plastic holder. Ï fasten the rear brake hose to the stay 1 with a plastic holder. Ð route the throttle cable through the cable holder. È É Ê É Ë Ì Î Ï Ð 2 4 5 6 7 8 9 1 3 0 Í.

  • Page 94: 2 - 54

    2 - 54 spec 1 brake hose holder 1 2 front brake hose 3 speed sensor 4 plastic holder 5 brake hose holder 2 6 speed sensor lead 7 stay1 8 brake hose holder 3 9 rear brake hose 1 È fasten the speed sensor lead along the inside of the brake hose. É 50 ~ 60 mm (1.97 ~ 2.36 in) Ê turn the handlebar compl...

  • Page 95: 2 - 55

    2 - 55 spec cable routing Î make sure that brake pipe touches the projec- tion. Ï make sure that the slot in the speed sensor fits stopper on the outer tube. Ð make sure that the stopper touches the outer tube stay. Ñ pass the speed sensor lead between the brake hose and front fork. Ò fasten the spe...

  • Page 96: 2 - 56

    2 - 56 spec cable routing xp500a 1 main switch/immobilizer unit 2 ecu (abs) 3 throttle cable 4 brake hose 5 fail-safe relay 6 meter assembly 7 coolant system air bleed hose 8 horn lead 9 ignition coil 0 radiator filer hose a coolant reservoir hose b throttle position sensor coupler c radiator fan mo...

  • Page 97: 2 - 57

    2 - 57 spec cable routing k o 2 sensor coupler l fuel pump lead m fuel tank breather hose n rear brake lock lever cable o main switch lead p wire harness q seat lock cable r seat lock cable (left) s negative battery lead t rear wheel sensor lead u frame v storage box w v-belt replacement indicator r...

  • Page 98: 2 - 58

    2 - 58 spec cable routing È after adjusting the adjustment nut, attach the front and rear parts of the boot tightly. É pass the seat lock cable between wire harness and frame. Ê connect the wire harness (wire taped area) to the t stud of frame. Ë fasten the cooling system air bleed hose and rear bra...

  • Page 99: 2 - 59

    2 - 59 spec cable routing Ð after connecting the left headlight sub-wire har- ness and wire harness (by matching the coupler colors), fold back the lead facing to the right and insert it into the air filter case rib. Ñ connect the wire harness to the headlight sub- wire harness (cowling side). Ò fas...

  • Page 100: 2 - 60

    2 - 60 spec cable routing × fasten the radiator fan motor lead and sidestand switch lead to the frame with a plastic holder. Ø fasten the wire harness and positive battery leads with a plastic band. Face the end of the plastic band upward. Ù to the starter relay Ú pass the wire harness, rectifier/re...

  • Page 101: 2 - 61

    2 - 61 spec cable routing À fasten the o 2 sensor lead to the frame with a plastic band. Á fasten the starter motor lead and negative bat- tery lead to the frame with a plastic band. Posi- tion the band clasp on the bottom of the frame and face the band end to the outside. Make sure that the v-belt ...

  • Page 102: 2 - 62

    2 - 62 spec cable routing fasten the rear wheel sensor lead to the swin- garm with the plastics holders. The open end of each holder should be facing downward. Route the rear wheel sensor lead behind the relay leads. 10 ~ 20 mm (0.39 ~ 0.79 in) fasten the rear wheel sensor lead and wire harness to t...

  • Page 103: 2 - 63

    2 - 63 spec cable routing t stud for position setting route the seat lock cable through the frame bracket side and under the wire harness. Install the band’s fastened part between frame and storage box. A q a r a s Ð Ñ Ò a-a b-b d-d f-f j-j k-k h-h c-c e-e g-g i-i p p c b o q d r t d d t p u u u p u...

  • Page 104: 2 - 64

    2 - 64 spec cable routing 1 rear brake lock lever cable 2 throttle cable (decelerator cable, double lock- nut) 3 fast idle inlet hose 4 rear brake hose 5 a.C. Magneto lead 6 fuel tank breather hose 7 coolant hose 8 sidestand switch 9 fast idle outlet hose 0 radiator outlet hose a crankcase breather ...

  • Page 105: 2 - 65

    2 - 65 spec cable routing Ë pass the wire harness by the outside of the rear footrest mounting boss. (when installing the rear footrest, do not catch or pinch the a.C. Magneto lead in the bracket.) Ì fasten the wire harness to the frame with a plas- tic holder. Í pass the storage box light switch le...

  • Page 106: 2 - 66

    2 - 66 spec cable routing 1 rear brake lock lever cable 2 cooling system air bleed hose 3 thermostat outlet hose 4 fuel tank breather hose 5 fuel hose 6 turn signal/hazard relay 7 starting circuit cut-off relay 1 8 negative battery lead 9 starting circuit cut-off relay 2 0 rectifier/regulator a star...

  • Page 107: 2 - 67

    2 - 67 spec cable routing È route the wire harness against the stay 1 wire guide. É fasten the lean angle cut-off switch lead to the stay 1 with a plastic band. Face the band end to the downward. Ê to the main switch Ë route the lean angle cut-off switch lead through the back of the mirror stay (cro...

  • Page 108: 2 - 68

    2 - 68 spec cable routing Ñ connect the seat lock cable (black) to the right seat lock. Ò pass the seat lock cable (black) between the negative battery lead, starter motor lead and the frame. Ó route the negative battery lead and the fuse box lead from the storage box opening to the bottom of the cr...

  • Page 109: 2 - 69

    2 - 69 spec cable routing Ú fasten the wire harness, positive battery lead and seat lock cable to the mad guard with a plastic holder. Û route the positive battery lead through the under the seat lock cable. Ü fasten the wire harness to the frame with a plas- tic holder. Ý connect the seat lock cabl...

  • Page 110: 2 - 70

    2 - 70 spec cable routing fasten the fuel injector lead (#1/#2), intake air pressure sensor lead to the frame with a plas- tic holder. Pass the intake air pressure sensor lead over the fuel hose. Bundle the fuel injector lead (#1) to the frame with a plastic band softly (the band possible to turn), ...

  • Page 111: 2 - 71

    2 - 71 spec cable routing 1 throttle cable 2 fail-safe relay 3 ecu (abs) 4 abs test coupler 5 cooling system air bleed hose 6 storage box light switch lead 7 coolant reservoir hose 8 spark plug lead #2 9 radiator fan motor lead 0 sidestand switch lead a spark plug lead #1 b rear brake lock lever cab...

  • Page 112: 2 - 72

    2 - 72 spec cable routing Ë route the main switch lead over the tube of the stay 1. Ì fasten the cooling system air bleed hose to the stay 1 with a plastic holder. Í after checking the abs, install the abs test cou- pler into the stay 1. Î the main switch lead couplers should not pro- trude to the o...

  • Page 113: 2 - 73

    2 - 73 spec cable routing 1 front wheel sensor 2 abs motor coupler 3 fail-safe relay 4 ecu (abs) 5 hydraulic unit solenoid coupler 6 hydraulic unit overflow hose 7 brake hose (front brake master cylinder to hydraulic unit) 8 brake hose (rear brake master cylinder to hydraulic unit) 9 hydraulic unit ...

  • Page 114: 2 - 74

    2 - 74 spec cable routing Ë route the hydraulic unit overflow hose to the outside of the stay 1. Ì fasten the hydraulic unit overflow hose with the lower hose holder first, and then fasten it with the upper hose holder. Make sure that the lower hose holder is contacting the top of the bracket welded...

  • Page 115: 2 - 75

    2 - 75 spec cable routing Ñ route the hydraulic unit solenoid lead and abs motor lead under the hydraulic unit when install- ing the unit, making sure not to pinch the leads between the hydraulic unit and hydraulic unit bracket. Ò install the ecu (abs) lead coupler boot all the way onto the ecu (abs...

  • Page 116: 2 - 76

    2 - 76 spec cable routing 1 plastic holder 2 brake hose holder 2 3 brake hose holder 1 4 front brake hose 5 front wheel sensor lead 6 front wheel sensor 7 front housing È engage the hose holder rib more than 3 notch. Face the hose holder projection to the back. É make sure that the white paint on th...

  • Page 117: 2 - 77

    2 - 77 spec cable routing Í install the stopper to lower bracket projection. Î fasten the front wheel sensor lead to the center of brake hose holder. Ï fasten the front wheel sensor lead along the outside of the brake hose. Ð pass the front wheel sensor lead between the brake hose and front fork. Ñ ...

  • Page 119: Chk

    Chk adj 3.

  • Page 120: Chk

    Chk adj chapter 3 periodic checks and adjustments introduction .............................................................................................. 3-1 periodic maintenance and lubrication chart ............................ 3-1 seat ............................................................

  • Page 121: Chk

    Chk adj chassis ....................................................................................................... 3-46 adjusting the rear brake lock lever cable ....................... 3-46 checking the brake fluid level................................................. 3-47 checking the brake ...

  • Page 122: 3 - 1

    3 - 1 chk adj eas00036 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the ne...

  • Page 123: 3 - 2

    3 - 2 chk adj periodic maintenance and lubrication chart note: ● the air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. • every two years replace the internal componen...

  • Page 124: 3 - 3

    3 - 3 chk adj seat seat 1 2 order job/part q’ty remarks removing the seat removing the parts in the order listed. 1 fuel lid 1 2 seat 1 for installation, reverse the removal pro- cedure..

  • Page 125: 3 - 4

    3 - 4 chk adj cover and panel cover and panel front cowling order job/part q’ty remarks removing the front cowling removing the parts in the order listed. 1 footrest board mat (left and right) 2 2 front side cover moulding (left and right) 2 3 rearview mirror (left and right) 2 4 front cowling upper...

  • Page 126: 3 - 5

    3 - 5 chk adj cover and panel side cover mouldings and leg shield order job/part q’ty remarks removing the side cover mouldings and leg shield removing the parts in the order listed. 1 upper side cover mole (left and right) 2 2 lower side cover mole (left and right) 2 3 center cover 1 4 hinge cover ...

  • Page 127: 3 - 6

    3 - 6 chk adj cover and panel rear covers and tail/brake light assembly order job/part q’ty remarks removing the rear covers and tail/ brake light assembly removing the parts in the order listed. Seat open. Upper side cover mole (left and right) refer to “side cover mouldings and leg shield”. 1 grab...

  • Page 128: 3 - 7

    3 - 7 chk adj fuel tank fuel tank 1 2 3 4 10 11 13 13 14 16 19 17 23 5 9 15 new 20 18 22 21 12 13 7 8 6 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) t r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib...

  • Page 129: 3 - 8

    3 - 8 chk adj fuel tank 1 2 3 4 10 11 13 13 14 16 19 17 23 5 9 15 new 20 18 22 21 12 13 7 8 6 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) t r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . ...

  • Page 130: 3 - 9

    3 - 9 chk adj fuel tank removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose connector cover 1 3. Disconnect: • fuel hose 2 • fuel pump coupler 3 • fuel tank breather hose 4 caution: • be sure to disconnect the fuel hose by hand. D...

  • Page 131: 3 - 10

    3 - 10 chk adj fuel tank installing the fuel pump 1. Install: • fuel pump gasket • fuel pump • fuel pump bracket note: • do not damage the installation surfaces of the fuel tank when installing the fuel pump. • always use a new fuel pump gasket. • align the projection a on the fuel pump with the pro...

  • Page 132: 3 - 11

    3 - 11 chk adj adjusting the valve clearance eas00045 engine adjusting the valve clearance the following procedure applies to all of the valves. Note: • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the pist...

  • Page 133: 3 - 12

    3 - 12 chk adj adjusting the valve clearance 7. Measure: • valve clearance out of specification → adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the “i” mark a on the a.C. Magneto rotor...

  • Page 134: 3 - 13

    3 - 13 chk adj adjusting the valve clearance 8. Remove: • intake camshaft • exhaust camshaft caution: before removing the camshafts from the cylinder head, tilt up the engine at least 25°. Note: • refer to “camshafts” in chapter 5. • when removing the timing chain and cam- shafts, fasten a wire to t...

  • Page 135: 3 - 14

    3 - 14 chk adj adjusting the valve clearance c. Round off the original valve pad number according to the following table. Example: original valve pad number = 148 (thickness = 1.48 mm (0.058 in)) rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clear-...

  • Page 136: 3 - 15

    3 - 15 chk adj f. Install the exhaust and intake camshafts, timing chain and camshaft caps. Note: • refer to “camshafts” in chapter 5. • lubricate the camshaft bearings, camshaft lobes and camshaft journals. • first, install the exhaust camshaft. • align the camshaft sprocket marks with the edge of ...

  • Page 137: 3 - 16

    3 - 16 chk adj adjusting the valve clearance valve pad selection table intake exhaust measured valve clearance original valve pad number 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180...

  • Page 138: 3 - 17

    3 - 17 chk adj adjusting the valve clearance/ synchronizing the throttle bodies 10.Install: • all removed parts note: for installation, reverse the removal proce- dure. Synchronizing the throttle bodies note: prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed...

  • Page 139: 3 - 18

    3 - 18 chk adj synchronizing the throttle bodies 6. Measure: • engine idling speed out of specification → adjust. Refer to “adjusting the engine idling speed”. Engine idling speed 1,100 ~ 1,300 r/min 7. Adjust: • throttle body synchronization ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn...

  • Page 140: 3 - 19

    3 - 19 chk adj synchronizing the throttle bodies/ adjusting the exhaust gas volume 9. Stop the engine and remove the measuring equipment. 10.Adjust: • throttle cable free play refer to “adjusting the throttle cable free play”. 11.Remove: • vacuum gauge 12.Install: • side cover (left and right) • cen...

  • Page 141: 3 - 20

    3 - 20 chk adj adjusting the exhaust gas volume/ checking the exhaust gas at idle 5. Press the “select” 1 and “reset” 2 buttons to select a cylinder. Note: the selected cylinder number appears on the tripmeter lcd. • both the “select” button and “reset” but- ton can be used to change the selected cy...

  • Page 142: 3 - 21

    3 - 21 chk adj checking the exhaust gas at idle 2. Remove: • center cover • side cover (left and right) refer to “side cover mouldings and leg shield”. 3. Install: • pocket tester 1 (onto the engine oil drain bolt) 4. Start the engine and warm it up until the specified oil temperature is reached. 5....

  • Page 143: 3 - 22

    3 - 22 chk adj checking the exhaust gas at idle/ adjusting the engine idling speed 7. Measure: • carbon monoxide density • hydrocarbon density out of specification → replace the muffler assembly. 8. After replacing the muffler assembly, recheck the exhaust gas at idle when cata- lytic converter is o...

  • Page 144: 3 - 23

    3 - 23 chk adj adjusting the engine idling speed/ adjusting the throttle cable free play 5. Adjust: • throttle cable free play refer to “adjusting the throttle cable free play”. 6. Install: • right side cover refer to “side cover mouldings and leg shield”. Throttle cable free play (at the flange of ...

  • Page 145: 3 - 24

    3 - 24 chk adj adjusting the throttle cable free play 3. Adjust: • throttle cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ note: when the scooter is accelerating, the acceler- ator cable 1 is pulled. Throttle body side a. Loosen the locknut 1 on the decelerator cable. B. Loosen th...

  • Page 146: 3 - 25

    3 - 25 chk adj adjusting the throttle cable free play/ checking the spark plugs e. Slide the rubber cover to its original posi- tion. Warning after adjusting the throttle cable free play, turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to ch...

  • Page 147: 3 - 26

    3 - 26 chk adj checking the spark plugs/ checking the ignition timing 5. Check: • electrode 1 damage/wear → replace the spark plug. • insulator 2 abnormal color → replace the spark plug. Normal color is a medium-to-light tan color. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7. ...

  • Page 148: 3 - 27

    3 - 27 chk adj checking the ignition timing/ measuring the compression pressure 3. Install: • timing light 1 (onto the spark plug lead of cylinder #1) timing light 90890-03141, ym-33277-b 4. Check: • ignition timing ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Start the engine, warm it up fo...

  • Page 149: 3 - 28

    3 - 28 chk adj measuring the compression pressure 1. Remove: • footrest board (left and right) • inner fender refer to “side cover mouldings and leg shield”. 2. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve clearance”. 3. Start the engine, warm it up for sev...

  • Page 150: 3 - 29

    3 - 29 chk adj measuring the compression pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main switch to “on”. B. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. Warning to prevent sparking, ground all spark plug leads before ...

  • Page 151: 3 - 30

    3 - 30 chk adj checking the engine oil level/ changing the engine oil checking the engine oil level 1. Stand the scooter on a level surface. Note: • place the scooter on a suitable stand. • make sure that the scooter is upright. 2. Start the engine when the engine is cool, let it idle for two minute...

