Yamaha Tmax XP500Z Service manual

2007
XP500
XP500A
SERVICE MANUAL
15B-28197-E0
EAS20040
XP500/XP500A 2007
SERVICE MANUAL
©2006 by Yamaha Motor Co., Ltd.
First edition, November 2006
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS20070
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
● This
Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
● Designs and specifications are subject to change without notice.
EAS20080
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
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
vehicle operator, a bystander or a person checking or repairing the vehicle.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the
vehicle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
EAS20090
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
● The manual is divided into chapters and each chapter is divided into sections. The current section title
is shown at the top of each page “1”.
● Sub-section titles appear in smaller print than the section title “2”.
● To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section “3”.
● Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step “4”.
● Symbols indicate parts to be lubricated or replaced “5”.
Refer to “SYMBOLS”.
● A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc “6”.
● Jobs requiring more information (such as special tools and technical data) are described sequentially
“7”.
1
3
4
7
5
6
2
EAS20100
SYMBOLS
The following symbols are used in this manual
for easier understanding.
NOTE:
The following symbols are not relevant to every
vehicle.
2
3
4
5
6
7
8
T.
1
R.
9
10
E
12
11
13
B
15
M
G
14
M
LS
16
LT
New
1. Serviceable with engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening torque
6. Wear limit, clearance
7. Engine speed
8. Electrical data
9. Engine oil
10. Gear oil
11. Molybdenum-disulfide oil
12. Wheel-bearing grease
13. Lithium-soap-based grease
14. Molybdenum-disulfide grease
15. Apply locking agent (LOCTITE®)
16. Replace the part
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION
1
SPECIFICATIONS
2
PERIODIC CHECKS AND
ADJUSTMENTS
3
CHASSIS
4
ENGINE
5
COOLING SYSTEM
6
FUEL SYSTEM
7
ELECTRICAL SYSTEM
8
TROUBLESHOOTING
9
GENERAL INFORMATION
IDENTIFICATION .......................................................................................... 1-1
VEHICLE IDENTIFICATION NUMBER ................................................... 1-1
MODEL LABEL........................................................................................ 1-1
FEATURES.................................................................................................... 1-2
OUTLINE OF FI SYSTEM ....................................................................... 1-2
FI SYSTEM.............................................................................................. 1-3
OUTLINE OF ANTI-LOCK BRAKE SYSTEM (XP500A) ......................... 1-4
MULTI-FUNCTION DISPLAY.................................................................. 1-15
IMPORTANT INFORMATION ....................................................................... 1-18
PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-18
REPLACEMENT PARTS......................................................................... 1-18
GASKETS, OIL SEALS AND O-RINGS .................................................. 1-18
LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-18
BEARINGS AND OIL SEALS .................................................................. 1-18
CIRCLIPS ................................................................................................ 1-19
CHECKING THE CONNECTIONS ................................................................ 1-20
1
2
3
4
SPECIAL TOOLS .......................................................................................... 1-21
5
6
7
8
9
IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the right side of the frame.
1
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame. This
information will be needed to order spare parts.
1
1-1
FEATURES
EAS20170
FEATURES
EAS15B1002
OUTLINE OF FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions. In a conventional carburetor system,
the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of
the intake air and the fuel that is metered by the jet used in the respective chamber. Despite the same
volume of intake air, the fuel volume requirement varies with the engine operating conditions, such as
acceleration, deceleration, or operation under a heavy load. Carburetors that meter the fuel through the
use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be
achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for engines to deliver more performance and cleaner exhaust gases increase, it
becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system in place
of a conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the
engine at all times by using a microprocessor that regulates the fuel injection volume according to the
engine operating conditions detected by various sensors.
Adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better
fuel economy, and reduced exhaust emissions.
18. Coolant temperature sensor
19. Spark plug
1. Ignition coil
2. Air filter case
3. Intake air temperature sensor
4. Fuel injection system relay
5. Lean angle sensor
6. Engine trouble warning light
7. ECU (engine)
8. Intake air pressure sensor
9. Throttle position sensor
10. Fuel injector
11. Fuel tank
12. Fuel delivery hose
13. Fuel pump
14. Battery
15. Catalyst
16. O2 sensor
17. Crankshaft position sensor
1-2
FEATURES
EAS15B1003
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel
pump) maintains the fuel pressure that is applied to the fuel injector at 240–260 kPa (2.40–2.60 kg/cm2,
34.1–37.0 psi) higher than the intake manifold pressure. Accordingly, when the energizing signal from
the ECU (engine) energizes the fuel injector, the fuel passage opens, causing the fuel to be injected
into the intake manifold only during the time the passage remains open. Therefore, the longer the
length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is
supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration),
the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU (engine). Signals that are input
from the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, coolant temperature sensor, and O2 sensor enable the ECU (engine) to determine the
injection duration. The injection timing is determined through the signals from the crankshaft position
sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions.
1. Fuel pump
2. Fuel injector
3. Ignition coil
4. ECU (engine)
5. Catalyst
6. O2 sensor
7. Coolant temperature sensor
8. Crankshaft position sensor
9. Intake air pressure sensor
10. Throttle body
11. Intake air temperature sensor
12. Air filter case
13. Throttle position sensor
A. Fuel system
B. Air system
C. Control system
1-3
FEATURES
EAS15B1004
OUTLINE OF ANTI-LOCK BRAKE SYSTEM (XP500A)
Yamaha ABS features
1. The Yamaha ABS (Anti-Lock Brake System) features a dual electronic control system, which acts
on the front and rear brakes independently.
2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of
the vehicle.
3. The hydraulic unit, which is the main component of the ABS, is centrally located on the vehicle to
increase mass centralization.
The operation of the Yamaha ABS brakes is the same as conventional vehicle, with a right hand brake
lever for operating the front wheel brake and a left hand brake lever for operating the rear wheel brake.
When wheel lockup is detected during emergency braking, hydraulic control is performed by the hydraulic system independently.
The ABS also includes a highly developed self-diagnostic function. The ABS detects any problem conditions and allows normal braking even if the ABS is not operating properly.
When this occurs, the ABS warning light on the meter assembly comes on.
The ABS stores the malfunction codes in the memory of the ECU (ABS) for easy problem identification
and troubleshooting.
ABS layout
1. ABS warning light
2. Fail-safe relay
3. Electronic control unit (ECU)
4. Hydraulic unit
5. Rear disc rotor
6. Rear brake caliper
7. Rear wheel sensor
8. Front brake caliper
9. Front wheel sensor
10. Front disc rotor
1-4
FEATURES
ABS block diagram
1.
2.
3.
4.
5.
6.
7.
8. Rear brake caliper
9. Front brake caliper
10. ECU (ABS)
11. Rear wheel sensor
12. Front wheel sensor
13. ABS warning light
Rear brake master cylinder
Hydraulic unit
Hydraulic pump
ABS motor
Buffer chamber
Hydraulic control valve
Front brake master cylinder
EAS15B1005
Useful terms
● Wheel speed:
The rotation speed of the front and rear wheels.
● Chassis speed:
The speed of the chassis.
When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis
travels forward by its inertia even though the wheel speed is reduced.
● Brake force:
The force applied by braking to reduce the wheel speed.
● Wheel lock:
A condition that occurs when the rotation of one or both of the wheels has stopped but the vehicle
continues to travel.
● Side force:
The force on the tires which supports the vehicle when cornering.
● Slip ratio:
When the brakes are applied, slipping occurs between the tires and the road surface. This causes a
difference between the wheel speed and the chassis speed. Slip ratio is the value that shows the rate
of wheel slippage and is defined by the following formula.
Slip ratio =
Chassis speed
– Wheel speed
Chassis speed
× 100 (%)
1-5
FEATURES
0%: There is no slip between the wheel and the road surface. The chassis speed is equal to the wheel
speed.
100%: The wheel speed is “0”, but the chassis is moving (i.e., wheel lock).
EAS15B1006
Brake force and vehicle stability
When the brake pressure is increased, wheel speed is reduced. Slip occurs between the tire and the
road surface and brake force is generated. The limit of this brake force is determined by the friction
force between the tire and the road surface and is closely related to wheel slippage. Wheel slippage is
represented by the slip ratio. Therefore, side force is also closely related to wheel slippage. See figure
“A”. If the brakes are applied while keeping the proper slip ratio, it is possible to obtain the maximum
brake force without losing much side force. ABS allows full use of the tire capabilities even on slippery
road surfaces or less slippery road surfaces. See figure “B” .
EAS15B1007
Wheel slip and hydraulic control
The ECU (ABS) calculates the wheel speed of each wheel according to the rotation signal received
from the front and rear wheel sensors. In addition, the ECU (ABS) calculates the vehicle chassis speed
and the rate of speed reduction based on the wheel speed values.
The difference between the chassis speed and the wheel speed calculated in the slip ratio formula is
equal to the wheel slip. When the wheel has a tendency to lock, the wheel speed is suddenly reduced.
When the wheel slip and the wheel speed reduction rate exceed the preset values, the ECU (ABS) determines that the wheel has a tendency to lock.
If the slip is large and the wheel has a tendency to lock (point A in the figure), the ECU (ABS) reduces
the brake fluid pressure in the brake caliper and increases the pressure of the brake fluid in the brake
caliper when the tendency to lock has diminished (point B in the figure).
1-6
FEATURES
EAS15B1008
ABS operation and vehicle control
If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the
limit of control. To make the rider aware of this condition, the ABS has been designed to generate a
reaction-force pulsating action in the brake lever.
NOTE:
When the ABS is activated, a pulsating action may be felt at the brake lever, but this does not indicate
a malfunction.
The higher the cornering force on a tire, the less traction there is available for braking. This is true
whether the vehicle is equipped with an ABS or not. Therefore, sudden braking while cornering is not
recommended. Excessive cornering force, which an ABS cannot prevent, could cause the tire to slip
sideways.
EWA15B1003
WARNING
The braking of the vehicle, even in the worst case, is principally executed when the vehicle is
advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of
the tires. Even in vehicles equipped with an ABS, overturning of the vehicle cannot be prevented if it is braked suddenly.
The ABS functions to prevent the tendency of the wheel to lock by controlling the brake hydraulic pres-
1-7
FEATURES
sure. But, if there is a tendency of the wheel to lock on a slippery road surface, due to engine braking,
the ABS may not be able to prevent the wheel from locking.
EWA15B1004
WARNING
The ABS controls only the tendency of the wheel to lock caused by applying the brakes. The
ABS cannot prevent wheel lock on slippery surfaces, such as ice, when it is caused by engine
braking, even if the ABS is operating.
EAS15B1009
ABS component functions
● Wheel sensors and sensor rotors
Wheel sensors “1” detect the wheel rotation speed and transmit the wheel rotation signal to the ECU
(ABS).
Each wheel sensor is composed of a permanent magnet and a coil. The wheel sensors are installed
in the sensor housing for each wheel. Sensor rotors “2” are installed inside the front and rear wheel
hubs and rotate with the wheels. Each sensor rotor has 40 serrations that face the sensor housing.
As the distance changes between the top and bottom of the serrations with the rotation of the wheels,
inductive electromotive force is generated in the wheel sensors. Wheel rotation speed is detected
based on the frequency of this alternating voltage.
c. Wheel sensor
d. Sensor rotor
a. At high speed
b. At low speed
● Hydraulic
unit
The hydraulic unit “1” is composed of a hydraulic control valve (solenoid valve, flow control valve), a
buffer chamber, and a hydraulic pump for each brake and an ABS motor. The hydraulic unit adjusts
the front and rear wheel brake fluid pressure to control the wheel rotation speed according to signals
transmitted from the ECU (ABS).
1-8
FEATURES
● Electronic
control unit (ECU)
The ECU (ABS) “1” controls the ABS and is located on the right side of the vehicle near the top of the
front fork. To protect the ECU (ABS) from water damage, it is protected by a cover.
1
● ABS
control operation
The ABS control operation performed in the ECU (ABS) is divided into the following two parts.
● Hydraulic control
● Self-diagnosis
These operations are performed once every 8/1,000 of a second. When a failure is detected in the
ABS, a malfunction code is stored in the memory of the ECU (ABS) for easy problem identification
and troubleshooting.
NOTE:
Some types of failures are not recorded in the memory of the ECU (ABS) (e.g., a drop in battery voltage).
1-9
FEATURES
1.
2.
3.
4.
5.
6. Receive signals
7. Control operation
8. Depressurize/pressurize
Software operation flow
Set the main switch to “ON”.
Initialize
Self-diagnosis (when static)
Self-diagnosis (when riding)
A. 8/1,000 of a second
● Fail-safe
relay
The fail-safe relay controls the power supply of the hydraulic unit and is located upper the ECU (ABS).
1
1. Fail-safe relay
1-10
FEATURES
Composition and operation
The fail-safe relay is composed of the solenoid relay “1” and fail-safe relay “2”. The solenoid relay is
activated (continuous) by signals transmitted from the ECU (ABS). As a result, the solenoid valve “3”
can be operated.
If a malfunction occurs in the circuit, the solenoid relay is deactivated and it becomes impossible for the
solenoid valve to reduce the hydraulic pressure of the brake fluid and normal braking is resumed.
The fail-safe relay is also activated by signals transmitted from the ECU (ABS) and operates simultaneously when the ABS starts to reduce the hydraulic pressure of the brake fluid.
If the solenoid relay is turned off, the motor relay is also deactivated and the motor stops operating if
there is a malfunction.
1. Solenoid relay
2. Fail-safe relay
3. Solenoid valve
4. ECU (ABS)
5. Pump motor relay coil
6. Pump motor monitor
7. ABS warning light
8. Fail-safe relay coil
9. Rear solenoid
10. Front solenoid
11. Power
12. Fail-safe relay
13. Hydraulic unit
1-11
FEATURES
ABS operation
The ABS hydraulic circuit consists of two systems: the front wheel and rear wheel. The following describes the front system only.
● Normal braking (ABS not activated)
When the ABS is not activated port D “11” of the solenoid valve is closed because a control signal
has not been transmitted from the ECU (ABS) and port A “7” and port B “9” of the flow control valve
are open. Therefore, when the brake lever is squeezed, the hydraulic pressure in the brake master
cylinder increases and the brake fluid is sent to the brake caliper via port A and port B.
At this time, the inlet and outlet check valves of the pump close the lines and brake fluid is not sent.
As a result, the brake master cylinder directly pressurizes the brake caliper during normal braking.
When the brake lever is released, the brake fluid in the brake caliper returns to the brake master cylinder via port A and port B.
11. Port D
12. Solenoid valve
13. Port C
14. Brake caliper
15. ECU (ABS)
16. ABS warning light
17. Brake fluid pressure
18. Time
19. Repressurizing
1. Brake master cylinder
2. Brake light switch
3. ABS motor
4. Pump
5. Buffer chamber
6. Flow control valve
7. Port A
8. Spool
9. Port B
10. Orifice
1-12
FEATURES
● Emergency
braking (ABS activated)
1.Depressurized state
When the front wheel is about to lockup, port D “11” of the solenoid valve is opened by the “depressurization” signal transmitted from the ECU (ABS). When this occurs, the spool of the flow control
valve compresses the return spring to close port B “9”. Brake fluid that has entered through port A
“7” is restricted by the orifice “10” and the brake fluid is sent to the brake caliper via port C “13” and
port D “11”, and the buffer chamber. As a result, the hydraulic pressure in the brake caliper is reduced.
The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the
fluid pressure pump linked to the pump motor.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10. Orifice
11. Port D
12. Solenoid valve
13. Port C
14. Brake caliper
15. ECU (ABS)
16. ABS warning light
17. Brake fluid pressure
18. Time
19. Repressurizing
Brake master cylinder
Brake light switch
ABS motor
Pump
Buffer chamber
Flow control valve
Port A
Spool
Port B
1-13
FEATURES
2.Pressurized state
Port D “11” is closed by the “pressurization” signal transmitted from the ECU (ABS). Before this occurs, the spool of the flow control valve has compressed the return spring to close port B “9”. Brake
fluid that has entered through port A “7” is further restricted by the orifice “10” and the brake fluid is
sent to the brake calipers via port A “7” and port C “13”. At this time, the brake is pressurized at a
constant speed regardless of the brake fluid pressure level since restriction of port A “7” changes
so that a constant pressure difference is maintained between chamber A “20” and chamber B “21”
of the flow control valve.
11. Port D
12. Solenoid valve
13. Port C
14. Brake caliper
15. ECU (ABS)
16. ABS warning light
17. Brake fluid pressure
18. Time
19. Repressurizing
20. Chamber A
21. Chamber B
1. Brake master cylinder
2. Brake light switch
3. ABS motor
4. Pump
5. Buffer chamber
6. Flow control valve
7. Port A
8. Spool
9. Port B
10. Orifice
1-14
FEATURES
EAS15B1001
NOTE:
MULTI-FUNCTION DISPLAY
● 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.
EWA12311
WARNING
Be sure to stop the vehicle before making
any setting changes to the multi-function
display.
ECA15B1001
1
2
3
CAUTION:
If bars “1” appear where the odometer and
tripmeters are normally displayed, the
multi-function display is malfunctioning.Replace the entire multi-function display.
4
5
6
1.
2.
3.
4.
5.
6.
Clock
Coolant temperature meter
Fuel meter
Odometer/tripmeters
“SELECT” button
“RESET” button
1
2
1
3 4
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 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
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 indicator
started flashing), a self-diagnosis device (engine and ABS)
● a clock
● an oil change indicator
● a V-belt replacement indicator
1
1. Fuel reserve tripmeter
1-15
FEATURES
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 will reset itself automatically
and the display will return to the prior mode after
refueling and traveling 5 km (3 mi).
ECA10020
NOTE:
CAUTION:
The display cannot be changed back to “TRIP F”
after pushing the “RESET” button.
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. Refer to “CHANGING THE
ENGINE OIL” on page 3-13.
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. “CHANGING THE ENGINE OIL” on page
3-13
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, check the
electrical circuit. Refer to “SIGNALING SYSTEM” on page 8-23.
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.
ECA15B1002
CAUTION:
If the fuel level is not displayed and the fuel
level warning symbol, triangular mark, “E”
line and “F” line flash in the fuel meter, the
fuel level monitoring system is malfunctioning. Check the fuel sender and 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.
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.
V-belt replacement indicator “V-BELT”
This indicator flashes every 20000 km (12000
mi) when the V-belt needs to be replaced.
The electrical circuit of the indicator can be
checked according to the following procedure.
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, check the
electrical circuit. Refer to “SIGNALING SYSTEM” on page 8-23.
To reset the V-belt replacement indicator
1. Turn the key to “ON” and make sure that the
1-16
FEATURES
engine stop switch is set to “ON”.
2. Disconnect the V-belt replacement reset coupler “1” for two to ten seconds.
3. And then, connect the V-belt replacement reset coupler, the V-belt replacement indicator
will come on for 1.4 seconds. And the V-belt
replacement indicator will go off.
NOTE:
If the V-belt is replaced before the V-belt replacement indicator comes on (i.e. before the
V-belt replacement interval has been reached),
the indicator must be reset after the V-belt replacement for the next periodic V-belt replacement to be indicated at the correct time.
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 check
the vehicle. Refer to “FUEL INJECTION SYSTEM” on page 8-33, “IMMOBILIZER SYSTEM”
on page 8-57, “ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)” on page 8-65.
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.
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.
1-17
IMPORTANT INFORMATION
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EAS20210
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
2. Use only the proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS” on page 1-21.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an assembly.
EAS20220
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
EAS20230
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When
installing oil seals “1”, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appropriate.
4. During disassembly, clean all of the parts and
place them in trays in the order of disassembly. This will speed up assembly and allow for
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-18
IMPORTANT INFORMATION
ECA13300
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Always replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
a. Shaft
1-19
CHECKING THE CONNECTIONS
EAS20250
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
● Lead
● Coupler
● Connector
2. Check:
● Lead
● Coupler
● Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several times.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
● If
there is no continuity, clean the terminals.
checking the wire harness, perform
steps (1) to (3).
● As a quick remedy, use a contact revitalizer
available at most part stores.
● When
3. Check:
● All connections
Loose connection → Connect properly.
NOTE:
If the pin “1” on the terminal is flattened, bend it
up.
4. Connect:
● Lead
● Coupler
● Connector
NOTE:
Make sure all connections are tight.
5. Check:
● Continuity
(with the pocket tester)
1-20
SPECIAL TOOLS
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
For others, use part number starting with “90890-”.
Tool name/Tool No.
