Yamaha XP500 2002, Supplementary Service Manual

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Page 2: ...t is necessary to use this Supplementa ry Service Manual together with the following manual XP500 N 2001 SERVICE MANUAL 5GJ1 AE1 XP500 P 2002 SUPPLEMENTARY SERVICE MANUAL E2001 by Yamaha Motor Co Ltd First Edition September 2001 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...iving to improve all its models Modifications and signifi cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice EAS00005 IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following ...

Page 4: ...hecks and Adjustments where the sub section title s appears In Chapter 3 Periodic Checks and Adjustments the sub section title appears at the top of each page instead of the section title 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers ...

Page 5: ...al system 9 Troubleshooting Symbols 10 to 17 indicate the following 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit clearance 16 Engine speed 17 Electrical data Symbols 18 to 23 in the exploded diagrams indi cate the types of lubricants and lubrication points 18 Engine oil 19 Gear oil 20 Molybdenum disulfide oil 21 Wheel bearing g...

Page 6: ...ODIC MAINTENANCE AND LUBRICATION INTERVALS 16 CHASSIS FRONT FORK 18 OVERHAULING THE ENGINE CLUTCH 20 REMOVING THE CLUTCH 20 CARBURETORS CARBURETORS 21 ELECTRICAL ELECTRICAL COMPONENTS 25 ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS 26 CHECKING THE SWITCHES 27 SIGNAL SYSTEM 28 CIRCUIT DIAGRAM for EUR 28 TROUBLESHOOTING 30 CHECKING THE SIGNAL SYSTEM 31 XP500 2002 WIRING DIAGRAM for EUR ...

Page 7: ...rew turns out Valve seat size Fuel level below the line on the float chamber BS30 MIKUNI 2 3 X 5 mm 5GJ1 20 102 5 80 4DK4 3 5 0 OM 910 85 170 0 8 22 5 0 8 0 8 0 8 2 1 0 6 5 X 7 5 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS ELECTRICAL SPECIFICATIONS Item Standard Limit Hazard relay for EUR Model manufacturer Coil resistance 5DM OMRON 94 5 X 115 5 Ω at 20_C SSS SSS Fuses a...

Page 8: ... 2 1 Coolant reservoir tank 2 Thermostat 3 Radiator 4 Water pump 5 Cooling fan 6 Radiator cap COOLANT FLOW DIAGRAMS SPEC COOLANT FLOW DIAGRAMS ...

Page 9: ...he stay left and right After making the connection push the coupler be tween the front cowling and the air filter case 1 Headlight sub harness 2 Horn 3 Horn H mark on the back of the horn A Attach the wireharness clamp protector terminal to the T stud B Install the wireharness to the top of the steering after each coupler connection C Route the wireharness between brake hose and upper bracket D Ro...

Page 10: ...he headlight sub harness left and right For EUR L Connect the turn signal light left and right M Securely fasten the wire strap to the front cowling hook to prevent it from being pulled out by the headlight assembly left and right N Route the horn lead through the wire guide O After passing the horn lead through the clamp crimp the clamp P Wiring is unnecessary left and right for OCE ...

Page 11: ...ten the starter motor lead and battery negative lead to the frame with a plastic clamp 1 Rectifier regulator 2 Starting circuit cut off relay 3 Pump relay 4 Flasher relay 5 Fuel pump 6 Main switch 7 Meter assembly 8 Horn lead 9 Ignition coil 10 Battery negative lead 11 Frame 12 Seat lock cable 13 Starter motor lead 14 Wireharness 15 Fuel hose 16 Sub harness CABLE ROUTING SPEC ...

Page 12: ...ight sub harness left and right C Fasten the starter motor lead battery negative lead V belt reset coupler and seat lock cable to the frame with a plastic band Position the band clasp on the bottom of the frame and face the band end to the outside D Fasten the fuel sender lead and fuel pump lead to the frame with a plastic clamp Route the fuel sender lead through the back of the fuel pipe and pass...

Page 13: ...re harness and the seat lock cable left side Z To the starter relay N Fasten the headlight sub harness to the stay 1 with a plastic clamp O Fasten the igniter lead to the stay 1 with a plastic clamp When fastening them using a plastic clamp make sure not to cross the branch leads P Fasten the horn lead with a clamp Q Fasten the fan motor lead sidestand switch lead and thermo switch lead to the fra...

Page 14: ...to the right and in sert it into the air filter case rib AB Fasten the coolant reservoir hose to the stay with a plastic clamp AC Route the ignition coil lead through the inside of the bracket AD Route the seat lock cable through the frame bracket side AE Install the band s fastened part between frame and box1 CABLE ROUTING SPEC ...

Page 15: ...lamp The fastening position is 0 to 5 m from edge of the frame bracket C Pass the wireharness by the outside of the rear footrest mounting boss When mounting the rear footrest do not catch or pinch the A C magneto lead in the bracket 1 Air vent pipe 2 Air vent hose 3 Vacuum hose 4 A C magneto lead 5 Sidestand switch 6 Thermo switch lead 7 Throttle cable accelerate side 8 Stay 1 CABLE ROUTING SPEC ...