  • Page 152: 3 - 31

    3 - 31 chk adj changing the engine oil 3. Remove: • engine oil filler cap 1 • engine oil drain bolt 2 (along with the gasket) 4. Drain: • engine oil (completely from the crankcase) 5. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

  • Page 153: 3 - 32

    3 - 32 chk adj changing the engine oil 8. Fill: • crankcase (with the specified amount of the recom- mended engine oil) 9. Install: • engine oil filler cap 10.Start the engine, warm it up for several min- utes, and then turn it off. 11.Check: • engine (for engine oil leaks) 12.Check: • engine oil le...

  • Page 154: 3 - 33

    3 - 33 chk adj measuring the engine oil pressure eas00077 measuring the engine oil pressure 1. Check: • engine oil level below the minimum level mark → add the recommended engine oil to the proper level. 2. Remove: • left lower side cover mole refer to “side cover mouldings and leg shield”. 3. Start...

  • Page 155: 3 - 34

    3 - 34 chk adj measuring the engine oil pressure/ cleaning the air filter element 6. Measure: • engine oil pressure (at the following conditions) out of specification → replace. 7. Install: • o-ring • main gallery plug 8. Install: • left lower side cover mole refer to “side cover mouldings and leg s...

  • Page 156: 3 - 35

    3 - 35 chk adj cleaning the air filter element/ cleaning the v-belt case air filter element 5. Install: • air filter element • air filter case cover caution: never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the e...

  • Page 157: 3 - 36

    3 - 36 chk adj cleaning the v-belt case air filter element 3. Remove: • v-belt case air filter element (left) 1 • v-belt case air filter element (right) 2 2 4. Clean: • v-belt case air filter element apply compressed air to the inner surface of v-belt case air filter element. 5. Check: • v-belt case...

  • Page 158: 3 - 37

    3 - 37 chk adj checking the throttle body joints and intake manifolds/ checking the fuel hoses and fuel tank breather hose/ checking the crankcase breather hose checking the throttle body joints and intake manifolds the following procedure applies to all of the throttle body joints and intake manifo...

  • Page 159: 3 - 38

    3 - 38 chk adj 2. Check: • crankcase breather hose 1 cracks/damage → replace. Loose connection → connect properly. Caution: make sure that the crankcase breather hose is routed correctly. 3. Install: • leg shield refer to “side cover mouldings and leg shield”. 1 eas00099 checking the exhaust system ...

  • Page 160: 3 - 39

    3 - 39 chk adj checking the exhaust system/ checking the coolant level 4. Install: • inner fender refer to “side cover mouldings and leg shield”. • right rear side cover refer to “rear covers and tail/ brake light assembly”. Eas00103 checking the coolant level 1. Stand the scooter on a level surface...

  • Page 161: 3 - 40

    3 - 40 chk adj checking the cooling system checking the cooling system 1. Remove: • footrest board (left and right) • leg shield • inner fender refer to “side cover mouldings and leg shield”. 2. Check: • radiator 1 • radiator inlet hose 2 • radiator outlet hose 3 • oil cooler inlet hose 4 • oil cool...

  • Page 162: 3 - 41

    3 - 41 chk adj changing the coolant changing the coolant 1. Remove: • left footrest board mat • front side cover mole (left and right) refer to “front cowling”. • coolant reservoir cap access panel • lower side cover mole (left and right) • inner fender refer to “side cover mouldings and leg shield”...

  • Page 163: 3 - 42

    3 - 42 chk adj changing the coolant 7. Check: • rubber washer 1 • drain bolt 2 8. Install: • drain bolt 9. Connect: • coolant reservoir hose t r . . 1.6 nm (0.16 m · kg, 1.2 ft · lb) 10.Fill: • cooling system (with the specified amount of the recom- mended coolant) handling notes for coolant coolant...

  • Page 164: 3 - 43

    3 - 43 chk adj changing the coolant/ checking the chain drive oil level • use only distilled water. Soft water may be used if distilled water is not available. • if coolant comes into contact with painted surfaces, immediately wash them with water. • do not mix different types of antifreeze. 11.Inst...

  • Page 165: 3 - 44

    3 - 44 chk adj 3. Remove: • chain drive oil filler cap 1 4. Check: • chain drive oil level wipe the dipstick clean, insert it into the oil filler hole (without screw it in), and then remove it to check the oil level. The chain drive oil level should be between the minimum level mark a and maximum le...

  • Page 166: 3 - 45

    3 - 45 chk adj 5. Fill: • chain drive oil (with the specified amount of the recom- mended chain drive oil) 6. Check: • chain drive oil level refer to “checking the chain drive oil level”. Quantity 0.70 l (0.62 imp qt, 0.74 us qt) checking the chain drive oil level.

  • Page 167: 3 - 46

    3 - 46 chk adj adjusting the rear brake lock lever cable chassis adjusting the rear brake lock lever cable warning do not use the rear brake lock lever while driving. Note: • place the scooter on the centerstand. • before adjusting the rear brake lock lever, check the rear brake fluid level. 1. Meas...

  • Page 168: 3 - 47

    3 - 47 chk adj checking the brake fluid level eas00116 checking the brake fluid level 1. Stand the scooter on a level surface. Note: • place the scooter on a suitable stand. • make sure that the scooter is upright. 2. Check: • brake fluid level below the minimum level mark a → add the recommended br...

  • Page 169: 3 - 48

    3 - 48 chk adj checking the brake pads/ checking the brake hoses checking the brake pads the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pad wear indicator groove 1 almost disap- peared → replace the brake pads as a set. Refer to “front and rea...

  • Page 170: 3 - 49

    3 - 49 chk adj bleeding the hydraulic brake system (xp500) eas00135 bleeding the hydraulic brake system (xp500) warning bleed the hydraulic brake system when- ever: • the system was disassembled. • a brake hose was loosened, disconnected or replaced. • the brake fluid level is very low. • brake oper...

  • Page 171: 3 - 50

    3 - 50 chk adj bleeding the hydraulic brake system (xp500)/ bleeding the brake system (xp500a) g. Loosen the bleed screw. Note: _ loosening the bleed screw will release the pressure and cause the brake levers to contact the handlebar. H. Tighten the bleed screw and then release the brake lever. I. R...

  • Page 172: 3 - 51

    3 - 51 chk adj bleeding the brake system (xp500a) warning bleed the abs whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. Note: • be careful not to spill any brake fluid or allow the brake m...

  • Page 173: 3 - 52

    3 - 52 chk adj bleeding the brake system (xp500a) g. Loosen the bleed screw. Note: loosening the bleed screw will release the pressure and cause the brake levers to contact the handlebar. H. Tighten the bleed screw, and then release the brake lever. I. Repeat steps (e) to (h) until all of the air bu...

  • Page 174: 3 - 53

    3 - 53 chk adj checking and adjusting the steering head eas00146 checking and adjusting the steering head 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. Note: place the scooter on a suitable stand so that the front wheel i...

  • Page 175: 3 - 54

    3 - 54 chk adj checking and adjusting the steering head 6. Adjust: • steering head ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 . B. Loosen the lower ring nut 4 and then tighten it to specification with a steering nut ...

  • Page 176: 3 - 55

    3 - 55 chk adj checking and adjusting the steering head 7. Install: • upper bracket 1 • steering stem nut 2 8. Tighten: • upper bracket pinch bolt • steering stem nut t r . . 30 nm (3.0 m · kg, 22 ft · lb) t r . . 110 nm (11.0 m · kg, 80 ft · lb) 9. Measure: • steering head tension (with the scooter...

  • Page 177: 3 - 56

    3 - 56 chk adj checking the front fork eas00149 checking the front fork 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. 2. Check: • inner tube damage/scratches → replace. • oil seal oil leakage → replace. 3. Hold the scoote...

  • Page 178: 3 - 57

    3 - 57 chk adj checking the tires checking the tires the following procedure applies to both of the tires. 1. Measure: • tire pressure out of specification → regulate. Warning • the tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • the...

  • Page 179: 3 - 58

    3 - 58 chk adj checking the tires 2. Check: • tire surfaces damage/wear → replace the tire. 1 tire tread depth 2 side wall warning • do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. • when using a tube tire, be sure t...

  • Page 180: 3 - 59

    3 - 59 chk adj checking the tires/ checking the wheels front tire rear tire warning after mounting a new tire, ride conserva- tively for a while to become accustomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim. Failure to do so could lead to an accident wit...

  • Page 181: 3 - 60

    3 - 60 chk adj checking and lubricating the cables/ lubricating the levers/ lubricating the centerstand eas00170 checking and lubricating the cables the following procedure applies to all of the cable sheaths and cables. Warning damaged cable sheaths may cause the cable to corrode and interfere with...

  • Page 182: 3 - 61

    3 - 61 chk adj lubricating the sidestand eas00172 lubricating the sidestand lubricate the pivoting point and metal-to-metal moving parts of sidestand. Recommended lubricant lithium-soap-based grease.

  • Page 183: 3 - 62

    3 - 62 chk adj checking and charging the battery eas00179 electrical system checking and charging the battery warning _ batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: •...

  • Page 184: 3 - 63

    3 - 63 chk adj checking and charging the battery note: _ since mf batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery...

  • Page 185: 3 - 64

    3 - 64 chk adj checking and charging the battery 5. Charge: • battery (refer to the appropriate charging method illustration) warning _ do not quick charge a battery. Caution: _ • never remove the mf battery sealing caps. • do not use a high-rate battery charger since it forces a high-amperage curre...

  • Page 186: 3 - 65

    3 - 65 chk adj checking and charging the battery charging method using a variable-current (voltage) charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the b...

  • Page 187: 3 - 66

    3 - 66 chk adj checking and charging the battery charging method using a constant voltage charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. No yes is the amperage higher than the standard charging amperage written on the batt...

  • Page 188: 3 - 67

    3 - 67 chk adj checking and charging the battery/ checking the fuses 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) caution: _ first, connect the positive battery lead 1 , and then the negative battery lead 2 . 8. Check: • battery terminals dirt → clean with a wire brus...

  • Page 189: 3 - 68

    3 - 68 chk adj checking the fuses 3. Check: • continuity ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. Note: set the pocket tester selector to “ Ω × 1”. B. If the pocket tester indicates “ ∞ ”, replace the fuse. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲...

  • Page 190: 3 - 69

    3 - 69 chk adj checking the fuses warning never use a fuse with an amperage other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition sys- tems to malfunction and could possibly cause a f...

  • Page 191: 3 - 70

    3 - 70 chk adj replacing the headlight bulbs eas00183 replacing the headlight bulbs the following procedure applies to both of the headlight bulbs. 1. Remove: • front cowling refer to “front cowling”. 2. Disconnect: • headlight coupler 1 3. Remove: • headlight bulb holder cover 2 4. Detach: • headli...

  • Page 192: 3 - 71

    3 - 71 chk adj replacing the headlight bulbs/ adjusting the headlight beam 8. Install: • headlight bulb holder cover 9. Connect: • headlight coupler 10.Install: • front cowling refer to “front cowling”. Eas00184 adjusting the headlight beam 1. Adjust: • headlight beam (vertically) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼...

  • Page 194: Chas

    Chas 4.

  • Page 195: Chas

    Chas chapter 4 chassis front wheel and brake disc ............................................................... 4-1 removing the front wheel (xp500) ............................................. 4-6 removing the front wheel and front wheel sensor (xp500a) .............................................

  • Page 196: Chas

    Chas front and rear brakes ....................................................................... 4-24 front brake pads ............................................................................ 4-24 rear brake pads............................................................................... 4-...

  • Page 197: Chas

    Chas rear shock absorber ......................................................................... 4-89 handling the rear shock absorber and gas cylinder.... 4-90 disposing of a rear shock absorber and gas cylinder ............................................................................ 4-90 rem...

  • Page 198: Chas

    Chas.

  • Page 199: 4 - 1

    4 - 1 chas chassis front wheel and brake disc 2 3 5 4 8 8 6 t r . . 59 nm (5.9 m • kg, 43 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 18 nm (1.8 m • kg, 13 ft • ib) 1 (6) 7 1 lt lt lt (6) order job/part q’ty re...

  • Page 200: 4 - 2

    4 - 2 chas front wheel and brake disc order job/part q’ty remarks disassembling the front wheel (xp500) remove the parts in the order listed. 1 oil seal 1 2 bearing 2 3 collar 1 for assembly, reverse the disassembly procedure..

  • Page 201: 4 - 3

    4 - 3 chas front wheel and brake disc eas00889 t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 59 nm (5.9 m • kg, 43 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) lt (6) (6) 1 2 3 7 8 11 6 11 10 9 4 5 2 lt t r . . 18 nm (1.8 m • kg, 13 ft • ib) t r . . 40 nm (...

  • Page 202: 4 - 4

    4 - 4 chas front wheel and brake disc t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 59 nm (5.9 m • kg, 43 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) lt (6) (6) 1 2 3 7 8 11 6 11 10 9 4 5 2 lt t r . . 18 nm (1.8 m • kg, 13 ft • ib) t r . . 40 nm (4.0 m • k...

  • Page 203: 4 - 5

    4 - 5 chas front wheel and brake disc 1 2 3 2 1 ls ls order job/part q’ty remarks disassembling the front wheel (xp500a) remove the parts in the order listed. 1 oil seal 2 2 bearing 2 3 collar 1 for assembly, reverse the disassembly procedure..

  • Page 204: 4 - 6

    4 - 6 chas front wheel and brake disc eas00520 removing the front wheel (xp500) 1. Stand the scooter on a level surface. Warning securely support the so that there is no danger of it falling over. Note: place the scooter on a suitable stand so that the front wheel is elevated. 2. Remove: • front bra...

  • Page 205: 4 - 7

    4 - 7 chas front wheel and brake disc 1. Stand the scooter on a level surface. Warning securely support the so that there is no danger of it falling over. Note: place the scooter on a suitable stand so that the front wheel is elevated. 2. Remove: • plastic clamp 1 • front wheel sensor lead guide 2 •...

  • Page 206: 4 - 8

    4 - 8 chas front wheel and brake disc eas00525 checking the front wheel 1. Check: • wheel axle roll the wheel axle on a flat surface. Bends → replace. Warning do not attempt to straighten a bent wheel axle. 2. Check: • tire • front wheel damage/wear → replace. Refer to “checking the tires” and “chec...

  • Page 207: 4 - 9

    4 - 9 chas front wheel and brake disc 5. Replace: • wheel bearings • oil seals ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Clean the outside of the front wheel hub. B. Remove the oil seals 1 with a flat-head screwdriver. Note: to prevent damaging the wheel, place a rag 2 between the screwdr...

  • Page 208: 4 - 10

    4 - 10 chas front wheel and brake disc b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is sta- tionary. C. Remove the brake caliper. D. Hold the dial gauge at a right angle against the brake disc surface. E. Measure the defl...

  • Page 209: 4 - 11

    4 - 11 chas front wheel and brake disc checking the front wheel sensor and sensor rotor (xp500a) 1. Check: • front wheel sensor 1 cracks/bends/distortion → replace. Iron powder/dust → clean. 2. Measure: • front wheel sensor resistance connect the pocket tester ( Ω × 1k) to the terminals of the front...

  • Page 210: 4 - 12

    4 - 12 chas front wheel and brake disc 2. Find: • front wheel’s heavy spot ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place the front wheel on a suitable balanc- ing stand. B. Spin the front wheel. C. When the front wheel stops, put an “x 1 ” mark at the bottom of the wheel. D. Turn the fr...

  • Page 211: 4 - 13

    4 - 13 chas front wheel and brake disc eas00542 installing the front wheel (xp500) 1. Lubricate: • oil seal lips • speedometer drive gear • speedometer driven gear recommended lubricant lithium-soap-based grease 2. Install: • speed sensor (to front wheel) note: make sure that the speed sensor unit a...

  • Page 212: 4 - 14

    4 - 14 chas front wheel and brake disc 5. Install: • front brake calipers warning make sure that the brake hoses are routed properly. 6. Tighten: • front brake caliper bracket bolt 1 1 t r . . 40 nm (4.0 m · kg, 29 ft · lb) eas00542 installing the front wheel and front wheel sensor (xp500a) 1. Lubri...

  • Page 213: 4 - 15

    4 - 15 chas front wheel and brake disc 3. Tighten: • front wheel axle 1 use the damper rod holder 2 . • front wheel axle pinch bolt 3 caution: before tightening the wheel axle pinch bolt, push down hand on the handlebar several times and check if the front fork rebounds smoothly. Damper rod holder (...

  • Page 214: 4 - 16

    4 - 16 chas rear wheel and brake disc rear wheel and brake disc order job/part q’ty remarks removing the rear wheel (xp500) remove the parts in the order listed. Note: place the scooter on a suitable stand so that the rear wheel is elevated. 1 rear brake caliper 1 2 chain drive case cover 1 3 rear w...