Illustration
Reference
pages
Rotor holding tool
90890-01235
Universal magneto & rotor holder
YU-01235
5-45, 5-48
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
4-66
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
5-26
Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01
6-3
YU-24460-01
Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-33984
6-3
YU-33984
1-21
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
4-59, 4-61
Damper rod holder
90890-01460
4-59, 4-61
Locknut wrench
90890-01348
YM-01348
5-55, 5-57
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
5-32
Frok seal driver weight
90890-01367
Replacement hammer
YM-A9409-7
4-62
YM-A9409-7/YM-A5142-4
Fork seal driver attachment (ø41)
90890-01381
Replacement 41 mm
YM-A5142-2
4-62
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
3-27
1-22
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Oil filter wrench
90890-01469
Oil filter wrench
YM-01469
Reference
pages
3-13
66.8
Sheave holder
90890-01481
5-54
Clutch spring compressor
90890-01482
5-45
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
5-32, 5-33
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
3-3
Compression gauge
90890-03081
Engine compression tester
YU-33223
3-11
Extension
90890-04082
3-11
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456
3-6
1-23
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1-20, 5-37,
8-103, 8-105,
8-106, 8-108,
8-110, 8-111,
8-112, 8-113,
8-114, 8-115,
8-116, 8-117,
8-118, 8-119,
8-120, 8-121
Timing light
90890-03141
Inductive clamp timing light
YU-03141
3-10
Test coupler adapter
90890-03149
4-50, 4-51
Pressure gauge
90890-03153
3-15, 7-7
Oil pressure adapter B
90890-03124
3-15
Carburetor angle driver
90890-03158
3-6
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
5-37
Fuel pressure adapter
90890-03181
7-7
1-24
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Valve spring compressor
90890-04019
YM-04019
5-18, 5-23
Valve spring compressor attachment
90890-04114
Valve spring compressor adapter 19.5
mm
YM-04114
5-18, 5-23
Middle driven shaft bearing driver
90890-04058
Bearing driver 40 mm
YM-04058
6-10
Mechanical seal installer
90890-04078
Water pump seal installer
YM-33221-A
6-10
Universal clutch holder
90890-04086
YM-91042
5-45, 5-48
Valve lapper
90890-04101
Valve lapping tool
YM-A8998
3-4
Valve guide remover (ø4)
90890-04111
Valve guide remover (4.0 mm)
YM-04111
5-19
Valve guide installer (ø4)
90890-04112
Valve guide installer (4.0 mm)
YM-04112
5-19
1-25
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Valve guide reamer (ø4)
90890-04113
Valve guide reamer (4.0 mm)
YM-04113
5-19
Sheave spring compressor
90890-04134
YM-04134
5-55, 5-57
Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135
5-55, 5-57
Plane bearing installer
90890-04139
5-62
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
8-113
Digital tachometer
90890-06760
YU-39951-B
3-8
Yamaha bond No. 1215 (Three Bond
No.1215®)
90890-85505
5-34, 5-68
1-26
SPECIAL TOOLS
1-27
SPECIFICATIONS
GENERAL SPECIFICATIONS ...................................................................... 2-1
ENGINE SPECIFICATIONS .......................................................................... 2-2
CHASSIS SPECIFICATIONS ........................................................................ 2-9
1
ELECTRICAL SPECIFICATIONS ................................................................. 2-12
TIGHTENING TORQUES .............................................................................. 2-15
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-15
ENGINE TIGHTENING TORQUES......................................................... 2-15
CHASSIS TIGHTENING TORQUES....................................................... 2-19
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-21
ENGINE................................................................................................... 2-21
CHASSIS................................................................................................. 2-22
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-25
ENGINE OIL LUBRICATION CHART ..................................................... 2-25
LUBRICATION DIAGRAMS .................................................................... 2-27
COOLING SYSTEM DIAGRAMS .................................................................. 2-33
2
3
4
5
CABLE ROUTING ......................................................................................... 2-35
6
7
8
9
GENERAL SPECIFICATIONS
EAS20280
GENERAL SPECIFICATIONS
Model
Model
XP500 15B1 (EUR)
XP500 15B4 (EUR)
XP500A 15B2 (EUR)
XP500A 15B5 (EUR)
XP500W 15B3 (AUS)
XP500W 15B6 (AUS)
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Ground clearance
Minimum turning radius
2235 mm (88.0 in)
775 mm (30.5 in)
1410 mm (55.5 in)
795 mm (31.3 in)
1575 mm (62.0 in)
130 mm (5.12 in)
2800 mm (110.2 in)
Weight
With oil and fuel
XP500 227.0 kg (500 lb)
XP500A 232.0 kg (511 lb)
XP500W 225.0 kg (496 lb)
XP500 188 kg (414 lb)
XP500A 183 kg (403 lb)
XP500W 190 kg (419 lb)
Maximum load
2-1
ENGINE SPECIFICATIONS
EAS20290
ENGINE SPECIFICATIONS
Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Standard compression pressure (at sea level)
Liquid cooled 4-stroke, DOHC
499.0 cm3
Forward-inclined parallel 2-cylinder
66.0 × 73.0 mm (2.60 × 2.87 in)
11.00 :1
1400 kPa/360 r/min (199.1 psi/360 r/min) (14.0
kgf/cm2/360 r/min)
Electric starter
Starting system
Fuel
Recommended fuel
XP500 Regular unleaded gasoline only
XP500A Regular unleaded gasoline only
XP500W Unleaded gasoline only
14.0 L (3.70 US gal) (3.08 Imp.gal)
Fuel tank capacity
Engine oil
Lubrication system
Type
Recommended engine oil grade
Dry sump
SAE10W30 or SAE10W40
API service SG type or higher, JASO standard
MA
Engine oil quantity
Total amount
Without oil filter cartridge replacement
With oil filter cartridge replacement
Oil pressure (hot)
3.60 L (3.81 US qt) (3.17 Imp.qt)
2.80 L (2.96 US qt) (2.46 Imp.qt)
2.90 L (3.07 US qt) (2.55 Imp.qt)
150.0 kPa/1200 r/min (21.8 psi/1200 r/min)
(1.50 kgf/cm2/1200 r/min)
Chain drive oil
Type
Quantity
Oil filter type
SAE80 API GL-4 Hypoid gear oil
0.70 L (0.74 US qt) (0.62 Imp.qt)
Paper
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Limit
Outer-rotor-to-oil-pump-housing clearance
Limit
Oil-pump-housing-to-inner-and-outer-rotor clearance
Limit
Bypass valve opening pressure
Relief valve operating pressure
Pressure check location
Trochoid
0.040–0.120 mm (0.0016–0.0047 in)
0.20 mm (0.0079 in)
0.045–0.085 mm (0.0018–0.0033 in)
0.155 mm (0.0061 in)
0.11–0.23 mm (0.0043–0.0091 in)
0.30 mm (0.0118 in)
80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20 kgf/
cm2)
450.0–550.0 kPa (65.3–79.8 psi) (4.50–5.50
kgf/cm2)
MAIN GALLERY
Cooling system
Radiator capacity (including all routes)
1.50 L (1.59 US qt) (1.32 Imp.qt)
Coolant reservoir capacity (up to the maximum level mark) 0.35 L (0.37 US qt) (0.31 Imp.qt)
Radiator cap opening pressure
107.9–137.3 kPa (15.6–19.9 psi) (1.08–1.37
kgf/cm2)
2-2
ENGINE SPECIFICATIONS
Thermostat
Model/manufacturer
Valve opening temperature
Valve full open temperature
Valve lift (full open)
Radiator core
Width
Height
Depth
Water pump
Water pump type
Reduction ratio
4JH/NIPPON THERMOSTAT
69.0–73.0 °C (156.20–163.40 °F)
85.0 °C (185.00 °F)
8.0 mm (0.31 in)
330.0 mm (12.99 in)
138.0 mm (5.43 in)
24.0 mm (0.94 in)
Single suction centrifugal pump
23/19 (1.210)
Spark plug (s)
Manufacturer/model
Spark plug gap
NGK/CR7E
0.7–0.8 mm (0.028–0.031 in)
Cylinder head
Volume
Warpage limit
14.97–15.57 cm3 (0.91–0.95 cu.in)
0.03 mm (0.0012 in)
Camshaft
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-cap clearance
Camshaft lobe dimensions
Intake A
Limit
Intake B
Limit
Exhaust A
Limit
Exhaust B
Limit
Chain drive (left)
23.000–23.021 mm (0.9055–0.9063 in)
22.967–22.980 mm (0.9042–0.9047 in)
0.020–0.054 mm (0.0008–0.0021 in)
33.252–33.352 mm (1.3091–1.3131 in)
33.152 mm (1.3052 in)
24.956–25.056 mm (0.9825–0.9865 in)
24.856 mm (0.9786 in)
33.252–33.352 mm (1.3091–1.3131 in)
33.152 mm (1.3052 in)
24.956–25.056 mm (0.9825–0.9865 in)
24.856 mm (0.9786 in)
AA
B
B
2-3
ENGINE SPECIFICATIONS
Camshaft runout limit
0.030 mm (0.0012 in)
Timing chain
Model/number of links
Tensioning system
SCR-0409 SV/132
Automatic
Valve, valve seat, valve guide
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Valve head diameter A (intake)
Valve head diameter A (exhaust)
0.15–0.20 mm (0.0059–0.0079 in)
0.25–0.30 mm (0.0098–0.0118 in)
24.90–25.10 mm (0.9803–0.9882 in)
21.90–22.10 mm (0.8622–0.8701 in)
A
Valve face width B (intake)
Valve face width B (exhaust)
1.140–1.980 mm (0.0449–0.0780 in)
1.140–1.980 mm (0.0449–0.0780 in)
B
Valve seat width C (intake)
Limit
Valve seat width C (exhaust)
Limit
0.90–1.10 mm (0.0354–0.0433 in)
1.6 mm (0.06 in)
0.90–1.10 mm (0.0354–0.0433 in)
1.6 mm (0.06 in)
C
Valve margin thickness D (intake)
Valve margin thickness D (exhaust)
0.60–0.80 mm (0.0236–0.0315 in)
0.60–0.80 mm (0.0236–0.0315 in)
D
Valve stem diameter (intake)
Limit
Valve stem diameter (exhaust)
Limit
Valve guide inside diameter (intake)
Limit
Valve guide inside diameter (exhaust)
Limit
3.975–3.990 mm (0.1565–0.1571 in)
3.945 mm (0.1553 in)
3.960–3.975 mm (0.1559–0.1565 in)
3.930 mm (0.1547 in)
4.000–4.012 mm (0.1575–0.1580 in)
4.050 mm (0.1594 in)
4.000–4.012 mm (0.1575–0.1580 in)
4.050 mm (0.1594 in)
2-4
ENGINE SPECIFICATIONS
Valve-stem-to-valve-guide clearance (intake)
Limit
Valve-stem-to-valve-guide clearance (exhaust)
Limit
Valve stem runout
0.010–0.037 mm (0.0004–0.0015 in)
0.080 mm (0.0032 in)
0.025–0.052 mm (0.0010–0.0020 in)
0.100 mm (0.0039 in)
0.040 mm (0.0016 in)
Cylinder head valve seat width (intake)
Limit
Cylinder head valve seat width (exhaust)
Limit
0.90–1.10 mm (0.0354–0.0433 in)
1.6 mm (0.06 in)
0.90–1.10 mm (0.0354–0.0433 in)
1.6 mm (0.06 in)
Valve spring
Free length (intake)
Limit
Free length (exhaust)
Limit
Installed length (intake)
Installed length (exhaust)
Spring rate K1 (intake)
Spring rate K2 (intake)
Spring rate K1 (exhaust)
Spring rate K2 (exhaust)
Spring tilt (intake)
Spring tilt (exhaust)
35.59 mm (1.40 in)
33.81 mm (1.33 in)
35.59 mm (1.40 in)
33.81 mm (1.33 in)
30.39 mm (1.20 in)
30.39 mm (1.20 in)
18.84 N/mm (107.60 lb/in) (1.92 kgf/mm)
24.52 N/mm (140.01 lb/in) (2.50 kgf/mm)
18.84 N/mm (107.60 lb/in) (1.92 kgf/mm)
24.52 N/mm (140.01 lb/in) (2.50 kgf/mm)
2.5 °/1.6 mm
2.5 °/1.6 mm
Winding direction (intake)
Winding direction (exhaust)
Clockwise
Clockwise
Valve lifter
Valve lifter outside diameter (intake)
Limit
Valve lifter outside diameter (exhaust)
Limit
24.476–24.500 mm (0.9636–0.9646 in)
24.451 mm (0.9626 in)
24.476–24.500 mm (0.9636–0.9646 in)
24.451 mm (0.9626 in)
Cylinder
Bore
66.000–66.010 mm (2.5984–2.5988 in)
2-5
ENGINE SPECIFICATIONS
Wear limit
Taper limit
Out of round limit
66.100 mm (2.6024 in)
0.050 mm (0.0020 in)
0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance
Limit
Diameter D
Height H
0.020–0.045 mm (0.0008–0.0018 in)
0.15 mm (0.0059 in)
65.965–65.980 mm (2.5970–2.5976 in)
9.0 mm (0.35 in)
H
D
Offset
Offset direction
Piston pin bore inside diameter
Limit
Piston pin outside diameter
Limit
0.50 mm (0.0197 in)
Intake side
15.002–15.013 mm (0.5906–0.5911 in)
15.043 mm (0.5922 in)
14.991–15.000 mm (0.5902–0.5906 in)
14.971 mm (0.5894 in)
Piston ring
Top ring
Ring type
Dimensions (B × T)
Barrel
0.80 × 2.45 mm (0.03 × 0.10 in)
B
T
End gap (installed)
Limit
Ring side clearance
Limit
2nd ring
Ring type
Dimensions (B × T)
0.15–0.25 mm (0.0059–0.0098 in)
0.50 mm (0.0197 in)
0.030–0.065 mm (0.0012–0.0026 in)
0.100 mm (0.0039 in)
Plain
0.80 × 2.50 mm (0.03 × 0.10 in)
B
T
End gap (installed)
Limit
Ring side clearance
Limit
Oil ring
Dimensions (B × T)
0.40–0.50 mm (0.0157–0.0197 in)
0.75 mm (0.0295 in)
0.020–0.055 mm (0.0008–0.0022 in)
0.100 mm (0.0039 in)
1.50 × 2.00 mm (0.06 × 0.08 in)
2-6
ENGINE SPECIFICATIONS
B
T
End gap (installed)
Ring side clearance
0.10–0.35 mm (0.0039–0.0138 in)
0.040–0.160 mm (0.0016–0.0063 in)
Connecting rod
Oil clearance (using plastigauge®)
Bearing color code
Small end inside diameter
0.026–0.050 mm (0.0010–0.0020 in)
1.Blue 2.Black 3.Brown 4.Green
15.005–15.018 mm (0.5907–0.5913 in)
Crankshaft
Width A
Width B
Runout limit C
Big end side clearance D
Big end radial clearance E
50.00–50.60 mm (1.969–1.992 in)
118.55–118.60 mm (4.67–4.67 in)
0.030 mm (0.0012 in)
0.160–0.262 mm (0.0063–0.0103 in)
0.026–0.050 mm (0.0010–0.0020 in)
Journal oil clearance (using plastigauge®)
Bearing color code
Balancer drive method
0.040–0.082 mm (0.0016–0.0032 in)
1.Blue 2.Black 3.Brown 4.Green
Piston
Clutch
Clutch type
Clutch release method
Friction plate thickness
Wear limit
Plate quantity
Clutch plate thickness
Plate quantity
Warpage limit
Clutch plate thickness
Plate quantity
Warpage limit
Clutch spring free length
Minimum length
Spring quantity
Clutch spring height “c”
Minimum height
Spring quantity
Clutch spring height “b”
Minimum height
Spring quantity
Wet, multiple-disc automatic
Automatic
2.75–3.05 mm (0.108–0.120 in)
2.65 mm (0.1043 in)
5 pcs
1.30–1.50 mm (0.051–0.059 in)
4 pcs
0.10 mm (0.0039 in)
1.80–2.00 mm (0.071–0.079 in)
2 pcs
0.20 mm (0.0079 in)
25.90 mm (1.02 in)
25.40 mm (1.00 in)
6 pcs
4.70 mm (0.19 in)
4.40 mm (0.17 in)
1 pcs
3.30 mm (0.13 in)
2.9 mm (0.11 in)
6 pcs
2-7
ENGINE SPECIFICATIONS
V-belt
V-belt width
Limit
32.0 mm (1.26 in)
30.5 mm (1.20 in)
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
V-belt automatic
Spur gear/helical gear
52/32 × 36/22 (2.659)
Chain drive
41/25 × 40/29 (2.262)
Centrifugal automatic type
Air filter
Air filter element
Dry element
Fuel pump
Pump type
Model/manufacturer
Maximum consumption amperage
Output pressure
Electrical
5VU/AISAN
1.9 A
246.0–254.0 kPa (35.7–36.8 psi) (2.46–2.54
kgf/cm2)
Fuel injector
Model/quantity
Manufacturer
1100-87B60/1100-87B70
AISAN
Throttle body
Type/quantity
Manufacturer
ID mark
ACW31/1
MIKUNI
5VU1 00
Idling condition
Engine idling speed
Intake vacuum
Water temperature
Oil temperature
Throttle cable free play
1100–1300 r/min
33.0 kPa (9.7 inHg) (248 mmHg)
85.0–100.0 °C (185.00–212.00 °F)
70.0 °C (158.00 °F)
3.0–5.0 mm (0.12–0.20 in)
2-8
CHASSIS SPECIFICATIONS
EAS20300
CHASSIS SPECIFICATIONS
Chassis
Frame type
Caster angle
Trail
Diamond
28.00 °
95.0 mm (3.74 in)
Front wheel
Wheel type
Rim size
Rim material
Wheel travel
Radial wheel runout limit
Lateral wheel runout limit
Wheel axle bending limit
Cast wheel
14M/C x MT3.50
Aluminum
120.0 mm (4.72 in)
1.0 mm (0.04 in)
0.5 mm (0.02 in)
0.25 mm (0.01 in)
Rear wheel
Wheel type
Rim size
Rim material
Wheel travel
Radial wheel runout limit
Lateral wheel runout limit
Wheel axle bending limit
Cast wheel
15M/C x MT5.00
Aluminum
117.0 mm (4.61 in)
1.0 mm (0.04 in)
0.5 mm (0.02 in)
0.25 mm (0.01 in)
Front tire
Type
Size
Manufacturer/model
Manufacturer/model
Wear limit (front)
Tubeless
120/70R14 M/C 55H
DUNLOP/D252F
BRIDGESTONE/TH01F
1.6 mm (0.06 in)
Rear tire
Type
Size
Manufacturer/model
Manufacturer/model
Wear limit (rear)
Tubeless
160/60R15 M/C 67H
DUNLOP/D252
BRIDGESTONE/TH01R
1.6 mm (0.06 in)
Tire air pressure (measured on cold tires)
Loading condition
Front
Rear
Loading condition
0–90 kg (0–198 lb)
225 kPa (33 psi) (2.25 kgf/cm2) (2.25 bar)
250 kPa (36 psi) (2.50 kgf/cm2) (2.50 bar)
XP500 90–188 kg (198–414 lb)
XP500A 90–183 kg (198–403 lb)
XP500W 90–190 kg (198–419 lb)
225 kPa (33 psi) (2.25 kgf/cm2) (2.25 bar)
280 kPa (41 psi) (2.80 kgf/cm2) (2.80 bar)
Front
Rear
Front brake
Type
Operation
Front disc brake
Disc outside diameter × thickness
Brake disc thickness limit
Brake disc deflection limit
Dual disc brake
Right hand operation
267.0 × 4.0 mm (10.51 × 0.16 in)
3.5 mm (0.14 in)
0.12 mm (0.0047 in)
2-9
CHASSIS SPECIFICATIONS
Brake pad lining thickness (inner)
Limit
Brake pad lining thickness (outer)
Limit
Master cylinder inside diameter
Caliper cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
6.2 mm (0.24 in)
0.8 mm (0.03 in)
6.2 mm (0.24 in)
0.8 mm (0.03 in)
14.00 mm (0.55 in)
30.16 mm (1.19 in)
25.40 mm (1.00 in)
DOT 4
Rear brake
Type
Operation
Rear disc brake
Disc outside diameter × thickness
Brake disc thickness limit
Brake disc deflection limit
Brake pad lining thickness (inner)
Limit
Brake pad lining thickness (outer)
Limit
Master cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
Single disc brake
Left hand operation
267.0 × 5.0 mm (10.51 × 0.20 in)
4.5 mm (0.18 in)
0.15 mm (0.0059 in)
8.3 mm (0.33 in)
0.8 mm (0.03 in)
8.3 mm (0.33 in)
0.8 mm (0.03 in)
12.7 mm (0.50 in)
38.10 mm (1.50 in)
DOT 4
Steering
Steering bearing type
Center to lock angle (left)
Center to lock angle (right)
Angular bearing
38.5 °
38.5 °
Front suspension
Type
Spring/shock absorber type
Front fork travel
Fork spring free length
Limit
Collar length
Installed length
Spring rate K1
Spring rate K2
Spring stroke K1
Spring stroke K2
Inner tube outer diameter
Inner tube bending limit
Optional spring available
Recommended oil
Quantity
Level
Telescopic fork
Coil spring/oil damper
120.0 mm (4.72 in)
405.0 mm (15.94 in)
400.0 mm (15.75 in)
145.0 mm (5.71 in)
400.0 mm (15.75 in)
15.60 N/mm (89.08 lb/in) (1.59 kgf/mm)
23.60 N/mm (134.76 lb/in) (2.41 kgf/mm)
0.0–80.0 mm (0.00–3.15 in)
80.0–120.0 mm (3.15–4.72 in)
41.0 mm (1.61 in)
0.2 mm (0.01 in)
No
Fork oil 7.5W or equivalent
512.0 cm3 (17.31 US oz) (18.06 Imp.oz)
109.0 mm (4.29 in)
Rear suspension
Type
Spring/shock absorber type
Rear shock absorber assembly travel
Spring free length
Installed length
Spring rate K1
Swingarm
Coil spring/gas-oil damper
43.0 mm (1.69 in)
191.2 mm (7.53 in)
180.0 mm (7.09 in)
225.60 N/mm (1288.18 lb/in) (23.00 kgf/mm)
2-10
CHASSIS SPECIFICATIONS
Spring rate K2
Spring stroke K1
Spring stroke K2
Optional spring available
Enclosed gas/air pressure (STD)
294.00 N/mm (1678.74 lb/in) (29.98 kgf/mm)
0.0–28.8 mm (0.00–1.13 in)
28.8–43.0 mm (1.13–1.69 in)
No
4900 kPa (696.9 psi) (49.0 kgf/cm2)
Swingarm
Swingarm end free play limit (radial)
Swingarm end free play limit (axial)
1.0 mm (0.04 in)
1.0 mm (0.04 in)
2-11
ELECTRICAL SPECIFICATIONS
EAS20310
ELECTRICAL SPECIFICATIONS
Voltage
System voltage
12 V
Ignition system
Ignition system
Advancer type
Ignition timing (B.T.D.C.)
Crankshaft position sensor resistance
Transistorized coil ignition (digital)
Digital
10.0 °/1200 r/min
189–231 Ω (Gy-B)
Engine control unit
Model/manufacturer
XP500 TBDF48/DENSO
XP500A TBDF49/DENSO
XP500W TBDF07/DENSO
Ignition coil
Model/manufacturer
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
JO313/DENSO
6.0 mm (0.24 in)
1.87–2.53 Ω
12.00–18.00 kΩ
Spark plug cap
Material
Resistance
Resin
10.0 kΩ
AC magneto
Model/manufacturer
Standard output
Stator coil resistance
F4T383/MITSUBISHI
14.0 V350 W5000 r/min
0.216–0.264 Ω
Rectifier/regulator
Regulator type
Model/manufacturer
Regulated voltage (DC)
Rectifier capacity (DC)
Withstand voltage
Semi conductor-short circuit
SH719AA/SHINDENGEN
14.1–14.9 V
25.0 A
240.0 V
Battery
Model
Voltage, capacity
Specific gravity
Manufacturer
Ten hour rate amperage
GT9B-4
12 V, 8.0 Ah
1.320
GYM
0.80 A
Headlight
Bulb type
Halogen bulb
Bulb voltage, wattage × quantity
Headlight
Headlight
Auxiliary light
12 V, 60 W/55.0 W × 1
12 V, 55.0 W × 1
XP500 12 V, 5.0 W × 2
XP500A 12 V, 5.0 W × 2
XP500W 12 V, 5.0 W × 2 (AUS)
12 V, 5.0 W/21.0 W × 2
12 V, 21 W/5.0 W × 2
12 V, 21.0 W × 2
Tail/brake light
Front turn signal/position light
Rear turn signal light
2-12
ELECTRICAL SPECIFICATIONS
12 V, 5.0 W × 1
14 V, 2.0 W × 3
License plate light
Meter lighting
Indicator light
Turn signal indicator light
High beam indicator light
Engine trouble warning light
ABS warning light
Immobilizer system indicator light
14 V, 1.4 W × 2
14 V, 1.4 W × 1
14 V, 1.4 W × 1
XP500A 14 V, 1.4 W × 1
LED
Electric starting system
System type
Constant mesh
Starter motor
Model/manufacturer
Power output
Armature coil resistance
Brush overall length
Limit
Brush spring force
Commutator diameter
Limit
Mica undercut (depth)
SM-13/MITSUBA
0.70 kW
0.0015–0.0025 Ω
12.0 mm (0.47 in)
4.00 mm (0.16 in)
7.65–10.01 N (27.54–36.03 oz) (780–1021 gf)
28.0 mm (1.10 in)
27.0 mm (1.06 in)
0.70 mm (0.03 in)
Starter relay
Model/manufacturer
Amperage
Coil resistance
MS5F-561/JIDECO
180.0 A
4.18–4.62 Ω
Horn
Horn type
Quantity
Model/manufacturer
Maximum amperage
Coil resistance
Performance
Plane
2 pcs
YF-12/NIKKO
3.0 A
1.15–1.25 Ω
105–113 dB/2m
Turn signal/hazard relay
Relay type
Model/manufacturer
Built-in, self-canceling device
Turn signal blinking frequency
Wattage
Full transistor
FE246BH/DENSO
No
75.0–95.0 cycles/min
21 W × 2.0 +3.4 W
Fuel sender unit
Model/manufacturer
Sender unit resistance (full)
Sender unit resistance (empty)
5VU/AISAN
19.0–21.0 Ω
137.0–143.0 Ω
Fuses
Main fuse
Headlight fuse
Signaling system fuse
30.0 A
15.0 A
XP500 20.0 A
XP500A 15.0 A
XP500W 20.0 A
10.0 A
15.0 A
Ignition fuse
Radiator fan fuse
2-13
ELECTRICAL SPECIFICATIONS
Parking lighting fuse
Fuel injection system fuse
ABS motor fuse
ABS control unit fuse
Backup fuse
Reserve fuse
Reserve fuse
10.0 A
10.0 A
XP500A 30.0 A
XP500A 5.0 A
10.0 A
30.0 A
XP500 20.0 A
XP500A 15.0 A
XP500W 20.0 A
XP500 15.0 A
XP500A 10.0 A
XP500W 15.0 A
XP500 10.0 A
XP500A 5.0 A
XP500W 10.0 A
Reserve fuse
Reserve fuse
2-14
TIGHTENING TORQUES
EAS20320
TIGHTENING TORQUES
EAS20330
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special components or assemblies are provided for each
chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications require clean, dry threads. Components should be
at room temperature.
A. Distance between flats
B. Outside thread diameter
General tightening torques
A (nut)
B (bolt)
Nm
m•kg
ft•lb
10 mm
6 mm
6
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
EAS20340
ENGINE TIGHTENING TORQUES
Thread
size
Q’ty
Tightening torque
Spark plug
M10
2
13 Nm (1.3 m•kg, 9.4 ft•lb)
Cylinder head cover
M6
10
10 Nm (1.0 m•kg, 7.2 ft•lb)
Camshaft cap
M6
12
10 Nm (1.0 m•kg, 7.2 ft•lb)
Cylinder head and cylinder body
M9
4
35 Nm (3.5 m•kg, 25 ft•lb)
E
Cylinder head and cylinder body
M9
2
46 Nm (4.6 m•kg, 33 ft•lb)
E
Cylinder head and cylinder body
M6
2
10 Nm (1.0 m•kg, 7.2 ft•lb)
Cylinder head (exhaust pipe)
M8
4
15 Nm (1.5 m•kg, 11 ft•lb)
Cylinder body
M6
1
10 Nm (1.0 m•kg, 7.2 ft•lb)
Connecting rod cap
M7
4
See NOTE*1
M
Connecting rod cap (balancer)
M9
2
60 Nm (6.0 m•kg, 43 ft•lb)
M
Balancer piston cylinder
M10
4
58 Nm (5.8 m•kg, 42 ft•lb)
A.C. magneto rotor
M18
1
See NOTE*2
Timing chain tensioner
M6
2
10 Nm (1.0 m•kg, 7.2 ft•lb)
Timing chain tensioner cap bolt
M6
1
7 Nm (0.7 m•kg, 5.1 ft•lb)
Item
2-15
Remarks
LT
E
TIGHTENING TORQUES
Thread
size
Q’ty
Tightening torque
Chain guide (intake side)
M6
2
10 Nm (1.0 m•kg, 7.2 ft•lb)
Water pump housing cover
M6
2
10 Nm (1.0 m•kg, 7.2 ft•lb)
Water pump assembly
M6
2
10 Nm (1.0 m•kg, 7.2 ft•lb)
Coolant pipe
M6
2
10 Nm (1.0 m•kg, 7.2 ft•lb)
Radiator filler neck
M6
1
7 Nm (0.7 m•kg, 5.1 ft•lb)
Radiator drain bolt
M12
1
1.6 Nm (0.16 m•kg, 1.2 ft•lb)
Water pump inlet pipe
M6
1
10 Nm (1.0 m•kg, 7.2 ft•lb)
Water pump outlet pipe
M6
1
10 Nm (1.0 m•kg, 7.2 ft•lb)
Thermostat cover
M6
2
10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil pump assembly
M6
3
10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil strainer assembly
M6
2
10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil cooler assembly
M20
1
63 Nm (6.3 m•kg, 45 ft•lb)
Oil filter cartridge
M20
1
17 Nm (1.7 m•kg, 12 ft•lb)
Oil delivery pipe
M6
1
10 Nm (1.0 m•kg, 7.2 ft•lb)
Intake manifold and cylinder head
M6
4
10 Nm (1.0 m•kg, 7.2 ft•lb)
Silencer assembly
M6
2
9 Nm (0.9 m•kg, 6.5 ft•lb)
Air filter case assembly
M6
3
9 Nm (0.9 m•kg, 6.5 ft•lb)
Exhaust pipe
M8
4
20 Nm (2.0 m•kg, 14 ft•lb)
Muffler
M10
1
31 Nm (3.1 m•kg, 22 ft•lb)
Muffler protector 1
M6
2
10 Nm (1.0 m•kg, 7.2 ft•lb)
Muffler protector 2
M6
1
10 Nm (1.0 m•kg, 7.2 ft•lb)
Crankcase
M6
13
10 Nm (1.0 m•kg, 7.2 ft•lb)
Crankcase
M8
8
24 Nm (2.4 m•kg, 17 ft•lb)
Engine oil drain bolt
M14
1
43 Nm (4.3 m•kg, 31 ft•lb)
Main gallery bolt
M20
1
12 Nm (1.2 m•kg, 8.7 ft•lb)
Oil tank
M6
7
10 Nm (1.0 m•kg, 7.2 ft•lb)
Stator coil base
M6
3
12 Nm (1.2 m•kg, 8.7 ft•lb)
Timing plug
M16
1
8 Nm (0.8 m•kg, 5.8 ft•lb)
A.C. magneto cover
M6
19
10 Nm (1.0 m•kg, 7.2 ft•lb)
V-belt case
M6
4
10 Nm (1.0 m•kg, 7.2 ft•lb)
V-belt case
M8
6
24 Nm (2.4 m•kg, 17 ft•lb)
V-belt case cover 1
M6
3
7 Nm (0.7 m•kg, 5.1 ft•lb)
V-belt case cover 2
M6
2
7 Nm (0.7 m•kg, 5.1 ft•lb)
Plate and right crankcase cover
M6
3
10 Nm (1.0 m•kg, 7.2 ft•lb)
Item
2-16
Remarks
LT
LT
E
LT
LT
LT
LT
TIGHTENING TORQUES
Thread
size
Q’ty
Tightening torque
Right crankcase cover
M8
2
24 Nm (2.4 m•kg, 17 ft•lb)
V-belt case air filter cover and V-belt
case air filter element (right)
M6
3
7 Nm (0.7 m•kg, 5.1 ft•lb)
V-belt case air filter element (left)
M6
2
7 Nm (0.7 m•kg, 5.1 ft•lb)
Generator cover protector
M6
1
7 Nm (0.7 m•kg, 5.1 ft•lb)
Generator cover protector cover
M6
2
7 Nm (0.7 m•kg, 5.1 ft•lb)
Starter clutch
M8
3
30 Nm (3.0 m•kg, 22 ft•lb)
Clutch boss nut
M36
1
90 Nm (9.0 m•kg, 65 ft•lb)
Clutch assembly
M16
1
65 Nm (6.5 m•kg, 47 ft•lb)
Chain drive holder assembly
M8
3
30 Nm (3.0 m•kg, 22 ft•lb)
Chain drive drain bolt
M12
1
20 Nm (2.0 m•kg, 14 ft•lb)
Chain drive case (outer)
M6
18
10 Nm (1.0 m•kg, 7.2 ft•lb)
Chain drive case cover
M6
2
7 Nm (0.7 m•kg, 5.1 ft•lb)
Primary sheave assembly nut
M20
1
160 Nm (16.0 m•kg, 115 ft•lb)
Secondary sheave spring seat
M36
1
90 Nm (9.0 m•kg, 65 ft•lb)
Secondary sheave assembly
M18
1
90 Nm (9.0 m•kg, 65 ft•lb)
Primary bearing retainer
M6
1
11 Nm (1.1 m•kg, 8.0 ft•lb)
LT
Secondary shaft bearing retainer
M6
1
12 Nm (1.2 m•kg, 8.7 ft•lb)
LT
Stator coil assembly
M6
3
10 Nm (1.0 m•kg, 7.2 ft•lb)
LT
Crankshaft position sensor
M5
2
7 Nm (0.7 m•kg, 5.1 ft•lb)
LT
Starter motor
M6
2
10 Nm (1.0 m•kg, 7.2 ft•lb)
Starter motor lead
M6
1
5 Nm (0.5 m•kg, 3.6 ft•lb)
Thermostat cover
M6
2
10 Nm (1.0 m•kg, 7.2 ft•lb)
Fuel injector assembly
M6
2
12 Nm (1.2 m•kg, 8.7 ft•lb)
O2 sensor
M18
1
45 Nm (4.5 m•kg, 32 ft•lb)
Coolant temperature sensor
M12
1
18 Nm (1.8 m•kg, 13 ft•lb)
ECU (engine)
M6
2
3 Nm (0.3 m•kg, 2.2 ft•lb)
Intake air pressure sensor
M6
2
10 Nm (1.0 m•kg, 7.2 ft•lb)
Item
NOTE:
● *1:After
● *2:After
tightening to 16 Nm (1.6 m•kg, 11 ft•lb), tighten another 90°.
tightening to 60 Nm (6.0 m•kg, 43 ft•lb), tighten another 120°.
