Yamaha Tmax XP500Z Owner`s manual

OWNER’S MANUAL
XP500
XP500A
15B-28199-E0
EAU26943
DECLARATION of CONFORMITY
We
Company: MORIC CO., LTD.
Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan
Hereby declare that the product:
Kind of equipment: IMMOBILIZER
Type-designation: 5SL-00
is in compliance with following norm(s) or documents:
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950-1(2001)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Place of issue: Shizuoka, Japan
Date of issue: 1 Aug. 2002
Revolution record
No.
Contents
To change contact person and integrate type-designation.
1
Version up the norm of EN60950 to EN60950-1
2
Date
9 Jun. 2005
27 Feb. 2006
General manager of quality assurance div.
representative name and signature
MORIC CO., LTD.
1450-6 Mori-machi Shuchi-gun Shizuoka 437-0292 JAPAN Telephone +81-538-85-0757 Facsimile +81-538-85-0456
URL:http://www.moric-jp.com
INTRODUCTION
EAU10110
Welcome to the Yamaha world of motorcycling!
As the owner of the XP500/XP500A, you are benefiting from Yamaha’s vast experience and newest technology regarding
the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XP500/XP500A. The owner’s manual does not only instruct you in how to operate, inspect and maintain your scooter, but also in how to safeguard yourself and
others from trouble and injury.
In addition, the many tips given in this manual will help keep your scooter in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
IMPORTANT MANUAL INFORMATION
EAU34111
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the
scooter operator, a bystander, or a person inspecting or repairing the scooter.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to
the scooter.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
NOTE:
● This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your scooter and
this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
EWA12410
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER.
*Product and specifications are subject to change without notice.
IMPORTANT MANUAL INFORMATION
EAU10200
XP500/XP500A
OWNER’S MANUAL
©2006 by Yamaha Motor Co., Ltd.
1st edition, September 2006
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
TABLE OF CONTENTS
SAFETY INFORMATION ...................1-1
Further safe-riding points .................1-4
DESCRIPTION ...................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS ........................................3-1
Immobilizer system ..........................3-1
Main switch/steering lock .................3-2
Indicator and warning lights .............3-3
Speedometer ...................................3-4
Tachometer .....................................3-5
Multi-function display .......................3-5
Anti-theft alarm (optional) ................3-8
Handlebar switches .........................3-9
Front brake lever ...........................3-10
Rear brake lever ............................3-10
Rear brake lock lever .....................3-11
ABS (for ABS models) ...................3-11
Fuel tank cap .................................3-12
Fuel ................................................3-13
Catalytic converter .........................3-14
Seat ...............................................3-14
Adjusting the rider backrest ...........3-15
Helmet holder ................................3-15
Storage compartments ..................3-16
Shock absorber .............................3-17
Sidestand .......................................3-18
Ignition circuit cut-off system ......... 3-18
PRE-OPERATION CHECKS .............. 4-1
Pre-operation check list ................... 4-2
OPERATION AND IMPORTANT
RIDING POINTS .................................. 5-1
Starting the engine .......................... 5-1
Starting off ....................................... 5-2
Acceleration and deceleration ......... 5-2
Braking ............................................ 5-3
Tips for reducing fuel
consumption ................................ 5-4
Engine break-in ............................... 5-4
Parking ............................................ 5-5
PERIODIC MAINTENANCE AND
MINOR REPAIR .................................. 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance and lubrication
chart ............................................. 6-3
Removing and installing cowlings and
panels .......................................... 6-6
Checking the spark plugs ................ 6-9
Engine oil and oil filter cartridge .... 6-11
Chain drive oil ............................... 6-14
Coolant .......................................... 6-15
Cleaning the air filter element ....... 6-17
Adjusting the engine idling
speed ......................................... 6-18
Checking the throttle cable free
play ............................................ 6-19
Valve clearance ............................ 6-19
Tires .............................................. 6-19
Cast wheels .................................. 6-21
Front and rear brake lever free
play ............................................ 6-22
Adjusting the rear brake lock lever
cable .......................................... 6-22
Checking the front and rear brake
pads ........................................... 6-23
Checking the brake fluid level ....... 6-24
Changing the brake fluid ............... 6-25
Checking and lubricating the throttle
grip and cable ............................ 6-25
Lubricating the front and rear brake
levers ......................................... 6-26
Checking and lubricating the
centerstand and sidestand ........ 6-26
Checking the front fork .................. 6-27
Checking the steering ................... 6-28
Checking the wheel bearings ........ 6-28
Battery ........................................... 6-29
Replacing the fuses ...................... 6-30
Replacing the headlight bulb ........ 6-32
Tail/brake light ............................... 6-33
Replacing a front turn signal light
bulb ............................................ 6-34
Replacing a rear turn signal light
bulb ............................................ 6-34
License plate light ......................... 6-35
TABLE OF CONTENTS
Replacing an auxiliary light bulb ....6-35
Troubleshooting .............................6-35
Troubleshooting charts ..................6-36
SCOOTER CARE AND
STORAGE ...........................................7-1
Matte color caution ..........................7-1
Care .................................................7-1
Storage ............................................7-3
SPECIFICATIONS ..............................8-1
CONSUMER INFORMATION..............9-1
Identification numbers .....................9-1
SAFETY INFORMATION
EAU10261
1
SCOOTERS ARE SINGLE TRACK
VEHICLES. THEIR SAFE USE AND
OPERATION ARE DEPENDENT
UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS
SCOOTER.
HE OR SHE SHOULD:
● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
SCOOTER OPERATION.
THE WARNINGS
● OBSERVE
AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
● OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
● OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDI-
●
TIONS.
Safe riding
● Always
make
pre-operation
checks. Careful checks may help
prevent an accident.
● This scooter is designed to carry
the operator and passenger.
● The failure of motorists to detect
and recognize scooters in traffic is
the predominating cause of automobile/scooter accidents. Many
accidents have been caused by an
automobile driver who did not see
the scooter. Making yourself conspicuous appears to be very effective in reducing the chance of this
type of accident.
Therefore:
Wear a brightly colored jacket.
Use extra caution when approaching and passing through
intersections, since intersections are the most likely places
for scooter accidents to occur.
Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
●
●
●
1-1
Many accidents involve inexperienced operators. In fact, many operators who have been involved in
accidents do not even have a current driver’s license.
Make sure that you are qualified
and that you only lend your
scooter to other qualified operators.
Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
We recommend that you practice riding your scooter where
there is no traffic until you have
become thoroughly familiar with
the scooter and all of its controls.
Many accidents have been caused
by error of the scooter operator. A
typical error made by the operator
is veering wide on a turn due to
EXCESSIVE SPEED or undercornering (insufficient lean angle for
the speed).
Always obey the speed limit and
never travel faster than warranted by road and traffic conditions.
●
●
●
●
●
SAFETY INFORMATION
Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
The posture of the operator and
passenger is important for proper
control.
The operator should keep both
hands on the handlebar and
both feet on the footboard during
operation to maintain control of
the scooter.
The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.
Never ride under the influence of
alcohol or other drugs.
This scooter is designed for
on-road use only. It is not suitable
for off-road use.
●
●
●
●
●
●
●
Protective apparel
The majority of fatalities from scooter
accidents are the result of head inju-
ries. The use of a safety helmet is the
single most critical factor in the prevention or reduction of head injuries.
● Always wear an approved helmet.
● Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision which could delay seeing
a hazard.
● The use of a jacket, substantial
shoes, trousers, gloves, etc., is effective in preventing or reducing
abrasions or lacerations.
● Never wear loose-fitting clothes,
otherwise they could catch on the
control levers or wheels and cause
injury or an accident.
● Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protective clothing that covers your legs,
ankles, and feet.
● Passengers should also observe
the above precautions.
Modifications
Modifications made to this scooter not
1-2
approved by Yamaha, or the removal of
original equipment, may render the
scooter unsafe for use and may cause
severe personal injury. Modifications
may also make your scooter illegal to
use.
Loading and accessories
Adding accessories or cargo to your
scooter can adversely affect stability
and handling if the weight distribution of
the scooter is changed. To avoid the
possibility of an accident, use extreme
caution when adding cargo or accessories to your scooter. Use extra care
when riding a scooter that has added
cargo or accessories. Here are some
general guidelines to follow if loading
cargo or adding accessories to your
scooter:
Loading
The total weight of the operator, passenger, accessories and cargo must
not exceed the maximum load limit.
Maximum load:
XP500 188 kg (414 lb)
XP500A 183 kg (403 lb)
1
SAFETY INFORMATION
1
When loading within this weight limit,
keep the following in mind:
● Cargo and accessory weight
should be kept as low and close to
the scooter as possible. Make sure
to distribute the weight as evenly
as possible on both sides of the
scooter to minimize imbalance or
instability.
● Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely
attached to the scooter before
riding. Check accessory mounts
and cargo restraints frequently.
● Never attach any large or heavy
items to the handlebar, front fork,
or front fender. Such items can
create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this scooter. Since Yamaha cannot test
all other accessories that may be available, you must personally be responsible for the proper selection, installation
and use of non-Yamaha accessories.
Use extreme caution when selecting
and installing any accessories.
Keep the following guidelines in mind,
as well as those provided under “Loading” when mounting accessories.
● Never install accessories or carry
cargo that would impair the performance of your scooter. Carefully
inspect the accessory before using
it to make sure that it does not in
any way reduce ground clearance
or cornering clearance, limit suspension travel, steering travel or
control operation, or obscure lights
or reflectors.
Accessories fitted to the handlebar or the front fork area can
create instability due to improper
weight distribution or aerodynamic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
Bulky or large accessories may
seriously affect the stability of
the scooter due to aerodynamic
●
●
1-3
effects. Wind may attempt to lift
the scooter, or the scooter may
become unstable in cross
winds. These accessories may
also cause instability when
passing or being passed by
large vehicles.
Certain accessories can displace the operator from his or
her normal riding position. This
improper position limits the freedom of movement of the operator and may limit control ability,
therefore, such accessories are
not recommended.
Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the
scooter’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
●
●
Gasoline and exhaust gas
● GASOLINE IS HIGHLY FLAMMABLE:
Always turn the engine off when
refueling.
●
SAFETY INFORMATION
Take care not to spill any gasoline on the engine or exhaust
system when refueling.
Never refuel while smoking or in
the vicinity of an open flame.
Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poisonous and may cause loss of
consciousness and death within a
short time. Always operate your
scooter in an area that has adequate ventilation.
Always turn the engine off before
leaving the scooter unattended
and remove the key from the main
switch. When parking the scooter,
note the following:
The engine and exhaust system
may be hot, therefore, park the
scooter in a place where pedestrians or children are not likely to
touch these hot areas.