  • Page 215: 4 - 17

    4 - 17 chas rear wheel and brake disc . Order job/part q’ty remarks removing the rear wheel (xp500a) remove the parts in the order listed. Note: place the scooter on a suitable stand so that the rear wheel is elevated. Tail/brake light assembly refer to “cover and panel” in chap- ter 3. 1 rear wheel...

  • Page 216: 4 - 18

    4 - 18 chas rear wheel and brake disc . Order job/part q’ty remarks 5 rear wheel axle pinch bolt 1 loosen. Refer to “installing the rear wheel sen- sor (xp500a)”. 6 rear wheel axle nut/washer 1/1 7 rear wheel axle 1 8 collar 1 refer to “installing the rear wheel sensor (xp500a)”. 9 sensor housing 1 ...

  • Page 217: 4 - 19

    4 - 19 chas rear wheel and brake disc order job/part q’ty remarks disassembling the rear wheel remove the parts in the order listed. 1 brake disc 1 2 rear wheel drive hub 1 3 o-ring 1 4 oil seal 1 5 bearing 2 for assembly, reverse the disassembly procedure..

  • Page 218: 4 - 20

    4 - 20 chas rear wheel and brake disc eas00561 removing the rear wheel (xp500) 1. Stand the scooter on a level surface. Warning _ securely support the scooter so that there is no danger of it falling over. Note: _ place the scooter on a suitable stand so that the rear wheel is elevated. 2. Remove: •...

  • Page 219: 4 - 21

    4 - 21 chas rear wheel and brake disc 3. Remove: • brake caliper note: _ do not squeeze the brake lever when remov- ing the brake caliper. Checking the rear wheel sensor and sensor rotor (xp500a) refer to “checking the front wheel sensor and sensor rotor (xp500a)”. Eas00565 checking the rear wheel 1...

  • Page 220: 4 - 22

    4 - 22 chas rear wheel and brake disc eas00575 adjusting the rear wheel static balance note: • after replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust: • rear w...

  • Page 221: 4 - 23

    4 - 23 chas rear wheel and brake disc 2. Install: • rear wheel sensor 1 note: _ when installing the rear wheel sensor, check the rear wheel sensor lead for twists and the sensor electrode for foreign materials. Caution: _ to route the rear wheel sensor lead, refer to “cable routing” in chapter 2. 1 ...

  • Page 222: 4 - 24

    4 - 24 chas front and rear brakes front and rear brakes front brake pads 1 2 3 4 4 5 5 6 7 7 ls t r . . 27 nm (2.7 m • kg, 19 ft • ib) order job/part q’ty remarks removing the front brake pads remove the parts in the order listed. 1 front brake caliper retaining bolt (lower) 1 refer to “replacing th...

  • Page 223: 4 - 25

    4 - 25 chas front and rear brakes rear brake pads order job/part q’ty remarks removing the rear brake pads remove the parts in the order listed. 1 rear brake caliper retaining bolt 1 2 rear brake caliper bracket bolt 2 3 brake caliper 1 refer to “replacing the rear brake pads”. 4 brake pad 2 5 brake...

  • Page 224: 4 - 26

    4 - 26 chas front and rear brakes eas00579 caution: disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the entire ...

  • Page 225: 4 - 27

    4 - 27 chas front and rear brakes 3. Measure: • brake pad thickness a out of specification → replace the brake pads as a set. Minimum brake pad thickness 0.8 mm (0.03 in) 4. Install: • brake pad spring 1 • brake pad springs 2 • brake pad shims 3 • brake pads 4 note: always install new brake pads, a ...

  • Page 226: 4 - 28

    4 - 28 chas front and rear brakes 6. Install: • brake caliper 1 • front brake caliper retaining bolts 2 t r . . 27 nm (2.7 m · kg, 19 ft · lb) 7. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level”...

  • Page 227: 4 - 29

    4 - 29 chas front and rear brakes 2. Remove: • brake pads 1 • brake pad springs 2 3. Measure: • brake pad thickness a out of specification → replace the brake pads as a set. Minimum brake pad thickness 0.8 mm (0.03 in) 4. Install: • brake pad springs 1 • brake pads 2 • rear brake caliper bracket 3 (...

  • Page 228: 4 - 30

    4 - 30 chas front and rear brakes ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a suitable hose 1 tightly to the brake caliper bleed screw 2 . Put the other end of this hose into an open container. B. Loosen the brake caliper bleed screw, and then turn the brake caliper piston 3 clock...

  • Page 229: 4 - 31

    4 - 31 chas front and rear brakes 5. Lubricate: • rear brake caliper retaining bolts caution: • do not allow grease to contact the brake pads. • remove any excess grease. 6. Install: • rear brake caliper retaining bolt 7. Install: • rear brake caliper bracket bolts 8. Check: • brake fluid level belo...

  • Page 230: 4 - 32

    4 - 32 chas front and rear brakes front brake master cylinder order job/part q’ty remarks removing the front brake master cylinder remove the parts in the order listed. Upper handlebar cover refer to “handlebar”. Brake fluid drain. 1 brake master cylinder reservoir cap 1 2 brake master cylinder rese...

  • Page 231: 4 - 33

    4 - 33 chas front and rear brakes order job/part q’ty remarks 6 union bolt 1 refer to “disassembling the front brake master cylinder” and “assembling and installing the front brake master cylin- der”. 7 brake hose 1 8 copper washer 2 9 brake master cylinder holder 1 10 brake master cylinder 1 11 fro...

  • Page 232: 4 - 34

    4 - 34 chas front and rear brakes order job/part q’ty remarks disassembling the front brake mas- ter cylinder remove the parts in the order listed. 1 dust boot 1 2 circlip 1 3 brake master cylinder kit 1 4 brake master cylinder body 1 for assembly, reverse the disassembly procedure..

  • Page 233: 4 - 35

    4 - 35 chas front and rear brakes rear brake master cylinder order job/part q’ty remarks removing the rear brake master cyl- inder remove the parts in the order listed. Upper handlebar cover refer to “handlebar”. Brake fluid drain. 1 brake master cylinder reservoir cap 1 2 brake master cylinder rese...

  • Page 234: 4 - 36

    4 - 36 chas front and rear brakes order job/part q’ty remarks 6 union bolt 1 refer to “disassembling the rear brake master cylinder” and “assembling and installing the rear brake master cylinder”. 7 brake hose 1 8 copper washer 2 9 brake master cylinder holder 1 10 brake master cylinder 1 11 rear br...

  • Page 235: 4 - 37

    4 - 37 chas front and rear brakes order job/part q’ty remarks disassembling the rear brake mas- ter cylinder remove the parts in the order listed. 1 dust boot 1 2 circlip 1 3 brake master cylinder kit 1 4 brake master cylinder body 1 for assembly, reverse the disassembly procedure..

  • Page 236: 4 - 38

    4 - 38 chas front and rear brakes eas00588 disassembling the front brake master cylinder note: before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hoses 3 note: to collect any remaining brake f...

  • Page 237: 4 - 39

    4 - 39 chas front and rear brakes eas00592 checking the front and rear brake master cylinders the following procedure applies to the both of the brake master cylinders. 1. Check: • brake master cylinder 1 damage/scratches/wear → replace. • brake fluid delivery passages (brake master cylinder body) o...

  • Page 238: 4 - 40

    4 - 40 chas front and rear brakes eas00596 assembling and installing the front brake master cylinder warning • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake components. 1. Install: • brake m...

  • Page 239: 4 - 41

    4 - 41 chas front and rear brakes 3. Install: • copper washers 1 • brake hose 2 • union bolt 3 warning proper brake hose routing is essential to insure safe scooter operation. Refer to “cable routing” in chapter 2. Note: • while holding the brake hose, tighten the union bolt as shown. • turn the han...

  • Page 240: 4 - 42

    4 - 42 chas front and rear brakes caution: brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 6. Bleed: • brake system refer to “bleeding the hydraulic brake system (xp500)” and “bleed- ing the brake system (xp500a)” in chapter 3....

  • Page 241: 4 - 43

    4 - 43 chas front and rear brakes 2. Install: • brake master cylinder 1 • brake master cylinder holder 2 • holder bolts note: • install the brake master cylinder holder with the “up” mark facing up a . • align the brake master cylinder with the pro- jection b on the handlebar. • first, tighten the u...

  • Page 242: 4 - 44

    4 - 44 chas front and rear brakes 4. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) warning • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill ...

  • Page 243: 4 - 45

    4 - 45 chas front and rear brakes front brake caliper 1 3 4 5 6 7 10 10 8 8 12 9 new ls 2 2 t r . . 27 nm (2.7 m • kg, 19 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) 11 t r . . 30 nm (3.0 m • kg, 22 ft • ib) 11 order job/part q’ty remarks removing the front brake caliper remove the parts in the ...

  • Page 244: 4 - 46

    4 - 46 chas 1 3 4 5 6 7 10 10 8 8 12 9 new ls 2 2 t r . . 27 nm (2.7 m • kg, 19 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) 11 t r . . 30 nm (3.0 m • kg, 22 ft • ib) 11 order job/part q’ty remarks 11 front brake caliper bracket bolt 2 2 refer to “assembling and install- ing the front brake calip...

  • Page 245: 4 - 47

    4 - 47 chas front and rear brakes eas00614 order job/part q’ty remarks disassembling the front brake cali- per remove the parts in the order listed. 1 bleed screw 1 2 dust seal 2 refer to “disassembling the front brake caliper” and “assembling and installing the front brake caliper”. 3 brake caliper...

  • Page 246: 4 - 48

    4 - 48 chas front and rear brakes rear brake caliper order job/part q’ty remarks removing the rear brake caliper remove the parts in the order listed. Brake fluid drain. 1 nut 1 refer to “disassembling the rear brake caliper”. 2 rear brake lock lever cable 1 3 pin 1 4 spring 1 5 union bolt 1 refer t...

  • Page 247: 4 - 49

    4 - 49 chas order job/part q’ty remarks 11 brake pad spring 2 refer to “assembling and install- ing the rear brake caliper”. 12 rear brake caliper bracket bolt 2 13 brake caliper bracket 1 for installation, reverse the removal pro- cedure. Front and rear brakes.

  • Page 248: 4 - 50

    4 - 50 chas front and rear brakes 1 2 3 4 5 t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) new new order job/part q’ty remarks disassembling the rear brake cali- per remove the parts in the order listed. 1 brake caliper piston 1 refer to “disassembling the rear brake caliper” and “assembling and installing ...

  • Page 249: 4 - 51

    4 - 51 chas front and rear brakes eas00619 disassembling the front brake caliper note: before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers • brake hose 2 note: put the end of the brake hose into a container and pump o...

  • Page 250: 4 - 52

    4 - 52 chas front and rear brakes 1. Remove: • nut 1 • rear brake lock lever cable 2 • pin 3 • spring 4 • union bolt 5 • copper washers 6 • brake hose 7 note: put the end of the brake hose into a container and pump out the brake fluid carefully. 2 4 3 1 7 5 6 2. Remove: • brake caliper piston 1 • du...

  • Page 251: 4 - 53

    4 - 53 chas front and rear brakes 1. Check: • brake caliper pistons 1 rust/scratches/wear → replace the brake caliper. • brake caliper cylinders 2 scratches/wear → replace the brake cali- per. • brake caliper body 3 cracks/damage → replace the brake cali- per. • brake fluid delivery passages (brake ...

  • Page 252: 4 - 54

    4 - 54 chas front and rear brakes eas00635 assembling and installing the front brake caliper warning _ • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake components as they will cause the pisto...

  • Page 253: 4 - 55

    4 - 55 chas front and rear brakes 4. Remove: • brake caliper 5. Install: • brake pad springs • brake pads • brake caliper • front brake caliper retaining bolts refer to “replacing the front brake pads”. 6. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake ...

  • Page 254: 4 - 56

    4 - 56 chas front and rear brakes 8. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 9. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to “b...

  • Page 255: 4 - 57

    4 - 57 chas front and rear brakes 2. Install: • brake caliper piston 1 turn the brake caliper piston clockwise until section a of the brake caliper piston is level with the surface of the brake caliper body. Note: align the recesses b in the brake caliper pis- ton with the brake caliper body as show...

  • Page 256: 4 - 58

    4 - 58 chas front and rear brakes 6. Install: • brake pad springs • brake pads • brake caliper • rear brake caliper retaining bolts refer to “replacing the rear brake pads”. 7. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning • use only the designate...

  • Page 257: 4 - 59

    4 - 59 chas front and rear brakes 9. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 10.Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to “b...

  • Page 258: 4 - 60

    4 - 60 chas front and rear brakes eas00888 ecu (abs) and fail-safe relay (xp500a) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 5 4 4 3 1 2 order job/part q’ty remarks removing the ecu (abs) and fail- safe relay (xp500a) remove the parts in the order listed. Front cowling refer to “cover and panel” in chap...

  • Page 259: 4 - 61

    4 - 61 chas front and rear brakes eas00891 hydraulic unit (xp500a) t r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) 5 6 5 3 4 3 7 8 7 9 10 9 1 13 11 2 12 12 t r . . 16 nm (1.6 m • kg, 11 ft • ib) 12 new new new new new new new new o...

  • Page 260: 4 - 62

    4 - 62 chas front and rear brakes t r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) 5 6 5 3 4 3 7 8 7 9 10 9 1 13 11 2 12 12 t r . . 16 nm (1.6 m • kg, 11 ft • ib) 12 new new new new new new new new order job/part q’ty remarks 9 unio...

  • Page 261: 4 - 63

    4 - 63 chas front and rear brakes caution: _ do not remove the hydraulic unit to check the resistance of the solenoid valves and the abs motor for continuity. Warning _ refill with the same type of brake fluid that is already in the system. Mixing fluids may result in a harmful chemical reaction, le...

  • Page 262: 4 - 64

    4 - 64 chas front and rear brakes removing the hydraulic unit 1. Remove: • brake hose 1 (from the front brake master cylinder) • brake hose 2 (to the front brake caliper) • brake hose 3 (from the rear brake master cylinder) • brake hose 4 (to the rear brake caliper) note: _ do not operate the brake ...

  • Page 263: 4 - 65

    4 - 65 chas front and rear brakes installing the hydraulic unit proceed in the reverse order of disassembly. Pay attention to the following items. 1. Install: • hydraulic unit note: _ • when tightening the hydraulic unit nuts, first temporarily tighten the front nuts, and then tighten the rear nut a...

  • Page 264: 4 - 66

    4 - 66 chas front and rear brakes 4. Fill: • brake master cylinder reservoirs 5. Bleed the brake system. 6. Check the operation of the hydraulic unit according to the brake levers response. (refer to “[d-6-3-1] hydraulic unit operation test 1”.) caution: _ always check the operation of the hydrau- l...

  • Page 265: 4 - 67

    4 - 67 chas handlebar handlebar order job/part q’ty remarks removing the handlebar remove the parts in the order listed. 1 upper handlebar cover 1 2 band 3 3 grip end 2 4 front brake light switch connector 2 disconnect. 5 right handlebar switch 1 refer to “installing the handlebar”. 6 throttle cable...

  • Page 266: 4 - 68

    4 - 68 chas handlebar order job/part q’ty remarks 11 parking brake lever/holder 1/1 refer to “installing the handlebar”. 12 rear brake lock lever cable 1 disconnect. 13 left handlebar switch 1 14 rear brake master cylinder holder 1 15 rear brake master cylinder 1 16 handlebar grip 1 refer to “removi...

  • Page 267: 4 - 69

    4 - 69 chas handlebar eas00666 removing the handlebar 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. 2. Remove: • handlebar grip 1 note: blow compressed air between the handlebar and the handlebar grip, and gradually push ...

  • Page 268: 4 - 70

    4 - 70 chas handlebar 2. Install: • handlebar 1 • handlebar upper holders 2 warning first, tighten the bolts on the front side of the handlebar holder, then on the rear side. Note: • the upper handlebar holders should be installed with the arrow marks a facing for- ward È . • align the match mark b ...

  • Page 269: 4 - 71

    4 - 71 chas handlebar 5. Connect: • rear brake lock lever cable note: lubricate the inside of the rear brake lock lever cable and parking brake lever with a thin coat of lithium-soap-based grease. 6. Install: • left handlebar switch 1 note: align the projection a on the right handlebar switch with t...

  • Page 270: 4 - 72

    4 - 72 chas handlebar 9. Install: • right handlebar switch 1 warning _ make sure the throttle grip operates smoothly. Note: align the projection a on the right handlebar switch with the hole b in the handlebar. 10.Adjust: • throttle cable free play refer to “adjusting the throttle cable free play” i...