2-17
Remarks
LT
BEL-RAY
assembly
lube®
Shell BT
grease®
TIGHTENING TORQUES
Crankcase tightening sequence:
Cylinder head tightening sequence:
2-18
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES
Thread
size
Q’ty
Tightening torque
Upper bracket pinch bolt
M8
2
30 Nm (3.0 m•kg, 22 ft•lb)
Steering stem nut
M22
1
110 Nm (11.0 m•kg, 80 ft•lb)
Lower ring nut
M25
1
20 Nm (2.0 m•kg, 14 ft•lb)
Front fork cap bolt
M38
1
24 Nm (2.4 m•kg, 17 ft•lb)
Lower bracket pinch bolt
M8
4
23 Nm (2.3 m•kg, 17 ft•lb)
Front fender
M6
4
7 Nm (0.7 m•kg, 5.1 ft•lb)
Damper rod assembly bolt
M10
2
23 Nm (2.3 m•kg, 17 ft•lb)
Upper handlebar holder
M8
4
23 Nm (2.3 m•kg, 17 ft•lb)
Brake hose holder and upper
bracket
M6
1
7 Nm (0.7 m•kg, 5.1 ft•lb)
Brake hose union bolt
M10
8
30 Nm (3.0 m•kg, 22 ft•lb)
Brake master cylinder holder
M6
4
10 Nm (1.0 m•kg, 7.2 ft•lb)
Master cylinder reservoir cap
M4
8
1 Nm (0.1 m•kg, 0.7 ft•lb)
Handlebar grip end
M16
2
26 Nm (2.6 m•kg, 19 ft•lb)
Engine mounting front mounting nut
(upper)
M12
1
87 Nm (8.7 m•kg, 63 ft•lb)
Engine mounting front mounting bolt
(lower)
M10
2
48 Nm (4.8 m•kg, 35 ft•lb)
Engine mounting rear mounting nut
M12
1
87 Nm (8.7 m•kg, 63 ft•lb)
Front wheel axle
M14
1
59 Nm (5.9 m•kg, 43 ft•lb)
Front wheel axle pinch bolt
M8
1
23 Nm (2.3 m•kg, 17 ft•lb)
Rear wheel axle nut
M14
1
100 Nm (10.0 m•kg, 72 ft•lb)
Rear wheel axle pinch bolt
M8
1
17 Nm (1.7 m•kg, 12 ft•lb)
Front brake caliper bracket
M10
2
40 Nm (4.0 m•kg, 29 ft•lb)
Front brake caliper retaining bolt
M10
2
27 Nm (2.7 m•kg, 19 ft•lb)
Front brake disc
M8
6
18 Nm (1.8 m•kg, 13 ft•lb)
Rear brake caliper bracket
M10
2
40 Nm (4.0 m•kg, 29 ft•lb)
Rear brake caliper retaining bolt
M10
2
27 Nm (2.7 m•kg, 19 ft•lb)
Rear brake disc
M8
6
18 Nm (1.8 m•kg, 13 ft•lb)
LT
Rear wheel drive hub
M10
4
69 Nm (6.9 m•kg, 50 ft•lb)
LT
Rear brake lock lever cable holder
M8
1
22 Nm (2.2 m•kg, 16 ft•lb)
Brake caliper bleed screw
M7
2
6 Nm (0.6 m•kg, 4.3 ft•lb)
Rear wheel sensor (XP500A)
M8
1
30 Nm (3.0 m•kg, 22 ft•lb)
Front wheel sensor (XP500A)
M8
1
30 Nm (3.0 m•kg, 22 ft•lb)
Item
2-19
Remarks
See
NOTE.
LS
LT
LS
TIGHTENING TORQUES
Thread
size
Q’ty
Tightening torque
ECU (ABS) bracket (XP500A)
M6
2
7 Nm (0.7 m•kg, 5.1 ft•lb)
Hydraulic unit (XP500A)
M8
3
16 Nm (1.6 m•kg, 11 ft•lb)
Brake lever
M6
1
7 Nm (0.7 m•kg, 5.1 ft•lb)
Swingarm and pivot shaft
M22
1
7 Nm (0.7 m•kg, 5.1 ft•lb)
Pivot shaft and lock nut
M22
1
100 Nm (10.0 m•kg, 72 ft•lb)
Chain drive case and swingarm
M10
3
40 Nm (4.0 m•kg, 29 ft•lb)
Rear shock absorber (front side)
M16
1
68 Nm (6.8 m•kg, 49 ft•lb)
Rear shock absorber (rear side)
M12
1
53 Nm (5.3 m•kg, 38 ft•lb)
Front cowling and frame
M6
4
7 Nm (0.7 m•kg, 5.1 ft•lb)
Inner fender and frame
M6
2
7 Nm (0.7 m•kg, 5.1 ft•lb)
Headlight unit and front cowling
M6
2
7 Nm (0.7 m•kg, 5.1 ft•lb)
Tail/brake light assembly and frame
M6
2
7 Nm (0.7 m•kg, 5.1 ft•lb)
Footrest board and frame
M6
4
7 Nm (0.7 m•kg, 5.1 ft•lb)
Upper side cover moulding and passenger footrest
M6
6
7 Nm (0.7 m•kg, 5.1 ft•lb)
Rear side cover and frame
M6
6
7 Nm (0.7 m•kg, 5.1 ft•lb)
Leg shield, footrest board and frame
M6
2
7 Nm (0.7 m•kg, 5.1 ft•lb)
Seat damper
M8
1
16 Nm (1.6 m•kg, 11 ft•lb)
Fuel tank
M6
4
10 Nm (1.0 m•kg, 7.2 ft•lb)
Fuel pump
M5
6
4 Nm (0.4 m•kg, 2.9 ft•lb)
Grab bar
M8
4
16 Nm (1.6 m•kg, 11 ft•lb)
Seat lock
M6
4
7 Nm (0.7 m•kg, 5.1 ft•lb)
Storage box
M6
6
10 Nm (1.0 m•kg, 7.2 ft•lb)
Windshield
M5
6
0.4 Nm (0.04 m•kg, 0.3 ft•lb)
Coolant reservoir
M6
1
4 Nm (0.4 m•kg, 2.9 ft•lb)
Centerstand bracket
M10
2
55 Nm (5.5 m•kg, 40 ft•lb)
Centerstand
M10
2
55 Nm (5.5 m•kg, 40 ft•lb)
Sidestand (bolt and frame)
M10
1
9 Nm (0.9 m•kg, 6.5 ft•lb)
Sidestand (bolt and nut)
M10
1
40 Nm (4.0 m•kg, 29 ft•lb)
Passenger footrest
M8
4
23 Nm (2.3 m•kg, 17 ft•lb)
Item
Remarks
NOTE:
● First,
tighten the lower ring nut to approximately 52 Nm (5.2 m•kg, 37 ft•lb) with a torque wrench, then
loosen the lower ring nut completely.
● Retighten the lower ring nut to 20 Nm (2.0 m•kg, 14 ft•lb) with a torque wrench.
2-20
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20360
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20370
ENGINE
Lubrication point
Lubricant
Oil seal lips
LS
O-rings
LS
Bearing and bushes
E
Crankshaft pins
E
Piston surfaces
E
Piston pins and connecting rod small end
E
Balancer surface
E
Connecting rod big end thrust surface
E
Connecting rod bolts and nuts
M
Crankshaft thrust surface
E
Crankshaft journals
E
Camshaft lobs
M
Camshaft journals
M
Camshaft cap
M
Valve stems (intake and exhaust)
M
Valve stem ends (intake and exhaust)
E
Cylinder head nut
E
Water pump impeller shaft
M
Oil pump shaft
E
Oil pump rotors (inner and outer)
E
Oil pump O-ring
LS
Oil cooler union bolt
E
O-ring (fuel injector assembly)
Silicone oil
Starter clutch idle gear inner surface
E
Starter clutch
E
Main axle thrust surface
E
2-21
or
LS
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point
Lubricant
Main and drive axle serration
E
or
LS
Drive axle spline
E
or
LS
Chain drive case and taper bearing
LS
Bearing (chain drive case)
Chain drive oil
Primary sheave spacer
Shell BT grease 3®
Primary sheave nut
Shell BT grease 3®
Secondary sheave nut
BEL-RAY assembly
lube®
Primary sheave
BEL-RAY assembly
lube®
Secondary sheave
BEL-RAY assembly
lube®
Swingarm pivot shaft bearing
LS
Crankcase mating surface
Yamaha bond No.1215
A.C. magneto lead
Yamaha bond No.1215
Cylinder head cover (gasket mating surface)
Yamaha bond No.1215
Cylinder head cover (guide stopper mating surface)
Yamaha bond No.1215
Right crankcase cover (air duct seal mating surface)
Yamaha bond No.1215
EAS20380
CHASSIS
Lubrication point
Lubricant
Front wheel oil seal lip
LS
Steering bearings and oil seal lip
LS
Throttle grip inner surface and throttle cables
LS
Brake lever pivoting point and metal-to-metal moving parts (left and right)
LS
Parking brake lock lever cable and parking brake lock lever (cable connection
area)
LS
Sidestand pivoting point, metal-to-metal moving parts
LS
Centerstand shaft pivoting point and metal-to-metal moving parts
LS
Oil seal lip (chain drive case)
LS
Rear wheel drive hub spline
LS
Rear wheel oil seal lip
LS
Passenger footrest pivoting point
LS
2-22
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point
Lubricant
Rear shock absorber bearing and collar inner surface
LS
Swingarm, oil seal lip and collar inner surface
LS
Rear shock absorber bolt (front side)
LS
2-23
LUBRICATION POINTS AND LUBRICANT TYPES
2-24
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20390
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20400
ENGINE OIL LUBRICATION CHART
2-25
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Exhaust camshaft
2. Intake camshaft
3. Piston cooler
4. Crankshaft
5. Oil tank
6. Oil pan
7. Strainer
8. Suction oil pump
9. Flush oil pump
10. Check valve
11. Relief valve
12. Oil cooler
13. Oil filter cartridge
2-26
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20410
LUBRICATION DIAGRAMS
2-27
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Oil pump
2. Oil tank
3. Oil strainer
4. Relief valve
5. Oil cooler
6. Oil filter cartridge
7. Exhaust camshaft
8. Intake camshaft
9. Oil pipe
10. Oil delivery pipe
2-28
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-29
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Oil strainer
2. Crankshaft
2-30
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-31
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Clutch
2. Right main journal bearing
3. Main gallery plug
2-32
COOLING SYSTEM DIAGRAMS
EAS20420
COOLING SYSTEM DIAGRAMS
2-33
COOLING SYSTEM DIAGRAMS
1.
2.
3.
4.
5.
6.
7.
Coolant reservoir
Thermostat
Radiator
Water pump
Radiator fan
Radiator cap
Fast idle plunger
2-34
CABLE ROUTING
EAS20430
CABLE ROUTING
2-35
CABLE ROUTING
1. Headlight sub-wire harness
2. Horn
3. Horn (H mark on the back of the horn)
A. Securely fasten the wire strap to the front cowling hook to prevent it from being pulled out by
the headlight assembly. (left and right)
B. Connect the headlight sub-wire harness to the
wire harness on top of the stay (left and right).
After making the connection, push the coupler
between the front cowling and the air filter case.
C. Connect the taped headlight lead coupler to the
headlights white marked side (left side: high
beam side). (For GB the right side is the high
beam side.)
D. Fasten the headlight sub-wire harness using a
lead holder. (left and right)
E. Connect the turn signal light. (left and right)
F. Route the horn lead through the wire guide.
G. After passing the horn lead through the lead
holder, crimp the lead holder.
H. Install a wire harness guide to hold down the
wire harness.
I. Route the throttle cables between handle under
cover and upper bracket.
J. Route the throttle cables through the hole of the
lower handlebar cover.
K. Connect the brake light switch lead through the
handlebar switch side.
L. Fasten the handlebar switch lead to the handlebar using a plastic band. The fastening location
is the bend area on the bottom of the handlebar.
M. Route the left handlebar switch leads under the
right handlebar switch leads.
N. Fasten the right handlebar switch leads to the
handlebar with a plastic band.
O. Route the rear brake hose and left handlebar
switch leads over the wire harness.
2-36
CABLE ROUTING
2-37
CABLE ROUTING
1.
2.
3.
4.
Rear brake hose
Front brake hose
Rear brake lock lever cable
Left handlebar switch
A. Route the rear brake lock lever cable in front of
the handlebar, then down through the space
between the handlebar and the upper bracket.
B. Fasten the wire harness by sliding the plastic
holder on the wire harness onto the stud on the
handlebar.
C. Fasten the grommets on the brake hoses with
the holder.
D. Install the rear brake lock lever cable after lubricating the grease to the cable end.
E. Install the rear brake lock lever cable after turning the parking brake lever as illustration.
F. Install the cable end (Face the notch side to
lever).
2-38
CABLE ROUTING
2-39
CABLE ROUTING
1. Grommet
2. Fuel over flow hose
3. Fuel tank
4. Fuel overflow tray
5. Fuel tank cap
6. Upper side cover moulding (left)
7. Hose guide
8. Grommet
9. Footrest board
10. Hose clamp
11. Fuel tank breather hose
12. Rear footrest assembly
13. Fuel tank breather hose
14. Hose holder
15. Hose holder
16. Fuel hose
17. Fuel pump lead
18. Hose guide
19. Roll over valve assembly
20. Holder
21. Fuel pump
22. Fuel pump bracket
23. Fuel hose connector cover
A. Do not protrude from the upper side cover
moulding (left).
B. Fix the fuel tank breather hose with the white
paint mark.
C. Pass the fuel tank breather hose to the hose
guide of frame (both right and left).
D. Pass the fuel tank breather hose to the hose
guide of rear footrest assembly.
E. Pass the fuel tank breather hose to the hose
guide of frame.
F. 50 – 70 mm (1.97 – 2.76 in)
G. 2 – 5 mm (0.08 – 0.20 in)
H. Install the grommet to the footrest board
securely.
I. Install the grommet to the fuel tank securely.
J. Make sure that the clip end faces to the front
side.
K. Install the grommet to the fuel tank securely
after installing the hoses.
L. Fasten the fuel hose and fuel pump lead with a
hose holder, making sure that there are no
twists in the hose or lead.
M. Align the projection on the fuel pump with the
projection on the fuel tank when installing the
fuel pump.
N. Tighten the fuel pump bolts in the proper tightening sequence as shown.
O. Pass the fuel hose to the hose guide.
P. Pass the fuel hose to the inside of the frame
guide.
Q. After connecting the fuel hose connector to the
fuel tank, install the fuel hose connector cover
completely onto the connector. Install and
remove the fuel hose connector and cover manually. Do not use tools.
R. Make sure that the pipe guide contact to the
frame when install the pipe guide.
2-40
CABLE ROUTING
2-41
CABLE ROUTING
L. Route the ignition coil lead through the inside of
the ignition coil bracket.
M. Fasten the radiator fan motor lead and sidestand switch lead to the frame with a plastic
holder.
N. Insert the tail/brake light coupler between the
wire harness and the seat lock cable (left).
O. To the tail/brake light.
P. To the starter relay.
Q. Route the wire harness and rectifier/regulator
lead through the frame wire holder. Place the
rectifier/regulator lead under the wire harness.
R. Make sure that the seat lock cable do not lean
over the storage box.
S. Fasten the starter motor lead, negative battery
lead and seat lock cable (left) to the frame with
a plastic holder.
T. Fasten the starter motor lead and negative battery lead to the frame with a plastic holder.
U. Fasten the wire harness to the frame with the
plastic band. The buckle of the plastic band
should be facing towards the storage box.
V. Insert the seat lock cable and the cylinder
mounting rubber into the frame stay.
W. Fasten the starter motor lead and negative battery lead to the frame with a plastic band. Position the band clasp on the bottom of the frame
and face the band end to the outside.
X. Install the clamshell cover around the V-belt
replacement indicator reset coupler and O2
sensor coupler.
Y. Make sure that the V-belt replacement indicator
reset coupler does not project out of the clamshell cover.
Z. Fasten the O2 sensor lead and V-belt replacement indicator reset coupler lead to the frame
with a plastic holder.
AA. Pass the wire harness and seat lock cable in
the frame holder.
AB. Pass the rear brake lock lever cable under the
coolant pipe.
AC. 40 – 50 mm (1.57 – 1.97 in)
AD. Fasten the O2 sensor lead to the frame with a
plastic band.
AE. Pass the O2 sensor lead to the lead guide.
1. Main switch/immobilizer unit
2. Throttle cable
3. Brake hose
4. Meter assembly
5. Cooling system air bleed hose
6. Horn lead
7. Radiator filer hose
8. Ignition coil
9. Coolant reservoir hose
10. Radiator fan motor lead
11. Throttle position sensor coupler
12. Starter motor lead
13. Rectifier/regulator
14. Starting circuit cut-off relay 1
15. Turn signal/hazard relay
16. O2 sensor
17. V-belt replacement indicator reset coupler
18. O2 sensor coupler
19. Fuel pump lead
20. Fuel tank breather hose
21. Rear brake lock lever cable
22. Negative battery lead
23. Seat lock cable (left)
24. Frame
25. Wire harness
26. Storage box
27. V-belt replacement indicator reset coupler lead
28. O2 sensor lead
29. Fuel hose
30. Tail/brake light assembly
31. Main switch lead
A. After adjusting the adjustment nut, attach the
front and rear parts of the boot tightly. Apply the
silicone grease to the inside of the boot and surface of the adjusting nut possible, when installing the boot.
B. Pass the seat lock cable between wire harness
and frame.
C. Use the plastic holder on the back of the frame
to hold the radiator fan motor lead.
D. Connect the wire harness (wire taped area) to
the T stud of frame.
E. Pass the main switch lead between stay 1 and
seat lock cable.
F. After connecting the wire harness and meter
assembly lead, use a plastic holder to connect
them to stay 1.
G. After connecting the left headlight sub-wire harness and wire harness (by matching the coupler colors), fold back the lead facing to the right
and insert it into the air filter case rib.
H. Connect the wire harness to the headlight sub
wire harness (cowling side).
I. Fasten the headlight and turn signal sub-wire
harness to the stay 1 with a plastic holder.
J. Fasten the ECU (engine) lead to the stay 1 with
a plastic holder. When fastening them using a
plastic holder, make sure not to cross the
branch leads.
K. Fasten the coolant reservoir hose to the stay 1
with a plastic holder.
AF. Pass the wire harness to the frame wire harness holder.
AG. After making the connections, push the couplers into the space inside the frame above the
mudguard.
AH. Install the band fastened part between frame
and storage box.
AI. Route the seat lock cable through the frame
bracket side and under the wire harness.
AJ. T stud for position setting
AK. Fasten the wire harness, main switch lead and
seat lock cable with a clamp to under the cowling stay (Fasten the seat lock cables metal pipe
section).
AL. Route the taillight lead onto the seat lock cable,
wire harness and positive battery lead.
AM. Install the turn signal light lead, make sure
does not hide the turn signal light lead under
the tail light assembly as shown area.
2-42
CABLE ROUTING
2-43
CABLE ROUTING
1. Rear brake lock lever cable
2. Throttle cable (decelerator cable, double locknut)
3. Fast idle inlet hose
4. Rear brake hose
5. A.C. magneto lead
6. Fuel tank breather hose
7. Coolant hose
8. Sidestand switch
9. Fast idle outlet hose
10. Radiator outlet hose
11. Crankcase breather hose
12. Throttle cable (accelerator cable, single locknut)
A. Pass the rear brake lock lever cable to the cable
guide.
B. Route the wire harness through the frame
guide. At this time, place the protector (for the
handle cover inner side) on the bottom side.
C. Pass the fuel tank breather hose by the outside
of the wire harness.
D. Pass the wire harness by the outside of the rear
footrest mounting boss. (When installing the
rear footrest, do not catch or pinch the A.C.
magneto lead in the bracket.)
E. Fasten the wire harness to the frame with a
plastic holder.
F. Pass the storage box light switch lead by the
front of the frame back stay pipe.
G. Fasten the sidestand switch lead to the frame
with a plastic holder.
H. Pass the speed sensor lead to the lead holder
(2locations).
2-44
CABLE ROUTING
2-45
CABLE ROUTING
Q. Fasten the wire harness and seat lock cable to
the frame with a plastic holder.
R. Pass the wire harness, lead and cable the outside of the frame bracket.
S. Install the starter relay to the mad guard.
T. Fasten the wire harness, positive battery lead
and seat lock cable to the mad guard with a
plastic holder.
U. Route the positive battery lead through the
under the seat lock cable.
V. Fasten the wire harness to the frame with a
plastic holder.
W. Connect the seat lock cable (gray) to the left
seat lock.
X. Install the fuse box assembly to the storage
box.
Y. Install the storage box light switch to the storage
box.
Z. To the rear brake caliper
AA. To the storage box light switch on the seat
hinge.
AB. Fasten the fuel injector lead (#1/#2), intake air
pressure sensor lead to the frame with a plastic
holder.
AC. Route the intake air pressure sensor lead over
the fuel hose.
AD. Bundle the fuel injector lead (#2) to the frame
with a plastic band softly (the band possible to
turn), face the end of the plastic band to the
inside of the frame.
AE. 10 – 15 mm (0.39 – 0.59 in)
AF. Route the wire harness through the wire guide.
AG. Pass the speed sensor lead under the stay
1and cross pipe, and then over the brake hose
guide.
AH. Place the speed sensor lead between the ribs
of the air filter case.
AI. Pass the wire harness over the wire guide.
AJ. Connect the storage box light lead connectors
to the storage box light with the leads routed
downward.
1. Rear brake lock lever cable
2. Coolant system air bleed hose
3. Thermostat outlet hose
4. Fuel tank breather hose
5. Fuel hose
6. Negative battery lead
7. Starter motor lead
8. Turn signal/hazard relay
9. Starting circuit cut-off relay
10. Rectifier/regulator
11. Seat lock
12. Battery
13. Positive battery lead
14. Fuel pump lead
15. Fuel overflow hose
16. Intake air pressure sensor
17. Meter assembly coupler
18. Intake air temperature sensor
19. Seat lock cable
20. Wire harness
21. Storage box light connector
22. Fuel injector lead #2
23. Frame
A. Route the wire harness against the stay 1 wire
guide.
B. Fasten the lean angle cut-off switch lead to the
stay 1 with a plastic band. Face the band end to
the downward.
C. Route the lean angle cut-off switch lead through
the back of the mirror stay (cross pipe).
D. Fasten the cooling system air bleed hose to the
frame with a plastic holder.
E. Fasten the rear brake lock lever cable to the
frame with a plastic holder.
F. Be sure not to pinch the storage box light switch
lead when installing the fuel tank.
G. Connect the fuel injector leads and intake air
pressure sensor lead, storage box light switch
lead to the pipe guide with a plastic holder.
Connect the couplers in right side of the holder.
H. Pass the wire harness and seat lock cable
through the guide.
I. Fasten the negative battery lead and the starter
motor lead to the frame with a plastic holder.
J. Fasten the fuel tank breather hose to the frame
with a plastic holder.
K. Pass the seat lock cable (black) between the
negative battery lead, starter motor lead and
the frame.
L. Connect the seat lock cable (black) to the right
seat lock.
M. Route the negative battery lead and the fuse
box lead from the storage box opening to the
bottom of the cross pipe.
N. Route the fuse box lead above the starter motor
lead.
O. Place the rubber cover over the starter relay,
starter relay coupler, positive battery lead terminal, and starter motor lead terminal.
P. Align the plastic clamp with the white tape on
the wire harness and fasten to the frame.
2-46
CABLE ROUTING
XP500
2-47
CABLE ROUTING
1. Cooling system air bleed hose
2. Storage box light switch lead
3. Coolant reservoir hose
4. Spark plug lead #2
5. Radiator fan motor lead
6. Sidestand switch lead
7. Spark plug lead #1
8. Rear brake lock lever cable
9. Rear brake hose
10. Speed sensor lead
A. Pass the rear brake lock lever cable on the front
side of throttle cable.
B. Position of clamp.
C. Position the relay straighten.
D. Fasten the cooling system air bleed hose to the
stay 1 with a plastic holder.
E. The main switch lead couplers should not protrude to the outside of the frame.
F. Fasten the fuel injector leads with the plastic
holder.
G. Fasten the sidestand switch lead to the frame
with a plastic holder.
H. Fasten the rear brake hose to the stay 1 with a
plastic holder.
I. Route the throttle cable through the cable
holder.
J. Route only the main switch lead onto the cowling stay pipe.
2-48
CABLE ROUTING
2-49
CABLE ROUTING
1.
2.
3.
4.
5.
6.
7.
8.
9.
Brake hose holder 1
Front brake hose
Speed sensor
Plastic holder
Brake hose holder 2
Speed sensor lead
Stay 1
Brake hose holder 3
Rear brake hose 1
A. Fasten the speed sensor lead along the inside
of the brake hose.
B. 50 – 60 mm (1.97 – 2.36 in)
C. Turn the handlebar completely to the right, and
then fasten the brake hose and speed sensor
lead together with the plastic holder.
D. Install the stopper to lower bracket projection.
E. Fasten the speed sensor lead along the outside
of the brake hose.
F. 30 – 40 mm (1.18 – 1.57 in)
G. Make sure that brake pipe touches the projection.
H. Make sure that the slot in the speed sensor fits
stopper on the outer tube.
I. Make sure that the stopper touches the outer
tube stay.
J. Pass the speed sensor lead between the brake
hose and front fork.
K. Fasten the speed sensor lead to the center of
brake hose holder.
L. Install the hose holder to the innermost
securely.
M. Engage the hose holder rib more than 3 notch.
Face the hose holder projection to the back.
N. Make sure that the white paint on the brake
hose faces to back (right side only).
O. Install the stopper to the stay 1.
P. Fasten the front brake hose and rear brake
hose with a hose holder.
Q. Make sure that the brake hose joint touches the
projection of the outer tube.
R. Make sure that the brake hose holder touches
the projection of the outer tube.
S. 107 mm (4.21 in)
T. Clamp the speed sensor lead with a plastic
holder at the marking center.
2-50
CABLE ROUTING
2-51
CABLE ROUTING
H. Fasten the wire harness and ECU (engine) lead
to the stay 1 with a holder.
I. After connecting the left headlight sub-wire harness and wire harness (by matching the coupler colors), fold back the lead facing to the right
and insert it into the air filter case rib.
J. Connect the wire harness to the headlight sub
wire harness (cowling side).
K. Fasten the headlight and turn signal sub-wire
harness to the stay 1 with a plastic holder.
L. Fasten the ECU (engine) lead, ABS test coupler
lead and headlight sub-wire harness to the stay
1 with a plastic holder. When fastening them
using a plastic holder, make sure not to cross
the branch leads.
M. Fasten the coolant reservoir hose to the stay 1
with a plastic holder.
N. Route the ignition coil lead through the inside of
the ignition coil bracket.
O. Route the ignition coil lead through the inside of
the ignition coil bracket.
P. Use the plastic holder on the back of the frame
to hold the radiator fan motor lead.
Q. Fasten the radiator fan motor lead and sidestand switch lead to the frame with a plastic
holder.
R. Fasten the wire harness and positive battery
leads with a plastic band. Face the end of the
plastic band upward.
S. To the starter relay
T. Pass the wire harness, rectifier/regulator lead,
and rear wheel sensor lead through the guide,
making sure that the rectifier/regulator lead is
routed below the wire harness and rear wheel
sensor lead.
U. Make sure that the seat lock cable do not lean
over the storage box.
V. Fasten the starter motor lead, negative battery
lead and seat lock cable (left) to the frame with
a plastic holder.
W. Fasten the starter motor lead and negative battery lead to the frame with a plastic holder.
X. Insert the seat lock cable and the cylinder
mounting rubber into the frame stay.
Y. Pass the O2 sensor lead to the lead guide.
1. Main switch/immobilizer unit
2. ECU (ABS)
3. Throttle cable
4. Brake hose
5. Fail-safe relay
6. Meter assembly
7. Coolant system air bleed hose
8. Horn lead
9. Ignition coil
10. Radiator filer hose
11. Coolant reservoir hose
12. Throttle position sensor coupler
13. Radiator fan motor lead
14. Starter motor lead
15. Rectifier/regulator
16. Starting circuit cut-off relay 2
17. Starting circuit cut-off relay 1
18. Turn signal/hazard relay
19. O2 sensor
20. V-belt replacement indicator reset coupler
21. O2 sensor coupler
22. Fuel pump lead
23. Fuel tank breather hose
24. Rear brake lock lever cable
25. Main switch lead
26. Wire harness
27. Seat lock cable
28. Seat lock cable (left)
29. Negative battery lead
30. Rear wheel sensor lead
31. Frame
32. Storage box
33. V-belt replacement indicator reset coupler lead
34. O2 sensor lead
35. Fuel hose
36. Tail/brake light assembly
37. ECU lead
38. Stay
Z. Fasten the O2 sensor lead to the frame with a
plastic band.
AA. Fasten the starter motor lead and negative battery lead to the frame with a plastic band. Position the band clasp on the bottom of the frame
and face the band end to the outside.
AB. Make sure that the V-belt replacement indicator
reset coupler does not project out of the clamshell cover.
AC. Fasten the O2 sensor lead and V-belt replacement indicator reset coupler lead to the frame
with a plastic holder.
AD. Pass the wire harness and seat lock cable in
the frame holder.
AE. Pass the rear brake lock lever cable under the
coolant pipe.
AF. 40 – 50 mm (1.57 – 1.97 in)
AG. Fasten the wire harness to the frame with the
plastic band. The buckle of the plastic band
should be facing towards the storage box.
A. After adjusting the adjustment nut, attach the
front and rear parts of the boot tightly. Apply the
silicone grease to the inside of the boot and surface of the adjusting nut possible when installing the boot.
B. Pass the seat lock cable between wire harness
and frame.
C. Connect the wire harness (wire taped area) to
the T stud of frame.
D. Fasten the cooling system air bleed hose and
rear brake lock lever cable together with the
plastic clip. The open ends of the clip should
face downward.
E. Fasten the wire harness, main switch lead and
seat lock cable with a clamp to under the cowling stay (Fasten the seat lock cables metal pipe
section).
F. Fasten the wire harness, main switch lead, and
seat lock cable with the plastic band under the
stay 1. Be sure to fasten the seat lock cable on
the metal section of the outer cable.
G. Pass the main switch lead between stay 1 and
seat lock cable.
2-52
CABLE ROUTING
2-53
CABLE ROUTING
AH. Fasten the rear wheel sensor lead to the swingarm with the plastics holders. The open end of
each holder should be facing downward.