Do not park the scooter on a
slope or soft ground, otherwise it
may fall over.
Do not park the scooter near a
flammable source (e.g., a kero-
●
●
●
●
●
sene heater, or near an open
flame), otherwise it could catch
fire.
If you should swallow any gasoline, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediately. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.
EAU10371
Further safe-riding points
●
●
●
●
●
●
●
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●
1-4
Be sure to signal clearly when
making turns.
Braking can be extremely difficult
on a wet road. Avoid hard braking,
because the scooter could slide.
Apply the brakes slowly when
stopping on a wet surface.
Slow down as you approach a corner or turn. Once you have completed a turn, accelerate slowly.
Be careful when passing parked
cars. A driver might not see you
and open a door in your path.
Railroad crossings, streetcar rails,
iron plates on road construction
sites, and manhole covers become extremely slippery when
wet. Slow down and cross them
with caution. Keep the scooter upright, otherwise it could slide out
from under you.
The brake pads could get wet
when you wash the scooter. After
washing the scooter, check the
brakes before riding.
Always wear a helmet, gloves,
trousers (tapered around the cuff
1
SAFETY INFORMATION
●
1
and ankle so they do not flap), and
a bright colored jacket.
Do not carry too much luggage on
the scooter. An overloaded scooter is unstable.
1-5
SAFETY INFORMATION
1
1-6
DESCRIPTION
EAU10410
Left view
2
3
10 9 8 7 6
5
1
4
1
2
3
4
5
6
7
8
9
1. Fuel tank cap (page 3-12)
2. Rear storage compartment (page 3-16)
3. Helmet holder (page 3-15)
4. Grab bar (page 5-2)
5. Chain drive oil filler cap (page 6-14)
6. Engine oil filler cap (page 6-11)
7. V-belt air filter element (left)
8. Engine oil drain bolt (page 6-11)
9. Engine oil level check window (page 6-11)
10. Oil filter cartridge (page 6-11)
2-1
DESCRIPTION
EAU10420
Right view
1
2
3
4
5
2
3
4
5
6
7
9
8
7
1. Battery (page 6-29)
2. Fuses (page 6-30)
3. Owner’s tool kit (page 6-1)
4. Front storage compartment (page 3-16)
5. Air filter element (page 6-17)
6. Coolant level check window (page 6-15)
7. V-belt air filter element (right)
8. Centerstand (page 6-26)
6
9. Passenger footrest
8
9
2-2
DESCRIPTION
EAU10430
Controls and instruments
1
2
3
4
5
6
7
8
1
2
3
4
5
6
9
10
7
8
9
1. Rear brake lever (page 3-10)
2. Left handlebar switches (page 3-9)
3. Rear brake lock lever (page 3-11)
4. Speedometer (page 3-4)
5. Multi-function display (page 3-5)
6. Tachometer (page 3-5)
7. Right handlebar switches (page 3-9)
8. Front brake lever (page 3-10)
9. Throttle grip (page 6-19)
10. Main switch/steering lock (page 3-2)
2-3
INSTRUMENT AND CONTROL FUNCTIONS
EAU10972
Immobilizer system
●
an immobilizer system indicator
light (See page 3-3.)
The key with the red bow is used to register codes in each standard key. Since
re-registering is a difficult process, take
the vehicle along with all three keys to
a Yamaha dealer to have them re-registered. Do not use the key with the red
bow for driving. It should only be used
for re-registering the standard keys. Always use a standard key for driving.
●
●
●
●
ECA11820
1. Code re-registering key (red bow)
2. Standard keys (black bow)
This vehicle is equipped with an immobilizer system to help prevent theft by
re-registering codes in the standard
keys. This system consists of the following.
● a code re-registering key (with a
red bow)
● two standard keys (with a black
bow) that can be re-registered with
new codes
● a transponder (which is installed in
the code re-registering key)
● an immobilizer unit
● an ECU
CAUTION:
● DO NOT LOSE THE CODE
RE-REGISTERING KEY! CONTACT YOUR DEALER IMMEDIATELY IF IT IS LOST! If the code
re-registering key is lost, registering new codes in the standard keys is impossible. The
standard keys can still be used
to start the vehicle, however if
code re-registering is required
(i.e., if a new standard key is
made or all keys are lost) the entire immobilizer system must be
replaced. Therefore, it is highly
recommended to use either
standard key and keep the code
3-1
●
●
●
●
●
re-registering key in a safe
place.
Do not submerse any key in water.
Do not expose any key to excessively high temperatures.
Do not place any key close to
magnets (this includes, but not
limited to, products such as
speakers, etc.).
Do not place heavy items on any
key.
Do not grind any key or alter its
shape.
Do not disassemble the plastic
part of any key.
Do not put two keys of any immobilizer system on the same
key ring.
Keep the standard keys as well
as keys of other immobilizer
systems away from this vehicle’s code re-registering key.
Keep other immobilizer system
keys away from the main switch
as they may cause signal interference.
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU10471
Main switch/steering lock
come on, and the engine can be started. The key cannot be removed.
NOTE:
The headlights come on automatically
when the engine is started and stay on
until the key is turned to “OFF” or the
sidestand is moved down.
1
2
3
4
5
6
7
8
9
EAU10660
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering.
NOTE:
Be sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code
re-registering key (red bow), keep it in a
safe place and only use it for code
re-registering.
EAU34121
ON
All electrical circuits are supplied with
power; the meter lighting, taillight, license plate light and auxiliary lights
OFF
All electrical systems are off. The key
can be removed.
To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
EWA10060
WARNING
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving,
otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident. Make
sure that the vehicle is stopped before turning the key to “OFF” or
“LOCK”.
EAU10680
LOCK
The steering is locked, and all electrical
systems are off. The key can be removed.
To lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” position, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.
3-2
EAU39460
(Parking)
The steering is locked, and the taillights, license plate light and auxiliary
lights are on. The hazard lights and turn
signal lights can be turned on, but all
other electrical systems are off. The
key can be removed.
The steering must be locked before the
key can be turned to “ ”.
ECA11020
CAUTION:
Do not use the parking position for
an extended length of time, other-
INSTRUMENT AND CONTROL FUNCTIONS
wise the battery may discharge.
EAU11003
Indicator and warning lights
1
2 3 4 5
1. Turn signal indicator lights “
” and “
2. High beam indicator light “
”
”
3. Immobilizer system indicator light
4. Engine trouble warning light “
”
5. Anti-lock Brake System (ABS) warning
light “ ABS ” (for ABS models)
EAU11030
Turn signal indicator lights “ ” and
“ ”
The corresponding indicator light flashes when the turn signal switch is
pushed to the left or right.
EAU11080
High beam indicator light “ ”
This indicator light comes on when the
3-3
high beam of the headlight is switched
on.
EAU43020
Engine trouble warning light “ ”
This warning light comes on when an
electrical circuit monitoring the engine
is defective. When this occurs, have a
Yamaha dealer check the self-diagnosis system.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.
NOTE:
This warning light will come on when
the key is turned to “ON” and the start
switch is pushed, but this does not indicate a malfunction.
EAU43030
ABS warning light “
models)
ABS
” (for ABS
ECA10830
CAUTION:
If the ABS warning light comes on or
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
flashes while riding, the ABS may be
defective. If this occurs, have a
Yamaha dealer check the electrical
circuit.
1
2
3
4
5
See page 3-11 for an explanation of the
ABS.
The electrical circuit of the warning light
can be checked by setting the engine
stop switch to “ ” and turning the key
to “ON”. The warning light should come
on for a few seconds, and then go off. If
the warning light does not come on or
remains on, have a Yamaha dealer
check the electrical circuit.
EWA11350
6
7
8
9
WARNING
When the ABS warning light comes
on or flashes while riding, the brake
system reverts to conventional braking. Therefore, be careful not to
cause the wheel to lock during emergency braking.
EAU38620
Immobilizer system indicator light
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical circuit.
When the key is turned to “OFF” and 30
seconds have passed, the indicator
light will start flashing indicating the immobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobilizer system is still enabled.
This model is also equipped with a
self-diagnosis device for the immobilizer system. (See page 3-5 for an explanation of the self-diagnosis device.)
NOTE:
The ABS warning light may come on
while accelerating the engine with the
scooter on its centerstand, but this
does not indicate a malfunction.
3-4
EAU11601
Speedometer
1
1. Speedometer
The speedometer shows the riding
speed.
When the key is turned to “ON”, the
speedometer needle will sweep once
across the speed range and then return
to zero in order to test the electrical circuit.
INSTRUMENT AND CONTROL FUNCTIONS
EAU11872
Tachometer
EAU33519
1
Multi-function display
2
3 4
EWA12311
1
WARNING
Be sure to stop the vehicle before
making any setting changes to the
multi-function display.
2
2
1
2
3
1. Tachometer
2. Tachometer red zone
The electric tachometer allows the rider
to monitor the engine speed and keep it
within the ideal power range.
When the key is turned to “ON”, the tachometer needle will sweep once
across the r/min range and then return
to zero r/min in order to test the electrical circuit.
ECA10031
4
5
6
1. Clock
2. Coolant temperature meter
3. Fuel meter
4. Odometer/tripmeters
5. “SELECT” button
6. “RESET” button
CAUTION:
Do not operate the engine in the tachometer red zone.
Red zone: 8250 r/min and above
3-5
3
1. V-belt replacement indicator “V-BELT”
2. Fuel level warning indicator “ ”
3. Coolant temperature warning indicator
“
”
4. Oil change indicator “OIL”
The multi-function display is equipped
with the following:
● a fuel meter
● a coolant temperature meter
● an odometer (which shows the total distance traveled)
● two tripmeters (which show the
distance traveled since they were
last set to zero)
● a fuel reserve tripmeter (which
shows the distance traveled since
the bottom segment of the fuel
meter and fuel level warning indi-
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
●
●
●
●
cator started flashing)
a self-diagnosis device
a clock
an oil change indicator
a V-belt replacement indicator
NOTE:
● Be sure to turn the key to “ON” before using the “SELECT” and “RESET” buttons.