  • Page 271: 4 - 73

    4 - 73 chas front fork front fork order job/part q’ty remarks removing the front fork remove the parts in the order listed. The following procedure applies to both of the front fork legs. Front cowling/leg shield refer to “cover and panel” in chap- ter 3. Handlebar cover (upper and lower) refer to “...

  • Page 272: 4 - 74

    4 - 74 chas front fork order job/part q’ty remarks 5 upper bracket pinch bolt 2 loosen. Refer to “removing the front fork legs” and “installing the front fork legs”. 6 cap bolt 1 loosen. 7 lower bracket pinch bolt 4 loosen. 8 front fork leg 2 for installation, reverse the removal pro- cedure..

  • Page 273: 4 - 75

    4 - 75 chas front fork order job/part q’ty remarks disassembling the front fork leg remove the parts in the order listed. The following procedure applies to both of the front fork legs. 1 cap bolt 1 refer to “disassembling the front fork legs” and “assem- bling the front fork legs”. 2 o-ring 1 3 spa...

  • Page 274: 4 - 76

    4 - 76 chas front fork order job/part q’ty remarks b inner tube bushing 1 refer to “disassembling the front fork legs” and “assem- bling the front fork legs”. C dust seal 1 d oil seal clip 1 e oil seal 1 f washer 1 g outer tube bushing 1 for assembly, reverse the disassembly procedure..

  • Page 275: 4 - 77

    4 - 77 chas front fork eas00651 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. Note: place the scooter on a suitable stand so tha...

  • Page 276: 4 - 78

    4 - 78 chas front fork 2. Drain: • fork oil note: stroke the outer tube several times while draining the fork oil. 3. Remove: • damper rod assembly bolt note: while holding the cartridge cylinder with the damper rod holder 1 and t-handle 2 , loosen the damper rod assembly bolt. Damper rod holder 908...

  • Page 277: 4 - 79

    4 - 79 chas front fork eas00656 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 bends/damage/scratches → replace. Warning do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure:...

  • Page 278: 4 - 80

    4 - 80 chas front fork eas00659 assembling the front fork legs the following procedure applies to both of the front fork legs. Warning • make sure that the oil levels in both front fork legs are equal. • uneven oil levels can result in poor han- dling and a loss of stability. Note: • when assembling...

  • Page 279: 4 - 81

    4 - 81 chas front fork 5. Tighten: • damper rod assembly bolt 1 note: • apply the locking agent (loctite ® ) to the threads of the damper rod assembly bolt. • while holding the damper rod with the damper rod holder 2 and t-handle 3 , tighten the damper rod assembly bolt. T r . . Damper rod assembly ...

  • Page 280: 4 - 82

    4 - 82 chas front fork note: • before installing the oil seal, apply lithium- soap-based grease onto its lips. • apply fork oil onto the outer surface of the inner tube. • before installing the oil seal, cover the top of the front fork leg with a plastic bag 4 to pro- tect the oil seal during instal...

  • Page 281: 4 - 83

    4 - 83 chas front fork 11.Install: • fork spring • fork spring seat • spacer • cap bolt note: • install the spring with the smaller pitch facing up. • before installing the cap bolt, lubricate its o- ring with grease. • temporarily tighten the cap bolt. Eas00663 installing the front fork legs the fo...

  • Page 282: 4 - 84

    4 - 84 chas steering head steering head lower bracket order job/part q’ty remarks removing the lower bracket remove the parts in the order listed. Front cowling refer to “cover and panel” in chap- ter 3. Front wheel refer to “front wheel and brake disc”. Front fork legs refer to “front fork”. Handle...

  • Page 283: 4 - 85

    4 - 85 chas steering head order job/part q’ty remarks 9 bearing cover 1 10 bearing outer race 1 refer to “installing the steering head”. 11 upper bearing 1 12 bearing inner race 1 13 bearing outer race 1 14 lower bearing 1 15 bearing inner race 1 16 oil seal 1 17 lower bracket 1 for installation, re...

  • Page 284: 4 - 86

    4 - 86 chas steering head eas00678 removing the lower bracket 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. 2. Remove: • upper bracket 3. Remove: • lock washer 1 • upper ring nut 2 • rubber washer 3 • lower ring nut 4 (wi...

  • Page 285: 4 - 87

    4 - 87 chas steering head 3. Replace: • bearings • bearing races ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. B. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. C. Install a ne...

  • Page 286: 4 - 88

    4 - 88 chas steering head 3. Install: • upper bracket 1 • steering stem nut 2 4. Install: • front fork legs refer to “front fork”. Note: temporarily tighten the lower bracket pinch bolts. 5. Tighten: • steering stem nut 2 t r . . 110 nm (11.0 m · kg, 80 ft · lb).

  • Page 287: 4 - 89

    4 - 89 chas rear shock absorber rear shock absorber order job/part q’ty remarks removing the rear shock absorber remove the parts in the order listed. Muffler refer to “muffler assembly” in chapter 5. 1 bolt 1 2 lock washer 1 3 collar 1 4 bolt/nut 1/1 5 rear shock absorber 1 6 collar 1 7 washer 1 8 ...

  • Page 288: 4 - 90

    4 - 90 chas rear shock absorber eas00687 handling the rear shock absorber and gas cylinder warning this rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information. T...

  • Page 289: 4 - 91

    4 - 91 chas rear shock absorber eas00693 removing the rear shock absorber assembly 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. Note: place the scooter on a suitable stand so that the rear wheel is elevated. 2. Remove: •...

  • Page 290: 4 - 92

    4 - 92 chas rear shock absorber installing the rear shock absorber assembly 1. Lubricate: • spacer • bearings recommended lubricant lithium-soap-based grease 2. Install: • rear shock absorber assembly 1 • bolt (rear side) 2 • nut 3 t r . . 53 nm (5.3 m · kg, 38 ft · lb) 3. Install: • lock washer 1 •...

  • Page 291: 4 - 93

    4 - 93 chas anti-lock brake system (xp500a) anti-lock brake system (xp500a) eas00882 abs components 1 abs warning light 2 fail-safe relay 3 electronic control unit (ecu) 4 hydraulic unit 5 rear disc rotor 6 rear brake caliper 7 rear wheel sensor 8 front brake caliper 9 front wheel sensor 0 front dis...

  • Page 292: 4 - 94

    4 - 94 chas anti-lock brake system (xp500a).

  • Page 293: 4 - 95

    4 - 95 chas anti-lock brake system (xp500a) eas00884 circuit diagram off on p pass ( blue ) b lg ( blue ) b b lg b a on off b l l l l / r ch l / r br / g l / r dg l / r br / g b g b g b y b y d f e c b dc terminal sub-wire harness wire harness turn signal sub-wire harness 2 wire harness turn signal ...

  • Page 294: 4 - 96

    4 - 96 chas anti-lock brake system (xp500a) 4 main switch 9 abs control unit fuse b signaling system fuse g battery h abs motor fuse i main fuse m starting circuit cut-off relay 2 n starting circuit cut-off relay 1 r start switch s engine stop switch u front brake light switch w ecu (engine) d abs t...

  • Page 295: 4 - 97

    4 - 97 chas anti-lock brake system (xp500a) cautions for operation * wheel lock: a condition that occurs when the rotation of one or both of the wheels has stopped but the vehicles continues to travel. Abs warning light: • when the main switch is set to “on”, the abs warning light comes on for 2 sec...

  • Page 296: 4 - 98

    4 - 98 chas anti-lock brake system (xp500a) troubleshooting eas00881 abs troubleshooting outline use this section to troubleshoot the abs. Read this service manual carefully and make sure you understand the information provided before repairing any malfunctions or performing service. The electronic ...

  • Page 297: 4 - 99

    4 - 99 chas anti-lock brake system (xp500a) 3. Handling and service caution: handling the abs components with care since they have been accurately adjusted. Keep them away from dirt and do not subject them to shocks. • the ecu (abs), hydraulic unit, wheel sensors, and fail-safe relay cannot be disas...

  • Page 298: 4 - 100

    4 - 100 chas anti-lock brake system (xp500a) eas00886 basic troubleshooting process note: _ do not delete the malfunction codes during troubleshooting. Delete the malfunction codes only after service has been completed. Warning _ when maintenance or checks have been performed on components related t...

  • Page 299: 4 - 101

    4 - 101 chas anti-lock brake system (xp500a) eas00887 abs troubleshooting • [a] abs malfunction check using the abs warning light set the main switch to “on”. (do not start the engine.) 1) warning light does not come on. → [b-1] 2) warning light remains on. → [b-2] 3) warning light flashes. → [b-3] ...

  • Page 300: 4 - 102

    4 - 102 chas anti-lock brake system (xp500a) • [b-4] abs malfunction check using the abs self-diagnosis (past malfunction) to access the test coupler 1 . Remove the protective cap and connect the test coupler adaptor 2 to the test coupler. The t/c terminal (sky blue) is now grounded. 1) indicate the...

  • Page 301: 4 - 103

    4 - 103 chas anti-lock brake system (xp500a) • [b-5] abs malfunction check using the abs self-diagnosis (present malfunction) note: _ before proceeding, read [b-3], “function of the test coupler terminals”. To access the test coupler. Remove the protective cap and connect the test coupler adaptor to...

  • Page 302: 4 - 104

    4 - 104 chas anti-lock brake system (xp500a) • [c] determining the cause and location of the malfunction • [c-1] only the abs warning light does not come on when the main switch is set to “on” note: _ check following the steps in sequence. 1. Visual check 1) check the abs fuse. Determine the cause o...

  • Page 303: 4 - 105

    4 - 105 chas anti-lock brake system (xp500a) • [c-3] abs warning light flashes with the engine off, check the front and rear brake switches. Check if the brake light comes on when the front or rear brake is applied. 1) the light does not come on for only one brake. → the corresponding brake switch c...

  • Page 304: 4 - 106

    4 - 106 chas anti-lock brake system (xp500a) • [c-5] diagnosis by the malfunction code malfunction codes are used to determine the malfunctions that have occurred. (refer to “[b-4] abs malfunction check using the abs self-diagnosis (past malfunction)” and “[b-5] abs malfunction check using the abs s...

  • Page 305: 4 - 107

    4 - 107 chas anti-lock brake system (xp500a) *1 malfunction code 11 is indicated if the rear wheel rotates for more than 20 seconds with the front wheel stopped. Note: _ malfunction code 15 (front wheel sensor) or 16 (rear wheel sensor) is displayed if a defective con- nection to either the front or...

  • Page 306: 4 - 108

    4 - 108 chas anti-lock brake system (xp500a) • [c-5-1] malfunction code 11 (front wheel sensor signal is not received correctly.) set the main switch to “off”, then back to “on” after removing the test coupler adaptor. 1) abs warning light remains on. → defective connection in the front wheel sensor...

  • Page 307: 4 - 109

    4 - 109 chas anti-lock brake system (xp500a) • [c-5-3] malfunction codes 13 (front wheel) and 14 (rear wheel) (incorrect signal is detected from either the front or rear wheel.) 1) the wheel sensors or sensor rotors are not properly installed. 1 installation of the front or rear wheel sensor • check...

  • Page 308: 4 - 110

    4 - 110 chas anti-lock brake system (xp500a) • [c-5-6] malfunction code 31 (disconnection is detected between the fail-safe relay and the hydraulic unit solenoid.) check the following: 1) abs motor fuse • check if the abs motor fuse beside the battery is blown. 2) hydraulic unit solenoid coupler • c...

  • Page 309: 4 - 111

    4 - 111 chas anti-lock brake system (xp500a) • [c-5-8] malfunction code 33 (abs motor operation malfunction is detected. [abs motor stops and does not rotate.]) check the following: 1) abs motor fuse • check if the abs motor fuse beside the battery is blown. 2) fail-safe relay • check if the fail-sa...

  • Page 310: 4 - 112

    4 - 112 chas anti-lock brake system (xp500a) • [c-5-10] malfunction code 41 (front wheel does not recover from the locking tendency even though the signal is continuously transmitted from the ecu (abs) to release the hydraulic pressure [when the battery voltage is normal].) check the following: 1) r...

  • Page 311: 4 - 113

    4 - 113 chas anti-lock brake system (xp500a) 5) hydraulic unit solenoid coupler terminal • check if the front and rear hydraulic unit solenoid coupler terminals (hydraulic unit and wire har- ness (abs system circuit)) are reversed. 6) hydraulic unit if the malfunction is not corrected after performi...

  • Page 312: 4 - 114

    4 - 114 chas anti-lock brake system (xp500a) • check that the connections of the brake hose lines from the brake master cylinder to the hydrau- lic unit and to the rear brake caliper from the hydraulic unit are correct. Warning _ the rear brake will not function properly if the connections are rever...

  • Page 313: 4 - 115

    4 - 115 chas anti-lock brake system (xp500a) • [c-5-12] malfunction code 51 (front wheel does not recover from the locking tendency even though the signal is continuously transmitted from the ecu (abs) to release the hydraulic pressure [when the battery voltage is low].) check the following: 1) rota...

  • Page 314: 4 - 116

    4 - 116 chas anti-lock brake system (xp500a) • [d-1] maintenance of the ecu (abs) checking the ecu (abs) 1. Remove: • ecu (abs) 2. Check: • ecu (abs) terminals 1 cracks/damage → replace the ecu (abs). • ecu (abs) coupler terminals 2 defective connections/contamination/dis- connections → repair or cl...

  • Page 315: 4 - 117

    4 - 117 chas anti-lock brake system (xp500a) • [d-2] maintenance of the abs fail-safe relay checking the fail-safe relay 1. Check: • solenoid relay for continuity connect the pocket tester ( Ω × 1) to the ter- minals. Check for continuity between terminals 3 and 4 of the solenoid relay. Positive tes...

  • Page 316: 4 - 118

    4 - 118 chas anti-lock brake system (xp500a) 2. Check: • abs motor relay for continuity connect the pocket tester ( Ω × 1) to the ter- minals of the abs motor relay. Check for continuity between terminals 1 and 6 of the abs motor relay. Positive tester probe → terminal 1 negative tester probe → term...

  • Page 317: 4 - 119

    4 - 119 chas anti-lock brake system (xp500a) • [d-4] maintenance of the rear wheel sen- sor and sensor rotor checking the rear wheel sensor and sensor rotor refer to “checking the front wheel sensor and sensor rotor (xp500a)”. • [d-5] maintenance of the hydraulic unit caution: _ do not remove the hy...

  • Page 318: 4 - 120

    4 - 120 chas anti-lock brake system (xp500a) 3. Check: • abs motor for continuity connect the pocket tester ( Ω × 1) to the ter- minals of the abs motor coupler. Positive tester probe → terminal 1 negative tester probe → terminal 2 no continuity → replace the hydraulic unit. There is continuity. • [...

  • Page 319: 4 - 121

    4 - 121 chas anti-lock brake system (xp500a) 2. Check: • installation of the wheel sensors to the sen- sor housings (refer to “[d-3] maintenance of the front wheel sensor and sensor rotor” and “[d-4] maintenance of the rear wheel sensor and sensor rotor”.) t r . . Wheel sensor 30 nm (3.0 m · kg, 22 ...

  • Page 320: 4 - 122

    4 - 122 chas anti-lock brake system (xp500a) 4. Check: • battery voltage lower than 12.8 v → charge or replace the battery. Note: _ • if the battery voltage is lower than 12.8 v, charge the battery and perform hydraulic unit operation test 1. • if the battery voltage is lower than 10 v, the abs warn...

  • Page 321: 4 - 123

    4 - 123 chas anti-lock brake system (xp500a) 9. After releasing the start switch, operate the brake levers simultaneously. Note: • a reaction-force pulsating action is gener- ated in the front brake lever 1 0.5 second after the rear brake lever and front brake lever are operated simultaneously and c...

  • Page 322: 4 - 124

    4 - 124 chas anti-lock brake system (xp500a) 12.Set the main switch to “off”. 13.Remove the test coupler adaptor from the test coupler. 14.Set the main switch to “on”. 15.Set the engine stop switch to “ ”. • [d-6-3-2] hydraulic unit operation test 2 warning _ securely support the vehicle so that the...

  • Page 323: 4 - 125

    4 - 125 chas anti-lock brake system (xp500a) 6. Set the main switch to “on” while operating the brake levers simultaneously. Caution: _ when the main switch is set to “on”, be sure to operate both the brake levers simul- taneously. If only the brake levers are oper- ated, set the main switch to “off...

  • Page 324: 4 - 126

    4 - 126 chas anti-lock brake system (xp500a) 3. Set the engine stop switch 1 to “ ”. Caution: _ be sure to set the engine stop switch to “ ”. If the start switch is pushed without setting the engine stop switch to “ ”, the starter motor gears or other parts may be damaged. 4. Push the start switch 2...