AI. Route the rear wheel sensor lead behind the
relay leads.
AJ. 10 – 20 mm (0.39 – 0.79 in)
AK. Fasten the rear wheel sensor lead and wire
harness to the frame with the plastic band.
AL. Pass the wire harness and rear wheel sensor
lead to the frame wire harness holder.
AM. After making the connections, push the couplers into the space inside the frame above the
mudguard.
AN. 20 – 30 mm (0.79 – 1.18 in)
AO. To the tail/brake light
AP. Route the tail/brake light switch lead under the
seat lock cable, wire harness, and positive battery leads and then towards the inside of the
vehicle.
AQ. T stud for position setting
AR. Route the seat lock cable through the frame
bracket side and under the wire harness.
AS. Install the band fastened part between frame
and storage box.
AT. Fasten the wire harness and ECU lead with a
plastic band. Position the band clasp under the
joint connector and face the end of the plastic
band forward.
AU. Install the turn signal light lead, make sure
does not hide the turn signal light lead under
the taillight assembly as shown.
2-54
CABLE ROUTING
2-55
CABLE ROUTING
1. Rear brake lock lever cable
2. Throttle cable (decelerator cable, double locknut)
3. Fast idle inlet hose
4. Rear brake hose
5. A.C. magneto lead
6. Fuel tank breather hose
7. Coolant hose
8. Sidestand switch
9. Fast idle outlet hose
10. Radiator outlet hose
11. Crankcase breather hose
12. Throttle cable (accelerator cable, single locknut)
A. Pass the rear brake lock lever cable to the cable
guide.
B. Route the wire harness through the frame
guide.
C. Pass the fuel tank breather hose by the outside
of the wire harness.
D. Pass the wire harness by the outside of the rear
footrest mounting boss. (When installing the
rear footrest, do not catch or pinch the A.C.
magneto lead in the bracket.)
E. Fasten the wire harness to the frame with a
plastic holder.
F. Pass the storage box light switch lead by the
front of the frame back stay pipe.
G. Fasten the sidestand switch lead to the frame
with a plastic holder.
H. Pass the front wheel sensor lead to the lead
holder (2 locations).
2-56
CABLE ROUTING
2-57
CABLE ROUTING
P. Fasten the wire harness and seat lock cable to
the frame with a plastic holder.
Q. Pass the wire harness, lead and cable the outside of the frame bracket.
R. Install the starter relay to the mad guard.
S. Fasten the wire harness, positive battery lead
and seat lock cable to the mad guard with a
plastic holder.
T. Route the positive battery lead through the
under the seat lock cable.
U. Fasten the wire harness to the frame with a
plastic holder.
V. Connect the seat lock cable (gray) to the left
seat lock.
W. Install the fuse box assembly to the storage
box.
X. Connect the ABS motor fuse box to the fuse
box 2.
Y. Install the storage box light switch to the storage
box.
Z. Fasten the negative battery lead and the starter
motor lead to the frame with a plastic holder.
AA. Fasten the fuel tank breather hose to the frame
with a plastic holder.
AB. To the rear brake caliper
AC. To the storage box light switch on the seat
hinge.
AD. Fasten the fuel injector lead (#1/#2), intake air
pressure sensor lead to the frame with a plastic
holder.
AE. Pass the intake air pressure sensor lead over
the fuel hose.
AF. Bundle the fuel injector lead (#1) to the frame
with a plastic band softly (the band possible to
turn), face the end of the plastic band to the
inside of the frame.
AG. 10 – 15 mm (0.39 – 0.59 in)
AH. Route the wire harness through the wire guide.
AI. Pass the front wheel sensor lead under the stay
1 and cross pipe.
AJ. Place the front wheel sensor lead between the
ribs of the air filter case.
AK. Fasten the protective tube around the lean
angle cut-off switch lead to the stay 1 with a
plastic band. Face the end of the plastic band
downward.
AL. Pass the wire harness over the wire guide.
AM. Connect the storage box light lead connectors
to the storage box light with the leads routed
downward.
1. Rear brake lock lever cable
2. Cooling system air bleed hose
3. Thermostat outlet hose
4. Fuel tank breather hose
5. Fuel hose
6. Turn signal/hazard relay
7. Starting circuit cut-off relay 1
8. Negative battery lead
9. Starting circuit cut-off relay 2
10. Rectifier/regulator
11. Starter motor lead
12. Battery
13. Seat lock
14. Positive battery lead
15. Fuel pump lead
16. Fuel overflow hose
17. Intake air pressure sensor
18. Hydraulic unit solenoid coupler
19. ABS motor coupler
20. Meter assembly coupler
21. Intake air temperature sensor
22. Frame
23. Fuel injector lead #2
24. Seat lock cable
25. Wire harness
26. Storage box light connector
A. Route the wire harness against the stay 1 wire
guide.
B. Fasten the lean angle cut-off switch lead to the
stay 1 with a plastic band. Face the band end to
the downward.
C. To the main switch
D. Route the lean angle cut-off switch lead through
the back of the mirror stay (cross pipe).
E. Fasten the cooling system air bleed hose to the
frame with a plastic holder.
F. Fasten the rear brake lock lever cable to the
frame with a plastic holder.
G. Be sure not to pinch the storage box light switch
lead when installing the fuel tank.
H. Connect the fuel injector leads and intake air
pressure sensor lead, storage box light switch
lead to the pipe guide with a plastic holder.
Connect the couplers in right side of the holder.
I. Pass the wire harness and seat lock cable
through the guide.
J. Connect the seat lock cable (black) to the right
seat lock.
K. Pass the seat lock cable (black) between the
negative battery lead, starter motor lead and
the frame.
L. Route the negative battery lead and the fuse
box lead from the storage box opening to the
bottom of the cross pipe.
M. Route the fuse box lead above the starter motor
lead.
N. Place the rubber cover over the starter relay,
starter relay coupler, positive battery lead terminal, and starter motor lead terminal.
O. Align the plastic clamp with the white tape on
the wire harness and fasten to the frame.
2-58
CABLE ROUTING
2-59
CABLE ROUTING
1. Throttle cable
2. Fail-safe relay
3. ECU (ABS)
4. ABS test coupler
5. Cooling system air bleed hose
6. Storage box light switch lead
7. Coolant reservoir hose
8. Spark plug lead #2
9. Radiator fan motor lead
10. Sidestand switch lead
11. Spark plug lead #1
12. Rear brake lock lever cable
13. Stay 1
14. Rear brake hose
15. Hydraulic unit
16. Hydraulic unit solenoid coupler
17. Front wheel sensor coupler
A. Pass the rear brake lock lever cable on the front
side of throttle cable.
B. Position of clamp.
C. Position the relay straighten.
D. Route the main switch lead over the tube of the
stay 1.
E. Fasten the cooling system air bleed hose to the
stay 1 with a plastic holder.
F. After checking the ABS, install the ABS test
coupler into the stay 1.
G. The main switch lead couplers should not protrude to the outside of the frame.
H. Fasten the fuel injection leads with a plastic
holder.
I. Fasten the sidestand switch lead to the frame
with a plastic holder.
J. Fasten the storage box light switch lead to the
frame with a plastic clamp. Face the clamp
clasp to the up side.
K. Route the rear brake lock lever cable to the left
of the bracket welded to the stay 1.
L. Fasten the rear brake hose to the stay 1 with a
plastic holder.
M. Route the throttle cable through the cable
holder.
2-60
CABLE ROUTING
2-61
CABLE ROUTING
1.
2.
3.
4.
5.
6.
7.
Front wheel sensor
ABS motor coupler
Fail-safe relay
ECU (ABS)
Hydraulic unit solenoid coupler
Hydraulic unit overflow hose
Brake hose (front brake master cylinder to
hydraulic unit)
8. Brake hose (rear brake master cylinder to
hydraulic unit)
9. Hydraulic unit
10. Brake hose (hydraulic unit to rear brake caliper)
11. Brake hose (hydraulic unit to front brake caliper)
A. Route the front wheel sensor lead in front of the
brake hose (hydraulic unit to front brake calipers) as shown in the illustration.
B. Fasten the grommets on the front wheel sensor
lead and brake hose (hydraulic unit to front
brake calipers) with the holder.
C. Install the holder with its projections inserted
into the slots in the stay 1.
D. Route the hydraulic unit overflow hose to the
outside of the stay 1.
E. Fasten the hydraulic unit overflow hose with the
lower hose holder first, and then fasten it with
the upper hose holder. Make sure that the lower
hose holder is contacting the top of the bracket
welded to the stay 1 and the end of the hose
extends 70 – 100 mm (2.76 – 3.94 in) past the
holder.
F. 40 – 60 mm (1.57 – 2.36 in)
G. 70 – 100 mm (2.76 – 3.94 in)
H. Install the brake hose (hydraulic unit to front
brake caliper) onto the hydraulic unit. The brake
hose and its union bolt hole are identified by
white paint marks.
I. Install the hydraulic unit solenoid coupler
bracket onto the hydraulic unit, making sure that
the projections on the bracket are aligned with
the edges of the hydraulic unit.
J. Route the hydraulic unit solenoid lead and ABS
motor lead under the hydraulic unit when installing the unit, making sure not to pinch the leads
between the hydraulic unit and hydraulic unit
bracket.
K. Install the ECU (ABS) lead coupler boot all the
way onto the ECU (ABS), making sure that the
section of the boot that covers the ECU (ABS)
is not pinched between the ends of the upper
and lower ECU (ABS) brackets.
L. Fasten the grommets on the brake hose (front
brake master cylinder to hydraulic unit) and the
brake hose (rear brake master cylinder to
hydraulic unit) with the brake hose holder.
M. When tightening the union bolt, make sure that
the brake hose contacts the left side of the stopper on the hydraulic unit.
N. Install the hydraulic unit overflow hose onto the
hydraulic unit, making sure that the hose contacts the unit.
O. 5 – 7 mm (0.20 – 0.28 in)
2-62
CABLE ROUTING
2-63
CABLE ROUTING
1.
2.
3.
4.
5.
6.
7.
Plastic holder
Brake hose holder 2
Brake hose holder 1
Front brake hose
Front wheel sensor lead
Front wheel sensor
Front housing
A. Engage the hose holder rib more than 3
notch.Face the hose holder projection to the
back.
B. Make sure that the white paint on the brake
hose faces to back (right side only).
C. Install the hose holder to the innermost
securely.
D. Turn the handlebar completely to the right, and
then fasten the brake hose and front wheel sensor lead together with the plastic holder.
E. Fasten the front wheel sensor lead along the
inside of the brake hose.
F. Install the stopper to lower bracket projection.
G. Fasten the front wheel sensor lead to the center
of brake hose holder.
H. Fasten the front wheel sensor lead along the
outside of the brake hose.
I. Pass the front wheel sensor lead between the
brake hose and front fork.
J. Make sure that the stopper touches the outer
tube stay.
K. 30 – 40 mm (1.18 – 1.57 in)
L. Make sure that brake pipe touches the projection.
M. Make sure that the slot in the sensor housing
fits stopper on the outer tube.
N. Make sure that the brake hose holder touches
the projection of the outer tube.
O. Make sure that the brake hose joint touches the
projection of the outer tube.
P. Install the brake hose to the brake caliper, and
then tighten the brake hose holder.
Q. Tighten the union bolt before install the brake
hose to the outer tube.
2-64
CABLE ROUTING
2-65
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE .......................................................................... 3-1
INTRODUCTION ..................................................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ..................... 3-1
ENGINE ......................................................................................................... 3-3
ADJUSTING THE VALVE CLEARANCE ................................................ 3-3
SYNCHRONIZING THE THROTTLE BODIES........................................ 3-5
ADJUSTING THE EXHAUST GAS VOLUME ......................................... 3-7
ADJUSTING THE ENGINE IDLING SPEED ........................................... 3-8
ADJUSTING THE THROTTLE CABLE FREE PLAY .............................. 3-8
CHECKING THE SPARK PLUGS ........................................................... 3-9
CHECKING THE IGNITION TIMING....................................................... 3-10
MEASURING THE COMPRESSION PRESSURE.................................. 3-11
CHECKING THE ENGINE OIL LEVEL.................................................... 3-12
CHANGING THE ENGINE OIL ............................................................... 3-13
MEASURING THE ENGINE OIL PRESSURE ........................................ 3-14
CLEANING THE AIR FILTER ELEMENT................................................ 3-15
CLEANING THE V-BELT CASE AIR FILTER ELEMENT ....................... 3-16
CHECKING THE THROTTLE BODY JOINTS AND INTAKE
MANIFOLDS.......................................................................................... 3-16
CHECKING THE FUEL HOSES AND FUEL TANK BREATHER
HOSE .................................................................................................... 3-17
CHECKING THE CYLINDER HEAD BREATHER HOSE ....................... 3-17
CHECKING THE EXHAUST SYSTEM.................................................... 3-17
CHECKING THE COOLANT LEVEL....................................................... 3-18
CHECKING THE COOLING SYSTEM .................................................... 3-18
CHANGING THE COOLANT................................................................... 3-19
CHASSIS ....................................................................................................... 3-22
CHECKING THE BRAKE FLUID LEVEL................................................. 3-22
CHECKING THE FRONT BRAKE PADS ................................................ 3-22
CHECKING THE REAR BRAKE PADS .................................................. 3-22
CHECKING THE FRONT BRAKE HOSES ............................................. 3-23
CHECKING THE REAR BRAKE HOSE .................................................. 3-23
ADJUSTING THE REAR BRAKE LOCK LEVER CABLE ....................... 3-23
BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500) ..................... 3-24
CHECKING THE CHAIN DRIVE OIL LEVEL .......................................... 3-26
CHANGING THE CHAIN DRIVE OIL ...................................................... 3-26
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-27
CHECKING THE FRONT FORK ............................................................. 3-29
CHECKING THE TIRES.......................................................................... 3-29
CHECKING THE WHEELS ..................................................................... 3-31
CHECKING AND LUBRICATING THE CABLES .................................... 3-31
LUBRICATING THE LEVERS ................................................................. 3-31
LUBRICATING THE SIDESTAND........................................................... 3-31
LUBRICATING THE CENTERSTAND .................................................... 3-31
ELECTRICAL SYSTEM................................................................................. 3-32
CHECKING AND CHARGING THE BATTERY....................................... 3-32
CHECKING THE FUSES ........................................................................ 3-32
1
2
3
4
5
6
7
8
9
REPLACING THE HEADLIGHT BULBS ................................................. 3-32
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-32
PERIODIC MAINTENANCE
EAS20450
PERIODIC MAINTENANCE
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already
in service as well as to new vehicles that are being prepared for sale. All service technicians should be
familiar with this entire chapter.
EAS17705
GENERAL MAINTENANCE AND LUBRICATION CHART
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.
ODOMETER READING (× 1000 km)
NO.
ITEM
CHECK OR MAINTENANCE JOB
1
1 *
Fuel line
2
Spark plugs
● Check fuel hoses for cracks or
damage.
● Check condition.
● Clean and regap.
10
20
30
40
√
√
√
√
√
3 *
Valves
4
Air filter element
5 *
V-belt case air filter
elements
6 *
Front brake
● Check valve clearance.
● Adjust.
√
● Clean.
√
● Clean.
vehicle for fluid leakage.
√
√
9 *
Brake hoses
10 *
Wheels
√
√
√
√
√
√
√
√
Whenever worn to the limit
vehicle for fluid leakage.
√
√
● Replace brake pads.
Rear brake lock
√
√
● Replace.
● Check operation, fluid level and
8
√
√
● Replace.
● Replace brake pads.
Rear brake
√
Every 40000 km
● Check operation, fluid level and
7 *
√
√
√
● Replace.
ANNUAL
CHECK
√
√
Whenever worn to the limit
● Check operation.
● Adjust.
√
● Check for cracks or damage.
√
√
√
√
√
√
√
√
√
√
● Replace.
Every 4 years
● Check runout and for damage.
√
√
√
√
√
√
√
√
√
√
√
√
● Check tread depth and for
damage.
11 *
Tires
12 *
Wheel bearings
● Replace if necessary.
● Check air pressure.
● Correct if necessary.
● Check bearing for looseness or
damage.
3-1
√
PERIODIC MAINTENANCE
ODOMETER READING (× 1000 km)
NO.
ITEM
CHECK OR MAINTENANCE JOB
● Check bearing play and steer-
ing for roughness.
13 *
Steering bearings
1
10
20
30
40
√
√
√
√
√
● Lubricate with lith-
Every 20000 km
ium-soap-based grease.
● Make sure that all nuts, bolts
14 *
Chassis fasteners
15
Sidestand,
centerstand
● Check operation.
● Lubricate.
16 *
Sidestand switch
● Check operation.
17 *
Front fork
18 *
Shock absorber
assembly
19 *
Fuel injection
and screws are properly tightened.
√
● Check operation and for oil
leakage.
● Check operation and shock
absorber for oil leakage.
● Adjust engine idling speed and
√
synchronization.
● Change.
20
Engine oil
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
Engine oil filter cartridge
● Check oil level and vehicle for
√
● Check coolant level and vehicle
22 *
Cooling system
√
√
for coolant leakage.
● Change.
23
Chain drive oil
● Check vehicle for oil leakage.
● Change.
24 *
V-belt
● Replace.
25 *
Front and rear brake
switches
● Check operation.
26
Moving parts and
cables
● Lubricate.
27 *
Throttle grip housing and cable
√
Every 5000 km
● Replace.
√
When the oil change indicator flashes (every 5000
km)
oil leakage.
21
ANNUAL
CHECK
√
√
√
√
√
Every 3 years
√
√
√
√
When the V-belt replacement indicator flashes (every 20000 km)
√
● Check operation and free play.
● Adjust the throttle cable free
play if necessary.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
● Lubricate the throttle grip hous-
ing and cable.
28 *
Lights, signals and
switches
● Check operation.
● Adjust headlight beam.
√
EAS34490
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.
3-2
ENGINE
6. Remove:
● V-belt case cover “1”
EAS20470
ENGINE
EAS20490
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
1
NOTE:
● Valve
clearance adjustment should be made
on a cold engine, at room temperature.
● When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove:
● Front cowling
Refer to “GENERAL CHASSIS” on page 4-1.
● Footrest boards
● Leg shield
● Inner fender
Refer to “GENERAL CHASSIS” on page 4-1.
2. Remove:
● Radiator
Refer to “RADIATOR” on page 6-1.
3. Remove:
● Spark plug
● Cylinder head cover “1”
● Cylinder head cover gasket
7. Measure:
● Valve clearance
Out of specification → Adjust.
Valve clearance (cold)
Intake
0.15–0.20 mm (0.0059–0.0079 in)
Exhaust
0.25–0.30 mm (0.0098–0.0118 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
1
b. When piston #1 is at TDC on the compression stroke, align the TDC mark “a” on the
generator rotor with the mark “b” on the
crankcase.
4. Remove:
● Throttle body
● Intake manifold
Refer to “THROTTLE BODIES” on page 7-4.
5. Remove:
● Timing plug “1”
b
a
1
NOTE:
● TDC
on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
3-3
ENGINE
● In
order to be sure that the piston is at TDC, the
alignment mark “c” on the intake camshaft
sprocket and the alignment mark “d” on the exhaust camshaft sprocket must align with the
cylinder head mating surface as shown in the
illustration.
● Exhaust
camshaft
ECA15B1015
CAUTION:
Before removing the camshafts from the cylinder head, tilt up the engine at least 25°.
NOTE:
● Refer
to “CAMSHAFTS” on page 5-6.
removing the timing chain and camshafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase.
● When
d
c
9. Adjust:
● Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve lifter “1” and the valve pad
“2” with a valve lapper “3”.
c. Measure the valve clearance with a thickness
gauge “1”.
2
1
1
Valve lapper
90890-04101
Valve lapping tool
YM-A8998
NOTE:
● If
the valve clearance is incorrect, record the
measured reading.
● Measure the valve clearance in the following
sequence.
NOTE:
● Cover
the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
● Make a note of the position of each valve lifter
“1” and valve pad “2” so that they can be installed in the correct place.
Valve clearance measuring sequence
Cylinder #1 → #2 → #4 → #3
d. Turn the crankshaft 360° counterclockwise
and check the valve clearance of piston #2.
Cylinder #2
180°
Cylinder #4
360°
Cylinder #3
540°
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Remove:
● Intake camshaft
2
1
b. Select the proper valve pad from the following table.
Valve pad range
3-4
Nos. 120–240
ENGINE
Valve pad thickness
1.20–2.40 mm
(0.0472–0.0945 in)
Available valve pads
25 thicknesses in 0.05
mm (0.002 in) increments
2
1
NOTE:
● The
thickness “a” of each valve pad is marked
in hundredths of millimeters on the side that
touches the valve lifter.
● Since valve pads of various sizes are originally
installed, the valve pad number must be rounded in order to reach the closest equivalent to
the original.
NOTE:
● Lubricate
the valve pad with molybdenum
disulfide grease.
● Lubricate the valve lifter with molybdenum
disulfide oil.
● The valve lifter must turn smoothly when rotated by hand.
● Install the valve lifter and the valve pad in the
correct place.
a
f. Install the exhaust and intake camshafts, timing chain and camshaft caps.
T.
R.
c. Round off the original valve pad number according to the following table.
Last digit
Rounded value
0 or “2”
0
5
5
8
10
Camshaft cap bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
● Refer
to “CAMSHAFTS” on page 5-6.
● Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.
● First, install the exhaust camshaft.
● Align the camshaft marks with the camshaft
cap marks.
● Turn the crankshaft counterclockwise several
full turns to seat the parts.
EXAMPLE:
Original valve pad number = 148 (thickness =
1.48 mm (0.058 in))
Rounded value = 150
d. Locate the rounded number of the original
valve pad and the measured valve clearance
in the valve pad selection table. The point
where the column and row intersect is the
new valve pad number.
g. Measure the valve clearance again.
h. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is
obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE:
10.Install:
● All removed parts
The new valve pad number is only an approximation. The valve clearance must be measured
again and the above steps should be repeated if
the measurement is still incorrect.
NOTE:
For installation, reverse the removal procedure.
Note the following points.
e. Install the new valve pad “1” and the valve lifter “2”.
EAS20570
SYNCHRONIZING THE THROTTLE BODIES
NOTE:
Prior to synchronizing the throttle bodies, the
valve clearance and the engine idling speed
3-5
ENGINE
should be properly adjusted and the ignition timing should be checked.
Engine idling speed
1100–1300 r/min
1. Stand the vehicle on a level surface.
7. Adjust:
● Throttle body synchronization
NOTE:
Place the vehicle on a suitable stand.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Remove:
● Seat
Refer to “GENERAL CHASSIS” on page 4-1.
● Center cover
● Side cover (left and right)
Refer to “GENERAL CHASSIS” on page 4-1.
3. Remove:
● Synchronizing pipe caps “1”
a. Turn the throttle body #1 air screw “1”, and #2
air screw “2”. Using the carburetor angle driver “3”.
2
3
1
1
NOTE:
● After
each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
● If the air screw is removed, turn the screw 3/4
turn in and be sure to synchronize the throttle
body.
4. Install:
● Vacuum gauge “1”
(onto the synchronizing hose)
● Digital tachometer
ECA14900
CAUTION:
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456
Do not use the throttle valve adjusting
screws to adjust the throttle body syncronization.
Carburetor angle driver
90890-03158
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456
1
Intake vacuum
33.0 kPa (9.7 inHg) (248 mmHg)
NOTE:
The difference in vacuum pressure between two
throttle bodies should not exceed 1.33 kPa (10
mm Hg).
5. Start the engine and let it warm up for several
minutes.
6. Check:
● Engine idling speed
Out of specification → Adjust.
Refer to “ADJUSTING THE ENGINE IDLING
SPEED” on page 3-8.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Measure:
● Engine idling speed
3-6
ENGINE
Out of specification → Adjust.
Make sure that the vacuum pressure is within
specification.
9. Stop the engine and remove the measuring
equipment.
10.Adjust:
● Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-8.
tion.
1
2
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in)
5. Press the “SELECT” “1” and “RESET” “2”
buttons to select a cylinder.
11.Remove:
● Vacuum gauge
12.Install:
● Side cover (left and right)
● Center cover
Refer to “GENERAL CHASSIS” on page 4-1.
● Seat
Refer to “GENERAL CHASSIS” on page 4-1.
NOTE:
The selected cylinder number appears on the
clock LCD.
● To decrease the selected cylinder number,
press the “RESET” button.
● To increase the selected cylinder number,
press the “SELECT” button.
EAS20600
ADJUSTING THE EXHAUST GAS VOLUME
NOTE:
Be sure to set the CO density level to standard,
and then adjust the exhaust gas volume.
1
1. Turn the main switch to “OFF” and set the engine stop switch to “ON”.
2. Simultaneously press and hold the “SELECT” “1” and “RESET” “2” buttons, turn the
main switch to “ON”, and continue to press
the buttons for 8 seconds or more.
2
6. After selecting the cylinder, simultaneously
press the “SELECT” and “RESET” buttons
for 2 seconds or more to execute the selection.
7. Change the CO adjustment volume by pressing the “SELECT” “1” and “RESET” “2” buttons.
NOTE:
● All
displays on the meter disappear except the
clock and tripmeter displays.
● “dIAG” appears on the clock LCD.
NOTE:
The CO adjustment volume appears on the
tripmeter LCD.
● To decrease the CO adjustment volume, press
the “RESET” button.
● To increase the CO adjustment volume, press
the “SELECT” button.
1
2
3. Press the “SELECT” button to select the CO
adjustment mode “CO” or the diagnostic
mode “dIAG”.
4. After selecting “CO”, simultaneously press
the “SELECT” “1” and “RESET” “2” buttons
for 2 seconds or more to execute the selec-
3-7
ENGINE
Direction “a”
Engine idling speed is increased.
Direction “b”
Engine idling speed is decreased.
1
2
a
8. Release the switch to execute the selection.
9. Simultaneously press the “SELECT” and
“RESET” buttons to return to the cylinder selection (step 5).
10.Turn the main switch to “OFF” to cancel the
mode.
1
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS20610
ADJUSTING THE ENGINE IDLING SPEED
6. Adjust:
● Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-8.
NOTE:
Prior to adjusting the engine idling speed, the
carburetor synchronization should be adjusted
properly, the air filter element should be clean,
and the engine should have adequate compression.
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in)
1. Remove:
● Right side cover
Refer to “GENERAL CHASSIS” on page 4-1.
2. Start the engine and let it warm up for several
minutes.
3. Install:
● Digital tachometer
(onto the spark plug lead of cylinder #1)
EAS20630
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free play, the
engine idling speed and carburetor synchronization should be adjusted properly.
1. Check:
● Throttle cable free play “a”
Out of specification → Adjust.
Digital tachometer
90890-06760
YU-39951-B
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in)
4. Check:
● Engine idling speed
Out of specification → Adjust.
Engine idling speed
1100–1300 r/min
5. Adjust:
● Engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a
a. Turn the idle adjust screw “1” in direction “a”
or “b” until the specified engine idling speed is
obtained.
2. Remove:
● Center cover
● Left side cover
3-8
ENGINE
Refer to “GENERAL CHASSIS” on page 4-1.
3. Adjust:
● Throttle cable free play
b. Turn the adjusting nut “2” in direction “a” or
“b” until the specified throttle cable free play
is obtained.
NOTE:
Direction “a”
Throttle cable free play is increased.
Direction “b”
Throttle cable free play is decreased.
When the throttle is opened, the accelerator cable “1” is pulled.
1
c. Tighten the locknut “1”.
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Throttle body side
a. Loosen the locknut “1” on the decelerator cable.
b. Loosen the locknut “2” on the accelerator cable.
c. Turn the adjusting nut “3” in direction “a” or
“b” until the specified throttle cable free play
is obtained.
1 b
d. Slide the rubber cover to its original position.
EWA15B1010
WARNING
After adjusting the throttle cable free play,
turn the handle bar to the right and to the left
to ensure that this does not cause the engine
idling speed to change.
Direction “a”
Throttle cable free play is increased.
Direction “b”
Throttle cable free play is decreased.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
● Left side cover
● Center cover
Refer to “GENERAL CHASSIS” on page 4-1.
d. Tighten the locknuts “1”, “3”.
NOTE:
If the specified throttle cable free play cannot be
obtained on the throttle body side of the cable,
use the adjusting nut on the handlebar side.
EAS20680
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:
● Center cover
● Side cover (left and right)
● inner fender
Refer to “GENERAL CHASSIS” on page 4-1.
2. Disconnect:
● Spark plug cap
3. Remove:
● Spark plug
2
b
a
a
3
1
ECA13320
CAUTION:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Handlebar side
a. Loosen the locknut “1”.
3-9
Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
with compressed air to prevent it from falling
ENGINE
into the cylinders.
EAS20700
CHECKING THE IGNITION TIMING
4. Check:
● Spark plug type
Incorrect → Change.