● When the key is turned to “ON”, all
of the display segments of the
multi-function display will appear
one after the other and then disappear, in order to test the electrical
circuit.
automatically change to the fuel reserve tripmeter mode “TRIP F” and
start counting the distance traveled
from that point. In that case, pushing
the “SELECT” button switches the display between the various tripmeter and
odometer modes in the following order:
TRIP F → TRIP (top) → TRIP (bottom)
→ ODO → TRIP F
6
7
8
9
Odometer and tripmeter modes
Pushing the “SELECT” button switches
the display between the odometer
mode “ODO” and the tripmeter modes
“TRIP” in the following order:
ODO → TRIP (top) → TRIP (bottom) →
ODO
When approximately 2.8 L (0.74 US
gal) (0.62 Imp.gal) of fuel remains in the
fuel tank, the bottom segment of the
fuel meter and fuel level warning indicator will start flashing, and the display will
1
will reset itself automatically and the
display will return to the prior mode after refueling and traveling 5 km (3 mi).
NOTE:
The display cannot be changed back to
“TRIP F” after pushing the “RESET”
button.
Fuel meter
With the key in the “ON” position, the
fuel meter indicates the amount of fuel
in the fuel tank. The display segments
of the fuel meter disappear towards “E”
(Empty) as the fuel level decreases.
When the fuel level reaches the bottom
segment near “E”, the fuel level warning indicator and the bottom segment
will flash. Refuel as soon as possible.
1. Fuel reserve tripmeter
To reset a tripmeter, select it by pushing the “SELECT” button until “TRIP” or
“TRIP F” begins flashing (“TRIP” or
“TRIP F” will only flash for five seconds). While “TRIP” or “TRIP F” is
flashing, push the “RESET” button for
at least one second. If you do not reset
the fuel reserve tripmeter manually, it
3-6
Coolant temperature meter
With the key in the “ON” position, the
coolant temperature meter indicates
the temperature of the coolant. The
coolant temperature varies with changes in the weather and engine load. If
the top segment and coolant temperature warning indicator flash, stop the
vehicle and let the engine cool. (See
INSTRUMENT AND CONTROL FUNCTIONS
page 6-36.)
ECA10020
CAUTION:
Do not operate the engine if it is
overheated.
Oil change indicator “OIL”
This indicator flashes at the initial 1000
km (600 mi), then at 5000 km (3000 mi)
and every 5000 km (3000 mi) thereafter
to indicate that the engine oil should be
changed.
After changing the engine oil, reset the
oil change indicator. (See page 6-11.)
If the engine oil is changed before the
oil change indicator comes on (i.e. before the periodic oil change interval has
been reached), the indicator must be
reset after the oil change for the next
periodic oil change to be indicated at
the correct time. (See page 6-11.)
The electrical circuit of the indicator can
be checked according to the following
procedure.
1. Set the engine stop switch to “ ”
and turn the key to “ON”.
2. Check that the indicator comes on
for a few seconds and then goes
off.
3. If the indicator does not come on,
have a Yamaha dealer check the
electrical circuit.
NOTE:
The oil change indicator may flash
when the engine is revved with the
scooter on the centerstand, but this
does not indicate a malfunction.
V-belt replacement indicator
“V-BELT”
This indicator flashes every 20000 km
(12500 mi) when the V-belt needs to be
replaced.
The electrical circuit of the indicator can
be checked according to the following
procedure.
3-7
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
2. If the indicator does not come on,
have a Yamaha dealer check the
electrical circuit.
Self-diagnosis device
This model is equipped with a self-diagnosis device for various electrical circuits.
If any of those circuits are defective, the
multi-function display will indicate a
two-digit error code.
If the multi-function display indicates
such an error code, note the code number, and then have a Yamaha dealer
check the vehicle.
ECA11790
CAUTION:
If the multi-function display indicates an error code, the vehicle
should be checked as soon as possible in order to avoid engine damage.
This model is also equipped with a
self-diagnosis device for the immobilizer system.
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
If any of the immobilizer system circuits
are defective, the immobilizer system
indicator light will flash, and then the
multi-function display will indicate a
two-digit error code when the key is
turned to “ON”.
NOTE:
If the multi-function display indicates error code 52, this could be caused by
transponder interference. If this error
appears, try the following.
1. Use the code re-registering key to
start the engine.
NOTE:
Make sure there are no other immobilizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interference, which may prevent the engine
from starting.
key and both standard keys to a
Yamaha dealer and have the standard keys re-registered.
If the multi-function display indicates
any error codes, note the code number,
and then have a Yamaha dealer check
the vehicle.
Clock mode
To set the clock:
1. Push the “SELECT” button and
“RESET” button together for at
least two seconds.
2. When the hour digits start flashing,
push the “RESET” button to set the
hours.
3. Push the “SELECT” button, and
the minute digits will start flashing.
4. Push the “RESET” button to set
the minutes.
5. Push the “SELECT” button and
then release it to start the clock.
2. If the engine starts, turn it off, and
try starting the engine with the
standard keys.
3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering
3-8
EAU12331
Anti-theft alarm (optional)
This model can be equipped with an
optional anti-theft alarm by a Yamaha
dealer. Contact a Yamaha dealer for
more information.
INSTRUMENT AND CONTROL FUNCTIONS
EAU12347
Handlebar switches
Right
leased, the switch returns to the center
position. To cancel the turn signal
lights, push the switch in after it has returned to the center position.
1
Left
1
2
EAU12500
Horn switch “
”
Press this switch to sound the horn.
3
2
3
EAU12660
1. Engine stop switch “
4
1. Pass switch “
2. Hazard switch “
3. Start switch “
”
2. Dimmer switch “
/
3. Turn signal switch “
4. Horn switch “
”
”
”
”
”
/
/
EAU12360
”
Pass switch “PASS”
Press this switch to flash the headlight.
EAU12400
Dimmer switch “ / ”
Set this switch to “ ” for the high
beam and to “ ” for the low beam.
EAU12460
Turn signal switch “ / ”
To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When re3-9
Engine stop switch “ / ”
Set this switch to “ ” before starting
the engine. Set this switch to “ ” to
stop the engine in case of an emergency, such as when the vehicle overturns
or when the throttle cable is stuck.
EAU12720
Start switch “ ”
With the sidestand up, push this switch
while applying the front or rear brake to
crank the engine with the starter.
ECA10050
CAUTION:
See page 5-1 for starting instructions prior to starting the engine.
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU41700
EAU12900
Front brake lever
1
2
3
4
5
6
7
8
The engine trouble warning light will
come on when the key is turned to “ON”
and the start switch is pushed, but this
does not indicate a malfunction.
EAU12950
Rear brake lever
1
1
EAU12733
Hazard switch “ ”
With the key in the “ON” or “ ” position, use this switch to turn on the hazard lights (simultaneous flashing of all
turn signal lights).
The hazard lights are used in case of
an emergency or to warn other drivers
when your vehicle is stopped where it
might be a traffic hazard.
ECA10061
1. Front brake lever
1. Rear brake lever
The front brake lever is located on the
right handlebar grip. To apply the front
brake, pull this lever toward the handlebar grip.
CAUTION:
Do not use the hazard lights for an
extended length of time with the engine not running, otherwise the battery may discharge.
9
3-10
The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS
EAU12962
Rear brake lock lever
●
1
rear brake lock lever is applied.
To provide secure locking of the
rear wheel, apply the rear brake lever first before moving the rear
brake lock lever to the left.
EWA12361
1. Rear brake lock lever
This vehicle is equipped with a rear
brake lock lever to prevent the rear
wheel from moving while stopped at
traffic signals, railroad crossings, etc.
WARNING
Never move the rear brake lock lever
to the left while the vehicle is moving, otherwise loss of control or an
accident may result. Make sure that
the vehicle is stopped before moving the rear brake lock lever to the
left.
EAU12991
ABS (for ABS models)
The Yamaha ABS (Anti-lock Brake
System) features a dual electronic control system, which acts on the front and
rear brakes independently. The ABS
securely controls wheel lockup during
emergency braking on changing road
surfaces and under various weather
conditions, thereby maximizing tire adhesion and performance while providing a smooth braking action. The ABS
is monitored by an ECU (Electronic
Control Unit), which will have recourse
to manual braking if a malfunction occurs.
EWA10090
●
To lock the rear wheel
Push the rear brake lock lever to the left
until it snaps into place.
●
To unlock the rear wheel
Push the rear brake lock lever back to
the original position.
NOTE:
● Be sure to check that the rear
wheel does not move when the
3-11
WARNING
The ABS performs best on long
braking distances.
On certain (rough or gravel)
roads, the braking distance may
be longer with than without the
ABS. Therefore, always keep a
sufficient distance to the vehicle ahead to match the riding
speed.
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU13174
1
2
3
4
5
6
7
8
NOTE:
● When the ABS is activated, the
brakes are operated in the usual
way. A pulsating action may be felt
at the brake levers, but this does
not indicate a malfunction.
● This ABS has a test mode which
allows the owner to experience the
pulsating at the brake levers when
the ABS is operating. However,
special tools are required, so
please consult your Yamaha dealer when performing this test.
Fuel tank cap
To remove the fuel tank cap
1. Open the lid by pulling the lever up.
1
1
1. Fuel tank cap
To install the fuel tank cap
1. Align the match marks, insert the
fuel tank cap into the tank opening,
and then push down on the cap.
2
1. Lid
2. Opening lever
2. Insert the key into the lock and turn
it clockwise. The lock will be released and the fuel tank cap can
be removed.
1
9
1. Match marks
2. Turn the key counterclockwise to
the original position, and then re3-12
INSTRUMENT AND CONTROL FUNCTIONS
move it.
3. Close the lid.
EAU13211
Fuel
fuel may deteriorate painted surfaces or plastic parts.
EWA11260
WARNING
Make sure that the fuel tank cap is
properly installed and locked in
place before riding the scooter.
EAU33520
1
Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
14.0 L (3.70 US gal) (3.08 Imp.gal)
2
ECA11400
1. Fuel tank filler tube
2. Fuel level
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
EWA10880
●
●
WARNING
Do not overfill the fuel tank, otherwise it may overflow when the
fuel warms up and expands.
Avoid spilling fuel on the hot engine.
ECA10070
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
3-13
CAUTION:
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane number of
91 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand
or premium unleaded fuel. Use of unleaded fuel will extend spark plug life
and reduce maintenance costs.
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU13431
Catalytic converter
This model is equipped with a catalytic
converter in the exhaust system.
1
2
3
EAU13932
Seat
EWA10860
WARNING
The exhaust system is hot after operation. Make sure that the exhaust
system has cooled down before doing any maintenance work.
To open the seat
1. Place the scooter on the centerstand.
2. Insert the key into the main switch,
and then turn it counterclockwise
to “OPEN”.
4
5
6
7
8
9
CAUTION:
The following precautions must be
observed to prevent a fire hazard or
other damages.
● Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.
● Never park the vehicle near possible fire hazards such as grass
or other materials that easily
burn.
● Do not allow the engine to idle
too long.
To close the seat
1. Fold the seat down, and then push
it down to lock it in place.