  • Page 325: 4 - 127

    4 - 127 chas anti-lock brake system (xp500a) • [d-6-6] delete function test 1. Place the vehicle on the centerstand. 2. Set the main switch to “off”. 3. Connect the test coupler adapter to the test coupler. 4. Set the main switch to “on”. 5. Check: • ecu (abs) voltage connect the pocket tester (dc 2...

  • Page 327: Eng

    Eng 5.

  • Page 328: Eng

    Eng chapter 5 engine engine removal ........................................................................................ 5-1 muffler assembly ............................................................................. 5-1 leads and hoses............................................................

  • Page 329: Eng

    Eng oil pump ...................................................................................................... 5-42 checking the oil pump ................................................................... 5-45 checking the relief valve .............................................................

  • Page 330: Eng

    Eng transmission ............................................................................................ 5-84 removing the transmission ........................................................ 5-85 checking the transmission ......................................................... 5-85 assembli...

  • Page 331: Eng

    Eng.

  • Page 332: 5 - 1

    5 - 1 eng engine engine removal muffler assembly order job/part q’ty remarks removing the muffler assembly remove the parts in the order listed. Right rear side cover/inner fender refer to “cover and panel” in chap- ter 3. 1 o 2 sensor coupler 1 disconnect. 2 protector 1 1 3 o 2 sensor 1 4 protector...

  • Page 333: 5 - 2

    5 - 2 eng engine removal leads and hoses t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) 6 4 5 5 2 1 1 3 7 order job/part q’ty remarks disconnecting the leads and hoses disconnect the parts in the order listed. Leg shield/footrest...

  • Page 334: 5 - 3

    5 - 3 eng engine removal t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) 6 4 5 5 2 1 1 3 7 order job/part q’ty remarks v-belt case air filter element (left)/water pump inlet pipe/water pump outlet pipe refer to “water pump” in cha...

  • Page 335: 5 - 4

    5 - 4 eng t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) 6 4 5 5 2 1 1 3 7 order job/part q’ty remarks 6 intake air pressure sensor hose 1 disconnect. 7 right passenger footrest 1 for installation, reverse the removal pro- cedure...

  • Page 336: 5 - 5

    5 - 5 eng engine removal engine t r . . 87 nm (8.7 m • kg, 63 ft • lb) t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 48 nm (4.8 m • kg, 35 ft • ib) 1 1 5 3 4 4 3 1 1 2 order job/part q’ty remarks removing the engine remove the parts in the order listed. 1 front lower mounting bolt/washer 4/4 refer ...

  • Page 337: 5 - 6

    5 - 6 eng engine removal installing the engine 1. Install: • rear mounting bolt/nut 1 • front upper mounting bolt/nut 2 • washers • spacer 3 • front lower mounting bolts 4 note: do not fully tighten the bolts. 2. Tighten: • rear mounting nut 1 • front upper mounting nut 2 • front lower mounting bolt...

  • Page 338: 5 - 7

    5 - 7 eng camshafts camshafts cylinder head cover order job/part q’ty remarks removing the cylinder head cover remove the parts in the order listed. Engine refer to “engine removal”. Intake manifold refer to “throttle body” in chapter 7. 1 spark plug 2 2 cylinder head cover 1 3 cylinder head cover g...

  • Page 339: 5 - 8

    5 - 8 eng camshafts camshafts e e t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) m m 4 4 6 5 3 3 1 2 4 new t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) new order job/part q’ty remarks removing the camshafts remove the parts in the order listed. 1 timing chain tensioner 1 r...

  • Page 340: 5 - 9

    5 - 9 eng camshafts removing the camshafts 1. Remove: • timing plug 1 2. Align: • “i” mark a on the a.C. Magneto rotor (with the stationary pointer b on the a.C. Magneto cover) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise. B. When piston #1 is at tdc on t...

  • Page 341: 5 - 10

    5 - 10 eng camshafts 5. Remove: caution: before removing the camshafts from the cylinder head, tilt up the engine at least 25°. • intake camshaft cap 1 • exhaust camshaft cap 2 • dowel pins caution: to prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in ...

  • Page 342: 5 - 11

    5 - 11 eng camshafts 2. Measure: • camshaft lobe dimensions a and b out of specification → replace the cam- shaft. 3. Measure: • camshaft runout out of specification → replace. Camshaft lobe dimension intake a 33.252 ~ 33.352 mm (1.3091 ~ 1.3131 in) : 33.152 mm (1.3052 in) b 24.956 ~ 25.056 mm (0.98...

  • Page 343: 5 - 12

    5 - 12 eng camshafts c. Install the dowel pins and camshaft caps. Note: • tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • do not turn the camshaft when measuring the camshaft-journal-to-camshaft cap clear- ance with the plastigauge ® . D. Remo...

  • Page 344: 5 - 13

    5 - 13 eng camshafts 2. Check: • timing chain guide (intake side) 1 • timing chain guide (exhaust side) 2 • timing chain guide (top side) 3 damage/wear → replace the defective part(-s). Checking the timing chain tensioner 1. Check: • timing chain tensioner cracks/damage/rough movement → replace. ▼▼▼...

  • Page 345: 5 - 14

    5 - 14 eng camshafts ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the “i” mark a on the a.C. Magneto rotor with the stationary pointer b on the a.C. Magneto cover. C. Install the timing chain...

  • Page 346: 5 - 15

    5 - 15 eng camshafts 3. Install: • timing chain tensioner gasket • timing chain tensioner ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. B. While pressing the timing chain tensioner rod, wind it clock...

  • Page 347: 5 - 16

    5 - 16 eng 6. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve clearance” in chapter 3. 7. Install: • cylinder head cover gasket • cylinder head cover note: tighten the cylinder head cover bolts in stages and in a crisscross pattern. New t r . . 10 nm (1.0 m · ...

  • Page 348: 5 - 17

    5 - 17 eng cylinder head cylinder head order job/part q’ty remarks removing the cylinder head remove the parts in the order listed. Intake and exhaust camshafts refer to “camshafts”. 1 cylinder head 1 refer to “removing the cylinder head” and “installing the cylin- der head”. 2 cylinder head gasket ...

  • Page 349: 5 - 18

    5 - 18 eng cylinder head removing the cylinder head 1. Remove: • cylinder head bolts • cylinder head nuts note: • loosen the nuts and bolts in the proper sequence as shown. • loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. Eas00229 checking the cylinde...

  • Page 350: 5 - 19

    5 - 19 eng cylinder head installing the cylinder head 1. Install: • dowel pins • cylinder head gasket 2. Install: • cylinder head note: pass the timing chain through the timing chain cavity. 3. Tighten: • cylinder head nuts 1 • cylinder head nuts 2 • cylinder head bolts 3 note: • apply engine oil on...

  • Page 351: 5 - 20

    5 - 20 eng valves and valve springs valves and valve springs order job/part q’ty remarks removing the valves and valve springs remove the parts in the order listed. Cylinder head refer to “cylinder head”. 1 valve lifter 8 refer to “removing the valves” and “installing the valves”. 2 valve pad 8 3 va...

  • Page 352: 5 - 21

    5 - 21 eng valves and valve springs eas00237 removing the valves the following procedure applies to all of the valves and related components. Note: before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Remove...

  • Page 353: 5 - 22

    5 - 22 eng valves and valve springs 4. Remove: • valve retainer 1 • valve spring 2 • valve stem seal 3 • valve spring seat 4 • valve 5 note: identify the position of each part very carefully so that it can be reinstalled in its original place. Eas00239 checking the valves and valve guides the follow...

  • Page 354: 5 - 23

    5 - 23 eng valves and valve springs ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve guide with a valve guide remover 1 . B. Install the new valve guide with a valve guide installer 2 and valve guide remover 1 . C. After installing the valve guide, bore the valve guide with a va...

  • Page 355: 5 - 24

    5 - 24 eng valves and valve springs 6. Measure: • valve stem runout out of specification → replace the valve. Note: • when installing a new valve, always replace the valve guide. • if the valve is removed or replaced, always replace the oil seal. Valve stem runout 0.04 mm (0.0016 in) eas00240 checki...

  • Page 356: 5 - 25

    5 - 25 eng valves and valve springs b. Install the valve into the cylinder head. C. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. D. Measure the valve seat width. Note: where the valve seat and valve face contacted one another, the blueing will have be...

  • Page 357: 5 - 26

    5 - 26 eng valves and valve springs e. Apply a fine lapping compound to the valve face and repeat the above steps. F. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. G. Apply mechanic’s blueing dye (dykem) onto the valve face. H. In...

  • Page 358: 5 - 27

    5 - 27 eng valves and valve springs 3. Measure: • valve spring tilt a out of specification → replace the valve spring. Maximum spring tilt intake valve spring 1.6 mm (0.06 in) exhaust valve spring 1.6 mm (0.06 in) eas00242 checking the valve lifters the following procedure applies to all of the valv...

  • Page 359: 5 - 28

    5 - 28 eng valves and valve springs 3. Install: • valve 1 • valve spring seat 2 • valve stem seal 3 • valve spring 4 • valve retainer 5 (into the cylinder head) note: • make sure that each valve is installed in its original place. • install the valve spring with the larger pitch a facing up. B small...

  • Page 360: 5 - 29

    5 - 29 eng valves and valve springs 6. Lubricate: • valve pad (with the recommended lubricant) 7. Install: • valve pad • valve lifter caution: caution: after making sure that the valve pads are fully inserted, install the valve lifter taking care so that the pads do not fall. Note: • the valve lifte...

  • Page 361: 5 - 30

    5 - 30 eng cylinder and piston cylinder and piston order job/part q’ty remarks removing the cylinder and piston remove the parts in the order listed. Cylinder head refer to “cylinder head”. 1 timing chain guide (exhaust side) 1 2 cylinder 1 3 cylinder gasket 1 4 dowel pin 2 5 piston pin clip 4 refer...

  • Page 362: 5 - 31

    5 - 31 eng cylinder and piston removing the cylinders and pistons the following procedure applies to all of the pistons. 1. Remove: • piston pin clip 1 • piston pin 2 • piston 3 caution: do not use a hammer to drive the piston pin out. Note: • before removing the piston pin clip, cover the crankcase...

  • Page 363: 5 - 32

    5 - 32 eng cylinder and piston eas00256 checking the cylinders and pistons the following procedure applies to all of the cylinders and pistons. 1. Check: • piston wall • cylinder wall vertical scratches → rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: •...

  • Page 364: 5 - 33

    5 - 33 eng cylinder and piston c. Measure piston skirt diameter “p” with the micrometer. A 9.0 mm (0.35 in) from the bottom edge of the piston d. If out of specification, replace the piston and piston rings as a set. E. Calculate the piston-to-cylinder clearance with the following formula. F. If out...

  • Page 365: 5 - 34

    5 - 34 eng cylinder and piston 2. Install: • piston ring (into the cylinder) note: level the piston ring in the cylinder with the piston crown as shown. A 10 mm (0.39 in) 3. Measure: • piston ring end gap out of specification → replace the piston ring. Note: the oil ring expander spacer’s end gap ca...

  • Page 366: 5 - 35

    5 - 35 eng cylinder and piston 2. Measure: • piston pin outside diameter a out of specification → replace the piston pin. Piston pin outside diameter 14.991 ~ 15.000 mm (0.5902 ~ 0.5906 in) : 14.971 mm (0.5894 in) 3. Measure: • piston pin bore diameter b (in the piston) out of specification → replac...

  • Page 367: 5 - 36

    5 - 36 eng cylinder and piston 2. Install: • piston • piston pin • piston pin clip note: • apply engine oil onto the piston pin. • make sure that the punch mark a on the pis- ton points towards the exhaust side of the cylinder. • before installing the piston pin clip, cover the crankcase opening wit...

  • Page 368: 5 - 37

    5 - 37 eng starter clutch and a.C. Magneto rotor starter clutch and a.C. Magneto rotor order job/part q’ty remarks removing the starter clutch and a.C. Magneto rotor remove the parts in the order listed. Left side panel/lower side cover mould- ing/footrest board refer to “cover and panel” in chap- t...

  • Page 369: 5 - 38

    5 - 38 eng starter clutch and a.C. Magneto rotor order job/part q’ty remarks 5 oil tank 1 6 gasket 1 7 dowel pin 2 8 oil strainer 1 9 starter coil assembly 1 10 a.C. Magneto rotor nut 1 refer to “removing the a.C. Mag- neto rotor” and “installing the a.C. Magneto rotor”. 11 spacer 1 12 a.C. Magneto ...

  • Page 370: 5 - 39

    5 - 39 eng starter clutch and a.C. Magneto rotor removing the a.C. Magneto rotor 1. Remove: • a.C. Magneto rotor cover note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • a.C. Magneto rotor nut 1 ...

  • Page 371: 5 - 40

    5 - 40 eng starter clutch and a.C. Magneto rotor checking the starter clutch 1. Check: • starter clutch damage/wear → replace. 2. Check: • starter clutch idle gear • starter clutch idle gear shaft • starter clutch gear pitting/burrs/chips/roughness/wear → replace the defective parts. 3. Check: • sta...

  • Page 372: 5 - 41

    5 - 41 eng starter clutch and a.C. Magneto rotor 2. Tighten: • a.C. Magneto rotor nut 1 note: • while holding the a.C. Magneto rotor 2 with the sheave holder 3 , tighten the a.C. Mag- neto rotor nut. • do not allow the sheave holder to touch the projection on the a.C. Magneto rotor. Caution: • when ...

  • Page 373: 5 - 42

    5 - 42 eng oil pump oil pump order job/part q’ty remarks removing the oil pump removing the parts in the order listed. Left side panel/lower side cover mould- ing/footrest board refer to “cover and panel” in chap- ter 3. Coolant drain. Refer to “changing the coolant” in chapter 3. Engine oil drain. ...

  • Page 374: 5 - 43

    5 - 43 eng oil pump order job/part q’ty remarks 5 oil delivery pipe 1 6 relief valve assembly 1 for installation, reverse the removal pro- cedure..

  • Page 375: 5 - 44

    5 - 44 eng oil pump order job/part q’ty remarks disassembling the oil pump remove the parts in the order listed. 1 oil pump housing 1 2 oil pump outer rotor 2 3 oil pump inner rotor 2 refer to “assembling the oil pump”. 4 pin 2 5 dowel pin 4 6 oil pump housing center 1 7 washer 1 8 oil pump cover 1 ...

  • Page 376: 5 - 45

    5 - 45 eng oil pump checking the oil pump 1. Check: • oil pump driven gear 1 • oil pump housing 2 • oil pump cover 3 cracks/damage/wear → replace the defec- tive part(s). 2. Measure: the following procedure applies to all of the inner rotor and outer rotor. • inner-rotor-to-outer-rotor-tip clearance...

  • Page 377: 5 - 46

    5 - 46 eng oil pump eas00365 checking the relief valve 1. Check: • relief valve body 1 • relief valve 2 • spring 3 • o-ring 4 damage/wear → replace the defective part(s). Eas00367 checking the oil delivery pipes the following procedure applies to all of the oil delivery pipes. 1. Check: • oil delive...

  • Page 378: 5 - 47

    5 - 47 eng oil pump 2. Install: • pins • inner rotors note: when installing the inner rotor, align the pin 1 in the oil pump shaft with the groove a on the inner rotor. 3. Check: • oil pump operation refer to “checking the oil pump”. 1 a 1 a.

  • Page 379: 5 - 48

    5 - 48 eng clutch clutch order job/part q’ty remarks removing the clutch remove the parts in the order listed. A.C. Magneto cover refer to “starter clutch and a.C. Magneto rotor”. 1 clutch assembly nut 1 refer to “removing the clutch” and “installing the clutch”. 2 clutch assembly 1 for installation...

  • Page 380: 5 - 49

    5 - 49 eng clutch order job/part q’ty remarks disassembling the clutch remove the parts in the order listed. 1 circlip 1 refer to “disassembling the clutch” and “assembling the clutch”. 2 spring stopper plate 1 3 clutch damper spring 2 1 4 pressure plate 1 5 clutch plate 2 2 6 clutch damper spring 1...

  • Page 381: 5 - 50

    5 - 50 eng clutch order job/part q’ty remarks d circlip 1 e bearing 1 f clutch boss 1 g collar 1 h weight 12 i clutch housing 1 for assembly, reverse the disassembly procedure..

  • Page 382: 5 - 51

    5 - 51 eng clutch removing the clutch 1. Remove: • clutch assembly nut 1 • clutch assembly 2 note: • before removal, apply a and b alignment marks. • while holding the clutch assembly with the rotor holding tool 3 , loosen the clutch assembly nut. • align these marks during reassembly. Rotor holding...

  • Page 383: 5 - 52

    5 - 52 eng clutch 3. Remove: • clutch boss nut 1 note: while holding the clutch boss 2 with the clutch holding tool 3 , loosen the clutch boss nut. Clutch holding tool 90890-04086, ym-91042 1 2 3 eas00280 checking the friction plates the following procedure applies to all of the friction plates. 1. ...