NOTE:
Prior to checking the ignition timing, check the
wiring connections of the entire ignition system.
Make sure all connections are tight and free of
corrosion.
Manufacturer/model
NGK/CR7E
1. Remove:
● Center cover
● Side cover (left and right)
● Left footrest board
Refer to “GENERAL CHASSIS” on page 4-1.
2. Connect:
● Timing light “1”
● Digital tachometer
5. Check:
● Electrode “1”
Damage/wear → Replace the spark plug.
● Insulator “2”
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
Timing light
90890-03141
Inductive clamp timing light
YU-03141
a
2
1
6. Clean:
● Spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
● Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.
1
3. Install:
● Timing light “1”
(onto the spark plug lead of cylinder #1)
Spark plug gap
0.7–0.8 mm (0.028–0.031 in)
Timing light
90890-03141
Inductive clamp timing light
YU-03141
8. Install:
● Spark plug
T.
Spark plug
13 Nm (1.3 m•kg, 9.4 ft•lb)
R.
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
1
9. Connect:
● Spark plug
10.Install:
● Inner fender
● Side cover (left and right)
● Center cover
Refer to “GENERAL CHASSIS” on page 4-1.
4. Check:
● Ignition timing
3-10
ENGINE
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed.
Engine idling speed
1100–1300 r/min
b. Check that the stationary pointer “a” is within
the firing rang “b” on the A.C. magneto.
Incorrect firing range → Check the ignition
system.
Refer to “ADJUSTING THE VALVE CLEARANCE” on page 3-3.
3. Start the engine, warm it up for several minutes, and then turn it off.
4. Disconnect:
● Spark plug cap
5. Remove:
● Spark plug
ECA13340
CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from
falling into the cylinders.
NOTE:
The ignition timing is not adjustable.
6. Install:
● Compression gauge “1”
a
Compression gauge
90890-03081
Engine compression tester
YU-33223
Extension
90890-04082
b
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
● Timing plug
T.
Timing plug
8 Nm (0.8 m•kg, 5.8 ft•lb)
R.
6. Install:
● Left footrest board
● Side cover (left and right)
● Center cover
Refer to “GENERAL CHASSIS” on page 4-1.
7. Measure:
● Compression pressure
Out of specification → Refer to steps (c) and
(d).
EAS20710
Standard compression pressure
(at sea level)
1400 kPa/360 r/min (199.1 psi/
360 r/min) (14.0 kgf/cm2/360 r/
min)
Maximum compression pressure
1570 kPa/360 r/min (223.3 psi/
360 r/min) (15.7 kgf/cm2/360 r/
min)
Minimum compression pressure
1200 kPa/360 r/min (170.7 psi/
360 r/min) (12.0 kgf/cm2/360 r/
min)
MEASURING THE COMPRESSION
PRESSURE
The following procedure applies to all of the cylinders.
NOTE:
Insufficient compression pressure will result in a
loss of performance.
1. Remove:
● Footrest board (left and right)
● Inner fender
Refer to “GENERAL CHASSIS” on page 4-1.
2. Measure:
● Valve clearance
Out of specification → Adjust.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
3-11
ENGINE
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Wait two minutes until the oil settles, and then
check the oil level through the check window
located at the bottom-left side of the crankcase.
4. Check:
● Engine oil level
The engine oil level should be between the
minimum level mark “a” and maximum level
mark “b”.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
b. With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilizes.
EWA12940
WARNING
To prevent sparking, ground all spark plug
leads before cranking the engine.
NOTE:
The difference in compression pressure between cylinders should not exceed 100 kPa (1
kg/cm2, 14 psi).
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure
again.
Refer to the following table.
b
a
Compression pressure (with oil applied into
the cylinder)
Reading
Diagnosis
Higher than without
oil
Piston ring(s) wear or
damage → Repair.
Same as without oil
Piston, valves, cylinder head gasket or
piston possibly defective → Repair.
Type
SAE10W30 or SAE10W40
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Install:
● Spark plug
T.
Spark plug
13 Nm (1.3 m•kg, 9.4 ft•lb)
R.
9. Connect:
● Spark plug cap
10.Install:
● Inner fender
● Footrest board (left and right)
Refer to “GENERAL CHASSIS” on page 4-1.
ECA15B1035
CAUTION:
● Engine
oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD “c” or higher and do
not use oils labeled “ENERGY CONSERVING II”“b”.
● Do not allow foreign materials to enter the
crankcase.
EAS20730
CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle on a level surface.
NOTE:
● Place
● Make
the vehicle on a suitable stand.
sure the vehicle is upright.
3-12
ENGINE
c
4. Drain:
● Engine oil
(completely from the crankcase)
5. If the oil filter cartridge is also to be replaced,
perform the following procedure.
d
a. Remove the oil filter cartridge “1” with an oil
filter wrench “2”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Oil filter wrench
90890-01426
YU-38411
Oil filter wrench
90890-01469
YM-01469
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
5. Start the engine, warm it up for several minutes, and then turn it off.
6. Check the engine oil level again.
1
NOTE:
2
Before checking the engine oil level, wait a few
minutes until the oil has settled.
EAS20790
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
3. Remove:
● Engine oil filler cap “1”
● Engine oil drain bolt “2”
(along with the gasket)
b. Lubricate the O-ring “3” of the new oil filter
cartridge with a thin coat of engine oil.
ECA13390
CAUTION:
Make sure the O-ring “3” is positioned correctly in the groove of the oil filter cartridge.
1
3
c. Tighten the new oil filter cartridge to specification with an oil filter wrench.
T.
Oil filter cartridge
17 Nm (1.7 m•kg, 12 ft•lb)
R.
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-13
ENGINE
6. Check:
● Engine oil drain bolt gasket
Damage → Replace.
7. Install:
● Engine oil drain bolt
(along with the gasket)
button, otherwise repeat the procedure.
T.
Engine oil drain bolt
43 Nm (4.3 m•kg, 31 ft•lb)
R.
1
8. Fill:
● Crankcase
(with the specified amount of the recommended engine oil)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Engine oil quantity
Total amount
3.60 L (3.81 US qt) (3.17 Imp.qt)
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)
EAS20820
MEASURING THE ENGINE OIL PRESSURE
1. Check:
● Engine oil level
Below the minimum level mark → Add the
recommended engine oil to the proper level.
2. Remove:
● Left lower side cover mole
Refer to “GENERAL CHASSIS” on page 4-1.
3. Start the engine, warm it up for several minutes, and then turn it off.
9. Install:
● Engine oil filler cap
10.Start the engine, warm it up for several minutes, and then turn it off.
11.Check:
● Engine
(for engine oil leaks)
12.Check:
● Engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-12.
13.Reset:
● Engine oil change indicator light
ECA13410
CAUTION:
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the key to “ON”.
b. Hold the “OIL CHANGE” button “1” pushed
for two to eight seconds.
c. Release the “OIL CHANGE” button “1”, and
the oil change indicator light will go off.
4. Remove:
● Main gallery bolt “1”
● O-ring
EWA12980
WARNING
The engine, muffler and engine oil are extremely hot.
NOTE:
If the engine oil is changed before the oil change
indicator light comes on (i.e. before the periodic
oil change interval has been reached), the indicator light must be reset after the oil change for
the next periodic oil change to be indicated at
the correct time. To reset the oil change indicator light before the periodic oil change interval
has been reached, follow the above procedure,
but note that the indicator light will come on for
1.4 seconds after releasing the “OIL CHANGE”
1
5. Install:
● Oil pressure gauge “1”
3-14
ENGINE
●
Adapter “2”
EAS20920
CLEANING THE AIR FILTER ELEMENT
1. Remove:
● Front cowling upper cover
● Windshield
● Front cowling inner panel
Refer to “GENERAL CHASSIS” on page 4-1.
2. Remove:
● Air filter case cover “1”
● Air filter element
Pressure gauge
90890-03153
Oil pressure adapter B
90890-03124
1
1
2
6. Measure:
● Engine oil pressure
(at the following conditions)
3. Clean:
● Air filter element
Apply compressed air to the outer surface of
the air filter element.
Oil pressure (hot)
150.0 kPa/1200 r/min (21.8 psi/
1200 r/min) (1.50 kgf/cm2/1200 r/
min)
Oil temperature
70.0 °C (158.00 °F)
Out of specification → Adjust.
Engine oil
pressure
Possible causes
Faulty oil pump
Clogged oil filter
● Leaking oil passage
● Broken or damaged
oil seal
●
●
Below specification
4. Check:
● Air filter element
Damage → Replace.
5. Install:
● Air filter element
● Air filter case cover
(along with the gasket)
Leaking oil passage
Faulty oil filter
● Oil viscosity too
high
●
Above specification
●
7. Install:
● Main gallery bolt
● O-ring New
ECA1B706
CAUTION:
T.
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect carburetor
synchronization, leading to poor engine performance and possible overheating.
Main gallery bolt
12 Nm (1.2 m•kg, 8.7 ft•lb)
R.
8. Install:
lower side cover mole
Refer to “GENERAL CHASSIS” on page 4-1.
● Left
NOTE:
● Make
3-15
sure the air filter element is properly in-
ENGINE
4. Clean:
● V-belt case air filter element
Blow the compressed air to the outer surface
of the V-belt case air filter element.
stalled in the air filter case.
● Make sure the air filter is installed with its mesh
side facing towards the rear of the vehicle.
6. Install:
● Front cowling inner panel
● Windshield
● Front cowling upper cover
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20980
CLEANING THE V-BELT CASE AIR FILTER
ELEMENT
1. Remove:
● Left upper side cover mole
● Left footrest board
Refer to “GENERAL CHASSIS” on page 4-1.
2. Remove:
● V-belt case cover 2 “1”
● V-belt case air filter cover “2”
2
5. Check:
● V-belt case air filter element
Damage → Replace.
1
ECA13440
CAUTION:
3. Remove:
● V-belt case air filter element (left) “1”
● V-belt case air filter element (right) “2”
Since the V-belt case air filter element is a
dry type, do not let grease or water contact it.
6. Install:
● V-belt case air filter element
● V-belt case air filter cover seal
● V-belt case air filter cover
● V-belt case air filter cover screw
1
T.
V-belt case air filter cover screw
7 Nm (0.7 m•kg, 5.1 ft•lb)
R.
7. Install:
● Left footrest board
● Left upper side cover mole
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21010
CHECKING THE THROTTLE BODY JOINTS
AND INTAKE MANIFOLDS
The following procedure applies to all of the
throttle body joints and intake manifolds.
1. Remove:
● Leg shield
Refer to “GENERAL CHASSIS” on page 4-1.
2
3-16
ENGINE
2. Check:
● Throttle body joints “1”
Cracks/damage → Replace.
● Intake manifolds “2”
Cracks/damage → Replace.
Refer to “THROTTLE BODIES” on page 7-4.
EAS21070
CHECKING THE CYLINDER HEAD
BREATHER HOSE
1. Remove:
● Leg shield
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
● Cylinder head breather hose “1”
Cracks/damage → Replace.
Loose connection → Connect properly.
1
2
ECA15B1036
CAUTION:
Make sure the cylinder head breather hose is
routed correctly.
3. Install:
● Leg shield
Refer to “GENERAL CHASSIS” on page 4-1.
1
EAS21030
CHECKING THE FUEL HOSES AND FUEL
TANK BREATHER HOSE
The following procedure applies to all of the fuel,
vacuum and breather hoses.
1. Remove:
● Right footrest board
● Right upper side cover mole
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
● Fuel hose “1”
● Fuel tank breather hose “2”
Cracks/damage → Replace.
3. Install:
● Leg shield
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21080
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the exhaust pipes and gaskets.
1. Remove:
● Right rear side cover
Refer to “GENERAL CHASSIS” on page 4-1.
● Inner fender
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
● Exhaust pipe “1”
● Muffler “2”
Cracks/damage → Replace.
● Gasket “3”
Exhaust gas leaks → Replace.
3. Check:
● Tightening torque
ECA14940
CAUTION:
Make sure the fuel tank breather hose is
routed correctly.
2
1
T.
2
R.
3. Install:
● Right upper side cover mole
● Right footrest board
Refer to “GENERAL CHASSIS” on page 4-1.
3-17
Exhaust pipe nut “4”
20 Nm (2.0 m•kg, 14 ft•lb)
Muffler nut “5”
31 Nm (3.1 m•kg, 22 ft•lb)
ENGINE
2
a
b
3
5
3
1
3. Start the engine, warm it up for several minutes, and then turn it off.
4. Check:
● Coolant level
4
4. Install:
● Inner fender
Refer to “GENERAL CHASSIS” on page 4-1.
● Right rear side cover
Refer to “GENERAL CHASSIS” on page 4-1.
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
EAS21120
CHECKING THE COOLING SYSTEM
1. Remove:
● Footrest board (left and right)
● Leg shield
● Inner fender
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
● Radiator “1”
● Radiator inlet hose “2”
● Radiator outlet hose “3”
● Oil cooler inlet hose “4”
● Oil cooler outlet hose “5”
● Water jacket outlet joint “6”
● Water jacket inlet joint “7”
● Water pump inlet pipe “8”
● Water pump outlet pipe “9”
Cracks/damage → Replace.
Refer to “RADIATOR” on page 6-1, “THERMOSTAT” on page 6-5 and “WATER PUMP”
on page 6-7.
EAS21110
CHECKING THE COOLANT LEVEL
1. Stand the vehicle on a level surface.
NOTE:
● Place
● Make
the vehicle on a suitable stand.
sure the vehicle is upright.
2. Check:
● Coolant level
The coolant level should be between the
maximum level mark “a” and minimum level
mark “b”.
Below the minimum level mark → Add the
recommended coolant to the proper level.
ECA13470
CAUTION:
● Adding
water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant.
● Use only distilled water. However, if distilled water is not available, soft water may
be used.
3-18
ENGINE
Lower side cover mole (left and right)
● Inner fender
Refer to “GENERAL CHASSIS” on page 4-1.
2. Disconnect:
● Coolant reservoir hose “1”
●
3. Drain:
● Coolant
(from the coolant reservoir)
4. Remove:
● Radiator cap “1”
EWA13030
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious injury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing
sound has stopped, press down on the radiator cap and turn it counterclockwise to remove.
The following procedure applies to all of the
coolant drain bolts and copper washers.
1
3. Install:
● Inner fender
● Leg shield
● Footrest board (left and right)
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21130
CHANGING THE COOLANT
1. Remove:
● Left footrest board mat
● Front side cover mole (left and right)
Refer to “GENERAL CHASSIS” on page 4-1.
● Coolant reservoir cap access panel
5. Remove:
● Coolant drain bolt (engine) “1”
(along with the copper washer)
3-19
ENGINE
handled with special care.
EWA13040
WARNING
● If
coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.
● If coolant splashes on your clothes, quickly
wash it away with water and then with soap
and water.
● If coolant is swallowed, induce vomiting
and get immediate medical attention.
1
6. Drain:
● Coolant
(from the engine and radiator)
7. Check:
● Rubber washer “1”
● Drain bolt “2”
ECA13480
CAUTION:
● Adding
water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant.
● Use only distilled water. However, if distilled water is not available, soft water may
be used.
● If coolant comes into contact with painted
surfaces, immediately wash them with water.
● Do not mix different types of antifreeze.
1
2
8. Install:
● Coolant drain bolt (water pump)
T.
Coolant drain bolt (water pump)
1.6 Nm (0.16 m•kg, 1.2 ft•lb)
R.
9. Connect:
● Coolant reservoir hose
10.Fill:
● Cooling system
(with the specified amount of the recommended coolant)
11.Install:
● Radiator cap
12.Fill:
● Coolant reservoir
(with the recommended coolant to the maximum level mark “a”)
Recommended antifreeze
High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
● Radiator
capacity (including all
routes)
1.50 L (1.59 US qt) (1.32 Imp.qt)
● Coolant reservoir capacity (up to
the maximum level mark)
0.35 L (0.37 US qt) (0.31 Imp.qt)
Handling notes for coolant
Coolant is potentially harmful and should be
3-20
ENGINE
13.Install:
● Coolant reservoir cap
14.Start the engine, warm it up for several minutes, and then stop it.
15.Check:
● Coolant level
Refer to “CHECKING THE COOLANT LEVEL” on page 3-18.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
16.Install:
● Inner fender
● Lower side cover mole (left and right)
● Coolant reservoir cap access panel
Refer to “GENERAL CHASSIS” on page 4-1.
● Front side cover mole (left and right)
● Left footrest board mat
Refer to “GENERAL CHASSIS” on page 4-1.
3-21
CHASSIS
the brake fluid and could cause vapor lock.
EAS21140
CHASSIS
ECA13540
CAUTION:
EAS21240
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
NOTE:
● Place
● Make
the vehicle on a suitable stand.
sure the vehicle is upright.
NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake fluid
reservoir is horizontal.
2. Check:
● Brake fluid level
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
EAS21250
CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
● Front brake pad
Wear indicator groove almost disappeared
“1” → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-21.
Recommended fluid
DOT 4
A
a
B
a
EAS21260
CHECKING THE REAR BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
● Rear brake pad
Wear indicators “1” almost touch the brake
disc → Replace the brake pads as a set.
Refer to “REAR BRAKE” on page 4-34.
A. Front brake
B. Rear brake
EWA13090
WARNING
● Use
only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
● Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
● When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
3-22
CHASSIS
EAS21280
EAS21320
CHECKING THE FRONT BRAKE HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:
● Brake hose
Cracks/damage/wear → Replace.
ADJUSTING THE REAR BRAKE LOCK
LEVER CABLE
EWA15B2001
WARNING
Do not apply the rear brake lock lever when
riding.
NOTE:
● Place
the vehicle on a suitable stand.
adjusting the rear brake lock lever,
check the rear brake fluid level.
● Before
1. Measure:
● Rear brake lock lever cable length “a”
Out of specification → Adjust.
Rear brake lock lever cable length
45–47 mm (1.77–1.85 in)
2. Check:
● Brake hose clamp
Loose → Tighten the clamp bolt.
3. Hold the vehicle upright and apply the brake
several times.
4. Check:
● Brake hose
Brake fluid leakage → Replace the damaged
hose.
Refer to “FRONT BRAKE” on page 4-21.
2. Adjust:
● Rear brake lock lever cable length
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting nut “1” in direction “b” or “c”
until the rear brake lock lever cable length “a”
is 42–44 mm (1.65–1.73 in) when the rear
brake lock lever is released.
b. Slowly apply the rear brake several times.
c. Set the rear brake lock lever and wait more
than “5” minutes.
d. Release the rear brake lock lever.
e. Turn the adjusting nut “1” in direction “b” or “c”
until the rear brake lock lever cable length “a”
is 45–47 mm (1.77–1.85 in).
EAS21290
CHECKING THE REAR BRAKE HOSE
1. Check:
● Brake hose
Cracks/damage/wear → Replace.
Direction “b”
Rear brake lock lever cable length is increased.
Direction “c”
Rear brake lock lever cable length is decreased.
a
2. Check:
● Brake hose clamp
Loose Connection → Tighten the clamp bolt.
3. Hold the vehicle upright and apply the front
brake several times.
4. Check:
● Brake hose
Brake fluid leakage → Replace the damaged
hose.
Refer to “REAR BRAKE” on page 4-34.
1
c
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-23
CHASSIS
EAS21350
B
BLEEDING THE HYDRAULIC BRAKE
SYSTEM (XP500)
1
EWA13100
WARNING
Bleed the hydraulic brake system whenever:
● the system is disassembled.
● a brake hose is loosened, disconnected or
replaced.
● the brake fluid level is very low.
● brake operation is faulty.
2
A. Front
B. Rear
NOTE:
● Be
careful not to spill any brake fluid or allow
the brake master cylinder reservoir or brake
fluid reservoir to overflow.
● When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this precaution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.
● If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully pull the brake lever and hold it in position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the pressure and cause the brake lever to contact the
throttle grip to fully extend.
1. Bleed:
● Hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
T.
a. Fill the brake fluid reservoir to the proper level
with the recommended brake fluid.
b. Install the diaphragm (brake master cylinder
reservoir or brake fluid reservoir).
c. Connect a clear plastic hose “1” tightly to the
bleed screw “2”.
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
R.
k. Fill the brake fluid reservoir to the proper level
with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-22.
A
2
h. Tighten the bleed screw and then release the
brake lever.
i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in
the plastic hose.
j. Tighten the bleed screw to specification.
1
EWA13110
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Bleeding the
(XP500A)
hydraulic
brake
system
EWA15B1005
WARNING
Always bleed the brake system when the
brake related parts are removed.
ECA15B1016
CAUTION:
Bleed the brake system in the following or-
3-24
CHASSIS
der.
1st: Front brake caliper
2nd: Rear brake caliper
B
1
EWA15B1006
WARNING
Bleed the ABS whenever:
● the system is disassembled.
● a brake hose is loosened, disconnected or
replaced.
● the brake fluid level is very low.
● brake operation is faulty.
2
A. Front
B. Rear
NOTE:
● Be
careful not to spill any brake fluid or allow
the brake master cylinder reservoir to overflow.
● When bleeding the ABS, make sure there is always enough brake fluid before applying the
brake. Ignoring this precaution could allow air
to enter the ABS, considerably lengthening the
bleeding procedure.
● If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours.
● Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever and do not release it.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the pressure and cause the brake levers to contact the
handlebar.
1. Bleed:
● ABS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake master cylinder reservoir to the
proper level with the recommended brake fluid.
b. Install the brake master cylinder reservoir diaphragm.
c. Connect a clear plastic hose “1” tightly to the
bleed screw “2”.
ECA15B1017
CAUTION:
Make sure that the main switch is set to
“OFF” before checking the operation of the
hydraulic unit.
A
2
h. Tighten the bleed screw, and then release
the brake lever.
i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in
the plastic hose.
j. Check the operation of the hydraulic unit. Refer to “HYDRAULIC UNIT OPERATION
TEST” on page 4-49.
1
k. After operating the ABS, repeat steps (e) to
(i), and then fill the primary circuit with 60 cm3
(2.11 Imp oz, 2.03 US oz) of the recommended brake fluid.
l. Tighten the bleed screw to the specified
torque.
T.
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
R.
m. Fill the brake fluid reservoir to the proper level
with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
EWA15B1007
WARNING
After bleeding the ABS, check the brake op-
3-25
CHASSIS
eration.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21480
CHECKING THE CHAIN DRIVE OIL LEVEL
1. Stand the vehicle on a level surface.
b
NOTE:
● Place
● Make
a
the vehicle on a suitable stand.
sure that the vehicle up right.
4. Install:
● Chain drive oil filler cap
● Chain drive case cover
2. Remove:
● Chain drive case cover “1”
● Chain drive oil filler cap “2”
EAS21490
CHANGING THE CHAIN DRIVE OIL
1. Place a container under the chain drive.
2. Remove:
● Chain drive oil drain bolt “1”
● Chain drive oil filler cap
Completely drain the chain drive of its oil.
1
2
1
3. Check:
● Drain bolt gasket
Damage → Replace.
4. Install:
● Chain drive oil drain bolt
T.
3. Check:
● Chain drive oil level
Wipe the dipstick clean, insert it into the oil filler hole (without screw it in), and then remove
it to check the oil level.
The chain drive oil level should be between
the minimum level mark “a” and maximum
level mark “b”.
Below the minimum level mark → Add the
recommended transfer oil to the proper level.
Chain drive oil drain bolt
20 Nm (2.0 m•kg, 14 ft•lb)
R.
5. Fill:
● Chain drive oil
(with the specified amount of the recommended chain drive oil)
Quantity
0.70 L (0.74 US qt) (0.62 Imp.qt)
Type
SAE80 API GL-4 Hypoid gear oil
6. Check:
● Chain drive oil level
Refer to “CHECKING THE CHAIN DRIVE
OIL LEVEL” on page 3-26.
3-26
CHASSIS
EAS21500
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the vehicle on a level surface.
1
2
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
3
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.
4
b. Loosen the lower ring nut “4” and then tighten
it to specification with a steering nut wrench
“5”.
2. Check:
● Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3. Remove:
● Handlebar
Refer to “HANDLEBAR” on page 4-53.
4. Loosen:
● Upper bracket pinch bolts “1”
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
T.
Lower ring nut (initial tightening
torque)
20 Nm (2.0 m•kg, 14 ft•lb)
R.
1
5
5. Remove:
● Steering stem nut “1”
● Upper bracket “2”
1
4
c. Loosen the lower ring nut “4” completely,
then tighten it to specification.
2
EWA13140
WARNING
Do not overtighten the lower ring nut.
T.
R.
6. Adjust:
● Steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the lock washer “1”, the upper ring
nut “2”, and the rubber washer “3”.
3-27
Lower ring nut (final tightening
torque)
20 Nm (2.0 m•kg, 14 ft•lb)
d. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 4-64.
CHASSIS
b. Install a plastic locking tie “1” loosely around
the end of the handlebar as shown.
c. Hook a spring gauge “2” onto the plastic locking tie.
e. Install the rubber washer “3”.
f. Install the upper ring nut “2”.
g. Finger tighten the upper ring nut “2”, then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned “1”.
h. Install the lock washer.
1
NOTE:
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.
2
1
2
d. Hold the spring gauge at a 45° angle from the
handlebar, pull the spring gauge, and then
record the measurement when the handlebar
starts to run.
a
b
3
Steering head tension
1.96–4.90 N (200–500 gf)
(7.06–17.65 oz)
4
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
● Upper bracket “1”
● Steering stem nut “2”
2
1
e. Repeat the above procedure on the opposite
handlebar.
f. If the steering head tension is out of specification (both handlebars should be within
specification), remove the upper bracket and
loosen or tighten the upper ring nut.
g. Reinstall the upper bracket and measure the
steering head tension again as described
above.
h. Repeat the above procedure until the steering head tension is within specification.
i. Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
8. Tighten:
● Upper bracket pinch bolt
● Steering stem nut
T.
R.
Upper bracket pinch bolt
30 Nm (3.0 m•kg, 22 ft•lb)
Steering stem nut
110 Nm (11.0 m•kg, 80 ft•lb)
9. Measure:
● Steering head tension
NOTE:
Make sure all of the cables and wires are properly routed.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Point the front wheel straight ahead.
3-28
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHASSIS
equals the ambient air temperature.
● The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and accessories) and the anticipated riding
speed.
● Operation of an overloaded vehicle could
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE.
EAS21530
CHECKING THE FRONT FORK
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:
● Inner tube
Damage/scratches → Replace.
● Oil seal
Oil leakage → Replace.
3. Hold the vehicle upright and apply the front
brake.
4. Check:
● Front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” on page 4-57.
Tire air pressure (measured on
cold tires)
Loading condition
0–90 kg (0–198 lb)
Front
225 kPa (33 psi) (2.25 kgf/cm2)
(2.25 bar)
Rear
250 kPa (36 psi) (2.50 kgf/cm2)
(2.50 bar)
Loading condition
XP500 90–188 kg (198–414 lb)
XP500A 90–183 kg (198–403 lb)
XP500W 90–190 kg (198–419 lb)
Front
225 kPa (33 psi) (2.25 kgf/cm2)
(2.25 bar)
Rear
280 kPa (41 psi) (2.80 kgf/cm2)
(2.80 bar)
Maximum load
XP500 188 kg (414 lb)
XP500A 183 kg (403 lb)
XP500W 190 kg (419 lb)
EAS21650
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
● Tire pressure
Out of specification → Regulate.
*Total weight of rider, passenger, cargo and accessories
EWA13190
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, replace the tire immediately.
2. Check:
● Tire surfaces
Damage/wear → Replace the tire.
EWA13180
WARNING
● The
tire pressure should only be checked
and regulated when the tire temperature
3-29
CHASSIS
1
Tube wheel
Tube tire only
Tubeless wheel
Tube or tubeless tire
EWA14090
WARNING
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one
approved by Yamaha is used on this vehicle.
2
1. Tire tread depth
2. Side wall
Wear limit (front)
1.6 mm (0.06 in)
Wear limit (rear)
1.6 mm (0.06 in)
Front tire
Size
120/70R14 M/C 55H
Manufacturer/model
DUNLOP/D252F
Manufacturer/model
BRIDGESTONE/TH01F
EWA14080
WARNING
● Do
not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden
deflation.
● When using a tube tire, be sure to install the
correct tube.
● Always replace a new tube tire and a new
tube as a set.
● To avoid pinching the tube, make sure the
wheel rim band and tube are centered in the
wheel groove.
● Patching a punctured tube is not recommended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality replacement.
A
B
Rear tire
Size
160/60R15 M/C 67H
Manufacturer/model
DUNLOP/D252
Manufacturer/model
BRIDGESTONE/TH01R
EWA13210
WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
NOTE:
For tires with a direction of rotation mark “1”:
● Install the tire with the mark pointing in the direction of wheel rotation.
● Align the mark “2” with the valve installation
point.