2. Remove the key from the main
switch if the scooter will be left unattended.
1
ECA10700
NOTE:
Make sure that the seat is properly secured before riding.
1. Open.
NOTE:
Do not push inward when turning the
key.
3. Fold the seat up.
3-14
INSTRUMENT AND CONTROL FUNCTIONS
EAU14270
EAU14340
Adjusting the rider backrest
Helmet holder
The rider backrest can be adjusted to
the three different positions shown.
1
1
1
2
2
3
1. Rider backrest
2. Bolt
1. Rider backrest
Adjust the backrest as follows.
1. Open the seat. (See page 3-14.)
2. Remove the backrest bolts.
3. Slide the backrest forward or backward to the desired position.
4. Install and securely tighten the
backrest bolts.
5. Close the seat.
3-15
1. Helmet holder
4
The helmet holder is located under the
seat. A helmet holding cable is provided beside the owner’s tool kit to secure
a helmet to the helmet holder.
5
To secure a helmet to the helmet
holder
1. Open the seat. (See page 3-14.)
2. Pass the helmet holding cable
through the buckle on the helmet
strap as shown, and then hook the
cable loop over the helmet holder.
3. Securely close the seat.
7
6
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU14503
EWA10160
1
WARNING
Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of control and possibly an accident.
2
3
4
Storage compartments
Front storage compartment
To open the front storage compartment, slide the lever up, and then pull
on the lever.
To release the helmet from the helmet holder
Open the seat, remove the helmet
holding cable from the helmet holder
and the helmet, and then close the
seat.
Rear storage compartment
A helmet can be stored in the rear storage compartment under the seat. (See
page 3-14.) To store a helmet in the
rear storage compartment, place the
helmet upside-down with the front facing forward.
1
2
5
1
6
7
8
1. Storage compartment opening lever
2. Lid
1. Rear storage compartment
To close the front storage compartment, push the lid into the original position.
EWA11160
9
WARNING
Do not store heavy items in this
compartment.
NOTE:
● Some helmets cannot be stored in
the rear storage compartment because of their size or shape.
● Do not leave your scooter unattended with the seat open.
ECA10080
CAUTION:
Keep the following points in mind
3-16
INSTRUMENT AND CONTROL FUNCTIONS
when using the storage compartment.
● Since the storage compartment
accumulates heat when exposed to the sun, do not store
anything susceptible to heat inside it.
● To avoid humidity from spreading through the storage compartment, wrap wet articles in a
plastic bag before storing them
in the compartment.
● Since the storage compartment
may get wet while the scooter is
being washed, wrap any articles
stored in the compartment in a
plastic bag.
● Do not keep anything valuable
or breakable in the storage compartment.
EAU15090
EWA11241
●
●
WARNING
Do not exceed the load limit of
5 kg (11 lb) for the rear storage
compartment.
Do not exceed the maximum
load of XP500 188 kg (414 lb)
XP500A 183 kg (403 lb) for the
vehicle.
ECA11270
CAUTION:
Do not leave the seat open for an extended period of time, otherwise the
light may cause the battery to discharge.
3-17
Shock absorber
EWA10220
WARNING
This shock absorber contains highly
pressurized nitrogen gas. For proper handling, read and understand
the following information before
handling the shock absorber. The
manufacturer cannot be held responsible for property damage or
personal injury that may result from
improper handling.
● Do not tamper with or attempt to
open the gas cylinder.
● Do not subject the shock absorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.
● Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping performance.
● Always have a Yamaha dealer
service the shock absorber.
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU15301
Sidestand
1
2
3
4
pair it if it does not function properly.
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.
The ignition circuit cut-off system (comprising the sidestand switch and brake
light switches) has the following functions.
● It prevents starting when the sidestand is up, but neither brake is applied.
● It prevents starting when either
brake is applied, but the sidestand
is still down.
● It cuts the running engine when the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)
EWA10240
5
6
7
8
9
EAU15371
Ignition circuit cut-off system
WARNING
The vehicle must not be ridden with
the sidestand down, or if the sidestand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check
this system regularly as described
below and have a Yamaha dealer re-
EWA10250
WARNING
If a malfunction is noted, have a
Yamaha dealer check the system before riding.
3-18
INSTRUMENT AND CONTROL FUNCTIONS
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Keep the front or rear brake applied.
5. Push the start switch.
Does the engine start?
NO
NOTE:
This check is most reliable if performed with
a warmed-up engine.
2
The sidestand switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
YES
With the engine still off:
6. Move the sidestand up.
7. Keep the front or rear brake applied.
8. Push the start switch.
Does the engine start?
YES
4
5
The brake switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
NO
6
7
With the engine still running:
9. Move the sidestand down.
Does the engine stall?
YES
3
The sidestand switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
NO
The system is OK. The scooter can be ridden.
3-19
8
9
PRE-OPERATION CHECKS
EAU15592
1
2
3
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.
EWA11150
4
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.
5
6
7
8
9
4-1
PRE-OPERATION CHECKS
EAU15605
Pre-operation check list
ITEM
CHECKS
●
Fuel
●
●
●
Engine oil
●
●
Chain drive oil
●
●
Coolant
●
●
●
●
●
Front brake
●
●
●
●
●
●
●
Rear brake
●
●
●
●
●
Throttle grip
●
●
Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.
Check vehicle for oil leakage.
Check coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
Make sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.
4-2
PAGE
3-13
6-11
6-14
2
3
6-15
4
5
6-23, 6-24
6
7
6-23, 6-24
8
9
6-19, 6-25
PRE-OPERATION CHECKS
ITEM
CHECKS
●
Wheels and tires
1
●
●
Brake levers
2
●
Centerstand, sidestand
3
Chassis fasteners
4
Instruments, lights, signals
and switches
Sidestand switch
●
●
●
●
●
●
●
●
●
●
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
Make sure that operation is smooth.
Lubricate lever pivoting points if necessary.
Make sure that operation is smooth.
Lubricate pivots if necessary.
Make sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.
Check operation.
Correct if necessary.
Check operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.
5
6
7
8
9
4-3
PAGE
6-19, 6-21
6-26
6-26
—
—
3-18
OPERATION AND IMPORTANT RIDING POINTS
EAU15970
EAU36510
Starting the engine
●
●
●
●
EWA11250
ECA10250
WARNING
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer regarding any control or function
that you do not thoroughly understand.
Never start the engine or operate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of consciousness and death within a
short time. Always make sure
that there is adequate ventilation.
For safety, always start the engine with the centerstand down.
When the centerstand is down
and the engine is idling, keep
your hands and feet away from
the rear wheel.
CAUTION:
See page 5-4 for engine break-in instructions prior to operating the vehicle for the first time.
In order for the ignition circuit cut-off
system to enable starting, the sidestand must be up.
EWA10290
●
●
WARNING
Before starting the engine,
check the function of the ignition circuit cut-off system according to the procedure
described on page 3-18.
Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
ECA15020
CAUTION:
The following warning lights, indicator light and indicators should come
on for a few seconds, then go off.
● Engine trouble warning light
5-1
●
ABS warning light (for ABS
models)
● Immobilizer system indicator
light
● V-belt replacement indicator
● Oil change indicator
If a warning light, indicator light or
indicator does not go off, see page
3-3 or 3-5 for the corresponding
warning light, indicator light or indicator circuit check.
2. Close the throttle completely.
3. Start the engine by pushing the
start switch while applying the front
or rear brake.
NOTE:
If the engine does not start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one
attempt.
ECA11040
CAUTION:
For maximum engine life, never accelerate hard when the engine is
2
3
4
5
6
7
8
9
OPERATION AND IMPORTANT RIDING POINTS
cold!
1
2
3
EAU16760
Starting off
NOTE:
Before starting off, allow the engine to
warm up.
1. While pulling the rear brake lever
with your left hand and holding the
grab bar with your right hand, push
the scooter off the centerstand.
(a)
The speed can be adjusted by opening
and closing the throttle. To increase the
speed, turn the throttle grip in direction
(a). To reduce the speed, turn the throttle grip in direction (b).
5
6
7
1. Grab bar
9
(b)
1
4
8
EAU16780
Acceleration and deceleration
2. Sit astride the seat, and then adjust the rear view mirrors.
3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip (on
the right) in order to take off.
5. Switch the turn signal off.
5-2
OPERATION AND IMPORTANT RIDING POINTS
EAU16792
Braking
Rear
cult.
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually increasing the pressure.
2
Front
3
EWA10300
●
●
●
●
WARNING
Avoid braking hard or suddenly
(especially when leaning over to
one side), otherwise the scooter
may skid or overturn.
Railroad crossings, streetcar
rails, iron plates on road construction sites, and manhole
covers become extremely slippery when wet. Therefore, slow
down when approaching such
areas and cross them with caution.
Keep in mind that braking on a
wet road is much more difficult.
Ride slowly down a hill, as braking downhill can be very diffi5-3
4
5
6
7
8
9
OPERATION AND IMPORTANT RIDING POINTS
EAU16820
Tips for reducing fuel
consumption
1
2
3
4
5
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
● Avoid high engine speeds during
acceleration.
● Avoid high engine speeds with no
load on the engine.
● Turn the engine off instead of letting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throttle operation or any condition that might
result in engine overheating must be
avoided.
6
EAU36530
7
8
9
0–1000 km (0–600 mi)
Avoid prolonged operation above
4000 r/min.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above
6000 r/min.
ECA11281
CAUTION:
After 1000 km (600 mi) of operation,
5-4
the engine oil must be changed, and
the oil filter cartridge or element replaced.
1600 km (1000 mi) and beyond
The vehicle can now be operated normally.
ECA10310
CAUTION:
● Keep the engine speed out of
the tachometer red zone.
● If any engine trouble should occur during the engine break-in
period, immediately have a
Yamaha dealer check the vehicle.
OPERATION AND IMPORTANT RIDING POINTS
EAU17212
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10310
●
●
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them.
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
2
3
4
5
ECA10380
6
CAUTION:
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
7
8
9
5-5
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17280
1
2
3
4
5
6
7
8
9
Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a general guide under normal riding conditions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHICAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTERVALS MAY NEED TO BE SHORTENED.
operated in abnormally dusty, muddy or wet conditions, the air filter element should be cleaned or
replaced more frequently, otherwise
rapid engine wear may result. Consult a Yamaha dealer for proper
maintenance intervals.
EAU17390
Owner’s tool kit
1
2
1. Helmet holding cable
2. Owner’s tool kit
The owner’s tool kit is located under the
seat. (See page 3-14.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. However, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
EWA10320
WARNING
If you are not familiar with maintenance work, have a Yamaha dealer
do it for you.