  • Page 384: 5 - 53

    5 - 53 eng clutch checking the clutch springs and clutch damper springs the following procedure applies to all of the clutch springs. 1. Check: • clutch spring damage → replace the clutch springs as a set. 2. Measure: • clutch spring free length a out of specification → replace the clutch spring. Cl...

  • Page 385: 5 - 54

    5 - 54 eng clutch eas00285 checking the clutch boss 1. Check: • clutch boss splines damage/pitting/wear → replace the clutch boss. Note: pitting on the clutch boss splines will cause erratic clutch operation. Eas00286 checking the pressure plate and thrust plate 1. Check: • pressure plate • thrust p...

  • Page 386: 5 - 55

    5 - 55 eng 2. Install: • clutch boss • primary drive gear • clutch boss nut 1 3. Tighten: • clutch boss nut note: while holding the clutch boss 2 with the clutch holding tool 3 , tighten the clutch boss nut. Clutch holding tool 90890-04086, ym-91042 1 2 3 t r . . 90 nm (9.0 m · kg, 65 ft · lb) 4. In...

  • Page 387: 5 - 56

    5 - 56 eng installing the clutch 1. Install: • clutch assembly 1 • clutch assembly nut 2 note: • align the a and b during reassembly. • while holding the clutch assembly with the rotor holding tool 3 , tighten the clutch assembly nut. Rotor holding tool 90890-01235, yu-01235 t r . . 65 nm (6.5 m · k...

  • Page 388: 5 - 57

    5 - 57 eng v-belt automatic transmission v-belt automatic transmission v-belt case order job/part q’ty remarks removing the v-belt case remove the parts in the order listed. Muffler refer to “engine removal”. 1 v-belt case cover 1 1 2 v-belt case cover 2 1 3 v-belt case air filter cover 1 4 v-belt c...

  • Page 389: 5 - 58

    5 - 58 eng v-belt automatic transmission v-belt and primary/secondary sheave * 1 shell bt grease 3 ® * 2 bel-ray assembly lube ® order job/part q’ty remarks removing the v-belt and primary/ secondary sheave remove the parts in the order listed. V-belt case air filter element (left) refer to “water p...

  • Page 390: 5 - 59

    5 - 59 eng v-belt automatic transmission * 1 shell bt grease 3 ® * 2 bel-ray assembly lube ® order job/part q’ty remarks 12 v-belt case air duct joint clamp 1 loosen. Refer to “installing the primary sheave assembly, second- ary sheave assem- bly and v-belt”. 13 v-belt case air duct 1 14 plate 1 15 ...

  • Page 391: 5 - 60

    5 - 60 eng v-belt automatic transmission * bel-ray assembly lube ® order job/part q’ty remarks disassembling the primary sheave remove the parts in the order listed. 1 cam 1 refer to “disassembling the pri- mary sheave” and “assembling the primary sheave”. 2 slider 4 3 weight 8 4 primary sliding she...

  • Page 392: 5 - 61

    5 - 61 eng v-belt automatic transmission * bel-ray assembly lube ® order job/part q’ty remarks disassembly the secondary sheave remove the parts in the order listed. 1 secondary sheave spring seat nut 1 refer to “disassembling the sec- ondary sheave” and “assembling the secondary sheave”. 2 upper sp...

  • Page 393: 5 - 62

    5 - 62 eng v-belt automatic transmission removing the primary sheave assembly, secondary sheave assembly and v-belt 1. Remove: • primary sheave nut 1 • secondary sheave nut 2 note: while holding the primary and secondary sheave with the sheave holder, loosen the nut. Sheave holder 90890-01481 1 2 2....

  • Page 394: 5 - 63

    5 - 63 eng v-belt automatic transmission disassembling the primary sheave 1. Remove: • cam 1 • slider 2 • weight 3 1 2 3 disassembling the secondary sheave 1. Remove: • secondary sheave spring seat nut 1 note: install the sheave spring compressor 2 onto the secondary sheave as shown. Then, com- pres...

  • Page 395: 5 - 64

    5 - 64 eng v-belt automatic transmission checking the v-belt case air duct 1. Check • v-belt case air duct cracks/damage → replace. Checking the primary sheave 1. Check: • primary sliding sheave 1 • primary fixed sheave 2 cracks/damage/wear → replace the pri- mary sliding sheave and primary fixed sh...

  • Page 396: 5 - 65

    5 - 65 eng v-belt automatic transmission eas00322 checking the secondary sheave 1. Check: • secondary fixed sheave • secondary sliding sheave cracks/damage/wear → replace the sec- ondary fixed and sliding sheaves as a set. 2. Check: • torque cam groove 1 damage/wear → replace the secondary fixed and...

  • Page 397: 5 - 66

    5 - 66 eng v-belt automatic transmission eas00324 assembling the secondary sheave 1. Lubricate: • secondary fixed sheave shaft’s outer and inner surfaces 1 • secondary sliding sheave’s outer and inner surfaces 2 • grease nipple groove • oil seals (with the recommended lubricant) recommended lubrican...

  • Page 398: 5 - 67

    5 - 67 eng v-belt automatic transmission 6. Tighten: • secondary sheave spring seat nut note: attach the sheave spring compressor 2 onto the secondary sheave as shown. Then compress the spring, and tighten the secondary sheave spring seat nut 1 with lock- nut wrench 3 . Sheave spring compressor 2 90...

  • Page 399: 5 - 68

    5 - 68 eng 2. Install: • primary fixed sheave 1 • v-belt 2 • secondary sheave assembly 3 caution: do not allow grease to contact the v-belt, primary and secondary pulleys. Note: • when installing the belt, screw m6 (more than 45 mm (1.77 in)) bolts 4 to spread apart the secondary sheave and then ins...

  • Page 400: 5 - 69

    5 - 69 eng 5. Tighten: • primary sheave nut 1 caution: • before tightening the nut to remount the primary sheave, make sure that the serra- tions of the cam are fitted firmly into the serrations of the crankshaft. Also, make sure that cam is properly seated. • apply grease to the thread and seat of ...

  • Page 401: 5 - 70

    5 - 70 eng crankcase and crankshaft crankcase and crankshaft crankshaft assembly order job/part q’ty remarks removing the crankshaft assembly remove the parts in the order listed. Engine refer to “engine removal”. Cylinder head refer to “cylinder head”. Cylinder/piston refer to “cylinder and piston”...

  • Page 402: 5 - 71

    5 - 71 eng crankcase and crankshaft order job/part q’ty remarks 5 dowel pin 2 6 crankshaft assembly 1 refer to “installing the crank- shaft”. 7 balancer cylinder 1 8 right crankcase 1 9 oil strainer 1 10 dowel pin 2 11 crankshaft main journal bearing 2 refer to “removing the crank- shaft main journa...

  • Page 403: 5 - 72

    5 - 72 eng crankcase and crankshaft connecting rod order job/part q’ty remarks removing the connecting rod remove the parts in the order listed. 1 connecting rod 2 refer to “removing the connect- ing rods” and “installing the connecting rods”. 2 connecting rod (balancer) 1 3 connecting rod cap 3 4 b...

  • Page 404: 5 - 73

    5 - 73 eng crankcase and crankshaft eas00385 disassembling the crankcase 1. Remove: • crankcase bolts note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • left crankcase caution: tap on one side of...

  • Page 405: 5 - 74

    5 - 74 eng crankcase and crankshaft eas00391 removing the connecting rods the following procedure applies to all of the connecting rods. 1. Remove: • connecting rod 1 • big end bearings note: identify the position of each big end bearing so that it can be reinstalled in its original place. Eas00399 ...

  • Page 406: 5 - 75

    5 - 75 eng crankcase and crankshaft 2. Check: • crankshaft journal surfaces • crankshaft pin surfaces • bearing surfaces scratches/wear → replace the crankshaft. 3. Measure: • crankshaft-pin-to-big-end-bearing clear- ance out of specification → replace the big end bearings. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼...

  • Page 407: 5 - 76

    5 - 76 eng crankcase and crankshaft d. Assemble the connecting rod halves. Note: • do not move the connecting rod or crank- shaft until the clearance measurement has been completed. • apply molybdenum disulfide grease onto the bolts, threads, and nut seats. • make sure that the “y” mark c on the con...

  • Page 408: 5 - 77

    5 - 77 eng crankcase and crankshaft 4. Select: • big end bearings (p 1 , p 2 , p 3 ) note: • the numbers È stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. • “p 1 , p 2 , p 3 ” refer to the bearings shown in the cra...

  • Page 409: 5 - 78

    5 - 78 eng crankcase and crankshaft a. Clean the surface of main journal and jour- nal bearings. B. Check the bearing surface. If the bearing surface is worn or scratched, the bearings should be replace. Note: if either of the right or left journal bearing is worn or scratched, both bearings should ...

  • Page 410: 5 - 79

    5 - 79 eng crankcase and crankshaft 6. Select: • crankshaft journal bearings (j 1 , j 2 ) note: • the numbers È stamped into the crankshaft web and the numbers 1 on the crankcase are used to determine the replacement crankshaft journal bearing size. • “j 1 , j 2 ” refer to the bearings shown in the ...

  • Page 411: 5 - 80

    5 - 80 eng crankcase and crankshaft installing the crankshaft main journal bearings 1. Attach: • crankshaft main journal bearings note: attach the crankshaft main journal bearing to the plane bearing installer 1 . 2. Install: • crankshaft main journal bearings 2 note: • align the projection a on the...

  • Page 412: 5 - 81

    5 - 81 eng crankcase and crankshaft 3. Install: • connecting rod cap note: be sure that the characters a on the side of the cap and connecting rod are aligned. 4. Tighten: • nuts (connecting rod cap) note: apply molybdenum disulfide grease to the rod cap bolt threads and nut surfaces. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ...

  • Page 413: 5 - 82

    5 - 82 eng crankcase and crankshaft 5. Install: • balancer connecting rod • connecting rod cap caution: • when tightening the nuts be sure to use an f-type torque wrench. • without pausing, tighten to full torque specification. Apply continuous torque 57 ~ 63 nm (5.7 ~ 6.3 m · kg, 41 ~ 45 ft · lb). ...

  • Page 414: 5 - 83

    5 - 83 eng crankcase and crankshaft 2. Apply: • sealant (onto the crankcase mating surfaces) note: do not allow any sealant to come into contact with the oil gallery. 3. Install: • dowel pins • left crankcase yamaha bond no. 1215 90890-85505 sealant (quick gasket ® ) acc-11001-05-01.

  • Page 415: 5 - 84

    5 - 84 eng transmission transmission order job/part q’ty remarks removing the transmission remove the parts in the order listed. Left crankcase refer to “crankcase and crank- shaft”. 1 secondary shaft 1 2 main axle 1 3 primary driven gear 1 4 first pinion gear 1 5 washer 1 6 drive axle 1 7 first whe...

  • Page 416: 5 - 85

    5 - 85 eng transmission removing the transmission 1. Remove: • left crankcase refer to “crankcase and crank- shaft”. 2. Remove: • secondary shaft 1 • main axle 2 • drive axle 3 • primary driven gear 4 • first wheel gear 5 • first pinion gear eas00425 checking the transmission 1. Measure: • main axle...

  • Page 417: 5 - 86

    5 - 86 eng transmission 4. Check: • transmission gears blue discoloration/pitting/wear → replace the defective gear(s). 5. Check: • transmission gear movement rough movement → replace the defective part(s). 6. Check: • circlips damage/bends/looseness → replace. Eas00418 assembling the crankcase refe...

  • Page 418: 5 - 87

    5 - 87 eng chain drive chain drive order job/part q’ty remarks removing the chain drive assembly remove the parts in the order listed. Chain drive oil drain. Refer to “changing the chain drive oil” in chapter 3. Rear shock absorber refer to “rear shock absorber” in chapter 4. Rear brake caliper/rear...

  • Page 419: 5 - 88

    5 - 88 eng chain drive order job/part q’ty remarks 8 collar 1 9 oil seal 1 10 bearing 1 11 left rear footrest 1 12 chain drive assembly 1 13 chain drive holder assembly 1 14 o-ring 1 for installation, reverse the removal pro- cedure..

  • Page 420: 5 - 89

    5 - 89 eng chain drive order job/part q’ty remarks disassembling the chain drive assembly remove the parts in the order listed. 1 chain drive case (outer) 1 2 secondary drive chain 1 3 secondary drive gear 1 4 secondary driven gear 1 5 middle shaft 1 6 primary drive chain 1 7 primary drive gear 1 8 ...

  • Page 421: 5 - 90

    5 - 90 eng order job/part q’ty remarks c retainer 1 for assembly, reverse the disassembly procedure. Chain drive.

  • Page 422: 5 - 91

    5 - 91 eng chain drive checking the swingarm 1. Check: • swingarm 1 damage/wear → replace. 2. Check: • pivot shaft 1 • collar • bearing • oil seal damage/wear → replace. Checking the chain drive assembly 1. Check: • primary drive chain 1 • secondary drive chain 2 damage/stiffness → replace the drive...

  • Page 423: 5 - 92

    5 - 92 eng installing the chain drive 1. Install: • chain drive assembly • swingarm • pivot shaft • washer • nut 2. Tighten: • swingarm bolt 3. Tighten: • pivot shaft • nut note: • with your fingers, screw in the pivot shaft until it touches the collar and then tighten the pivot shaft to the tighten...

  • Page 424: Cool

    Cool 6.

  • Page 425: Cool

    Cool chapter 6 cooling system radiator and oil cooler ...................................................................... 6-1 checking the radiator.................................................................... 6-3 checking the oil cooler ........................................................

  • Page 426: Cool

    Cool.

  • Page 427: 6 - 1

    6 - 1 cool cooling system radiator and oil cooler order job/part q’ty remarks removing the radiator and oil cooler remove the parts in the order listed. Footrest board/leg shield/inner fender refer to “cover and panel” in chap- ter 3. Engine oil drain. Refer to “changing the engine oil” in chapter 3...

  • Page 428: 6 - 2

    6 - 2 cool radiator and oil cooler order job/part q’ty remarks 7 coolant pipe 1 8 fast idle outlet hose 1 disconnect. 9 radiator outlet hose 1 disconnect. 10 radiator fan motor coupler 1 disconnect. 11 radiator filler neck 1 12 radiator filler hose 1 13 stay 1 14 radiator 1 15 radiator fan 1 16 oil ...

  • Page 429: 6 - 3

    6 - 3 cool eas00455 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radi- ator. Damage → repair or replace. Note: note: straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: • radiator hoses cracks/damage → replace. ...

  • Page 430: 6 - 4

    6 - 4 cool radiator and oil cooler eas00458 checking the oil cooler 1. Check: • oil cooler cracks/damage → replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose cracks/damage/wear → replace. Eas00459 installing the oil cooler and radiator 1. Clean: • mating surfaces of the oil cooler a...

  • Page 431: 6 - 5

    6 - 5 cool radiator and oil cooler 4. Check: • cooling system leaks → repair or replace any faulty part. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Attach the radiator cap tester 1 to the radi- ator. B. Apply 100 kpa (1.0 kg/cm 2 , 14.22 psi) of pressure. C. Measure the indicated pressure ...

  • Page 432: 6 - 6

    6 - 6 cool thermostat thermostat new t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 18 nm (1.8 m • kg, 13 ft • ib) 2 3 4 1 5 6 order job/part q’ty remarks removing the thermostat remove the parts in the order listed. Center cover/side cover refer to “cover and panel” in chap- ter 3. Coolant drain. ...

  • Page 433: 6 - 7

    6 - 7 cool thermostat eas00462 checking the thermostat 1. Check: • thermostat does not open at 69 ~ 73 °c (156.2 ~ 163.4 °f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat in a container filled with water. B. Slowly heat the water. C. Place a thermometer in th...

  • Page 434: 6 - 8

    6 - 8 cool thermostat 3. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 4. Check: • cooling system leaks → repair or replace any faulty part. 5. Measure: • radiator cap opening pressure below the specified pressure → repl...

  • Page 435: 6 - 9

    6 - 9 cool water pump water pump order job/part q’ty remarks removing the water pump remove the parts in the order listed. Left upper side cover moulding/left footrest board refer to “cover and panel” in chap- ter 3. Coolant drain. Refer to “changing the coolant” in chapter 3. 1 v-belt case air filt...

  • Page 436: 6 - 10

    6 - 10 cool order job/part q’ty remarks 10 water pump assembly 1 refer to “installing the water pump”. For installation, reverse the removal pro- cedure. Water pump.

  • Page 437: 6 - 11

    6 - 11 cool water pump order job/part q’ty remarks disassembling the water pump remove the parts in the order listed. Note: note: it is not necessary to remove the impeller shaft, unless the coolant level is extremely low or coolant contains engine oil. 1 water pump housing cover 1 2 o-ring 1 3 circ...