Page 16: ...and the hole to the arrow mark and tighten the bolt G Fasten the sidestand switch lead to the frame with a plastic clamp Route the sidestand switch lead through the out side of the air vent pipe H When adjusting the throttle cable completely tight en the hut on the throttle cable return side I Through the speed sensor lead to the lead holder J Through the speed sensor lead between front brake cali...

Page 17: ...seat lock E Install the starter relay to the mad guard F Fasten the wireharness battery positive lead and seat lock cable to the mad guard with a clamp G Connect the gray seat lock cable to the left seat lock 1 Fuel hose 2 Battery negative lead 3 Seat lock 4 Starter motor lead 5 Fuse box 6 Battery 7 Battery positive lead 8 Fuel sender 9 Breather hose 10 Lean angle cut off switch lead 11 Wireharnes...

Page 18: ...he battery negative lead and starter motor lead and out to the inside of the frame H Install the box light to the box 1 I Fasten the auto choke leads left and right and throttle position sensor lead to the frame with a clamp Leave some slack in the lead wires so that when the vacuum hose is install it does not press against them J Fasten the auto choke leads left and right to the frame with a plas...

Page 19: ...stic clamp with the white tape on the wireharness and fasten to the frame V Fasten the wireharness and seat lock cable to the frame with a plastic clamp W Pass the wireharnesses past the outside of the frame bracket X Apply silicone grease when inserting the starter relay Y Fasten the wireharness to the frame with a plastic clamp Z Use a plastic band to hold the auto choke leads left and right thr...

Page 20: ...ith a plastic clamp F Fasten the carburetor air vent hose and drain hoses 2 hoses to the frame with a plastic clamp When fastening with a clamp there should be no deformation and twist of pipes G Drop the carburetor drain hose 1 Rear brake hose 2 Vacuum hose 3 Switch assembly lead 4 Auto choke lead 5 Throttle position sensor lead 6 Fan motor lead 7 Air vent pipe 8 Drain hoses 9 Sidestand switch le...

Page 21: ...the end of clamp to the frame must range from 0 to 5 mm I Pass the spark plug lead 1 by the front side of the air vent pipe and right carburetor drain pipe J Fasten the rear brake hose and vacuum hose with a plastic clamp K Faster the rear brake hose to the stay 1 with a plastic clamp L Pass the right carburetor drain hose and air vent hose between the spark plug lead 1 and 2 CABLE ROUTING SPEC ...

Page 22: ...g S Replace p p 4 Valves S Check valve clearance S Adjust Every 40 000 km 5 Air filter element S Clean p p 5 Air filter element S Replace p p 6 V belt case air filter S Clean p p 6 elements S Replace p p 7 Front brake S Check operation fluid level and vehicle for fluid leakage See NOTE p p p p p p S Replace brake pads Whenever worn to the limit 8 Rear brake S Check operation fluid level and vehicl...

Page 23: ...cle for oil leakage S Change p p p p 24 V belt S Replace When the V Belt replacement indication light comes on every 20 000 km 25 Front and rear brake switches S Check operation p p p p p p 26 Moving parts and cables S Lubricate p p p p p 27 Lights signals and switches S Check operation S Adjust headlight beam p p p p p p EAU03541 D The air filter needs more frequent service if you are riding in u...

Page 24: ...racket Front brake caliper 1 1 1 Remove the parts in the order listed The following procedure applies to both of the front fork legs Refer to COVER AND PANEL in chapter 3 Manual No 5GJ1 AE1 Refer to FRONT WHEEL AND BRAKE DISC Manual No 5GJ1 AE1 Refer to HANDLEBAR Manual No 5GJ1 AE1 23 Nm 2 3 mSkg 24 Nm 2 4 mSkg 40 Nm 4 0 mSkg 30 Nm 3 0 mSkg FRONT FORK CHAS CHASSIS FRONT FORK ...

Page 25: ...holder Speed sensor holder Cap bolt Upper bracket pinch bolt Lower bracket pinch bolt Front fork leg 1 1 1 2 2 1 Loosen Loosen Loosen For installation reverse the removal procedure 23 Nm 2 3 mSkg 24 Nm 2 4 mSkg 40 Nm 4 0 mSkg 30 Nm 3 0 mSkg FRONT FORK CHAS ...

Page 26: ...nt marks Align these marks during reassembly 3 Remove Scirclip 4 Install the clutch spring holder 5 onto the clutch assembly as shown Then compress the spring and remove the circlip 4 Clutch spring compressor 90890 01482 4 Remove Sspring stopper plate 6 Sclutch spring Spressure plate Sfriction and clutch plates Sweight thrust plate Sweights Ssprings Before removing check that the balance ad justin...