A. Tire
B. Wheel
3-30
CHASSIS
EAS21700
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
1
2
Recommended lubricant
Lithium-soap-based grease
EAS21720
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
EAS21670
CHECKING THE WHEELS
The following procedure applies to both of the
wheels.
1. Check:
● Wheel
Damage/out-of-round → Replace.
Recommended lubricant
Lithium-soap-based grease
EAS21730
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the centerstand.
EWA13260
WARNING
Recommended lubricant
Lithium-soap-based grease
Never attempt to make any repairs to the
wheel.
NOTE:
After a tire or wheel has been changed or replaced, always balance the wheel.
EAS21690
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the inner and outer cables.
EWA13270
WARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Replace damaged outer cable and inner cables
as soon as possible.
1. Check:
● Outer cable
Damage → Replace.
2. Check:
● Cable operation
Rough movement → Lubricate.
Recommended lubricant
Engine oil or a suitable cable lubricant
NOTE:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suitable lubricating device.
3-31
ELECTRICAL SYSTEM
6. Install:
● Headlight bulb New
Secure the new headlight bulb with the headlight bulb holder.
EAS21750
ELECTRICAL SYSTEM
EAS21760
CHECKING AND CHARGING THE BATTERY
Refer to “ELECTRICAL COMPONENTS” on
page 8-97.
ECA13690
CAUTION:
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
EAS21770
CHECKING THE FUSES
Refer to “ELECTRICAL COMPONENTS” on
page 8-97.
EAS21790
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
headlight bulbs.
1. Remove:
● Front cowling
Refer to “GENERAL CHASSIS” on page 4-1.
2. Disconnect:
● Headlight coupler “1”
3. Remove:
● Headlight bulb holder “2”
7. Install:
● Headlight bulb holder cover
8. Connect:
● Headlight coupler
9. Install:
● Front cowling
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21810
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of the
headlights.
1. Adjust:
● Headlight beam (vertically)
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a” or
“b”.
1
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
4. Detach:
● Headlight bulb holder “1”
5. Remove:
● Headlight bulb “2”
EWA13320
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
● Headlight beam (horizontally)
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting knob “2” in direction “c” or
“d”.
3-32
ELECTRICAL SYSTEM
Left headlight
Direction “c”
Headlight beam moves to the right.
Direction “d”
Headlight beam moves to the left.
Right headlight
Direction “c”
Headlight beam moves to the left.
Direction “d”
Headlight beam moves to the right.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-33
ELECTRICAL SYSTEM
3-34
CHASSIS
GENERAL CHASSIS..................................................................................... 4-1
FRONT WHEEL............................................................................................. 4-6
REMOVING THE FRONT WHEEL (XP500) ........................................... 4-10
Removing the front wheel (XP500A) ....................................................... 4-10
CHECKING THE FRONT WHEEL .......................................................... 4-10
MAINTENANCE OF THE FRONT WHEEL SENSOR AND
SENSOR ROTOR (XP500A)................................................................. 4-11
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-12
INSTALLING THE FRONT WHEEL (XP500) .......................................... 4-13
Installing the front wheel (XP500A) ......................................................... 4-14
REAR WHEEL ............................................................................................... 4-16
REMOVING THE REAR WHEEL (XP500).............................................. 4-19
Removing the rear wheel (XP500A) ........................................................ 4-19
CHECKING THE REAR WHEEL............................................................. 4-19
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-19
MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR
ROTOR.................................................................................................. 4-19
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-19
INSTALLING THE REAR WHEEL (XP500A) .......................................... 4-19
FRONT BRAKE ............................................................................................. 4-21
INTRODUCTION ..................................................................................... 4-26
CHECKING THE FRONT BRAKE DISCS............................................... 4-26
REPLACING THE FRONT BRAKE PADS .............................................. 4-27
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-28
DISASSEMBLING THE FRONT BRAKE CALIPERS.............................. 4-29
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-29
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-30
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-30
REMOVING THE FRONT BRAKE MASTER CYLINDER ....................... 4-31
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-31
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-32
INSTALLING THE FRONT BRAKE MASTER CYLINDER...................... 4-32
REAR BRAKE ............................................................................................... 4-34
INTRODUCTION ..................................................................................... 4-39
CHECKING THE REAR BRAKE DISC.................................................... 4-39
REPLACING THE REAR BRAKE PADS................................................. 4-39
REMOVING THE REAR BRAKE CALIPER ............................................ 4-41
DISASSEMBLING THE REAR BRAKE CALIPER .................................. 4-41
CHECKING THE REAR BRAKE CALIPER............................................. 4-42
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-42
INSTALLING THE REAR BRAKE CALIPER........................................... 4-43
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-44
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-44
ASSEMBLING THE REAR BRAKE MASTER CYLINDER...................... 4-45
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-45
1
2
3
4
5
6
7
8
9
ABS (Anti-Lock Brake System)................................................................... 4-47
REMOVING THE HYDRAULIC UNIT...................................................... 4-48
CHECKING THE HYDRAULIC UNIT ...................................................... 4-48
INSTALLING THE HYDRAULIC UNIT .................................................... 4-49
HYDRAULIC UNIT OPERATION TEST .................................................. 4-49
TRIAL RUN.............................................................................................. 4-52
HANDLEBAR ................................................................................................ 4-53
REMOVING THE HANDLEBARS ........................................................... 4-55
CHECKING THE HANDLEBAR .............................................................. 4-55
INSTALLING THE HANDLEBAR ............................................................ 4-55
FRONT FORK................................................................................................ 4-57
REMOVING THE FRONT FORK LEGS.................................................. 4-59
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-59
CHECKING THE FRONT FORK LEGS .................................................. 4-60
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-61
INSTALLING THE FRONT FORK LEGS ................................................ 4-63
STEERING HEAD.......................................................................................... 4-64
REMOVING THE LOWER BRACKET..................................................... 4-66
CHECKING THE STEERING HEAD ....................................................... 4-66
INSTALLING THE STEERING HEAD ..................................................... 4-67
REAR SHOCK ABSORBER ASSEMBLY .................................................... 4-68
HANDLING THE REAR SHOCK ABSORBER ........................................ 4-69
DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-69
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................... 4-69
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-69
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-69
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Seat
2
1
Order
1
2
Job/Parts to remove
Q’ty
Fuel tank cap
Fuel lid
Seat
Remarks
1
1
For installation, reverse the removal procedure.
4-1
GENERAL CHASSIS
Front cowling
3
4
5
1
2
6
7
1
7
2
8
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Q’ty
Footrest board mat (left and right)
Front side cover moulding (left and right)
Rear view mirror (left and right)
Front cowling upper cover
Windshield
Front cowling inner panel
Headlight sub-wire harness coupler
Front cowling
2
2
2
1
1
1
4
1
Remarks
Disconnect.
For installation, reverse the removal procedure.
4-2
GENERAL CHASSIS
Side cover mouldings and leg shield
9
7 Nm (0.7 m • kg, 5.1 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
10
3
4
5
7
6
1
8
5
2
6
11
7 Nm (0.7 m • kg, 5.1 ft • Ib)
2
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Parts to remove
Q’ty
Upper side cover mole (left and right)
Lower side cover mole (left and right)
Center cover
Hinge cover
Side cover (left and right)
Footrest board (left and right)
Coolant reservoir cap access panel
Meter assembly coupler
Meter assembly
Leg shield
Inner fender
2
2
1
1
2
2
1
1
1
1
1
Remarks
Disconnect.
For installation, reverse the removal procedure.
4-3
GENERAL CHASSIS
Rear covers and tail/brake light assembly
16 Nm (1.6 m • kg, 12 ft • Ib)
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
3
4
2
LT
5
LT
3
Order
1
2
3
4
5
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Parts to remove
Q’ty
Seat
Upper side cover mole (left/right)
Grab bar
Rear cover
Rear side cover (left/right)
Tail/brake light assembly coupler
Tail/brake light assembly
Remarks
Open.
1
1
1/1
1
1
Disconnect.
For installation, reverse the removal procedure.
4-4
GENERAL CHASSIS
Strage box
7 Nm (0.7 m • kg, 5.1 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
9
12
6
10
13
11
4
5
5
13
7
8
2
13
16 Nm (1.6 m • kg, 12 ft • Ib)
3
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Parts to remove
Q’ty
Battery cover
Negative battery lead
Positive battery lead
Battery
Fuse box assembly coupler
Fuse box assembly
ABS motor fuse box
Storage box light connector
Fuel tank cover
Storage box light
Storage box
Storage box light switch coupler
Hinge/damper
1
1
1
1
2
1
1
2
1
1
1
1
2/1
Remarks
Disconnect.
Disconnect.
Disconnect.
(XP500A)
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
4-5
FRONT WHEEL
EAS21880
FRONT WHEEL
Removing the front wheel and brake disc (XP500)
40 Nm (4.0 m • kg, 29 ft • Ib)
59 Nm (5.9 m • kg, 43 ft • Ib)
40 Nm (4.0 m • kg, 29 ft • Ib)
1
3
1
23 Nm (2.3 m • kg, 17 ft • Ib)
2
(6)
LT
6
7
LT
LT
(6)
8
5
4
Order
8
Job/Parts to remove
18 Nm (1.8 m • kg, 13 ft • Ib)
Q’ty
Remarks
NOTE:
Place the vehicle on a suitable stand so that
the front wheel is elevated.
Refer to “GENERAL CHASSIS” on page
4-1.
Front cowling upper cover
1
2
3
4
5
6
7
8
Front brake caliper (left and right)
Front wheel axle pinch bolt
Front wheel axle
Front wheel
Speed sensor
Collar
Dust cover
Brake disc
2
1
1
1
1
1
1
2
Loosen.
For installation, reverse the removal procedure.
4-6
FRONT WHEEL
Disassembling the front wheel (XP500)
1
2
3
2
Order
1
2
3
Job/Parts to remove
Q’ty
Oil seal
Bearing
Collar
Remarks
1
2
1
For installation, reverse the removal procedure.
4-7
FRONT WHEEL
Removing the front wheel and brake disc (XP500A)
1
2
40 Nm (4.0 m • kg, 29 ft • Ib)
59 Nm (5.9 m • kg, 43 ft • Ib)
23 Nm (2.3 m • kg, 17 ft • Ib)
5
2
(6)
4
9
40 Nm (4.0 m • kg, 29 ft • Ib)
10
18 Nm (1.8 m • kg, 13 ft • Ib)
11
(6)
3
6
Order
11
8
Job/Parts to remove
30 Nm (3.0 m • kg, 22 ft • Ib)
7
Q’ty
Remarks
NOTE:
Place the vehicle on a suitable stand so that
the front wheel is elevated.
1
2
3
4
5
6
7
8
9
10
11
Front wheel sensor coupler
Front brake caliper (left and right)
Front wheel sensor
Front wheel axle pinch bolt
Front wheel axle
Front wheel
Sensor housing
Collar (left)
Collar (right)
Dust cover
Brake disc
1
2
1
1
1
1
1
1
1
1
2
Disconnect.
Loosen.
For installation, reverse the removal procedure.
4-8
FRONT WHEEL
Disassembling the front wheel (XP500A)
LS
1
2
3
LS
2
1
Order
1
2
3
Job/Parts to remove
Q’ty
Oil seal
Bearing
Collar
Remarks
2
2
1
For installation, reverse the removal procedure.
4-9
FRONT WHEEL
Bends → Replace.
EAS21900
REMOVING THE FRONT WHEEL (XP500)
1. Stand the vehicle on a level surface.
EWA13460
WARNING
EWA13120
Do not attempt to straighten a bent wheel axle.
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.
2. Remove:
● Front brake calipers
NOTE:
Do not squeeze the brake lever when removing
the brake caliper.
2. Check:
● Tire
● Front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page
3-29 and “CHECKING THE WHEELS” on
page 3-31.
3. Measure:
● Radial wheel runout “1”
● Lateral wheel runout “2”
Over the specified limits → Replace.
3. Elevate:
● Front wheel
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.
EAS21900b
Removing the front wheel (XP500A)
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.
2. Remove:
● Front wheel sensor
● Front brake calipers
ECA15B1041
CAUTION:
● Be
sure not to contact the sensor electrode
to any metal part when removing the front
wheel sensor from the sensor housing.
● Do not operate the brake lever and brake
pedal when removing the brake calipers.
4. Check:
● Wheel bearings
Front wheel turns roughly or is loose → Replace the wheel bearings.
● Oil seals
Damage/wear → Replace.
3. Elevate:
● Front wheel
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.
EAS21920
CHECKING THE FRONT WHEEL
1. Check:
● Wheel axle
Roll the wheel axle on a flat surface.
4-10
FRONT WHEEL
the wheel bearing outer race and oil seal.
5. Replace:
● Wheel bearings New
● Oil seals New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub.
b. Remove the oil seals “1” with a flat-head
screwdriver.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22010
MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR (XP500A)
NOTE:
ECA14450
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface.
CAUTION:
● Handle
the ABS components with care
since they have been accurately adjusted.
Keep them away from dirt and do not subject them to shocks.
● The ABS wheel sensor cannot be disassembled. Do not attempt to disassemble it.
If faulty, replace with a new one.
Checking the front wheel sensor and sensor rotor
1. Check:
● Front wheel sensor “1”
Cracks/bends/distortion → Replace.
Iron powder/dust → Clean.
c. Remove the wheel bearings “3” with a general bearing puller.
2. Measure:
● Front wheel sensor resistance
Connect the pocket tester (Ω× 1k) to the terminals of the front wheel sensor coupler.
d. Install the new wheel bearings and oil seals in
the reverse order of disassembly.
ECA14130
CAUTION:
Do not contact the wheel bearing inner race
“4” or balls “5”. Contact should be made
only with the outer race “6”.
Tester positive probe →
Terminal “1”
Tester negative probe →
Terminal “2”
NOTE:
Use a socket “7” that matches the diameter of
4-11
FRONT WHEEL
b. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.
Regulated resistance
1.2–1.6 kΩ at 20°C (68°F)
Out of specification → Replace.
c. Turn the front wheel 90° so that the “X1” mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.
3. Check:
● Front wheel sensor rotor “1”
Cracks/damage → Replace the front wheel
assembly.
NOTE:
The wheel sensor rotor of the vehicle is inserted
under pressure by a special process and cannot
be replaced as a single unit. To replace the sensor rotor, replace the wheel assembly.
1
f. Repeat steps (d) through (f) several times until all the marks come to rest at the same spot.
g. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
● Front wheel static balance
EAS21970
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a balancing weight “1” onto the rim exactly opposite the heavy spot “X”.
NOTE:
● After
replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
● Adjust the front wheel static balance with the
brake disc installed.
NOTE:
Start with the lightest weight.
1. Remove:
● Balancing weight(s)
2. Find:
● Front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing
stand.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Spin the front wheel.
4-12
FRONT WHEEL
b. Turn the front wheel 90° so that the heavy
spot is positioned as shown.
NOTE:
Make sure the speed sensor and the wheel hub
are installed with the two projections meshed
into the two slots respectively.
c. If the heavy spot does not stay in that position, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.
3. Install:
● Front wheel
NOTE:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
● Front wheel static balance
Make sure the slot “a” in the speedometer gear
unit fits over the stopper “b” on the outer tube.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays at
each position shown.
4. Tighten:
● Wheel axle “1”
Use the damper rod holder “2”
● Wheel axle pinch bolt “3”
● Brake caliper bolts
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Wheel axle
59 Nm (5.9 m•kg, 43 ft•lb)
Wheel axle pinch bolt
23 Nm (2.3 m•kg, 17 ft•lb)
EAS21990
INSTALLING THE FRONT WHEEL (XP500)
1. Lubricate:
● Wheel axle
● Wheel bearings
● Oil seal lips
● Speedometer drive gear
● Speedometer driven gear
ECA14140
CAUTION:
Before tightening the wheel axle nut, push
down hard on the handlebar(s) several times
and check if the front fork rebounds smoothly.
Recommended lubricant
Lithium-soap-based grease
2. Install:
● Speed sensor (to front wheel)
4-13
FRONT WHEEL
5. Install:
● Front brake calipers
3. Tighten:
● Front wheel axle “1”
Use the damper rod holder “2”
● Front wheel axle pinch bolt “3”
EWA15B1009
WARNING
Make sure the brake cable is routed properly.
T.
6. Install:
● Front brake caliper bracket bolt “1”
R.
T.
Front brake caliper bracket bolt
40 Nm (4.0 m•kg, 29 ft•lb)
Front wheel axle
59 Nm (5.9 m•kg, 43 ft•lb)
Front wheel axle pinch bolt
23 Nm (2.3 m•kg, 17 ft•lb)
R.
1
ECA15B1018
CAUTION:
EAS21990b
Before tightening the wheel axle pinch bolt,
push down hand on the handlebar several
times and check if the front fork rebounds
smoothly.
Installing the front wheel (XP500A)
1. Lubricate:
● Oil seal lips
Recommended lubricant
Lithium-soap-based grease
4. Install:
● Front wheel sensor “1”
●
NOTE:
●
T.
2. Install:
● Front wheel
● Front wheel axle
● Front wheel axle pinch bolt
Front wheel sensor bolt
30 Nm (3.0 m•kg, 22 ft•lb)
R.
Front wheel sensor lead holder
Brake caliper “2”
Align the slot in the sensor housing with the projection of the front fork before assembly.
T.
Front brake caliper bolt
40 Nm (4.0 m•kg, 29 ft•lb)
R.
ECA14470
CAUTION:
●
Make sure there are no foreign materials in
the wheel hub. Foreign materials cause damage to the inner sensor rotor and wheel sensor.
4-14
Brake hose holder
FRONT WHEEL
2
1
NOTE:
When installing the front wheel sensor, check
the wheel sensor lead for twists and the sensor
electrode for foreign materials.
ECA14480
CAUTION:
To route the front wheel sensor lead, refer to
“CABLE ROUTING” on page 2-35.
5. Check:
● Front wheel sensor installation
Check if the wheel sensor housing is installed
properly.
6. Check:
● Front wheel sensor installation
Check if the wheel sensor housing is installed
properly.
Refer to “[D-1] MAINTENANCE OF THE
ECU (ABS)” on page 8-72.
4-15
REAR WHEEL
EAS22030
REAR WHEEL
Removing the rear wheel (XP500)
40 Nm (4.0 m • kg, 29 ft • Ib)
17 Nm (1.7 m • kg, 12 ft • Ib)
5
3
2
6
8
4
1
7
100 Nm (10.0 m • kg, 72 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
Job/Parts to remove
Q’ty
Remarks
NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
1
2
3
4
5
6
7
8
Rear brake caliper
Chain drive case cover
Rear wheel axle pinch bolt
Rear wheel axle nut/washer
Rear wheel axle
Collar
Rear wheel
Spacer
1
1
1
1/1
1
1
1
1
Loosen.
For installation, reverse the removal procedure.
4-16
REAR WHEEL
Removing the rear wheel (XP500A)
40 Nm (4.0 m • kg, 29 ft • Ib)
1
7
17 Nm (1.7 m • kg, 12 ft • Ib)
5
30 Nm (3.0 m • kg, 22 ft • Ib)
2
8
4
8
6
9
10
3
100 Nm (10.0 m • kg, 72 ft • Ib)
11
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
Job/Parts to remove
Q’ty
Remarks
NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
Tail/brake light assembly
1
2
3
4
5
6
7
8
9
10
11
Rear wheel sensor coupler
Rear wheel sensor
Brake caliper
Chain drive case cover
Rear wheel axle pinch bolt
Rear wheel axle nut/washer
Rear wheel axle
Collar
Sensor housing
Collar
Rear wheel
1
1
1
1
1
1/1
1
1
1
1
1
Refer to “GENERAL CHASSIS” on page
4-1.
Disconnect.
Loosen.
For installation, reverse the removal procedure.
4-17
REAR WHEEL
Disassembling the rear wheel
4
5
18 Nm (1.8 m • kg, 13 ft • Ib)
(6)
5
3
(4)
1
2
69 Nm (6.9 m • kg, 50 ft • Ib)
Order
1
2
3
4
5
Job/Parts to remove
Q’ty
Brake disc
Rear wheel drive hub
O-ring
Oil seal
Bearing
Remarks
1
1
1
1
2
For installation, reverse the removal procedure.
4-18
REAR WHEEL
3. Measure:
● Radial wheel runout
● Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-10.
EAS28760
REMOVING THE REAR WHEEL (XP500)
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
EAS15B4567
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
● Rear wheel drive hub “1”
Cracks/damage → Replace.
NOTE:
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
2. Remove:
● Brake caliper
NOTE:
Do not depress the brake lever when removing
the brake caliper.
EAS28760b
Removing the rear wheel (XP500A)
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
EAS22200
NOTE:
ECA15B1037
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
CAUTION:
MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR
● Be
sure not to contact the sensor electrode
to any metal part when removing the front
wheel sensor from the sensor housing.
● Do not operate the brake lever when removing the brake caliper.
2. Remove:
● Rear wheel sensor
● Rear brake caliper
ECA15B1042
CAUTION:
Checking the rear wheel sensor and sensor
rotor
Refer to “Checking the front wheel sensor and
sensor rotor”.
● Be
sure not to contact the sensor electrode
to any metal part when removing the wheel
sensor from the sensor housing.
● Do not operate the brake lever and brake
pedal when removing the brake caliper.
EAS22090
CHECKING THE REAR WHEEL
1. Check:
● Wheel axle
● Rear wheel
● Wheel bearings
● Oil seals
Refer to “CHECKING THE FRONT WHEEL”
on page 4-10.
2. Check:
● Tire
● Rear wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page
3-29 and “CHECKING THE WHEELS” on
page 3-31.
EAS22150
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
● After
replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
● Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
1. Adjust:
● Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-12.
EAS22200b
INSTALLING THE REAR WHEEL (XP500A)
1. Install:
● Rear wheel
4-19
REAR WHEEL
NOTE:
● Align
the slot “a” of the sensor housing “1” with
the projection “b” of the collar “2”, and then assemble them.
● After installation, check that the projection “c”
of the collar is inserted into the slot “d” of the
sensor housing.
1
2
3
3
2
3
c
ECA14500
CAUTION:
a
b
To route the rear wheel sensor lead, refer to
“CABLE ROUTING” on page 2-35.
4. Check:
● Rear wheel sensor installation
Check if the wheel sensor housing is installed
properly.
d
1
ECA14470
CAUTION:
Make sure there are no foreign materials in
the wheel hub. Foreign materials cause damage to the inner sensor rotor and wheel sensor.
2. Install:
● Rear wheel sensor “1”
T.
Rear wheel sensor bolt
30 Nm (3.0 m•kg, 22 ft•lb)
R.
NOTE:
When installing the rear wheel sensor, check the
rear wheel sensor lead for twists and the sensor
electrode for foreign materials.
1
ECA14500
CAUTION:
To route the rear wheel sensor lead, refer to
“CABLE ROUTING” on page 2-35.
3. Connect:
● Rear wheel sensor coupler “1”
● Rear wheel sensor lead holder “2”
● Clamp “3”
4-20
FRONT BRAKE
EAS22210
FRONT BRAKE
Removing the front brake pads
27 Nm (2.7 m • kg, 20 ft • Ib)
2
3
7
6
4
4
7
1
5
5
Order
1
2
3
4
5
6
7
Job/Parts to remove
Q’ty
Front brake caliper retaining bolt (lower)
Front brake caliper retaining bolt (upper)
Brake caliper
Brake pad
Brake pad shim
Brake pad spring
Brake pad spring
Remarks
1
1
1
2
2
1
2
For installation, reverse the removal procedure.
4-21
FRONT BRAKE
Removing the front brake master cylinder
1 Nm (0.1 m • kg, 0.7 ft • Ib)
30 Nm (3.0 m • kg, 22 ft • Ib)
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
2
9
3
10
8
5
6
8
7
4
11
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
Job/Parts to remove
Q’ty
Upper handlebar cover
Refer to “HANDLEBAR” on page 4-53
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
Brake fluid
1
2
3
4
5
6
7
8
9
10
11
Remarks
Brake master cylinder reservoir cap
Brake master cylinder reservoir diaphragm
holder
Brake master cylinder reservoir diaphragm
Brake lever
Front brake light switch connector
Union bolt
Brake hose
Copper washer
Brake master cylinder holder
Brake master cylinder
Front brake light switch
1
1
1
1
2
1
1
2
1
1
1
For installation, reverse the removal procedure.
4-22
FRONT BRAKE
Disassembling the front brake master cylinder
4
3
2
1
Order
1
2
3
4
Job/Parts to remove
Q’ty
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder body
Remarks
1
1
1
1
For assembly, reverse the disassembly procedure.
4-23
FRONT BRAKE
Removing the front brake calipers
8
10 9
8
7
10
12
1
3
2
11 2
6
5
11
4
27 Nm (2.7 m • kg, 20 ft • Ib)
30 Nm (3.0 m • kg, 22 ft • Ib)
40 Nm (4.0 m • kg, 29 ft • Ib)
Order
Job/Parts to remove
Q’ty
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
Brake fluid
1
2
3
4
5
6
7
8
9
10
11
12
Remarks
Union bolt
Copper washer
Brake hose
Front brake caliper retaining bolt (lower)
Front brake caliper retaining bolt (upper)
Brake caliper
Brake pad
Brake pad shim
Brake pad spring
Brake pad spring
Front brake caliper bracket bolt 2
Brake caliper bracket
1
2
1
1
1
1
2
2
1
2
2
1
For installation, reverse the removal procedure.
4-24
FRONT BRAKE
Disassembling the front brake calipers
6 Nm (0.6 m • kg, 4.3 ft • Ib)
3
2
4
1
5
3
4
Order
1
2
3
4
5
Job/Parts to remove
Q’ty
Bleed screw
Dust seal
Brake caliper piston seal
Brake caliper piston
Brake caliper body
Remarks
1
2
2
2
1
For assembly, reverse the disassembly procedure.
4-25
FRONT BRAKE
EAS22220
INTRODUCTION
Brake disc deflection limit
0.12 mm (0.0047 in)
EWA14100
WARNING
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Disc brake components rarely require disassembly. Therefore, always follow these preventive measures:
● Never disassemble brake components unless absolutely necessary.
● If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reassembly.
● Never use solvents on internal brake components.
● Use only clean or new brake fluid for cleaning brake components.
● Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
● Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
● FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
● Flush with water for 15 minutes and get immediate medical attention.
a. Place the vehicle on a suitable stand so that
the front wheel is elevated.
b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in) below the edge of the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Measure:
● Brake disc thickness
Measure the brake disc thickness at a few different locations.
Out of specification → Replace.
EAS22240
CHECKING THE FRONT BRAKE DISCS
The following procedure applies to both brake
discs.
1. Remove:
● Front wheel
Refer to “FRONT WHEEL” on page 4-6.
2. Check:
● Brake disc
Damage/galling → Replace.
3. Measure:
● Brake disc deflection
Out of specification → Correct the brake disc
deflection or replace the brake disc.
Brake disc thickness limit
3.5 mm (0.14 in)
5. Adjust:
● Brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
T.
R.
4-26
Brake disc bolt
18 Nm (1.8 m•kg, 13 ft•lb)
LOCTITE®
FRONT BRAKE
4
2
3
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
1
3
3. Measure:
● Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
Brake pad lining thickness (inner)
6.2 mm (0.24 in)
Limit
0.8 mm (0.03 in)
Brake pad lining thickness (outer)
6.2 mm (0.24 in)
Limit
0.8 mm (0.03 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
● Front wheel
Refer to “FRONT WHEEL” on page 4-6.
EAS22260
REPLACING THE FRONT BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Remove:
● Front brake caliper retaining bolts “1”
● Brake caliper “2”
4. Install:
● Brake pad spring “1”
● Brake pad springs “2”
● Brake pad shims “3”
● Brake pads “4”
NOTE:
Always install new brake pads and a new brake
pad spring as a set.
2. Remove:
● Brake pad springs “1”
● Brake pads “2”
● Brake pad shims “3”
● Brake pad spring “4”
1
4-27
FRONT BRAKE
2
3
3
4
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to the
bleed screw “2”. Put the other end of the hose
into an open container.
6. Install:
● Brake caliper “1”
● Front brake caliper retaining bolts “2”
T.
Brake caliper retaining bolt
27 Nm (2.7 m•kg, 19 ft•lb)
R.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with your
finger.
c. Tighten the bleed screw.
T.
7. Check:
● Brake fluid level
Below the minimum level mark “a”→ Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-22.
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
R.
d. Install new brake pads and a new brake pad
spring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Lubricate:
● Front brake caliper retaining bolts
Recommended lubricant
Lithium-soap-based grease
ECA14150
CAUTION:
8. Check:
● Brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
● Do
not allow grease to contact the brake
pads.
● Remove any excess grease.
EAS22300
REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
4-28
FRONT BRAKE
brake calipers.
ton.
NOTE:
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
● Union bolt “1”
● Copper washers “2”
● Brake hose
a
b. Remove the brake caliper piston seals.