  • Page 438: 6 - 12

    6 - 12 cool water pump eas00471 disassembling the water pump 1. Remove: • water pump seal 1 note: note: remove the water pump seal from the outside of the water pump housing. 2 water pump housing 2. Remove: • oil seal 1 (with a thin, flat-head screwdriver) note: note: remove the oil seal from the ou...

  • Page 439: 6 - 13

    6 - 13 cool water pump eas00474 checking the water pump 1. Check: • water pump housing cover 1 • water pump housing 2 • impeller shaft 3 • water pump seal 4 • oil seal 5 • rubber damper • rubber damper holder cracks/damage/wear → replace. 2. Check: • bearing rough movement → replace. Eas00475 assemb...

  • Page 440: 6 - 14

    6 - 14 cool water pump 3. Install: • water pump seal 1 caution: caution: never apply oil or grease onto the water pump seal surface. Note: note: • install the water pump seal with the special tools. • before installing the water pump seal, apply yamaha bond no.1215 or sealant (quick gasket ® ) 2 to ...

  • Page 441: 6 - 15

    6 - 15 cool water pump 5. Measure: • tilt out of specification → repeat steps (3) and (4). Caution: caution: make sure that the rubber damper and rub- ber damper holder are flush with the impel- ler. 1 straightedge 2 impeller maximum impeller shaft tilt 0.15 mm (0.006 in) installing the water pump 1...

  • Page 443

    Fi 7.

  • Page 444: Chapter  7

    Fi chapter 7 fuel injection system fuel injection system ............................................................................ 7-1 wiring diagram ................................................................................... 7-2 ecu (engine) self-diagnostic function.........................

  • Page 445

    Fi.

  • Page 446: 7 - 1

    7 - 1 fi fuel injection system fuel injection system fuel injection system 1 ignition coil 2 air filter case 3 intake air temperature sensor 4 fuel injection system relay 5 lean angle cut-off switch 6 engine trouble warning light 7 ecu (engine) 8 intake air pressure sensor 9 throttle position sensor...

  • Page 447: 7 - 2

    7 - 2 fi fuel injection system wiring diagram off on p pass ( blue ) b lg ( blue ) b b lg b \ on off b l l l l / r ch l / r br / g l / r dg l / r br / g b g b g b y b y d f e c b dc terminal sub-wire harness wire harness turn signal sub-wire harness 2 main harness turn signal sub-wire harness 1 wire...

  • Page 448: 7 - 3

    7 - 3 fi fuel injection system eas00899 ecu (engine) self-diagnostic function the ecu (engine) is equipped with a self-diagnostic function in order to ensure that the fuel injec- tion system is operating normally. If this function detects a malfunction in the system, it immediately operates the engi...

  • Page 449: 7 - 4

    7 - 4 fi fuel injection system eas00901 checking for a defective engine trouble warning light bulb the engine trouble warning light comes on for 1.4 seconds after the main switch has been turned to “on” and when the start switch is being pushed. If the warning light does not come on under these cond...

  • Page 450: 7 - 5

    7 - 5 fi fuel injection system communication error with the meter 37 faulty the fid valve stuck fid valve. (when fully open) -- able able 30 41 lean angle cut-off switch (latch up detected) (open or short circuit) the scooter has over turned. Lean angle cut-off switch-open or short circuit detected....

  • Page 451: 7 - 6

    7 - 6 fi eas00904 troubleshooting chart engine operation is not normal or the engine trouble warning light is on. * engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on. Check the fault code number displayed on the meter. ...

  • Page 452: 7 - 7

    7 - 7 fi fuel injection system eas00905 diagnostic mode setting the diagnostic mode 1. Turn the main switch to “off” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “select” 1 and “reset” 2 buttons, turn the main ...

  • Page 453: 7 - 8

    7 - 8 fi fuel injection system 8. Verify the operation of the sensor or actua- tor. • sensor operation the data representing the operating condi- tions of the sensor appears on the trip lcd. • actuator operation set the engine stop switch to “ ” to oper- ate the actuator. Note: if the engine stop sw...

  • Page 454: 7 - 9

    7 - 9 fi fuel injection system eas00906 fault code table fault code no. Symptom probable cause of malfunction diagnostic code 12 no normal signals are received from the crankshaft position sensor. • open or short circuit in wiring harness. • defective crankshaft position sensor. • malfunction in pic...

  • Page 455: 7 - 10

    7 - 10 fi fuel injection system eas00907 diagnostic mode table switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “diagnostic mode”. Note: • check the intake temperature and coolant temperature as close as possible to the intake temper- ature senso...

  • Page 456: 7 - 11

    7 - 11 fi fuel injection system 09 fuel system voltage (bat- tery voltage) displays the fuel system voltage (battery voltage). Engine stop switch is “ ”. 0 ~ 18.7 v normally, approximately 12.0 v 20 sidestand switch displays that the switch is on or off. Stand retracted: on stand extended: off 30 ig...

  • Page 457: 7 - 12

    7 - 12 fi fuel injection system eas00908 troubleshooting details this section describes the countermeasures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order in the “troubleshooting chart”. After...

  • Page 458: 7 - 13

    7 - 13 fi fuel injection system fault code no. 12 symptom no normal signals are received from the crankshaft position sensor. Used diagnostic code no. – – order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 installed condition of sensor check t...

  • Page 459: 7 - 14

    7 - 14 fi fuel injection system fault code no. 13 symptom intake air pressure sensor - open or short circuit detected. Used diagnostic code no. 03 (intake air pressure sensor) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 defective intake...

  • Page 460: 7 - 15

    7 - 15 fi fuel injection system fault code no. 14 symptom intake air pressure sensor - hose system malfunction (clogged or detached hose). Used diagnostic code no. 03 (intake air pressure sensor) order inspection operation item and probable cause operation item and countermeasure reinstatement metho...

  • Page 461: 7 - 16

    7 - 16 fi fuel injection system fault code no. 19 symptom open circuit is detected in the input line from the sidestand switch to the ecu (engine). Used diagnostic code no. 20 (sidestand switch) order inspection operation item and probable cause operation item and countermeasure reinstatement method...

  • Page 462: 7 - 17

    7 - 17 fi fuel injection system fault code no. 22 symptom open or short circuit detected from the intake air temperature sensor. Used diagnostic code no. 05 (intake air temperature sensor) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 ins...

  • Page 463: 7 - 18

    7 - 18 fi fuel injection system fault code no. 24 symptom no normal signal is received from the o 2 sensor. Used diagnostic code no. -- order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 installed state of o 2 sensor check the installed area f...

  • Page 464: 7 - 19

    7 - 19 fi fuel injection system fault code no. 30 symptom the scooter has overturned. Used diagnostic code no. 08 (lean angle cut-off switch) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 defective lean angle cut-off switch replace if def...

  • Page 465: 7 - 20

    7 - 20 fi fuel injection system fault code no. 37 symptom engine idling speed is too high. Used diagnostic code no. 01 (throttle position sensor) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 stuck fid valve detected. Inspect the throttle...

  • Page 466: 7 - 21

    7 - 21 fi fuel injection system fault code no. 43 symptom the ecu (engine) is unable to monitor the battery voltage. Used diagnostic code no. 09 (fuel system voltage) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 malfunction in ecu (engin...

  • Page 467: 7 - 22

    7 - 22 fi fuel injection system fault code no. 44 symptom error is detected while reading or writing on eeprom (co adjustment value). Used diagnostic no. 60 (eeprom improper cylinder indication) order inspection operation item and probable cause operation item and countermeasure reinstatement method...

  • Page 468: 7 - 23

    7 - 23 fi throttle body throttle body new new 9 11 11 11 11 12 1 2 8 3 3 4 4 5 6 10 13 14 14 15 15 7 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the...

  • Page 469: 7 - 24

    7 - 24 fi throttle body new new 9 11 11 11 11 12 1 2 8 3 3 4 4 5 6 10 13 14 14 15 15 7 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks 12 intake air pressure sen...

  • Page 470: 7 - 25

    7 - 25 fi new new 9 11 11 11 11 12 1 2 8 3 3 4 4 5 6 10 13 14 14 15 15 7 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks 15 intake manifold 2 for installation, r...

  • Page 471: 7 - 26

    7 - 26 fi order job/part q’ty remarks disassembling the throttle body remove the parts in the order listed. Note: before disassembling the throttle body, make sure to note the number of times the air screw is turned out from the seated position to its set position. 1 throttle position sensor 1 2 fas...

  • Page 472: 7 - 27

    7 - 27 fi throttle body eas00911 caution: the throttle body should not be disassem- bled. Eas00912 checking the fuel injectors 1. Check: • fuel injectors damage → replace. Eas00913 checking the throttle body 1. Check: • throttle body cracks/damage → replace the throttle body. 2. Check: • fuel passag...

  • Page 473: 7 - 28

    7 - 28 fi throttle body b. Disconnect the fuel hose 1 from the fuel pump. Caution: although the fuel has been removed from the fuel tank, be careful when removing the fuel hoses, since there may be fuel remain- ing in it. Note: before removing the hoses, place a few rags in the area under where it w...

  • Page 474: 7 - 29

    7 - 29 fi throttle body eas00916 checking and adjusting the throttle position sensor note: before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: • throttle position sensor ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the thro...

  • Page 475: 7 - 30

    7 - 30 fi throttle body note: check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide-open throttle) may differ slightly from those specified. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ throttle position sensor resis- tance (0.52 ~...

  • Page 476: Elec

    Elec 8 – +.

  • Page 477: Elec

    – + elec chapter 8 electrical system electrical components ........................................................................ 8-1 checking switch continuity ................................................................ 8-4 checking the switches .................................................

  • Page 478: Elec

    – + elec immobilizer system ................................................................................ 8-54 system diagram ................................................................................ 8-54 circuit diagram ........................................................................

  • Page 479: 8 - 1

    8 - 1 – + elec eas00729 electrical system electrical components 1 front brake light switch 2 rear brake light switch 3 turn signal/hazard relay 4 starting circuit cut-off relay 1 5 starting circuit cut-off relay 2 (xp500a) 6 battery 7 fuse box 8 starter relay 9 main fuse 0 rectifier/regulator a side...

  • Page 480: 8 - 2

    8 - 2 – + elec electrical components e speed sensor (xp500) f throttle position sensor g ignition coil h horn i lean angle cut-off switch j fuel injection system relay k headlight relay l radiator fan motor relay 1 2 3 4 5 6 7 8 9 0 a b c d e h f g j k l i.

  • Page 481: 8 - 3

    8 - 3 – + elec 1 ecu (abs) (xp500a) 2 fail-safe relay (xp500a) 3 main switch/immobilizer unit 4 intake air pressure sensor 5 coolant temperature sensor 6 abs motor fuse 7 fuel pump 8 rear wheel sensor (xp500a) 9 o 2 sensor 0 hydraulic unit (xp500a) a front wheel sensor (xp500a) b intake air temperat...

  • Page 482: 8 - 4

    8 - 4 – + elec checking switch continuity eas00730 checking switch continuity check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. Caution: _ never insert the tester probes into the cou...

  • Page 483: 8 - 5

    8 - 5 – + elec checking the switches eas00731 checking the switches check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “checking switch continuity”. Damage/wear → repair or replace. Improperly connected → properly connect. Incorrect co...

  • Page 484: 8 - 6

    8 - 6 – + elec checking the bulbs and bulb sockets eas00733 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected...

  • Page 485: 8 - 7

    8 - 7 – + elec checking the bulbs and bulb sockets checking the condition of the bulbs the following procedure applies to all of the bulbs. 1. Remove: • bulb warning _ since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Cau...

  • Page 486: 8 - 8

    8 - 8 – + elec checking the bulbs and bulb sockets checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Note: _ check each bulb socket for continuity in the sa...

  • Page 487: 8 - 9

    8 - 9 – + elec ignition system eas00734 ignition system circuit diagram off on p pass ( blue ) b lg ( blue ) b b lg b \ on off b l l l w w w w w w r l / w r b w r w b w b / l b / y b gy r br / l r br / l br / r l / r y / lg / l r / w b / w br / g r / w lg y / l r / g bb r / y br / r r / w br br / l ...

  • Page 488: 8 - 10

    8 - 10 – + elec ignition system eas00737 troubleshooting check: 1. Main and ignition fuses 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Crankshaft position sensor resistance 8. Main switch 9. Engine stop switch 10.Sidestand switch 11.Star...

  • Page 489: 8 - 11

    8 - 11 – + elec ignition system eas00743 yes no eas00745 yes no 4. Ignition spark gap the following procedure applies to all of the spark plugs. • disconnect the spark plug cap 1 from the spark plug. • connect the ignition checker 2 as shown. • set the main switch to “on”. • measure the ignition spa...

  • Page 490: 8 - 12

    8 - 12 – + elec ignition system eas00746 yes no eas00748 yes no eas00749 yes no 6. Ignition coil resistance • disconnect the ignition coil connectors from the ignition coil terminals. • connect the pocket tester ( Ω × 1) to the ignition coil as shown. Positive tester probe → red/black negative teste...

  • Page 491: 8 - 13

    8 - 13 – + elec ignition system eas00750 yes no eas00752 yes no eas00753 yes no 9. Engine stop switch • check the engine stop switch for continu- ity. Refer to “checking the switches”. • is the engine stop switch ok? Replace the right handlebar switch. 10.Sidestand switch • check the sidestand switc...

  • Page 492: 8 - 14

    8 - 14 – + elec ignition system yes no eas00754 yes no 12.Lean angle cut-off switch • remove the lean angle cut-off switch. • connect the pocket tester ( Ω × 1) to the lean angle cut-off switch terminals as shown. Positive tester probe → blue 1 negative tester probe → yellow/green 2 lean angle cut-o...

  • Page 493: 8 - 15

    8 - 15 – + elec electric starting system eas00755 electric starting system circuit diagram (xp500) off on p pass ( blue ) b lg ( blue ) b b lg b \ b l l l b w w w w w w r l / w r b w r w b w b / l b / y b gy r br / l r br / l br / r l / r y / lg / l r / w b / w br / g r / w lg y / l r / g bb bb bb l...

  • Page 494: 8 - 16

    8 - 16 – + elec electric starting system eas00755 circuit diagram (xp500a) off on p pass ( blue ) b lg ( blue ) b b lg b a on off b w w w w w w r l / w r r / w w r w b w b / l b / y b gy r br / l r br / l br / r l / r y / lg / l r / w b / w br / g r / w lg y / l r / g bb bb bb l / gr / g rl / g r / ...

  • Page 495: 8 - 17

    8 - 17 – + elec eas00756 starting circuit cut-off system operation (xp500) if the engine stop switch is set to “ ” and the main switch is set to “on” (both switches are closed), the starter motor can only operate if the following conditions are met: • a brake lever is pulled to the handlebar (the br...

  • Page 496: 8 - 18

    8 - 18 – + elec eas00756 starting circuit cut-off system operation (xp500a) if the engine stop switch is set to “ ” and the main switch is set to “on” (both switches are closed), the starter motor can only operate if the following conditions are met: • a brake lever is pulled to the handlebar (the b...

  • Page 497: 8 - 19

    8 - 19 – + elec electric starting system eas00757 troubleshooting check: 1. Main, ignition and signaling system fuses 2. Battery 3. Starter motor 4. Starting circuit cut-off relay 1 5. Starting circuit cut-off relay 2 (xp500a) 6. Starter relay 7. Main switch 8. Engine stop switch 9. Sidestand switch...

  • Page 498: 8 - 20

    8 - 20 – + elec electric starting system eas00759 yes no yes no 4. Starting circuit cut-off relay 1 • remove the starting circuit cut-off relay 1. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the starting circuit cut-off relay 1 terminals as shown. Positive battery terminal → red/bla...

  • Page 499: 8 - 21

    8 - 21 – + elec electric starting system eas00761 yes no eas00749 yes no eas00750 yes no eas00752 yes no eas00751 yes no 6. Starter relay • remove the starter relay. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the starter relay terminals as shown. Xp500 positive battery terminal → b...

  • Page 500: 8 - 22

    8 - 22 – + elec electric starting system eas00764 yes no eas00766 yes no 11.Start switch • check the start switch for continuity. Refer to “checking the switches”. • is the start switch ok? Replace the right handlebar switch. 12.Wiring • check the entire starting system’s wiring. Refer to “circuit d...

  • Page 501: 8 - 23

    8 - 23 – + elec starter motor eas00767 starter motor order job/part q’ty remarks removing the starter motor remove the parts in the order listed. Fuel tank refer to “fuel tank” in chapter 3. 1 negative battery lead 1 disconnect. 2 starter motor lead 1 disconnect. 3 starter motor 1 for installation, ...