EWA10330
NOTE:
If you do not have the tools or experience required for a particular job, have
WARNING
This scooter is designed for use on
paved roads only. If this scooter is
6-1
PERIODIC MAINTENANCE AND MINOR REPAIR
a Yamaha dealer perform it for you.
EWA10350
WARNING
Modifications not approved by
Yamaha may cause loss of performance and render the vehicle unsafe for use. Consult a Yamaha
dealer before attempting any changes.
2
3
4
5
6
7
8
9
6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17706
Periodic maintenance and lubrication chart
1
2
NOTE:
● The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
● From 50000 km, repeat the maintenance intervals starting from 10000 km.
● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
3
NO.
ITEM
CHECK OR MAINTENANCE JOB
ODOMETER READING (× 1000 km)
1
4
1 * Fuel line
●
●
5
2
Spark plugs
●
●
6
3 * Valves
4
7
8
Air filter element
●
●
●
●
V-belt case air filter ele5 *
ments
●
●
●
6 * Front brake
●
9
●
7 * Rear brake
●
8
Rear brake lock
●
●
Check fuel hoses for cracks or damage.
Check condition.
Clean and regap.
Replace.
Check valve clearance.
Adjust.
Clean.
Replace.
Clean.
Replace.
Check operation, fluid level and vehicle for fluid leakage.
Replace brake pads.
Check operation, fluid level and vehicle for fluid leakage.
Replace brake pads.
Check operation.
Adjust.
6-3
10
20
30
40
ANNUAL
CHECK
√
√
√
√
√
√
√
√
√
Every 40000 km
√
√
√
√
√
√
√
√
√
√
√
√
√
√
Whenever worn to the limit
√
√
√
√
√
√
Whenever worn to the limit
√
√
√
√
√
√
PERIODIC MAINTENANCE AND MINOR REPAIR
NO.
ITEM
CHECK OR MAINTENANCE JOB
ODOMETER READING (× 1000 km)
1
9 * Brake hoses
●
Check for cracks or damage.
Replace.
Check runout and for damage.
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
Check bearing for looseness or damage.
Check bearing play and steering for roughness.
Lubricate with lithium-soap-based grease.
Make sure that all nuts, bolts and screws are properly
tightened.
Check operation.
Lubricate.
Check operation.
Check operation and for oil leakage.
●
Check operation and shock absorber for oil leakage.
●
Adjust engine idling speed and synchronization.
√
●
Change. (See pages 3-5 and 6-11.)
√
●
●
Check oil level and vehicle for oil leakage.
Replace.
Check coolant level and vehicle for coolant leakage.
Change.
Check vehicle for oil leakage.
Change.
●
Replace.
●
●
10 * Wheels
●
●
11 * Tires
●
●
●
12 * Wheel bearings
13 * Steering bearings
●
●
●
14 * Chassis fasteners
15
Sidestand, centerstand
16 * Sidestand switch
17 * Front fork
Shock absorber assem18 *
bly
19 * Fuel injection
20
21
Engine oil
Engine oil filter cartridge
22 * Cooling system
●
●
●
●
●
●
●
23
Chain drive oil
24 * V-belt
●
√
√
√
40
ANNUAL
CHECK
√
√
√
√
√
Every 4 years
√
√
√
√
√
10
20
√
√
√
30
√
√
√
√
√
Every 20000 km
√
√
√
√
3
4
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
When the oil change indicator flashes (every
5000 km)
Every 5000 km
√
√
√
√
√
√
√
√
Every 3 years
√
√
√
√
When the V-belt replacement indicator flashes (every
20000 km)
6-4
2
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
NO.
ITEM
Front and rear brake
switches
Moving parts and cables
25 *
1
2
3
26
Throttle grip housing
and cable
27 *
Lights, signals and
switches
28 *
CHECK OR MAINTENANCE JOB
●
Check operation.
●
Lubricate.
Check operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.
Check operation.
Adjust headlight beam.
●
●
●
●
●
ODOMETER READING (× 1000 km)
1
10
20
30
40
ANNUAL
CHECK
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
EAU18670
4
5
6
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 components of the brake master cylinders and calipers, and change the brake
fluid.
Replace the brake hoses every four years and if cracked or damaged.
●
●
7
●
8
9
6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU18712
2
Removing and installing
cowlings and panels
4
2
The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
a cowling or panel needs to be removed and installed.
1
2
1
2
3
1. Panel A
2. Panel B
3. Panel C
4. Cowling A
4
1. Screw
2. Nut
4
2. Remove the cowling screws.
5
3
2
EAU33422
5
1
1. Panel D
2. Cowling B
3. Panel E
4. Cowling C
5. Panel F
3
Cowling A
To remove the cowling
1. Remove the rear view mirrors by
removing the nuts.
To install the cowling
1. Place the cowling in the original
position, and then install the
screws.
2. Install the rear view mirrors by installing the nuts.
Cowling B
To remove the cowling
1. Remove panels C and E. (See
page 6-7.)
6-6
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
2. Remove the cowling bolts, and
then pull the cowling off.
1
To install the cowling
1. Place the cowling in the original
position, and then install the bolts.
2. Install the battery cover by installing the screws.
1
2
2
3
4
5
6
7
8
9
EAU33431
1. Bolt
2. Screw
2. Remove the cowling screws and
bolts.
3. Unhook the cowling from the holder at the bottom.
4. Unhook the front of the cowling by
pushing it up, and then pull the
cowling out.
To install the cowling
1. Place the cowling in the original
position, and then install the
screws and bolts.
2. Install panels C and E.
Panels A and D
Cowling C
To remove the cowling
1. Remove the battery cover by removing the screws.
To remove one of the panels
1. Remove panel C (right side) or
panel E (left side).
1
2
1
1. Screw
1. Bolt
2. Screw
2. Remove the panel screws.
6-7
1
PERIODIC MAINTENANCE AND MINOR REPAIR
3. Pull outward on the front of the
panel.
1
1
To install the panel
Place the panel in the original position,
and then install the screws.
1
2
3
1. Screw
1. Screw
To install the panel
Place the panel in the original position,
and then install the screws.
To install the panel
Place the panel in the original position,
install the screws, and then place the
floorboard mat back.
Panels C and E
Panel B
To remove the panel
Remove the panel screws, and then
pull outward on the areas shown.
Panel F
To remove one of the panels
Pull the floorboard mat off, and then remove the panel screws.
To remove the panel
Remove the panel screws.
4
5
6
7
8
9
6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU19593
Checking the spark plugs
1
2
1
3
1. Screw
4
5
6
To install the panel
Place the panel in the original position,
and then install the screws.
3. Remove the spark plug cap.
The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition,
the condition of the spark plugs can reveal the condition of the engine.
1
1. Spark plug cap
To remove a spark plug
1. Remove
cowling
B.
(See
page 6-6.)
2. Remove the spark plug cover by
pulling it out as shown.
4. Remove the spark plug as shown
with the spark plug wrench included in the owner’s tool kit.
7
8
9
1
1
1. Spark plug wrench
1. Spark plug cover
6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medium-to-light tan (the ideal color
when the vehicle is ridden normally).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:
If any spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to
diagnose such problems yourself. Instead, have a Yamaha dealer check
the vehicle.
3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace
it if necessary.
Specified spark plug:
NGK/CR7E
essary, adjust the gap to specification.
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9 ft·lbf)
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the specified torque as soon as possible.
1
1. Spark plug gap
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
4. Install the spark plug cap.
5. Place the spark plug cover in the
original position as shown, and
then install the cowling.
4
5
7
8
1
1. Spark plug cover
6-10
3
6
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tighten it to the specified torque.
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
2
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU19854
Engine oil and oil filter
cartridge
1
2
3
4
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the vehicle on the centerstand.
tles, and then check the oil level
through the check window located
at the bottom-left side of the crankcase.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
1
2
3
ECA11290
5
6
7
8
9
CAUTION:
The engine must be cold before proceeding with the oil level check, otherwise the check will result in a false
reading.
NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
To change the engine oil (with or
without oil filter cartridge replacement)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
1
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. If the engine oil is below the minimum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
2. Start the engine, warm it up for two
minutes, and then turn it off.
3. Wait two minutes until the oil set6-11
1. Engine oil filler cap
PERIODIC MAINTENANCE AND MINOR REPAIR
2
1
1
2
1
3
1. Engine oil drain bolt
NOTE:
Skip steps 4–6 if the oil filter cartridge is
not being replaced.
4. Remove the oil filter cartridge with
an oil filter wrench.
1. Oil filter wrench
2. Oil filter cartridge
1. Torque wrench
NOTE:
An oil filter wrench is available at a
Yamaha dealer.
5. Apply a thin coat of engine oil to
the O-ring of the new oil filter cartridge.
NOTE:
Make sure that the O-ring is properly
seated.
6. Install the new oil filter cartridge,
and then tighten it to the specified
torque with a torque wrench.
6-12
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12.3 ft·lbf)
7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31.1 ft·lbf)
8. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replacement:
2.80 L (2.96 US qt) (2.46 Imp.qt)
With oil filter cartridge replacement:
2.90 L (3.07 US qt) (2.55 Imp.qt)
ECA11620
3
4
5
6
7
8
9
CAUTION:
● In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
● Make sure that no foreign material enters the crankcase.
9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, immediately turn the engine off and
check for the cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
11. Reset the oil change indicator according to the following procedure.
To reset the oil change indicator
1. Turn the key to “ON”.
2. Hold the “OIL CHANGE” button
pushed for two to eight seconds.
1
1. “OIL CHANGE” button
3. Release the “OIL CHANGE” button, and the oil change indicator
will go off.
NOTE:
If the engine oil is changed before the
oil change indicator comes on (i.e. before the periodic oil change interval has
been reached), the indicator must be
6-13
reset after the oil change for the next
periodic oil change to be indicated at
the correct time. To reset the oil change
indicator before the periodic oil change
interval has been reached, follow the
above procedure, but note that the indicator will come on for 1.4 seconds after
releasing the “OIL CHANGE” button,
otherwise repeat the procedure.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU19994
Chain drive oil
The chain drive oil should be changed
as follows at the intervals specified in
the periodic maintenance and lubrication chart.
1. Remove panel F. (See page 6-6.)
2. Place an oil pan under the chain
drive case to collect the used oil.
3. Remove the oil filler cap and drain
bolt to drain the oil from the chain
drive case.
1
Tightening torque:
Chain drive oil drain bolt:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
5. Add the specified amount of the
recommended oil.
1
Recommended chain drive oil:
See page 8-1.