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
EAS22390
CHECKING THE FRONT BRAKE CALIPERS
Recommended brake component replacement
schedule
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
EAS22350
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
1. Remove:
● Brake caliper pistons “1”
● Dust seals “2”
● Brake caliper piston seals “3”
Brake pads
If necessary
Piston seals
Every two years
Brake hoses
Every four years
Brake fluid
Every two years and
whenever the brake is
disassembled
1. Check:
● Brake caliper pistons “1”
Rust/scratches/wear → Replace the brake
caliper pistons.
● Brake caliper cylinders “2”
Scratches/wear → Replace the brake caliper
assembly.
● Brake caliper body “3”
Cracks/damage → Replace the brake caliper
assembly.
● Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
EWA13600
WARNING
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose joint
opening “a” to force out the piston from the
brake caliper.
EWA13580
WARNING
● Cover
the brake caliper piston with a rag.
Be careful not to get injured when the piston is expelled from the brake master cylinder.
● Never try to pry out the brake caliper pis-
4-29
Whenever a brake caliper is disassembled,
replace the piston seals.
FRONT BRAKE
2. Check:
● Brake caliper brackets “1”
Cracks/damage → Replace.
2. Install:
● Brake caliper bracket
T.
Brake caliper bracket bolt
40 Nm (4.0 m•kg, 29 ft•lb)
R.
EAS22440
1
INSTALLING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
1. Install:
● Brake caliper “1”
(temporarily)
● Copper washers New
● Brake hose “2”
● Union bolt “3”
EAS22410
ASSEMBLING THE FRONT BRAKE
CALIPERS
EWA13620
T.
WARNING
Brake hose union bolt
30 Nm (3.0 m•kg, 22 ft•lb)
R.
● Before
installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
● Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
● Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
EWA13530
WARNING
Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-35.
ECA14170
CAUTION:
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” touches the projection “b” on the brake
caliper.
Recommended fluid
DOT 4
1. Install:
● Brake caliper piston seal “1” New
● Dust seal “2” New
● Brake caliper piston “3”
2
1
a
3
2. Remove:
● Brake caliper
4-30
FRONT BRAKE
3. Install:
● Brake pads
● Brake pad springs
● Brake caliper retaining bolt
● Brake caliper
● Brake hose holder
T.
Brake caliper retaining bolt
27 Nm (2.7 m•kg, 19 ft•lb)
R.
Refer to “REPLACING THE FRONT BRAKE
PADS” on page 4-27.
4. Fill:
● Brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
7. Check:
● Brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
Recommended fluid
DOT 4
EAS22490
REMOVING THE FRONT BRAKE MASTER
CYLINDER
EWA13090
WARNING
only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
● Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
● When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
NOTE:
● Use
Before removing the front brake master cylinder,
drain the brake fluid from the entire brake system.
1. Remove:
● Union bolt “1”
● Copper washers “2”
● Brake hoses “3”
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
ECA13540
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
● Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
6. Check:
● Brake fluid level
Below the minimum level mark “a”→ Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-22.
EAS22500
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
● Brake master cylinder “1”
Damage/scratches/wear → Replace.
● Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
4-31
FRONT BRAKE
with clean or new brake fluid.
● Never use solvents on internal brake components.
Recommended fluid
DOT 4
1. Install:
● Master cylinder kit “1”
● Circlip “2” New
● Dust boot “3”
2. Check:
● Brake master cylinder kit “1”
Damage/scratches/wear → Replace.
EAS22530
T.
Brake master cylinder holder bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
R.
3. Check:
● Brake master cylinder reservoir cap “1”
Cracks/damage → Replace.
● Brake master cylinder reservoir diaphragm
holder “2”
● Brake master cylinder reservoir diaphragm
“3”
Damage/wear → Replace.
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
● Brake master cylinder “1”
● Brake master cylinder holder “2”
NOTE:
● Install
the brake master cylinder holder with the
“UP” mark facing up.
● Align the end of the brake master cylinder holder with the punch mark “a” on the handlebar.
● First, tighten the upper bolt, then the lower bolt.
1
b
4. Check:
● Brake hoses
Cracks/damage/wear → Replace.
a
2
EAS22520
ASSEMBLING THE FRONT BRAKE MASTER
CYLINDER
2. Install:
● Copper washers “1” New
● Brake hose “2”
● Union bolt “3”
EWA13520
WARNING
● Before
installation, all internal brake components should be cleaned and lubricated
4-32
FRONT BRAKE
any spilt brake fluid immediately.
T.
Brake hose union bolt
30 Nm (3.0 m•kg, 22 ft•lb)
R.
4. Bleed:
● Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
5. Check:
● Brake fluid level
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-22.
EWA13530
WARNING
Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-35.
NOTE:
● While
holding the brake hose, tighten the union
bolt .
● Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
6. Check:
● Brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
3. Fill:
● Brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended fluid
DOT 4
EWA13540
WARNING
● Use
only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
● Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
● When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause
vapor lock.
ECA13540
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
4-33
REAR BRAKE
EAS22550
REAR BRAKE
Removing the rear brake pads
5
2
4
5
2
3
1
40 Nm (4.0 m • kg, 29 ft • Ib)
27 Nm (2.7 m • kg, 20 ft • Ib)
6
Order
1
2
3
4
5
6
Job/Parts to remove
Q’ty
Rear brake caliper retaining bolt
Rear brake caliper bracket bolt
Brake caliper
Brake pad
Brake pad spring
Brake caliper bracket
Remarks
1
2
1
2
2
1
For installation, reverse the removal procedure.
4-34
REAR BRAKE
Removing the rear brake master cylinder
30 Nm (3.0 m • kg, 22 ft • Ib)
1 Nm (0.1 m • kg, 0.7 ft • Ib)
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
2
9
3
10
8
6
5
8
7
4
11
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
Job/Parts to remove
Q’ty
Upper handlebar cover
Refer to “HANDLEBAR” on page 4-53
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
Brake fluid
1
2
3
4
5
6
7
8
9
10
11
Remarks
Brake master cylinder reservoir cap
Brake master cylinder reservoir diaphragm
holder
Brake master cylinder reservoir diaphragm
Brake lever
Rear brake light switch connector
Union bolt
Brake hose
Copper washer
Brake master cylinder holder
Brake master cylinder
Rear brake light switch
1
1
1
1
2
1
1
2
1
1
1
For installation, reverse the removal procedure.
4-35
REAR BRAKE
Disassembling the rear brake master cylinder
4
3
2
1
Order
1
2
3
4
Job/Parts to remove
Q’ty
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder body
Remarks
1
1
1
1
For assembly, reverse the disassembly procedure.
4-36
REAR BRAKE
Removing the rear brake calipers
30 Nm (3.0 m • kg, 22 ft • Ib)
5
11
2
6
10
7
6
12
4
11
12
3
8
9
1
8
40 Nm (4.0 m • kg, 29 ft • Ib)
27 Nm (2.7 m • kg, 20 ft • Ib)
13
22 Nm (2.2 m • kg, 16 ft • Ib)
Order
Job/Parts to remove
Q’ty
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
Brake fluid
1
2
3
4
5
6
7
8
9
10
11
12
13
Remarks
Nut
Rear brake lock lever cable
Pin
Spring
Union bolt
Copper washer
Brake hose
Rear brake caliper retaining bolt
Brake caliper
Brake pad
Brake pad spring
Rear brake caliper bracket bolt
Brake caliper bracket
1
1
1
1
1
2
1
2
1
2
2
2
1
For installation, reverse the removal procedure.
4-37
REAR BRAKE
Disassembling the rear brake calipers
2
4
6 Nm (0.6 m • kg, 4.3 ft • Ib)
1
3
5
Order
1
2
3
4
5
Job/Parts to remove
Q’ty
Brake caliper piston
Dust seal
Piston seal
Bleed screw
Brake caliper body
Remarks
1
1
1
1
1
For assembly, reverse the disassembly procedure.
4-38
REAR BRAKE
EAS22560
INTRODUCTION
Brake disc thickness limit
4.5 mm (0.18 in)
EWA14100
WARNING
5. Adjust:
● Brake disc deflection
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-26.
Brake disc bolt
18 Nm (1.8 m•kg, 13 ft•lb)
LOCTITE®
T.
R.
Disc brake components rarely require disassembly. Therefore, always follow these preventive measures:
● Never disassemble brake components unless absolutely necessary.
● If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reassembly.
● Never use solvents on internal brake components.
● Use only clean or new brake fluid for cleaning brake components.
● Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
● Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
● FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
● Flush with water for 15 minutes and get immediate medical attention.
6. Install:
● Rear wheel
Refer to “REAR WHEEL” on page 4-16.
EAS22580
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Remove:
● Rear brake caliper retaining bolt (rear) “1”
● Brake caliper bracket bolts “2”
● Brake caliper “3”
EAS22570
CHECKING THE REAR BRAKE DISC
1. Remove:
● Rear wheel
Refer to “REAR WHEEL” on page 4-16.
2. Check:
● Brake disc
Damage/galling → Replace.
3. Measure:
● Brake disc deflection
Out of specification → Correct the brake disc
deflection or replace the brake disc.
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-26.
3
2
1
2. Remove:
● Brake pads “1”
● Brake pad springs “2”
Brake disc deflection limit
0.15 mm (0.0059 in)
4. Measure:
● Brake disc thickness
Measure the brake disc thickness at a few different locations.
Out of specification → Replace.
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-26.
3. Measure:
● Brake pad wear limit “a”
Out of specification → Replace the brake
4-39
REAR BRAKE
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
pads as a set.
a. Connect a suitable hose “1” tightly to the
brake caliper bleed screw “2”. Put the other
end of this hose into an open container.
Brake pad lining thickness (inner)
8.3 mm (0.33 in)
Limit
0.8 mm (0.03 in)
Brake pad lining thickness (outer)
8.3 mm (0.33 in)
Limit
0.8 mm (0.03 in)
1
2
b. Loosen the brake caliper bleed screw, and
then turn the brake caliper piston “3” clockwise until section “a” of the brake caliper piston is level with the surface of the brake
caliper body.
NOTE:
4. Install:
● Brake pad shims
(onto the brake pads)
● Brake pads “2” New
● Brake pad spring “1” New
● Rear brake caliper bracket “3”
(to brake caliper)
Align the recesses “b” in the brake caliper piston
with the brake caliper body as shown in the illustration.
NOTE:
Always install new brake pads, brake pad shims,
and a brake pad spring as a set.
3
1
2
3
a
1
b
c. Tighten the brake caliper bleed screw.
3
T.
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
R.
d. Install new brake pads, new pad springs, and
the rear brake caliper.
4-40
REAR BRAKE
NOTE:
Align the projection “c” on the piston side of the
brake pad with the lower recess in the brake caliper piston.
A
B
9. Check:
● Brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
c
A. Up
B. Down
EAS22590
REMOVING THE REAR BRAKE CALIPER
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
5. Lubricate:
● Rear brake caliper retaining bolts
1. Remove:
● Nut “1”
● Rear brake lock lever cable “2”
● Pin “3”
● Spring “4”
● Union bolt “5”
● Copper washers “6”
● Brake hose “7”
Recommended lubricant
Lithium-soap-based grease
ECA15B1019
CAUTION:
● Do
not allow grease to contact the brake
pads.
● Remove any excess grease.
6. Install:
● Rear brake caliper retaining bolt
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
T.
Rear brake caliper retaining bolt
27 Nm (2.7 m•kg, 20 ft•lb)
R.
7
5
7. Install:
● Rear brake caliper bracket bolts
6
2
T.
Rear brake caliper bracket bolts
40 Nm (4.0 m•kg, 29 ft•lb)
4
R.
3
8. Check:
● Brake fluid level
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-22.
1
EAS22630
DISASSEMBLING THE REAR BRAKE
CALIPER
1. Remove:
● Brake caliper piston “1”
● Dust seal “2”
● Brake caliper piston seal “3”
4-41
REAR BRAKE
(brake caliper body)
Obstruction → Blow out with compressed air.
EWA13610
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
2
1
3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Operate the rear brake lock lever “4” continuously in the direction shown by the arrow until
the piston comes out.
2. Check:
● Brake caliper brackets “1”
Cracks/damage → Replace.
4
b. Remove the dust seal and brake caliper piston seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22640
EAS22660
CHECKING THE REAR BRAKE CALIPER
ASSEMBLING THE REAR BRAKE CALIPER
EWA13620
WARNING
Recommended brake component
replacement schedule
Brake pads
If necessary
Piston seals
Every two years
Brake hoses
Every four years
Brake fluid
Every two years and
whenever the brake is
disassembled
1. Check:
● Brake calipe piston “1”
Rust/scratches/wear → Replace the brake
caliper pistons.
● Brake caliper cylinder “2”
Scratches/wear → Replace the brake caliper
assembly.
● Brake caliper body “3”
Cracks/damage → Replace the brake caliper
assembly.
● Brake fluid delivery passages
● Before
installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
● Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
● Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended fluid
DOT 4
1. Install:
● Brake caliper piston “1”
Turn the brake caliper piston clockwise until
section “a” of the brake caliper piston is level
with the surface of the brake caliper body.
NOTE:
Align the recesses “b” in the brake caliper piston
4-42
REAR BRAKE
with the brake caliper body as shown in the illustration.
b
2
a
3
1
1
2. Remove:
● Brake caliper
3. Install:
● Brake pads
● Brake pad springs
● Brake caliper retaining bolt
● Brake caliper
● Brake hose holder
Refer to “REPLACING THE REAR BRAKE
PADS” on page 4-39.
1
a
b
T.
Brake caliper retaining bolt
27 Nm (2.7 m•kg, 19 ft•lb)
R.
EAS22670
4. Fill:
● Brake fluid reservoir
(with the specified amount of the recommended brake fluid)
INSTALLING THE REAR BRAKE CALIPER
1. Install:
● Brake caliper bracket
● Brake caliper “1”
(temporarily)
● Copper washers New
● Brake hose “2”
● Union bolt “3”
Recommended fluid
DOT 4
EWA13090
WARNING
T.
R.
Brake caliper bracket
40 Nm (4.0 m•kg, 29 ft•lb)
Brake hose union bolt
30 Nm (3.0 m•kg, 22 ft•lb)
● Use
only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
● Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
● When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
EWA13530
WARNING
Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-35.
ECA14170
CAUTION:
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” touches the projection “b” on the brake
caliper.
ECA13540
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4-43
REAR BRAKE
5. Bleed:
● Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
6. Check:
● Brake fluid level
Below the minimum level mark “a”→ Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-22.
EAS22710
CHECKING THE REAR BRAKE MASTER
CYLINDER
The following procedure applies to the both of
the brake master cylinders.
1. Check:
● Brake master cylinder “1”
Damage/scratches/wear → Replace.
● Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
7. Check:
● Brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
8. Install:
● Spring
● Pin
● Rear brake lock lever cable
● Nut
9. Check:
● Rear brake lock lever cable length
Refer to “ADJUSTING THE REAR BRAKE
LOCK LEVER CABLE” on page 3-23.
2. Check:
● Brake master cylinder kit “1”
Damage/scratches/wear → Replace.
EAS22700
REMOVING THE REAR BRAKE MASTER
CYLINDER
NOTE:
Before disassembling the rear brake master cylinder, drain the brake fluid from the entire brake
system.
1. Remove:
● Union bolt “1”
● Copper washers “2”
● Brake hose “3”
3. Check:
● Brake fluid reservoir “1”
Cracks/damage → Replace.
● Brake fluid reservoir diaphragm holder “2”
● Brake fluid reservoir diaphragm “3”
Cracks/damage → Replace.
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
4-44
REAR BRAKE
Holder bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
● Install
the brake master cylinder holder with the
“UP” mark facing up “a”.
● Align the brake master cylinder with the projection “b” on the handlebar.
● First, tighten the upper bolt, then the lower bolt.
4. Check:
● Brake hoses
Cracks/damage/wear → Replace.
b
1
EAS22730
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
a
EWA13520
2
WARNING
● Before
installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
● Never use solvents on internal brake components.
2. Install:
● Copper washers “1” New
● Brake hoses “2”
● Union bolt “3”
Recommended fluid
DOT 4
T.
Brake hose union bolt
30 Nm (3.0 m•kg, 22 ft•lb)
R.
1. Install:
● Master cylinder kit “1”
● Circlip “2” New
● Dust boot “3”
Cylinder cup installer
90890-01996
EWA13530
WARNING
Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-35.
NOTE:
● While
holding the brake hose, tighten the union
bolt as shown.
● Turn the handlebar to the left and to the right to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
ECA14160
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection “a” as shown.
EAS22750
INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
● Brake master cylinder “1”
● Brake master cylinder holder “2”
4-45
REAR BRAKE
Below the minimum level mark “a”→ Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-22.
6. Check:
● Brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
3. Fill:
● Brake fluid reservoir
(to the maximum level mark)
Recommended fluid
DOT 4
EWA13090
WARNING
● Use
only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
● Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
● When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA13540
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
● Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page 3-24.
5. Check:
● Brake fluid level
4-46
ABS (Anti-Lock Brake System)
EAS22760
ABS (Anti-Lock Brake System)
Removing the hydraulic unit
16 Nm (1.6 m • kg, 12 ft • Ib)
30 Nm (3.0 m • kg, 22 ft • Ib)
30 Nm (3.0 m • kg, 22 ft • Ib)
9
10
9
7
3
12
4
3
8
7
5
6
5
1
2
12
12
13
11
16 Nm (1.6 m • kg, 12 ft • Ib)
Order
Job/Parts to remove
Q’ty
Front cowling
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)” on page
3-24.
Brake fluid
1
2
3
4
5
6
7
8
9
10
11
12
13
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Drain.
Hydraulic unit solenoid coupler (wire harness
side)
ABS motor coupler
Union bolt/Copper washer
Front brake hose
Union bolt/Copper washer
Front brake hose
Union bolt/Copper washer
Rear brake hose
Union bolt/Copper washer
Rear brake hose
ABS motor breather hose
Nut
Hydraulic unit
1
1
1/2
1
1/2
1
1/2
1
1/2
1
1
3
1
For installation, reverse the removal procedure.
4-47
ABS (Anti-Lock Brake System)
EAS22770
●
REMOVING THE HYDRAULIC UNIT
Brake hose “4” (to the rear brake caliper)
4
ECA15B1020
CAUTION:
Do not remove the hydraulic unit to check
the resistance of the solenoid valves and the
ABS motor for continuity.
2
3
1
NOTE:
Do not operate the brake lever while removing
the brake hoses.
ECA14530
CAUTION:
When removing the brake hoses, cover the
area around the hydraulic unit to catch any
spilt brake fluid. Do not allow the brake fluid
to contact other parts.
EWA13930
WARNING
Refill with the same type of brake fluid that is
already in the system. Mixing fluids may result in a harmful chemical reaction, leading
to poor braking performance.
ECA14520
2. Remove:
● Hydraulic unit “1”
NOTE:
CAUTION:
To avoid brake fluid leakage and to prevent foreign materials from entering the hydraulic unit,
insert a rubber plug “a” or a bolt (M10 × 1.25) into
each union bolt hole.
● Handle
the ABS components with care
since they have been accurately adjusted.
Keep them away from dirt and do not subject them to shocks.
● The ABS wheel sensor cannot be disassembled. Do not attempt to disassemble it.
If faulty, replace with a new one.
● Do not turn the main switch to “ON” when
removing the hydraulic unit.
● Do not clean with compressed air.
● Do not use reuse the brake fluid.
● Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
● Do not allow any brake fluid to contact the
couplers. Brake fluid may damage the couplers and cause bad contacts.
● If the union bolts for the hydraulic unit have
been removed, be sure to tighten them to
the specified torque and bleed the brake
system.
1
a
EAS22770b
CHECKING THE HYDRAULIC UNIT
1. Check:
● Hydraulic unit “1”
Cracks/damage → Replace the hydraulic
unit.
1. Remove:
● Brake hose “1” (from the front brake master
cylinder)
● Brake hose “2” (to the front brake caliper)
● Brake hose “3” (from the rear brake master
cylinder)
4-48
ABS (Anti-Lock Brake System)
1
3
2
1
4
EWA13940
EAS22770c
WARNING
INSTALLING THE HYDRAULIC UNIT
Proceed in the reverse order of disassembly.
Pay attention to the following items.
1. Install:
● Hydraulic unit
The brake hoses to the front and rear brake
calipers can be distinguished by the rubber
at the end of each hose. Be sure to connect
each brake hose to the correct union bolt
hole.
T.
Hydraulic unit bracket bolt
16 Nm (1.6 m•kg, 11 ft•lb)
ECA14760
R.
CAUTION:
To route the front and rear brake hoses, refer
to “CABLE ROUTING” on page 2-35.
NOTE:
● When
tightening the hydraulic unit nuts, first
temporarily tighten the front nuts, and then
tighten the rear nut and the front nuts to specification in the order given.
● Do not allow any foreign materials to enter the
hydraulic unit or the brake hoses when installing the hydraulic unit.
4. Fill:
● Brake master cylinder reservoir
Recommended brake fluid
DOT 4
5. Bleed the brake system.
6. Check the operation of the hydraulic unit according to the brake lever and the brake pedal response. (Refer to “HYDRAULIC UNIT
OPERATION TEST” on page 4-49.)
ECA15B1021
CAUTION:
Do not remove the rubber plugs or bolts
(M10×1.25) installed in the union bolt holes
before installing the hydraulic unit.
ECA14770
NOTE:
CAUTION:
Do not allow any foreign materials to enter the
hydraulic unit or the brake hoses when installing
the hydraulic unit.
Always check the operation of the hydraulic
unit according to the brake lever and the
brake pedal response.
2. Remove:
● Rubber plugs or bolts (M10 × 1.25)
3. Install:
● Copper washer New
● Brake hose “1” (to the rear brake caliper)
● Brake hose “2” (from the rear brake master
cylinder)
● Brake hose “3” (to the front brake caliper)
● Brake hose “4” (from the front brake master
cylinder)
● Union bolt
EAS22800
T.
HYDRAULIC UNIT OPERATION TEST
The reaction-force pulsating action generated in
the brake levers when the ABS is activated can
be tested when the vehicle is stopped.
The hydraulic unit operation can be tested by the
following two methods.
● Hydraulic unit operation test 1: this test generates the same reaction-force pulsating action
that is generated in the brake levers when the
ABS is activated.
● Hydraulic unit operation test 2: this test checks
the function of the ABS after the system was
disassembled, adjusted, or serviced.
Brake hose union bolt
30 Nm (3.0 m•kg, 22 ft•lb)
R.
4-49
ABS (Anti-Lock Brake System)
Hydraulic unit operation test 1
7. Set the main switch to “ON”.
EWA15B1001
NOTE:
WARNING
After setting the main switch to “ON”, wait (approximately 2 seconds) until the ABS warning
light goes off.
Securely support the vehicle so that there is
no danger of it falling over.
1. Place the vehicle on the centerstand.
2. Set the main switch to “OFF”.
3. Remove:
● Battery cover
Refer to “FUEL TANK” in chapter “3”.
4. Check:
● Battery voltage
Lower than 12.8 V → Charge or replace the
battery.
8. Push the start switch “2” for at least 4 seconds.
1
Battery voltage
Higher than 12.8 V
ON
2
ECA15B1008
CAUTION:
Do not operate the brake levers.
9. After releasing the start switch, operate the
brake levers simultaneously.
NOTE:
●A
reaction-force pulsating action is generated
in the front brake lever “1” 0.5 second after the
rear brake lever and front brake lever are operated simultaneously and continues for approximately 1 second.
● Be sure to continue to operate the brake levers
even after the pulsating action has stopped.
NOTE:
● If
the battery voltage is lower than 12.8 V,
charge the battery and perform hydraulic unit
operation test 1.
● If the battery voltage is lower than 10 V, the
ABS warning light comes on and the ABS does
not operate.
5. Connect the test coupler adaptor “1” to the
test coupler “2”.
Test coupler adapter
90890-03149
2
1
1
6. Set the engine stop switch “1” to “
”.
4-50
ABS (Anti-Lock Brake System)
10.After the pulsating action has stopped in the
front brake lever, it is generated in the rear
brake lever “1” 0.5 second after and continues for approximately 1 second.
●
Battery voltage
Lower than 12.8 V → Charge or replace the
battery.
Battery voltage
Higher than 12.8 V
NOTE:
Be sure to continue to operate the brake levers
even after the pulsating action has stopped.
1
NOTE:
● If
the battery voltage is lower than 12.8 V,
charge the battery and perform hydraulic unit
operation test 2.
● If the battery voltage is lower than 10 V, the
ABS warning light comes on and the ABS does
not operate.
11.After the pulsating action has stopped in the
rear brake lever, it is generated in the front
brake lever 0.5 second after and continues
for approximately 1 second.
ECA15B1009
CAUTION:
● Check
that the pulsating action is felt in the
front brake lever, rear brake lever, and
again in the front brake lever, in this order.
● If the pulsating action is felt in the rear
brake lever before it is felt in the front brake
lever, check that the brake hoses are connected correctly to the hydraulic unit.
● If the pulsating action is hardly felt in either
the brake levers, check that the brake hoses are connected correctly to the hydraulic
unit.
5. Connect the test coupler adaptor “1” to the
test coupler “2”.
Test coupler adapter
90890-03149
2
12.Set the main switch to “OFF”.
13.Remove the test coupler adaptor from the
test coupler.
14.Set the main switch to “ON”.
15.Set the engine stop switch to “ ”.
Hydraulic unit operation test 2
1
6. Set the main switch to “ON” while operating
the brake levers simultaneously.
EWA15B1001
WARNING
ECA15B1010
CAUTION:
Securely support the vehicle so that there is
no danger of it falling over.
When the main switch is set to “ON”, be sure
to operate both the brake levers simultaneously. If only the brake levers are operated, set the main switch to “OFF” and start
the procedure again.
1. Place the vehicle on the centerstand.
2. Set the main switch to “OFF”.
3. Remove:
● Front cowling
● Battery
Refer to “FUEL TANK” in chapter “3”.
4. Check:
4-51
ABS (Anti-Lock Brake System)
unit.
●
If the operation of the hydraulic unit is normal,
delete all of the malfunction codes.
EAS22820
TRIAL RUN
After all checks and services are completed, always ensure the vehicle has no problems by
performing the trial running at a speed of faster
than 10 km/h.
7. Check:
● Hydraulic unit operation
When the main switch is set to “ON”, the ABS
warning light comes on for 2 seconds, goes
off for 3 seconds, then starts flashing. When
the ABS warning light starts flashing, the front
brake lever “1” will return to its home position.
The rear brake lever “2” will then return to its
home position, then the front brake lever will
return to its home position again.
1
2
ECA15B1011
CAUTION:
Check that the front brake lever returns to
its home position before the rear brake lever returns to its home position.
● If the rear brake lever returns to its home
position before the front brake lever does,
check that the brake hoses are connected
correctly to the hydraulic unit.
● If either the brake levers returns to its home
position slowly, check that the brake hoses
are connected correctly to the hydraulic
●
4-52
HANDLEBAR
EAS22840
HANDLEBAR
Removing the handlebar
1
26 Nm (2.6 m • kg, 19 ft • Ib)
9
23 Nm (2.3 m • kg, 17 ft • Ib)
15
5
17
18
17
4
7
5
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
8
10
13
2
11 14
16
6
10 Nm (1.0 m • kg, 7.2 ft • Ib)
11
3
6
19
12
26 Nm (2.6 m • kg, 19 ft • Ib)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Job/Parts to remove
Q’ty
Upper handle cover
Band
Grip end
Front brake light switch connector
Right handlebar switch
Throttle cable
Throttle grip
Front brake master cylinder holder
Front brake master cylinder
Rear brake light switch connector
Parking brake lever/Holder
Rear brake lock lever cable
Left handlebar switch
Rear brake master cylinder holder
Rear brake master cylinder
Handlebar grip
Upper handlebar holder
Handlebar
Lower handlebar cover
1
3
2
2
1
2
1
1
1
2
1/1
1
1
1
1
1
2
2
1
4-53
Remarks
Disconnect.
Disconnect.
Disconnect.
Disconnect.
HANDLEBAR
Removing the handlebar
1
26 Nm (2.6 m • kg, 19 ft • Ib)
9
23 Nm (2.3 m • kg, 17 ft • Ib)
15
5
17
18
17
4
7
5
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
8
10
13
2
11 14
16
6
10 Nm (1.0 m • kg, 7.2 ft • Ib)
11
3
6
19
12
26 Nm (2.6 m • kg, 19 ft • Ib)
Order
Job/Parts to remove
Q’ty
Remarks
For installation, reverse the removal procedure.
4-54
HANDLEBAR
EAS22860
●
REMOVING THE HANDLEBARS
1. Stand the vehicle on a level surface.
Upper handlebar holders “2”
EWA13120
T.
R.
WARNING
Upper handlebar holder bolt
23 Nm (2.3 m•kg, 17 ft•lb)
ECA14250
Securely support the vehicle so that there is
no danger of it falling over.