  • Page 502: 8 - 24

    8 - 24 – + elec order job/part q’ty remarks disassembling the starter motor remove the parts in the order listed. 1 front bracket 1 2 o-ring 2 3 shims 4 lock washer 1 5 oil seal 1 6 bearing 1 7 rear bracket 1 8 shims 9 brush holder set 1 0 armature assembly 1 a starter motor yoke 1 for assembly reve...

  • Page 503: 8 - 25

    8 - 25 – + elec starter motor eas00770 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter a out of specification → replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3. Measure: • mica undercut a out of specificatio...

  • Page 504: 8 - 26

    8 - 26 – + elec starter motor b. If any resistance is out of specification, replace the starter motor. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ pocket tester 90890-03112, yu-03112-c armature coil commutator resistance 1 0.0015 ~ 0.0025 Ω at 20 °c (68 °f) insulation resistance 2 above 1 m Ω ...

  • Page 505: 8 - 27

    8 - 27 – + elec starter motor eas00772 assembling the starter motor 1. Install: • starter motor yoke 1 • front bracket 2 • rear bracket 3 note: _ align the match marks a on the starter motor yoke with the match marks b on the front and rear bracket..

  • Page 506: 8 - 28

    8 - 28 – + elec charging system eas00773 charging system circuit diagram off on p w w w w w w r l / w r b w r w b w b / l b / y b gy r br / l r br / l br / r l / r y / lg / l r / w b / w br / g r / w lg y / l r / g bb bb bb l / gr / g rl / g r / y br / r br / l l / r br br / l r / w r / y l / r l / ...

  • Page 507: 8 - 29

    8 - 29 – + elec charging system eas00774 troubleshooting check: 1. Main fuse 2. Battery 3. Charging voltage 4. Stator coil resistance 5. Wiring connections (of the entire charging system) note: _ • before troubleshooting, remove the following part(s): 1. Rear cover 2. Battery cover 3. Left side cove...

  • Page 508: 8 - 30

    8 - 30 – + elec charging system eas00775 no yes eas00776 yes no eas00779 yes no 3. Charging voltage • connect the pocket tester (dc 20 v) to the battery as shown. Positive tester probe → positive battery terminal negative tester probe → negative battery terminal • start the engine and let it run at ...

  • Page 509: 8 - 31

    8 - 31 – + elec lighting system eas00780 lighting system circuit diagram off on p pass ( blue ) b lg ( blue ) b b lg b \ on off b l l l l / r ch l / r br / g l / r dg l / r br / g b g b g b y b y d f e c b dc terminal sub-wire harness wire harness turn signal sub-wire harness 2 main harness turn sig...

  • Page 510: 8 - 32

    8 - 32 – + elec lighting system 4 main switch 6 storage box light switch 7 storage box light 0 backup fuse (storage box light, immobilizer unit and meter assembly) a signaling system fuse b headlight fuse e lighting system fuse f battery g main fuse t ecu (engine) k headlight relay m pass switch n d...

  • Page 511: 8 - 33

    8 - 33 – + elec lighting system eas00781 troubleshooting check: 1. Main, headlight, signaling system, lighting system and backup fuses 2. Battery 3. Main switch 4. Dimmer switch 5. Pass switch 6. Storage box light switch 7. Headlight relay 8. Wiring connections (of the entire lighting system) note: ...

  • Page 512: 8 - 34

    8 - 34 – + elec lighting system eas00786 yes no yes no yes no eas00787 yes no 5. Pass switch • check the pass switch for continuity. Refer to “checking the switches”. • is the pass switch ok? The pass switch is faulty. Replace the left handlebar switch. 6. Storage box light switch • check the storag...

  • Page 513: 8 - 35

    8 - 35 – + elec lighting system eas00788 checking the lighting system 1. The headlight and the high beam indicator light fail to come on. Yes no yes no yes no 1. Headlight bulb and socket • check the headlight bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. • are the ...

  • Page 514: 8 - 36

    8 - 36 – + elec lighting system eas00789 2. The meter light fails to come on. Yes no yes no eas00790 3. The tail/brake light fails to come on. Yes no yes no 1. Meter light bulb and socket • check the meter light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. • are th...

  • Page 515: 8 - 37

    8 - 37 – + elec lighting system eas00791 4. The auxiliary light fails to come on. Yes no yes no eas00792 5. The license plate light fails to come on. Yes no yes no 1. Auxiliary light bulb and socket • check the auxiliary light bulb and socket for continuity. Refer to “checking the bulbs and bulb soc...

  • Page 516: 8 - 38

    8 - 38 – + elec lighting system eas00792 6. The storage box light fails to come on. Yes no yes no 1. Storage box light bulb and socket • check the storage box light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. • are the storage box light bulb and socket ok? Replace...

  • Page 517: 8 - 39

    8 - 39 – + elec signaling system eas00793 signaling system circuit diagram off on p pass ( blue ) b lg ( blue ) b b lg b \ on off b l l l l / r ch l / r br / g l / r dg l / r br / g b g b g b y b y d f e c b dc terminal sub-wire harness wire harness turn signal sub-wire harness 2 main harness turn s...

  • Page 518: 8 - 40

    8 - 40 – + elec signaling system 4 main switch 0 backup fuse (storage box light, immobilizer unit and meter assembly) a signaling system fuse e lighting system fuse f battery g main fuse m fuel pump q hazard switch r front brake light switch t ecu (engine) a speed sensor i turn signal/hazard relay j...

  • Page 519: 8 - 41

    8 - 41 – + elec signaling system eas00794 troubleshooting check: 1. Main, signaling system, lighting system and backup fuses 2. Battery 3. Main switch 4. Wiring connections (of the entire signaling system) note: _ • before troubleshooting, remove the following part(s): 1. Battery cover 2. Rear cover...

  • Page 520: 8 - 42

    8 - 42 – + elec signaling system eas00796 checking the signaling system 1. The horn fails to sound. Yes no yes no no yes 1. Horn switch • check the horn switch for continuity. Refer to “checking the switches”. • is the horn switch ok? Replace the left han- dlebar switch. 2. Voltage • connect the poc...

  • Page 521: 8 - 43

    8 - 43 – + elec signaling system eas00798 2. The tail/brake light fails to come on. Yes no yes no yes no 1. Tail/brake light bulb and socket • check the tail/brake light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. • are the tail/brake light bulb and socket ok? Rep...

  • Page 522: 8 - 44

    8 - 44 – + elec signaling system eas00799 3. The turn signal light, turn signal indicator light or both fail to blink. Yes no yes no yes no yes no yes no 1. Turn signal light bulb and socket • check the turn signal light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”....

  • Page 523: 8 - 45

    8 - 45 – + elec signaling system yes no yes no 6. Voltage • connect the pocket tester (dc 20 v) to the turn signal/hazard relay coupler (wire har- ness side) as shown. Positive tester probe → brown/white 1 negative tester probe → ground • set the main switch to “on”. • measure the voltage (dc 12 v) ...

  • Page 524: 8 - 46

    8 - 46 – + elec signaling system 4. The v-belt replacement indicator fails to come on. Yes no yes no yes no 1. V-belt replacement indicator bulb and socket • check the v-belt replacement indicator bulb and socket for continuity. • are the v-belt replacement indicator bulb and socket ok? Replace the ...

  • Page 525: 8 - 47

    8 - 47 – + elec signaling system eas00803 5. The engine oil change indicator fails to come on. Yes no 6. The engine trouble warning light fails to come on. Yes no eas00804 7. The fuel meter fails to come on. Yes no 1. Engine oil change indicator bulb and socket • check the engine oil change indicato...

  • Page 526: 8 - 48

    8 - 48 – + elec signaling system yes no yes no 2. Voltage • connect the pocket tester (dc 20 v) to the meter assembly coupler (wire harness side) as shown. Positive tester probe → green 1 negative tester probe → black/white 2 • set the main switch to “on”. • measure the voltage (dc 12 v) of green 1 ...

  • Page 527: 8 - 49

    8 - 49 – + elec signaling system eas00806 8. The speedometer fails to operate. Yes no yes no 1. Speed sensor • connect the pocket tester (dc 20 v) to the speed sensor coupler (wire harness side) as shown. Positive tester probe → white 1 negative tester probe → black/blue 2 • set the main switch to “...

  • Page 528: 8 - 50

    8 - 50 – + elec cooling system eas00807 cooling system circuit diagram off on p pass ( blue ) b lg ( blue ) b b lg b \ on off b l l l l / r ch l / r br / g l / r dg l / r br / g b g b g b y b y d f e c b dc terminal sub-wire harness wire harness turn signal sub-wire harness 2 main harness turn signa...

  • Page 529: 8 - 51

    8 - 51 – + elec cooling system eas00808 troubleshooting check: 1. Main, ignition, and radiator fan motor fuses 2. Battery 3. Main switch 4. Radiator fan motor 5. Radiator fan motor relay 6. Coolant temperature sensor 7. Wiring connections (the entire cooling system) note: _ • before troubleshooting,...

  • Page 530: 8 - 52

    8 - 52 – + elec cooling system eas00809 yes no yes no 4. Radiator fan motor • disconnect the radiator fan motor coupler from the wire harness. • connect the battery (dc 12 v) as shown. Positive battery lead → blue 1 negative battery lead → black 2 • does the radiator fan motor turn? The radiator fan...

  • Page 531: 8 - 53

    8 - 53 – + elec cooling system eas00812 yes no eas00813 yes no 6. Coolant temperature sensor • remove the coolant temperature sensor from the cylinder head. • connect the pocket tester ( Ω × 10) to the coolant temperature sensor 1 as shown. • immerse the coolant temperature sensor in a container fil...

  • Page 532: 8 - 54

    8 - 54 – + elec immobilizer system immobilizer system system diagram 1 main switch and immobilizer unit 2 ecu (engine) 3 immobilizer system indicator light main switch ignition fuse immobilizer unit backup fuse anti-theft alarm (option) meter assembly immobilizer system indi- cator light main fuse b...

  • Page 533: 8 - 55

    8 - 55 – + elec immobilizer system circuit diagram off on p pass ( blue ) b lg ( blue ) b b lg b \ b l l l b w w w w w w r l / w r b w r w b w b / l b / y b gy r br / l r br / l br / r l / r y / lg / l r / w b / w br / g r / w lg y / l r / g bb bb bb l / gr / g rl / g r / y br / r r / w br br / l l ...

  • Page 534: 8 - 56

    8 - 56 – + elec immobilizer system general information this scooter is equipped with an immobilizer system to help prevent theft by registering codes in standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with black bows) that can b...

  • Page 535: 8 - 57

    8 - 57 – + elec immobilizer system key code registration code registration of the code re-registering key or standard keys may be required when parts are replaced or a standard key is lost. Note: each standard key is registered during production, therefore, registering the keys at purchase is not ne...

  • Page 536: 8 - 58

    8 - 58 – + elec immobilizer system 3. Insert the standard key to be registered into the main switch, and then turn the main switch to “on” within 5 seconds to activate the key registration mode. Note: all existing standard key codes will be erased from the memory when the key registration mode is ac...

  • Page 537: 8 - 59

    8 - 59 – + elec immobilizer system self-diagnosis malfunction codes when a system malfunction occurs, the malfunction code number is displayed on the lcd display of the meter assembly and is indicated by the immobilizer system indicator light flash patterns. Malfunction code part symptom cause actio...

  • Page 538: 8 - 60

    8 - 60 – + elec immobilizer system immobilizer system indicator light malfunction code indication units of 10: on for 1 second and off for 1.5 seconds. Units of 1: on for 0.5 second and off for 0.5 second. Light on light off malfunction code 52 1 1.5 1 1 1 1 0.5 0.5 0.5 3 1.5 1.5 1.5 1.5.

  • Page 539: 8 - 61

    8 - 61 – + elec immobilizer system eas00794 troubleshooting check: 1. Main, ignition, and backup fuses 2. Battery 3. Main switch 4. Wiring connections (of the entire immobilizer system) note: • before troubleshooting, remove the following part(s): 1. Battery cover 2. Rear cover 3. Front cowling 4. L...

  • Page 540: 8 - 62

    8 - 62 – + elec immobilizer system checking the immobilizer system 1. The immobilizer system indicator light does not come on. Yes no yes no 1. Voltage • connect the pocket tester (dc 20 v) to the immobilizer unit coupler as shown. Positive tester probe → red/white 1 or red/green 2 negative tester p...

  • Page 541: 8 - 63

    8 - 63 – + elec immobilizer system 2. No malfunction code is displayed on the lcd display of the meter assembly. Yes no 1. Voltage • connect the pocket tester (dc 20 v) to the meter assembly coupler as shown. Lcd display positive tester probe → red/white 1 or red/green 2 negative tester probe → blac...

  • Page 542: 8 - 64

    8 - 64 – + elec immobilizer system 3. When the main switch is turned to “on”, the immobilizer system indicator light flashes. • check if a metal object or other immobilizer system keys are placed near the immobilizer unit. If so, remove the object or keys, and then check the condition again. Turn th...

  • Page 543: 8 - 65

    8 - 65 – + elec immobilizer system part replacement key registration requirements *1 replace as a set with the main switch. *2 accessory locks include the fuel tank cap lock and storage compartment lock. Note: if the ecu (engine) or the immobilizer unit is replaced, both the code re-registering key ...

  • Page 545: Trbl

    Trbl shtg 9.

  • Page 546: Trbl

    Trbl shtg chapter 9 troubleshooting starting failure/hard starting ....................................................... 9-1 engine..................................................................................................... 9-1 fuel system.....................................................

  • Page 547: Trbl

    Trbl shtg faulty lighting or signaling system .............................................. 9-5 headlight does not come on ........................................................ 9-5 headlight bulb burnt out.............................................................. 9-5 tail/brake light does no...

  • Page 548: 9 - 1

    9 - 1 trbl shtg eas00845 troubleshooting note: the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man- ual for checks, adjustments, and replacement of p...

  • Page 549: 9 - 2

    9 - 2 trbl shtg incorrect engine idling speed/poor medium- and-high-speed performance/faulty clutch eas00847 incorrect engine idling speed engine cylinder(s) and cylinder head • incorrect valve clearance • damaged valve train components air filter • clogged air filter element fuel system throttle bo...

  • Page 550: 9 - 3

    9 - 3 trbl shtg faulty clutch/overheating/overcooling poor speed performance v-belt • oil or grease on the v-belt primary pulley weight(s) • faulty operation • worn primary pulley weight primary fixed sheave • worn primary fixed sheave primary sliding sheave • worn primary sliding sheave secondary f...

  • Page 551: 9 - 4

    9 - 4 trbl shtg poor braking performance/ faulty front fork legs/unstable handling eas00857 poor braking performance • worn brake pad • worn brake disc • air in hydraulic brake system • leaking brake fluid • faulty brake caliper kit • faulty brake caliper seal • loose union bolt • damaged brake hose...

  • Page 552: 9 - 5

    9 - 5 trbl shtg faulty lighting or signaling system eas00866 faulty lighting or signaling system headlight does not come on • wrong headlight bulb • too many electrical accessories • hard charging • incorrect connection • improperly grounded circuit • poor contacts (main or light switch) • burnt-out...

  • Page 554: Xp500 2005 Wiring Diagram

    Xp500 2005 wiring diagram 1 crankshaft position sensor 2 a.C. Magneto 3 rectifier/regulator 4 main switch 5 immobilizer unit 6 storage box light switch 7 storage box light 8 fuse box 9 fuel injection system fuse 0 backup fuse (storage box light, immobilizer unit and meter assembly) a signaling syste...

  • Page 555: Xp500A 2005 Wiring Diagram

    Xp500a 2005 wiring diagram 1 crankshaft position sensor 2 a.C. Magneto 3 rectifier/regulator 4 main switch 5 immobilizer unit 6 storage box light switch 7 storage box light 8 fuse box 9 abs control unit fuse 0 fuel injection system fuse a backup fuse (storage box light, immobilizer unit and meter as...

  • Page 557

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.

  • Page 558: Xp500 2005 Wiring Diagram

    Xp500 2005 wiring diagram off on p pass (blue) b lg (blue) b b lg b \ on off b l l l nr n nl l / r ch l / r br / g l / r dg l / r br / g b g b g b y b y d f e c b dc terminal sub-wire harness wire harness turn signal sub-wire harness 2 main harness turn signal sub-wire harness 1 wire harness headlig...

  • Page 559: Xp500A 2005 Wiring Diagram

    Xp500a 2005 wiring diagram off on p pass (blue) b lg (blue) b b lg b a on off b l l l nr n nl l / r ch l / r br / g l / r dg l / r br / g b g b g b y b y d f e c b dc terminal sub-wire harness wire harness turn signal sub-wire harness 2 wire harness turn signal sub-wire harness 1 wire harness headli...