Oil quantity:
0.70 L (0.74 US qt) (0.62 Imp.qt)
6. Wipe the dipstick clean, insert it
into the oil filler hole (without
screwing it in), and then remove it
to check the oil level.
NOTE:
The chain drive oil should be between
the minimum and maximum level
marks.
2
2
3
1. Maximum level mark
2. Minimum level mark
4
7. If the chain drive oil is below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
8. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
5
6
7
ECA15010
2
CAUTION:
● Make sure that no foreign material enters the chain drive case.
● Make sure that no oil gets on the
tire or wheel.
1. Chain drive oil filler cap
2. Chain drive oil drain bolt
4. Install the chain drive oil drain bolt,
and then tighten it to the specified
torque.
9. Check the chain drive case for oil
leakage. If leakage is found, check
for the cause.
6-14
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
10. Install the panel.
1
2
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the coolant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
1
2
3
EAU42831
3
4
5
6
7
8
9
To check the coolant level
1. Place the vehicle on a level surface and hold it in an upright position.
NOTE:
● The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
● Make sure that the vehicle is positioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
1. Maximum level mark
2. Minimum level mark
3. Coolant level check window
3. If the coolant is at or below the
minimum level mark, lift up the
right floorboard mat as shown.
1
2. Check the coolant level through
the check window.
NOTE:
The coolant should be between the
minimum and maximum level marks.
1. Right floorboard mat
4. Remove the coolant reservoir cov6-15
PERIODIC MAINTENANCE AND MINOR REPAIR
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
er by removing the screw.
1
EWA10380
2
WARNING
Never attempt to remove the radiator
cap when the engine is hot.
1
1. Coolant reservoir cap
1. Coolant reservoir cover
2. Screw
5. Open the reservoir cap, add coolant to the maximum level mark,
and then close the reservoir cap.
Coolant reservoir capacity (up to the
maximum level mark):
0.35 L (0.37 US qt) (0.31 Imp.qt)
ECA10471
CAUTION:
● If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
● If water has been used instead
of coolant, replace it with coolant as soon as possible, otherwise the cooling system will not
be protected against frost and
corrosion.
● If water has been added to the
6-16
6. Install the coolant reservoir cover
by installing the screw.
7. Place the right floorboard mat in
the original position.
NOTE:
● The radiator fan is automatically
switched on or off according to the
coolant temperature in the radiator.
● If the engine overheats, see page
6-36 for further instructions.
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21121
Cleaning the air filter element
1
2
3
4
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more frequently if you are riding in unusually
wet or dusty areas.
1. Remove
cowling
A.
(See
page 6-6.)
2. Remove the windshield by removing the screws.
1. Screw
2. Panel
1. Air filter element
1
7
1
8
1. Screw
9
1
1
1
4. Remove the air filter case cover by
removing the screws, and then pull
the air filter element out.
5
6
2
2
5. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.
2
1
3. Remove the panel shown by removing the screws.
1. Air filter case cover
2. Screw
6. Insert the air filter element into the
6-17
PERIODIC MAINTENANCE AND MINOR REPAIR
air filter case.
EAU33481
ECA10480
CAUTION:
● Make sure that the air filter element is properly seated in the
air filter case.
● The engine should never be operated without the air filter element installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
7. Install the air filter case cover by installing the screws.
8. Place the panel in the original position, and then install the screws.
9. Install the windshield and the cowling.
Adjusting the engine idling
speed
The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.
NOTE:
The engine is warm when it quickly responds to the throttle.
1. Remove panel B. (See page 6-6.)
2. Check the engine idling speed
and, if necessary, adjust it to specification by turning the idle adjusting screw. To increase the engine
idling speed, turn the screw in direction (a). To decrease the engine idling speed, turn the screw in
direction (b).
(b) (a)
1
2
3
1. Idle adjusting screw
Engine idling speed:
1100–1300 r/min
4
5
NOTE:
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
6
7
3. Install the panel.
8
9
6-18
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21382
Checking the throttle cable
free play
1
2
1
EAU21401
EAU33600
Valve clearance
Tires
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
To maximize the performance, durability, and safe operation of your vehicle,
note the following points regarding the
specified tires.
3
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
EWA10500
4
5
6
7
●
1. Throttle cable free play
The throttle cable free play should measure 3.0–5.0 mm (0.12–0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if necessary, have a Yamaha dealer adjust it.
●
8
9
6-19
WARNING
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
The tire air pressure must be adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, cargo, and accessories approved
for this model.
PERIODIC MAINTENANCE AND MINOR REPAIR
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb):
Front:
225 kPa (33 psi) (2.25 kgf/cm2)
Rear:
250 kPa (36 psi) (2.50 kgf/cm2)
XP500 90–188 kg (198–414 lb)
XP500A 90–183 kg (198–403 lb):
Front:
225 kPa (33 psi) (2.25 kgf/cm2)
Rear:
280 kPa (41 psi) (2.80 kgf/cm2)
Maximum load*:
XP500 188 kg (414 lb)
XP500A 183 kg (403 lb)
* Total weight of rider, passenger, cargo and accessories
●
●
●
●
total weight of rider, passenger,
cargo, and accessories does
not exceed the specified maximum load for the vehicle.
Do not carry along loosely
packed items, which can shift
during a ride.
Securely pack the heaviest
items close to the center of the
vehicle and distribute the
weight evenly on both sides.
Adjust the tire air pressure with
regard to the load.
Check the tire condition and air
pressure before each ride.
EWA11200
WARNING
Because loading has an enormous
impact on the handling, braking,
performance and safety characteristics of your vehicle, you should keep
the following precautions in mind.
● NEVER OVERLOAD THE VEHICLE! Operation of an overloaded vehicle may result in tire
damage, loss of control, or severe injury. Make sure that the
Tire inspection
2
1
2
3
1. Tire sidewall
2. Tire tread depth
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer replace the tire immediately.
Minimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
4
5
6
7
8
9
NOTE:
The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
Tire information
This model is equipped with tubeless
tires.
1
2
3
4
5
edge and experience.
To maximize the performance, durability, and safe operation of your vehicle,
note the following points regarding the
specified wheels.
● The wheel rims should be checked
for cracks, bends or warpage before each ride. If any damage is
found, have a Yamaha dealer replace the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.
● The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse handling characteristics, and a shortened tire life.
● Ride at moderate speeds after
changing a tire since the tire surface must first be “broken in” for it
to develop its optimal characteristics.
Front tire:
Size:
120/70R14 M/C 55H
Manufacturer/model:
DUNLOP/D252F
BRIDGESTONE/TH01F
Rear tire:
Size:
160/60R15 M/C 67H
Manufacturer/model:
DUNLOP/D252
BRIDGESTONE/TH01R
EWA10470
6
●
7
8
9
●
EAU21960
Cast wheels
WARNING
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehicle with excessively worn tires
decreases riding stability and
can lead to loss of control.
The replacement of all wheel
and brake related parts, including the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU33453
Front and rear brake lever free
play
Front
brake system.
EAU33473
EWA14211
WARNING
A soft or spongy feeling in the brake
lever can indicate the presence of air
in the hydraulic system. If there is air
in the hydraulic system, have a
Yamaha dealer bleed the system before operating the vehicle. Air in the
hydraulic system will diminish the
braking performance, which may result in loss of control and an accident.
Adjusting the rear brake lock
lever cable
2
1
(b)
(a)
Rear brake lock lever cable adjustment
may be required if the rear brake lock
lever does not hold properly. When the
rear brake lock lever is not in use, the
rear brake lock lever cable length
should measure 45 mm to 47 mm (1.77
in to 1.85 in) at the rear brake caliper.
Periodically check the rear brake lock
lever cable length and, if necessary,
adjust it as follows.
To increase the rear brake lock lever
cable length, turn the adjusting nut at
the rear brake caliper in direction (a).
There should be no free play at the
brake lever ends. If there is free play,
have a Yamaha dealer inspect the
6-22
3
4
1. Adjusting nut
2. Rear brake lock lever cable length
Rear
2
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
To decrease the rear brake lock lever
cable length, turn the adjusting nut in
direction (b).
EWA10650
1
2
WARNING
If proper adjustment cannot be obtained as described, have a Yamaha
dealer make this adjustment.
EAU22390
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals specified in the periodic maintenance and
lubrication chart.
indicator grooves have almost disappeared, have a Yamaha dealer replace
the brake pads as a set.
EAU22493
Rear brake pads
1. Remove the rear brake caliper by
removing the bolts.
EAU22430
3
Front brake pads
1
4
5
2
1
6
1
1. Bolt
2. Lining thickness
7
1. Brake pad wear indicator groove
8
9
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear without having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
6-23
2. Check each rear brake pad for
damage and measure the lining
thickness. If a brake pad is damaged or if the lining thickness is
less than 0.8 mm (0.03 in), have a
Yamaha dealer replace the brake
pads as a set.
3. Install the rear brake caliper by in-
PERIODIC MAINTENANCE AND MINOR REPAIR
stalling the bolts, then tightening
them to the specified torque.
Tightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf, 28.9 ft·lbf)
EAU22710
Checking the brake fluid level
Front brake
1
ECA12822
CAUTION:
Do not apply the rear brake or rear
brake lock after the brake caliper
has been removed, otherwise the
brake caliper piston will be forced
out.
1. Minimum level mark
Rear brake
1
enter the brake system, possibly causing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:
● When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.
● Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking performance.
Recommended brake fluid:
DOT 4
●
1. Minimum level mark
Insufficient brake fluid may allow air to
6-24
●
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
Be careful that water or dust does
not enter the brake fluid reservoir
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
1
●
2
3
4
5
●
when refilling. Water will significantly lower the boiling point of the
fluid and may result in vapor lock,
and dirt may clog the ABS hydraulic unit valves.
Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid
immediately.
As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a Yamaha dealer
check the cause.
EAU22730
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic maintenance and lubrication chart. In addition,
have the oil seals of the master cylinders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
● Oil seals: Replace every two
years.
● Brake hoses: Replace every four
years.
6
7
8
9
6-25
EAU23111
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23171
Lubricating the front and rear
brake levers
Front brake lever
tenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease (all-purpose grease)
EAU23211
Checking and lubricating the
centerstand and sidestand
2
3
4
5
Rear brake lever
6
7
8
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to-metal contact surfaces should be
lubricated if necessary.
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main6-26
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23271
EWA10740
1
WARNING
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or repair it.
2
Recommended lubricant:
Lithium-soap-based grease (all-purpose grease)
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
To check the condition
EWA10750
4
WARNING
Securely support the vehicle so that
there is no danger of it falling over.