Page 27: ...Coolant hose Silencer joint cramp Silencer Throttle cable Carburetor joint cramp Carburetor assembly Heat protector Intake manifold 1 1 2 2 2 4 1 2 2 1 1 2 Remove the parts in the order listed Disconnect Disconnect Loosen Loosen For installation reverse the removal procedure Refer to COVER AND PANEL in chapter 3 Manual No 5GJ1 AE1 8 5 Nm 0 85 mSkg 10 Nm 1 0 mSkg 5 Nm 0 5 mSkg CARBURETORS CARB CARB...

Page 28: ...4 5 6 7 8 Separating the carburetors Bracket Throttle stop screw Throttle stop screw bracket Spring Pipe Hose joint Fuel drain hose Throttle position sensor 1 1 1 1 2 1 2 1 Remove the parts in the order listed For installation reverse the removal procedure ...

Page 29: ...chamber cover Piston valve spring Jet needle kit Piston valve Screw plug Pilot screw Fuel drain bolt Float chamber Float chamber gasket Float pivot pin 1 1 1 1 1 1 1 1 1 1 1 Disassembly the parts in the order listed The following procedure applies to all of the carburetors NOTE 1 2 3 4 5 6 7 8 9 10 11 ...

Page 30: ... 24 CARBURETORS CARB Order Job Part Q ty Remarks Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet 1 1 1 1 1 1 For assembly reverse the disassembly procedure 13 14 15 16 17 12 ...

Page 31: ...6 Fuel pump relay 7 Flasher relay 8 Battery 9 Fuse box 10 Starter relay 11 Rectifire regulator 12 Sidestand switch 13 Pickup coil 14 Stator coil 15 Thermo switch 16 Radiator fan 17 Speed sensor 18 Horn 19 Throttle position sensor 20 Ignition coil 21 Lean angle cut off switch 22 Hazard relay for EUR 23 Main switch ELECTRICAL ELECTRICAL COMPONENTS ...

Page 32: ...COMPONENTS AND COUPLERS ELEC 1 Headlight couplers 2 Handlebar switch couplers 3 Lean angle cut off switch 4 Hazard relay for EUR 5 Meter 6 Horns 7 Speed sensor 8 Speed sensor coupler ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS ...

Page 33: ... brake light switch 12 Sidestand switch 13 Box light switch CHECKING THE SWITCHES ELEC EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Manual No 5GJ1 AE1 Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the swit...

Page 34: ... 28 SIGNAL SYSTEM ELEC SIGNAL SYSTEM CIRCUIT DIAGRAM for EUR ...

Page 35: ...y 51 Front turn signal light Left 52 Front turn signal light Right 53 Rear turn signal light Left 54 Rear turn signal light Right 55 Tail brake light 58 Turn signal indicator light 61 V belt indicator light 62 Engine oil change indicator light 63 Clock 64 Speedometer 65 Water temperature gauge 66 Fuel gauge 67 Thermo unit Water temperature 68 Fuel level sender 70 Backup fuse 71 Signal fuse 73 Igni...

Page 36: ... Open circuit voltage 12 8 V or more at 20_C SIs the battery OK YES NO SClean the battery terminals SRecharge or replace the battery NOTE EAS00738 1 Main signal hazard and ignition fuses SCheck the main signal hazard and ignition fuses for continuity Refer to CHECKING THE FUSES in CHAPTER 3 Manual No 5GJ1 AE1 SAre the main signal hazard and ignition fuses OK YES NO Replace the fuse s EAS00794 TROU...

Page 37: ...ntinuity Replace the hazard relay 4 Hazard relay for EUR SRemove the hazard relay from the wire har ness SConnect the pocket tester Ω 1 to the hazard relay terminals as shown 5 Hazard relay for EUR SRemove the hazard relay from the wire har ness SConnect the pocket tester Ω 1 and bat tery 12 V to the hazard relay terminals as shown Positive battery lead brown Negative battery lead black 1 1 Turn s...

Page 38: ...itch to or SMeasure the voltage 12 V of the chocolate or dark green on the turn signal light coupler wire harness side SIs the voltage within specification Left turn signal light Tester positive probe chocolate Tester negative probe ground Right turn signal light Tester positive probe dark green Tester negative probe ground NO YES The turn signal relay is faulty and must be replaced 8 Voltage SCon...

Page 39: ...he turn signal switch to or S Measure the voltage 12 V of the choco late or dark green on the meter as sembly coupler wire harness side S Is the voltage iwthin specification The wiring circuit from the turn signal switch hazard switch to the meter assembly coupler is faulty and must be repaired 9 Voltage SConnect the pocket tester 20 VDC to the meter assembly coupler wire harness side as shown Thi...

Page 40: ... White B L Black Blue 39 Pass switch 40 Dimmer switch 41 Horn switch 42 Turn signal switch 43 Hazard switch 44 Rear brake light switch 45 Horn 46 Turn signal relay 47 Hazard relay 48 Headlight Hi 49 Headlight Low 50 Auxiliary light 51 Front turn signal light Left 52 Front turn signal light Right 53 Rear turn signal light Left 54 Rear turn signal light Right 55 Tail brake light 56 License plate lig...