5
Check the inner tubes for scratches,
damage and excessive oil leakage.
3
6
7
8
9
To check the operation
1. Place the vehicle on a level surface and hold it in an upright position.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
6-27
ECA10590
CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23280
EAU23290
Checking the steering
Checking the wheel bearings
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrication chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
2
3
EWA10750
4
WARNING
Securely support the vehicle so that
there is no danger of it falling over.
5
2. Hold the lower ends of the front
fork legs and try to move them forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
6
7
8
9
6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
EWA10760
lowing FIRST AID.
EXTERNAL: Flush with plenty
of water.
INTERNAL: Drink large quantities of water or milk and immediately call a physician.
EYES: Flush with water for 15
minutes and seek prompt
medical attention.
Batteries produce explosive hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
charging it in an enclosed
space.
KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.
WARNING
Electrolyte is poisonous and
dangerous since it contains sulfuric acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and always shield your eyes when
working near batteries. In case
of contact, administer the fol-
To store the battery
1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
EAU23411
Battery
1
2
3
4
1
This model is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.
To access the battery
1. Open the seat. (See page 3-14.)
2. Remove the battery cover by removing the screws.
1
5
6
●
●
●
1. Battery
To charge the battery
Have a Yamaha dealer charge the battery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.
7
2
8
9
1. Screw
2. Battery cover
●
●
6-29
●
PERIODIC MAINTENANCE AND MINOR REPAIR
necessary.
3. Fully charge the battery before installation.
4. After installation, make sure that
the battery leads are properly connected to the battery terminals.
ECA10630
CAUTION:
keep the battery
● Always
charged. Storing a discharged
battery can cause permanent
battery damage.
● To charge a sealed-type (MF)
battery, a special (constant-voltage) battery charger is required.
Using a conventional battery
charger will damage the battery.
If you do not have access to a
sealed-type (MF) battery charger, have a Yamaha dealer
charge your battery.
EAU36543
Replacing the fuses
The main fuse box is located beside the
battery and can be accessed as follows:
1. Open the seat. (See page 3-14.)
2. Remove the battery cover. (See
page 6-29.)
3. Disconnect the negative battery
lead, and then lift the battery as
shown.
1
2
3
4
6-30
1
7
3
2
6
2
5
4
1. Negative battery lead
2. Fuse box
3. Battery
4. ABS motor fuse (for ABS models)
5. ABS control unit fuse (for ABS models)
6. Parking lighting fuse
7. Spare fuse
For non-ABS models
1. Negative battery lead
2. Fuse box
3. Battery
4. Parking lighting fuse
For ABS models
The fuse box, which contains the fuses
for the individual circuits, is located under the battery cover and can be accessed as follows.
1. Open the seat. (See page 3-14.)
2. Remove the battery cover.
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
For non-ABS models
amperage.
1
NOTE:
To access the main fuse, remove the
main fuse box cover as shown.
2
For ABS models
1
2
3
4
5
6
7
3
7
1
2
3
4
5
6
3
2
4
1
5
6
1. Main fuse
2. Spare main fuse
3. Main fuse box cover
1. Signaling system fuse
2. Headlight fuse
3. Ignition fuse
4. Radiator fan fuse
5. Fuel injection system fuse
6. Backup fuse (for odometer and clock)
7. Spare fuse
7
8
9
6-31
1. Signaling system fuse
2. Headlight fuse
3. Ignition fuse
4. Radiator fan fuse
5. Fuel injection system fuse
6. Backup fuse (for odometer and clock)
7. Spare fuse
PERIODIC MAINTENANCE AND MINOR REPAIR
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
Specified fuses:
Main fuse:
30.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
XP500 20.0 A
XP500A 15.0 A
Ignition fuse:
10.0 A
Parking lighting fuse:
10.0 A
Radiator fan fuse:
15.0 A
Fuel injection system fuse:
10.0 A
ABS control unit fuse:
XP500A 5.0 A
ABS motor fuse:
XP500A 30.0 A
Backup fuse:
10.0 A
EAU23760
Replacing the headlight bulb
This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
1. Disconnect the headlight coupler,
and then remove the bulb cover.
2
3
4
1
2
5
6
1. Headlight coupler
2. Headlight bulb cover
2. Unhook the headlight bulb holder,
and then remove the defective
bulb.
ECA10640
CAUTION:
Do not use a fuse of a higher amperage rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
7
8
9
3. Turn the key to “ON” and turn on
6-32
PERIODIC MAINTENANCE AND MINOR REPAIR
and the bulb life will be adversely affected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with alcohol or thinner.
1
2
1
2
1
3
4
1. Headlight bulb holder
2. Unhook.
EWA10790
5
6
7
8
9
WARNING
Headlight bulbs get very hot. Therefore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
3. Place a new headlight bulb into position, and then secure it with the
bulb holder.
1. Do not touch the glass part of the bulb.
4. Install the headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
ECA10660
CAUTION:
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
6-33
EAU43040
Tail/brake light
If the tail/brake light does not come on,
have a Yamaha dealer check its electrical circuit or replace the bulb.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU43050
Replacing a front turn signal
light bulb
1. Place the scooter on the centerstand.
2. Remove the socket (together with
the bulb) by turning it counterclockwise.
EAU24270
Replacing a rear turn signal
light bulb
1. Place the scooter on the centerstand.
2. Remove
cowling
C.
(See
page 6-6.)
3. Remove the socket (together with
the turn signal light bulb) by turning
it counterclockwise.
bulb) by turning it clockwise.
7. Install the cowling.
2
3
4
1
5
1
6
1. Turn signal light bulb socket
3. Remove the defective bulb by pulling it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with the
bulb) by turning it clockwise.
7
1. Turn signal light bulb socket
4. Remove the defective bulb by
pushing it in and turning it counterclockwise.
5. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
6. Install the socket (together with the
6-34
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU24330
License plate light
1
2
If the license plate light does not come
on, have a Yamaha dealer check the
electrical circuit or replace the bulb.
EAU43230
Replacing an auxiliary light
bulb
This model is equipped with two auxiliary lights. If an auxiliary light bulb burns
out, replace it as follows.
1. Remove the socket (together with
the bulb) by pulling it out.
3
4
5
1
6
7
8
9
1. Auxiliary light bulb socket
2. Remove the defective bulb by pulling it out.
3. Insert a new bulb into the socket.
4. Install the socket (together with the
bulb) by pushing it in.
6-35
EAU25880
Troubleshooting
Although Yamaha scooters receive a
thorough inspection before shipment
from the factory, trouble may occur during operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems yourself. However, should your scooter require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the scooter properly.
Use only genuine Yamaha replacement parts. Imitation parts may look like
Yamaha parts, but they are often inferior, have a shorter service life and can
lead to expensive repair bills.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU42500
Troubleshooting charts
Starting problems or poor engine
performance
EWA10840
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
2
1. Fuel
There is enough fuel.
Check the compression.
There is no fuel.
Supply fuel.
There is compression.
Check the ignition.
There is no compression.
Have a Yamaha dealer
check the vehicle.
Check the fuel level in
the fuel tank.
3
The engine does not start.
Check the compression.
2. Compression
4
5
Operate the electric starter.
3. Ignition
6
7
Wet
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Operate the electric starter.
Dry
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.
Remove the spark plugs
and check the electrodes.
8
9
4. Battery
The engine turns over
quickly.
The battery is good.
The engine turns over
slowly.
Check the battery lead connections,
and charge the battery if necessary.
Operate the electric starter.
6-36
The engine does not start.
Have a Yamaha dealer
check the vehicle.
PERIODIC MAINTENANCE AND MINOR REPAIR
Engine overheating
EWAT1040
●
1
●
2
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
Place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap
while turning it counterclockwise, and then remove the cap.
3
The coolant level is low.
Check the cooling system
for leakage.
4
5
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
There is
leakage.
There is
no leakage.
Have a Yamaha dealer check
and repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
6
7
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
8
9
6-37
SCOOTER CARE AND STORAGE
EAU37833
Matte color caution
EAU26100
Care
ECA15192
CAUTION:
Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use before cleaning the vehicle. Using a
brush, harsh chemical products or
cleaning compounds when cleaning
these parts will scratch or damage
their surface. Wax also should not
be applied to any matte colored finished parts.
While the open design of a scooter reveals the attractiveness of the technology, it also makes it more vulnerable.
Rust and corrosion can develop even if
high-quality components are used. A
rusty exhaust pipe may go unnoticed
on a car, however, it detracts from the
overall appearance of a scooter. Frequent and proper care does not only
comply with the terms of the warranty,
but it will also keep your scooter looking
good, extend its life and optimize its
performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod7-1
ucts onto seals, gaskets and wheel
axles. Always rinse the dirt and degreaser off with water.
Cleaning
ECA10780
CAUTION:
● Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a corrosion protection spray.
● Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.
● Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
2
3
4
5
6
7
8
9
SCOOTER CARE AND STORAGE
●
1
2
3
4
5
6
7
8
9
●
thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
Do not use high-pressure washers or steam-jet cleaners since
they cause water seepage and
deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes),
electric components (couplers,
connectors,
instruments,
switches and lights), breather
hoses and vents.
For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning compounds for plastic may leave
scratches on the windshield.
Test the product on a small hidden part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing
compound
after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.
NOTE:
Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the scooter with cold water
and a mild detergent after the engine has cooled down.
ECA10790
CAUTION:
Do not use warm water since it increases the corrosive action of the
7-2
salt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the scooter with a chamois or
an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainless-steel parts, including the exhaust system. (Even the thermally
induced discoloring of stainless-steel exhaust systems can be
removed through polishing.)
3. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated, surfaces.
4. Use spray oil as a universal cleaner to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the scooter dry completely before storing or covering it.
SCOOTER CARE AND STORAGE
EWA10940
●
●
what products to use.
WARNING
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or acetone, and wash the tires with
warm water and a mild detergent.
Before operating the scooter
test its braking performance
and cornering behavior.
EAU36550
Storage
Short-term
Always store your scooter in a cool, dry
place and, if necessary, protect it
against dust with a porous cover.
ECA10820
CAUTION:
● Storing the scooter in a poorly
ventilated room or covering it
with a tarp, while it is still wet,
will allow water and humidity to
seep in and cause rust.
● To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
ECA10800
CAUTION:
● Apply spray oil and wax sparingly and make sure to wipe off
any excess.
● Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
● Avoid using abrasive polishing
compounds as they will wear
away the paint.
Long-term
Before storing your scooter for several
months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
NOTE:
Consult a Yamaha dealer for advice on
7-3
2
3
4
5
6
7
8
9
SCOOTER CARE AND STORAGE
1
2
3
4
5
6
7
8
9
fuel from deteriorating.
3. Perform the following steps to protect the cylinders, piston rings, etc.
from corrosion.
a. Remove the spark plug caps
and the spark plugs.
b. Pour a teaspoonful of engine oil
into the spark plug bores.
c. Install the spark plug caps onto
the spark plugs, and then place
the spark plugs on the cylinder
head so that the electrodes are
grounded. (This will limit sparking during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder walls with oil.)
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
EWA10950
WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground. Alternatively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an excessively cold or warm place [less
than 0 °C (30 °F) or more than 30
°C (90 °F)]. For more information
on storing the battery, see page
6-29.
NOTE:
Make any necessary repairs before
storing the scooter.
4. Lubricate all control cables and the
7-4
SPECIFICATIONS
EAU2633J
Dimensions:
Overall length:
2235 mm (88.0 in)
Overall width:
775 mm (30.5 in)
Overall height:
1410 mm (55.5 in)
Seat height:
795 mm (31.3 in)
Wheelbase:
1575 mm (62.0 in)
Ground clearance:
130 mm (5.12 in)
Minimum turning radius:
2800 mm (110.2 in)
Weight:
With oil and fuel:
XP500 227.0 kg (500 lb)
XP500A 232.0 kg (511 lb)
Engine:
Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward-inclined parallel 2-cylinder
Displacement:
499.0 cm3
Bore × stroke:
66.0 × 73.0 mm (2.60 × 2.87 in)
Compression ratio:
11.00 :1
Starting system:
Electric starter
Lubrication system:
Dry sump
Fuel tank capacity:
14.0 L (3.70 US gal) (3.08 Imp.gal)
Fuel injector:
Engine oil:
Type:
SAE10W30 or SAE10W40
Recommended engine oil grade:
API service SG type or higher, JASO standard MA
Engine oil quantity:
Without oil filter cartridge replacement:
2.80 L (2.96 US qt) (2.46 Imp.qt)
With oil filter cartridge replacement:
2.90 L (3.07 US qt) (2.55 Imp.qt)
Chain drive oil:
Manufacturer:
AISAN
Model/quantity:
1100-87B60/1100-87B70
Spark plug (s):
Manufacturer/model:
NGK/CR7E
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Clutch:
Clutch type:
Wet, multiple-disc automatic
Transmission:
Type:
SAE80 API GL-4 Hypoid gear oil
Quantity:
0.70 L (0.74 US qt) (0.62 Imp.qt)
Cooling system:
Coolant reservoir capacity (up to the maximum level mark):
0.35 L (0.37 US qt) (0.31 Imp.qt)
Radiator capacity (including all routes):
1.50 L (1.59 US qt) (1.32 Imp.qt)
Air filter:
Air filter element:
Dry element
Primary reduction system:
Spur gear/helical gear
Primary reduction ratio:
52/32 × 36/22 (2.659)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
41/25 × 40/29 (2.262)
Transmission type:
V-belt automatic
Operation:
Centrifugal automatic type
Chassis:
Fuel:
Recommended fuel:
Regular unleaded gasoline only
8-1
Frame type:
Diamond
Caster angle:
28.00 °
2
3
4
5
6
7
8
9
SPECIFICATIONS
Trail:
95.0 mm (3.74 in)
Front tire:
1
2
3
4
5
6
Type:
Tubeless
Size:
120/70R14 M/C 55H
Manufacturer/model:
DUNLOP/D252F
Manufacturer/model:
BRIDGESTONE/TH01F
Rear tire:
Type:
Tubeless
Size:
160/60R15 M/C 67H
Manufacturer/model:
DUNLOP/D252
Manufacturer/model:
BRIDGESTONE/TH01R
Loading:
7
8
9
Maximum load:
XP500 188 kg (414 lb)
XP500A 183 kg (403 lb)
* (Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm2)
Rear:
250 kPa (36 psi) (2.50 kgf/cm2)
Loading condition:
XP500 90–188 kg (198–414 lb)
XP500A 90–183 kg (198–403 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm2)
Rear:
280 kPa (41 psi) (2.80 kgf/cm2)
Front wheel:
Wheel type:
Cast wheel
Rim size:
14M/C x MT3.50
Rear wheel:
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
120.0 mm (4.72 in)
Rear suspension:
Type:
Swingarm
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
117.0 mm (4.61 in)
Electrical system:
Wheel type:
Cast wheel
Rim size:
15M/C x MT5.00
Ignition system:
Transistorized coil ignition (digital)
Charging system:
AC magneto
Front brake:
Battery:
Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Left hand operation
Recommended fluid:
DOT 4
8-2
Model:
GT9B-4
Voltage, capacity:
12 V, 8.0 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage × quantity:
Headlight:
12 V, 60 W/55.0 W × 1
Headlight:
12 V, 55.0 W × 1
SPECIFICATIONS
Tail/brake light:
12 V, 5.0 W/21.0 W × 2
Front turn signal/position light:
12 V, 21 W/5.0 W × 2
Rear turn signal light:
12 V, 21.0 W × 2
Auxiliary light:
12 V, 5.0 W × 2
License plate light:
12 V, 5.0 W × 1
Meter lighting:
14 V, 2.0 W × 3
High beam indicator light:
14 V, 1.4 W × 1
Turn signal indicator light:
14 V, 1.4 W × 2
Engine trouble warning light:
14 V, 1.4 W × 1
ABS warning light:
XP500A 14 V, 1.4 W × 1
Immobilizer system indicator light:
LED
Radiator fan fuse:
15.0 A
Fuel injection system fuse:
10.0 A
ABS control unit fuse:
XP500A 5.0 A
ABS motor fuse:
XP500A 30.0 A
Backup fuse:
10.0 A
2
3
4
5
6
7
Fuses:
Main fuse:
30.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
XP500 20.0 A
XP500A 15.0 A
Ignition fuse:
10.0 A
Parking lighting fuse:
10.0 A
8
9
8-3
CONSUMER INFORMATION
EAU26351
Identification numbers
1
2
3
Record the key identification number,
vehicle identification number and model label information in the spaces provided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is stolen.
KEY IDENTIFICATION NUMBER:
4
VEHICLE IDENTIFICATION
NUMBER:
7
8
EAU26410
Vehicle identification number
1
1. Key identification number
2. Code re-registering key (red bow)
3. Standard keys (black bow)
5
6
EAU26381
Key identification number
The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new
key.
MODEL LABEL INFORMATION:
9
9-1
1. Vehicle identification number
The vehicle identification number is
stamped into the frame.
NOTE:
The vehicle identification number is
used to identify your vehicle and may
be used to register it with the licensing
authority in your area.
CONSUMER INFORMATION
EAU26500
Model label
2
1
3
4
1. Model label
The model label is affixed to the inside
of the rear storage compartment. (See
page 3-16.) Record the information on
this label in the space provided. This information will be needed when ordering
spare parts from a Yamaha dealer.
5
6
7
8
9
9-2
INDEX
A
ABS (for ABS models) ............................ 3-11
ABS warning light (for ABS models) ......... 3-3
Acceleration and deceleration................... 5-2
Air filter element, cleaning....................... 6-17
Anti-theft alarm (optional).......................... 3-8
Auxiliary light bulb, replacing .................. 6-35
Front and rear brake pads, checking .......6-23
Front fork, checking .................................6-27
Fuel..........................................................3-13
Fuel consumption, tips for reducing...........5-4
Fuel tank cap ...........................................3-12
Fuses, replacing ......................................6-30
D
Dimmer switch .......................................... 3-9
E
Engine break-in......................................... 5-4
Engine idling speed................................. 6-18
Engine oil and oil filter cartridge.............. 6-11
Engine stop switch .................................... 3-9
Engine trouble warning light...................... 3-3
F
Front and rear brake lever free play........ 6-22
S
Safe-riding points ...................................... 1-4
Safety information ..................................... 1-1
Seat ......................................................... 3-14
Shock absorber ....................................... 3-17
Sidestand ................................................ 3-18
Spark plugs, checking ............................... 6-9
Specifications ............................................ 8-1
Speedometer............................................. 3-4
Starting off ................................................. 5-2
Starting the engine .................................... 5-1
Start switch................................................ 3-9
Steering, checking................................... 6-28
Storage...................................................... 7-3
Storage compartments ............................ 3-16
Handlebar switches ...................................3-9
Hazard switch ..........................................3-10
Headlight bulb, replacing .........................6-32
Helmet holder ..........................................3-15
High beam indicator light ...........................3-3
Horn switch ................................................3-9
I
Identification numbers................................9-1
Ignition circuit cut-off system ...................3-18
Immobilizer system ....................................3-1
Immobilizer system indicator light..............3-4
Indicator and warning lights .......................3-3
C
Care .......................................................... 7-1
Catalytic converter .................................. 3-14
Centerstand and sidestand, checking and
lubricating ............................................. 6-26
Chain drive oil ......................................... 6-14
Coolant.................................................... 6-15
Cowlings and panels, removing and
installing.................................................. 6-6
Rear brake lock lever .............................. 3-11
Rear brake lock lever cable, adjusting .... 6-22
Rider backrest, adjusting......................... 3-15
H
B
Battery..................................................... 6-29
Brake fluid, changing .............................. 6-25
Brake fluid level, checking ...................... 6-24
Brake lever, front..................................... 3-10
Brake lever, rear ..................................... 3-10
Brake levers, lubricating.......................... 6-26
Braking...................................................... 5-3
Pre-operation check list............................. 4-2
R
K
Key identification number ..........................9-1
L
License plate light ....................................6-35
M
Main switch/steering lock...........................3-2
Matte color, caution ...................................7-1
Model label ................................................9-2
Multi-function display .................................3-5
P
Parking.......................................................5-5
Part locations .............................................2-1
Pass switch................................................3-9
Periodic maintenance and lubrication
chart ........................................................6-3
T
Tachometer ............................................... 3-5
Tail/brake light ......................................... 6-33
Throttle cable free play, checking............ 6-19
Throttle grip and cable, checking and
lubricating.............................................. 6-25
Tires ........................................................ 6-19
Tool kit....................................................... 6-1
Troubleshooting....................................... 6-35
Troubleshooting charts............................ 6-36
Turn signal indicator lights......................... 3-3
Turn signal light bulb (front), replacing .... 6-34
Turn signal light bulb (rear), replacing ..... 6-34
Turn signal switch...................................... 3-9
INDEX
V
Valve clearance .......................................6-19
Vehicle identification number.....................9-1
W
Wheel bearings, checking .......................6-28
Wheels.....................................................6-21
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2006.10–0.2×1 !
(E)