CAUTION:
● First,
tighten the bolts on the front side of
the handlebar holder, and then on the rear
side.
● Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
2. Remove:
● Handlebar grip “1”
NOTE:
Blow compressed air between the left handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
NOTE:
● The
upper handlebar holders should be installed with the arrow marks “a” facing forward
“A”.
● Align the match marks “b” on the handlebar
with the upper surface of the lower handlebar
holders.
EAS22880
CHECKING THE HANDLEBAR
1. Check:
● Handlebar “1”
Bends/cracks/damage → Replace.
EWA13690
WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
3. Install:
● Handlebar grip
● Grip end
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
EWA13700
WARNING
Do not touch the handlebar grip until the rubber adhesive has fully dried.
EAS22920
INSTALLING THE HANDLEBAR
1. Stand the vehicle on a level surface.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EWA13120
WARNING
4. Install:
● Rear brake master cylinder “1”
● Rear brake master cylinder holder “2”
Securely support the vehicle so that there is
no danger of it falling over.
2. Install:
● Handlebar “1”
4-55
HANDLEBAR
T.
R.
Rear brake master cylinder holder
bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
1
b
NOTE:
● Install
the rear brake master cylinder holder
with the “UP” mark facing up “a”.
● Align the rear brake master cylinder with the
projection “b” in the handlebar.
● First, tighten the upper bolt, then the lower bolt.
b
a
2
8. Install:
● Throttle grip
● Throttle cables
1
NOTE:
Lubricate the inside of the throttle grip with a thin
coat of lithium-soap-based grease and install it
onto the handlebar.
a
9. Install:
● Right handlebar switch “1”
2
EWA13720
WARNING
5. Connect:
● Rear brake lock lever cable
Make sure the throttle grip operates smoothly.
NOTE:
Lubricate the inside of the rear brake lock lever
cable and parking brake lever with a thin coat of
lithium-soap-based grease.
NOTE:
Align the projection “a” of the right handlebar
switch with the punch mark “b” on the handlebar.
6. Install:
● Left handlebar switch “1”
NOTE:
Align the projection “a” of the left handlebar
switch with the hole “b” on the handlebar.
1
a
10.Adjust:
● Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-8.
b
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in)
7. Install:
● Front brake master cylinder “1”
● Front brake master cylinder holder “2”
11.Adjust:
● Rear brake lock lever cable length
Refer to “ADJUSTING THE REAR BRAKE
LOCK LEVER CABLE” on page 3-23.
NOTE:
● Install
the front brake master cylinder holder
with the “UP” “a” mark facing up.
● Align the front brake master cylinder with the
projection “b” in the handlebar.
● First, tighten the upper bolt, then the lower bolt.
4-56
FRONT FORK
EAS22950
FRONT FORK
Removing the front fork legs
24 Nm (2.4 m • kg, 17 ft • Ib)
23 Nm (2.3 m • kg, 17 ft • Ib)
6
5
7
3
30 Nm (3.0 m • kg, 22 ft • Ib)
4
3
4
6
2
8
40 Nm (4.0 m • kg, 29 ft • Ib)
2
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Parts to remove
Q’ty
Front cowling/leg shield
Handlebar cover (upper and lower)
Front wheel
ECU (ABS)
1
2
3
4
5
6
7
8
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Refer to “HANDLEBAR” on page 4-53.
Refer to “FRONT WHEEL” on page 4-6.
For XP500A
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)” on page 8-65.
Front fender
Front brake caliper
Horn coupler
Horn
Upper bracket pinch bolt
Cap bolt
Lower bracket pinch bolt
Front fork leg
1
2
2
2
2
1
4
2
Disconnect.
Loosen.
Loosen.
Loosen.
For installation, reverse the removal procedure.
4-57
FRONT FORK
Disassembling the front fork legs
1
2
9
13
14
15
3
16
4
17
5
10
11
8
12
7
6
LT
23 Nm (2.3 m • kg, 17 ft • Ib)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Job/Parts to remove
Q’ty
Cap bolt
O-ring
Spacer
Fork spring seat
Fork spring
Damper rod assembly bolt
Copper washer
Damper rod assembly
Rebound spring
Oil flow stopper
Inner tube
Inner tube bushing
Dust seal
Oil seal clip
Oil seal
Washer
Outer tube bushing
Remarks
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly procedure.
4-58
FRONT FORK
(with a flat-head screwdriver)
EAS22960
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the vehicle on a level surface.
EWA13120
ECA14180
CAUTION:
Do not scratch the inner tube.
NOTE:
● Do
not remove the fork leg protector from the
outer tube.
● If the front fork leg protector must be removed,
always install a new one.
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.
2. Loosen:
● Upper bracket pinch bolt “1”
● Cap bolt “2”
● Lower bracket pinch bolt “3”
EWA13640
WARNING
Before loosening the upper and lower bracket pinch bolts, support the front fork leg.
2. Drain:
● Fork oil
NOTE:
Stroke the outer tube several times while draining the fork oil.
3. Remove:
● Damper rod assembly bolt
● Copper washer
NOTE:
While holding the damper rod assembly with the
damper rod holder “1” and T-handle “2”, loosen
the damper rod assembly bolt.
3. Remove:
● Front fork leg
EAS22980
Damper rod holder
90890-01460
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
● Dust seal “1”
● Oil seal clip “2”
4-59
FRONT FORK
tube as this may dangerously weaken it.
4. Remove:
● Inner tube
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in a
vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but carefully.
2. Measure:
● Spring free length “a”
Out of specification → Replace.
Fork spring free length
405.0 mm (15.94 in)
Limit
400.0 mm (15.75 in)
ECA14190
CAUTION:
● Excessive
force will damage the oil seal
and bushing. A damaged oil seal or bushing must be replaced.
● Avoid bottoming the inner tube into the
outer tube during the above procedure, as
the oil flow stopper will be damaged.
3. Check:
● Damper rod “1”
Damage/wear → Replace.
Obstruction → Blow out all of the oil passages with compressed air.
● Oil flow stopper “2”
Damage → Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS23010
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
● Inner tube “1”
● Outer tube “2”
Bends/damage/scratches → Replace.
4. Check:
● Cap bolt
Damage/wear → Replace.
EWA13650
WARNING
Do not attempt to straighten a bent inner
4-60
FRONT FORK
●
Inner tube’s outer surface “2”
Recommended oil
Fork oil 7.5W or equivalent
2
EAS23020
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1
EWA13660
4. Install:
● Outer tube (onto the inner tube)
● Copper washer New
● Damper rod assembly bolt
5. Tighten:
● Damper rod assembly bolt “1”
WARNING
● Make
sure the oil levels in both front fork
legs are equal.
● Uneven oil levels can result in poor handling and a loss of stability.
NOTE:
● When
T.
R.
assembling the front fork leg, be sure to
replace the following parts:
● Inner tube bushing
● Outer tube bushing
● Oil seal
● Dust seal
● Before assembling the front fork leg, make
sure all of the components are clean.
Damper rod assembly bolt
23 Nm (2.3 m•kg, 17 ft•lb)
LOCTITE®
NOTE:
● Apply
the locking agent (LOCTITE) to the
threads of the damper rod assembly bolt.
● While holding the damper rod assembly with
the damper rod holder “2” and T-handle “3”,
tighten the damper rod assembly bolt.
1. Install:
● Damper rod assembly “1”
● Rebound spring “2”
Damper rod holder
90890-01460
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
ECA14210
CAUTION:
Allow the damper rod assembly to slide
slowly down the inner tube “2” until it protrudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
6. Install:
● Outer tube bushing “1” New
● Washer “2”
(with the fork seal driver “3” and adapter “4”)
2. Install:
● Oil flow stopper “1”
3. Lubricate:
4-61
FRONT FORK
Frok seal driver weight
90890-01367
Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø41)
90890-01381
Replacement 41 mm
YM-A5142-2
8. Install:
● Oil seal clip “1”
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
7. Install:
● Oil seal New
“1”
(with the fork seal driver weight “2” and fork
seal driver attachment “3”)
ECA14220
CAUTION:
Make sure the numbered side of the oil seal
faces up.
9. Install:
● Dust seal “1” New
(with the fork seal driver weight “2” )
NOTE:
● Before
installing the oil seal, lubricate its lips
with lithium soap base grease.
● Lubricate the outer surface of the inner tube
with fork oil.
● Before installing the oil seal, cover the top of
the front fork leg with a plastic bag “4” to protect
the oil seal during installation.
Frok seal driver weight
90890-01367
Replacement hammer
YM-A9409-7
10.Fill:
● Front fork leg
(with the specified amount of the recommended fork oil “a”)
4-62
FRONT FORK
T.
Quantity
512.0 cm3 (17.31 US oz) (18.06
Imp.oz)
Recommended oil
Fork oil 7.5W or equivalent
Lower bracket pinch bolt
23 Nm (2.3 m•kg, 17 ft•lb)
R.
●
Cap bolt “2”
T.
Cap bolt
24 Nm (2.4 m•kg, 17 ft•lb)
R.
Level
109.0 mm (4.29 in)
●
Upper bracket pinch bolt “3”
NOTE:
filling the front fork leg, keep it upright.
filling, slowly pump the front fork leg up
and down to distribute the fork oil.
T.
● While
R.
● After
11.Install:
● Spring
● Spring seat
● Spacer
● Cap bolt
● O-ring New
NOTE:
● Install
the spring with the smaller pitch facing
down.
● Before installing the cap bolt, lubricate its
O-ring with grease.
● Temporarily tighten the cap bolt.
EAS23050
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
● Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
NOTE:
Make sure the inner fork tube is flush with the top
of the handlebar holder.
2. Tighten:
● Lower bracket pinch bolt “1”
4-63
Upper bracket pinch bolt
30 Nm (3.0 m•kg, 22 ft•lb)
STEERING HEAD
EAS23090
STEERING HEAD
Removing the lower bracket
13
110 Nm (11.0 m • kg, 80 ft • Ib)
14
15
7 Nm (0.7 m • kg, 5.1 ft • Ib)
2
17
3
16
4
5
6
7
8
9
12
11
10
1
1st 52 Nm (5.2 m • kg, 38 ft • Ib)
2nd 20 Nm (2.0 m • kg, 15 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
Job/Parts to remove
Q’ty
Front cowling
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Refer to “FRONT WHEEL” on page 4-6.
Refer to “FRONT FORK” on page 4-57.
Refer to “HANDLEBAR” on page 4-53.
Front wheel
Front fork legs
Handlebar
Horn bracket
Brake hose holder
Steering stem nut
Upper bracket
Lock washer
Upper ring nut
Rubber washer
Lower ring nut
Bearing cover
Bearing outer race
Upper bearing
Bearing inner race
Bearing outer race
Lower bearing
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4-64
STEERING HEAD
Removing the lower bracket
13
110 Nm (11.0 m • kg, 80 ft • Ib)
14
15
7 Nm (0.7 m • kg, 5.1 ft • Ib)
2
17
3
16
4
5
6
7
8
9
12
11
10
1
1st 52 Nm (5.2 m • kg, 38 ft • Ib)
2nd 20 Nm (2.0 m • kg, 15 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
15
16
17
Job/Parts to remove
Q’ty
Bearing inner race
Rubber seal
Lower bracket
Remarks
1
1
1
For installation, reverse the removal procedure.
4-65
STEERING HEAD
EAS23110
REMOVING THE LOWER BRACKET
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
● Upper bracket
3. Remove:
● Lock washer “1”
● Upper ring nut “2”
● Rubber washer “3”
● Lower ring nut “4”
(with the steering nut wrench)
3. Replace:
● Bearings
● Bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing races from the steering
head pipe with a long rod “1” and hammer.
b. Remove the bearing race from the lower
bracket with a floor chisel “2” and hammer.
c. Install a new rubber seal and new bearing
races.
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
ECA14270
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
EWA13730
WARNING
NOTE:
Securely support the lower bracket so that
there is no danger of it falling.
● Always
replace the bearings and bearing races
as a set.
● Whenever the steering head is disassembled,
replace the rubber seal.
EAS23120
CHECKING THE STEERING HEAD
1. Wash:
● Bearings
● Bearing races
Recommended cleaning solvent
Kerosene
2. Check:
● Bearings “1”
● Bearing races “2”
Damage/pitting → Replace.
4-66
STEERING HEAD
Refer to “FRONT FORK” on page 4-57.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE:
4. Check:
● Upper bracket
● Lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
Temporarily tighten the upper and lower bracket
pinch bolts.
5. Tighten:
● Steering stem nut “2”
T.
EAS23140
R.
INSTALLING THE STEERING HEAD
1. Lubricate:
● Upper bearing
● Lower bearing
● Bearing races
Recommended lubricant
Lithium-soap-based grease
2. Install:
● Lower ring nut “1”
● Rubber washer “2”
● Upper ring nut “3”
● Lock washer “4”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-27.
3. Install:
● Upper bracket “1”
● Steering stem nut “2”
NOTE:
Temporarily tighten the steering stem nut.
4. Install:
● Front fork legs
4-67
Steering stem nut
110 Nm (11.0 m•kg, 80 ft•lb)
REAR SHOCK ABSORBER ASSEMBLY
EAS23160
REAR SHOCK ABSORBER ASSEMBLY
Removing the rear shock absorber assembly
53 Nm (5.3 m • kg, 38 ft • Ib)
4
4
9
6
8
7
3
9
2
1
5
68 Nm (6.8 m • kg, 49 ft • Ib)
Order
1
2
3
4
5
6
7
8
9
Job/Parts to remove
Q’ty
Muffler
Bolt
Lock washer
Collar
Bolt/Nut
Rear shock absorber
Collar
Washer
Spacer
Bearing
Remarks
Refer to “ENGINE REMOVAL” on page 5-1.
1
1
1
1/1
1
1
1
1
2
For installation, reverse the removal procedure.
4-68
REAR SHOCK ABSORBER ASSEMBLY
EAS23180
HANDLING THE REAR SHOCK ABSORBER
NOTE:
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
EWA13740
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make sure
you understand the following information.
The manufacturer cannot be held responsible for property damage or personal injury
that may result from improper handling of
the rear shock absorber.
● Do not tamper or attempt to open the rear
shock absorber.
● Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion due
to excessive gas pressure.
● Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping performance.
2. Remove:
● Rear shock absorber bolts “1”
NOTE:
When removing the rear shock absorber bolts
“1”, hold the swingarm so that it does not drop
down.
3. Remove:
● Rear shock absorber assembly
EAS23190
DISPOSING OF A REAR SHOCK ABSORBER
1. Gas pressure must be released before disposing of a rear shock absorber. To release
the gas pressure, drill “a” 2–3-mm hole
through the rear shock absorber at “a” point
15–20 mm from its end as shown.
EAS23240
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
● Rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
● Rear shock absorber
Gas leaks/oil leaks → Replace the rear shock
absorber assembly.
● Spring
Damage/wear → Replace the rear shock absorber assembly.
● Bushings
Damage/wear → Replace.
● Dust seals
Damage/wear → Replace.
● Bolts
Bends/damage/wear → Replace.
EWA13760
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
EAS23300
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Lubricate:
● Spacers
● Bearings
EAS23210
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Recommended lubricant
Lithium-soap-based grease
Securely support the vehicle so that there is
no danger of it falling over.
2. Install:
● Rear shock absorber assembly “1”
4-69
REAR SHOCK ABSORBER ASSEMBLY
3. Tighten:
● Bolt (rear side) “1”
● Nut “3”
T.
Bolt (rear side)
53 Nm (5.3 m•kg, 38 ft•lb)
R.
4. Install:
● Lock washer “1” New
5. Tighten:
● Bolt (front side) “2”
T.
Bolt (front side) “2”
68 Nm (6.8 m•kg, 48 ft•lb)
R.
NOTE:
● When
installing the rear shock absorber assembly, lift up the swingarm.
● Bend the lock washer “2” tab along a flat side
of the bolt “1”.
4-70
ENGINE
ENGINE REMOVAL ...................................................................................... 5-1
INSTALLING THE ENGINE..................................................................... 5-5
CAMSHAFTS................................................................................................. 5-6
REMOVING THE CAMSHAFTS.............................................................. 5-8
CHECKING THE CAMSHAFTS .............................................................. 5-9
CHECKING THE TIMING CHAIN GUIDES............................................. 5-10
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-11
INSTALLING THE CAMSHAFTS ............................................................ 5-11
CYLINDER HEAD.......................................................................................... 5-14
REMOVING THE CYLINDER HEAD....................................................... 5-15
CHECKING THE CYLINDER HEAD ....................................................... 5-15
INSTALLING THE CYLINDER HEAD ..................................................... 5-15
VALVES AND VALVE SPRINGS.................................................................. 5-17
REMOVING THE VALVES...................................................................... 5-18
CHECKING THE VALVES AND VALVE GUIDES .................................. 5-18
CHECKING THE VALVE SEATS ............................................................ 5-20
CHECKING THE VALVE SPRINGS........................................................ 5-21
CHECKING THE VALVE LIFTERS ......................................................... 5-22
INSTALLING THE VALVES .................................................................... 5-22
CYLINDER AND PISTONS ........................................................................... 5-25
REMOVING THE PISTON ...................................................................... 5-26
CHECKING THE CYLINDERS AND PISTONS ...................................... 5-26
CHECKING THE PISTON RINGS........................................................... 5-27
CHECKING THE PISTON PIN ................................................................ 5-28
INSTALLING THE PISTONS AND CYLINDERS .................................... 5-28
GENERATOR AND STARTER CLUTCH...................................................... 5-30
REMOVING THE A.C. MAGNETO ROTOR............................................ 5-32
CHECKING THE STARTER CLUTCH .................................................... 5-32
INSTALLING THE A.C. MAGNETO ROTOR .......................................... 5-33
ELECTRIC STARTER ................................................................................... 5-35
CHECKING THE STARTER MOTOR ..................................................... 5-37
ASSEMBLING THE STARTER MOTOR................................................. 5-38
INSTALLING THE STARTER MOTOR ................................................... 5-38
OIL PUMP...................................................................................................... 5-39
CHECKING THE OIL PUMP ................................................................... 5-41
CHECKING THE RELIEF VALVE ........................................................... 5-41
CHECKING THE OIL DELIVERY PIPES ................................................ 5-42
CHECKING THE OIL STRAINER ........................................................... 5-42
CHECKING THE OIL PUMP DRIVE CHAIN ........................................... 5-42
ASSEMBLING THE OIL PUMP............................................................... 5-42
1
2
3
4
5
6
7
8
9
CLUTCH ........................................................................................................ 5-43
REMOVING THE CLUTCH ..................................................................... 5-45
DISASSEMBLING THE CLUTCH ........................................................... 5-45
CHECKING THE FRICTION PLATES..................................................... 5-46
CHECKING THE CLUTCH PLATES ....................................................... 5-46
CHECKING THE CLUTCH SPRING PLATE........................................... 5-46
CHECKING THE CLUTCH HOUSING .................................................... 5-47
CHECKING THE CLUTCH BOSS........................................................... 5-47
CHECKING THE PRESSURE PLATE .................................................... 5-47
CHECKING THE WEIGHT ...................................................................... 5-47
ASSEMBLING THE CLUTCH ................................................................. 5-48
INSTALLING THE CLUTCH.................................................................... 5-48
V-BELT AUTOMATIC TRANSMISSION ....................................................... 5-50
REMOVING THE PRIMARY SHEAVE.................................................... 5-54
REMOVING THE SECONDARY SHEAVE ............................................. 5-54
DISASSEMBLING THE PRIMARY SHEAVE .......................................... 5-54
DISASSEMBLING THE SECONDARY SHEAVE.................................... 5-55
CHECKING THE V-BELT........................................................................ 5-55
CHECKING THE PRIMARY SHEAVE .................................................... 5-55
CHECKING THE V-BELT CASE AIR DUCT ........................................... 5-55
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-55
CHECKING THE SLIDER ....................................................................... 5-56
CHECKING THE SECONDARY SHEAVE .............................................. 5-56
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-56
ASSEMBLING THE SECONDARY SHEAVE.......................................... 5-56
INSTALLING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY
SHEAVE ASSEMBLY AND V-BELT ..................................................... 5-57
CRANKCASE AND CRANKSHAFT ............................................................. 5-59
DISASSEMBLING THE CRANKCASE.................................................... 5-62
REMOVING THE CRANKSHAFT JOURNAL BEARING ........................ 5-62
REMOVING THE CONNECTING RODS ................................................ 5-62
CHECKING THE CRANKCASE .............................................................. 5-62
CHECKING THE TIMING CHAIN............................................................ 5-63
CHECKING THE CRANKSHAFT AND CONNECTING RODS............... 5-63
INSTALLING THE CRANKSHAFT MAIN JOURNAL BEARING ............. 5-66
INSTALLING THE CONNECTING RODS............................................... 5-67
INSTALLING THE CRANKSHAFT .......................................................... 5-68
ASSEMBLING THE CRANKCASE.......................................................... 5-68
TRANSMISSION............................................................................................ 5-70
REMOVING THE TRANSMISSION ........................................................ 5-71
CHECKING THE TRANSMISSION ......................................................... 5-71
CHAIN DRIVE TRANSMISSION ................................................................... 5-72
CHECKING THE SWINGARM ................................................................ 5-75
CHECKING THE CHAIN DRIVE ASSEMBLY......................................... 5-75
ASSEMBLING THE CHAIN DRIVE ASSEMBLY .................................... 5-75
INSTALLING THE CHAIN DRIVE ........................................................... 5-75
ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Removing the exhaust pipe
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5
3
45 Nm (4.5 m • kg, 33 ft • Ib)
4
6
2
6
10 Nm (1.0 m • kg, 7.2 ft • Ib)
31 Nm (3.1 m • kg, 22 ft • Ib)
20 Nm (2.0 m • kg, 15 ft • Ib)
Order
Job/Parts to remove
Q’ty
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Right rear side cover/inner fender
1
O2 sensor coupler
1
2
1
3
Protector 1
O2 sensor
1
4
5
6
Protector 2
Muffler assembly
Gasket
1
1
2
For installation, reverse the removal procedure.
5-1
ENGINE REMOVAL
Disconnecting the leads and hoses
5 Nm (0.5 m • kg, 3.6 ft • Ib)
2
5
4
5
6
7
1
23 Nm (2.3 m • kg, 17 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
3
Order
Job/Parts to remove
Q’ty
Refer to “GENERAL CHASSIS” on page
4-1.
Refer to “GENERAL CHASSIS” on page
4-1.
Refer to “FUEL TANK” on page 7-1.
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-13.
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-19.
Drain.
Refer to “CHECKING THE CHAIN DRIVE
OIL LEVEL” on page 3-26.
Leg shield/footrest board
Storage box
Fuel tank
Engine oil
Coolant
Chain drive oil
Thermostat outlet hose/coolant pipe/oil filter
cartridge
V-belt case air filter element (left)/water pump
inlet pipe/water pump outlet pipe
Throttle body/injector
Refer to “RADIATOR” on page 6-1.
Refer to “WATER PUMP” on page 6-7.
Refer to “THROTTLE BODIES” on page 7-4.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY” on page 4-68.
Refer to “CHAIN DRIVE TRANSMISSION”
on page 5-72.
Rear shock absorber
Chain drive assembly
1
Remarks
Spark plug cap
2
5-2
ENGINE REMOVAL
Disconnecting the leads and hoses
5 Nm (0.5 m • kg, 3.6 ft • Ib)
2
5
4
5
6
7
1
23 Nm (2.3 m • kg, 17 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
3
Order
2
3
4
5
6
7
Job/Parts to remove
Q’ty
Starter motor lead
Battery negative lead
Coolant temperature sensor coupler
A.C. magneto lead
Intake air temperature sensor hose
Right passenger footrest
1
1
1
2
1
1
Remarks
Disconnect.
Disconnect.
Disconnect.
For assembly, reverse the removal procedure.
5-3
ENGINE REMOVAL
Removing the engine
87 Nm (8.7 m • kg, 63 ft • Ib)
48 Nm (4.8 m • kg, 35 ft • Ib)
4
1
1
3
4
3
1
1
2
48 Nm (4.8 m • kg, 35 ft • Ib)
5
Order
1
2
3
4
5
Job/Parts to remove
Q’ty
Front lower mounting bolt/Washer
Spacer
Front upper mounting bolt/Nut
Rear mounting bolt/Nut
Engine
Remarks
4/4
1
1/1
1/1
1
For installation, reverse the removal procedure.
5-4
ENGINE REMOVAL
EAS23720
INSTALLING THE ENGINE
1. Install:
● Rear mounting bolt/nut “1”
● Front upper mounting bolt/nut “2”
● Washers.spacer “3”
● Front lower mounting bolts “4”
NOTE:
Do not fully tighten the bolts.
4
1
2
1
2
4
3
2. Tighten:
● Rear mounting nut “1”
T.
Rear mounting nut
87 Nm (8.7 m•kg, 63 ft•lb)
R.
● Front
upper mounting nut “2”
T.
Front upper mounting nut
87 Nm (8.7 m•kg, 63 ft•lb)
R.
● Front
lower mounting bolts
T.
Front lower mounting bolts
48 Nm (4.8 m•kg, 35 ft•lb)
R.
5-5
CAMSHAFTS
EAS23760
CAMSHAFTS
Removing the cylinder head cover
13 Nm (1.3 m • kg, 9.4 ft • Ib)
4
3
4
1
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Order
1
2
3
4
Job/Parts to remove
Q’ty
Engine
Intake manifold
Spark plug
Cylinder head cover
Cylinder head cover gasket
Dowel pin
Remarks
Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “THROTTLE BODIES” on page 7-4.
2
1
1
2
For installation, reverse the removal procedure.
5-6
CAMSHAFTS
Removing the camshafts
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
E
2
M
4
3
M
5
4
3
6
4
Order
1
2
3
Job/Parts to remove
Q’ty
Timing chain tensioner
Timing chain tensioner gasket
Camshaft cap
Remarks
1
1
2
NOTE:
4
Dowel pin
4
5
6
Intake camshaft
Exhaust camshaft
1
1
During removal, the dowel pins may still be
connected to the camshaft cap.
For installation, reverse the removal procedure.
5-7
CAMSHAFTS
EAS23810
REMOVING THE CAMSHAFTS
1. Remove:
● Timing plug “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Remove:
● Timing chain tensioner “1”
● Timing chain tensioner gasket “2”
2. Align:
● “I”mark “a” on the A.C. magneto rotor (with
the stationary pointer “b” on the A.C. magneto cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
1
2
4. Remove:
ECA15B1022
CAUTION:
Before removing the camshafts from the cylinder head, tilt up the engine at least 25°.
b. When piston #1 is at TDC on the compression stroke, align the “I” mark “a” with the stationary pointer “b” on the A.C magneto cover
Intake camshaft cap “1”
Exhaust camshaft cap “2”
● Dowel pins
●
●
NOTE:
● TDC
on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
● In order to be sure that the piston is at TDC, the
alignment mark “c” on the intake camshaft
sprocket and the alignment mark “d” on the exhaust camshaft sprocket must align with the
cylinder head mating surface as shown in the
illustration.
ECA15B1023
CAUTION:
To prevent damage to the cylinder head,
camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a crisscross pattern, working from the outside in.
1
2
5-8
CAMSHAFTS
5. Remove:
● Intake camshaft “1”
● Exhaust camshaft “2”
Camshaft lobe dimension limit
Intake A
33.252–33.352 mm
(1.3091–1.3131 in)
Limit
33.152 mm (1.3052 in)
Intake B
24.956–25.056 mm
(0.9825–0.9865 in)
Limit
24.856 mm (0.9786 in)
Exhaust A
33.252–33.352 mm
(1.3091–1.3131 in)
Limit
33.152 mm (1.3052 in)
Exhaust B
24.956–25.056 mm
(0.9825–0.9865 in)
Limit
24.856 mm (0.9786 in)
NOTE:
To prevent the timing chain from falling into the
crankcase, faster it with a wire “3”.
1
2
3
6. Remove:
● Timing chain guide (exhaust side)
EAS23850
CHECKING THE CAMSHAFTS
1. Check:
● Camshaft lobes
Blue discoloration/pitting/scratches → Replace the camshaft.
2. Measure:
● Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the camshaft.
3. Measure:
● Camshaft runout
Out of specification → Replace.
Camshaft runout limit
0.030 mm (0.0012 in)
5-9
CAMSHAFTS
4. Measure:
● Camshaft-journal-to-camshaft-cap clearance
Out of specification → Measure the camshaft
journal diameter.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
● Camshaft journal diameter “a”
Out of specification → Replace the camshaft.
Within specification → Replace the cylinder
head and the camshaft caps as a set.
Camshaft-journal-to-camshaft-cap clearance
0.020–0.054 mm (0.0008–0.0021
in)
Camshaft journal diameter
22.967–22.980 mm
(0.9042–0.9047 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
b. Position “a” strip of Plastigauge® “1” onto the
camshaft journal as shown.
EAS23950
CHECKING THE TIMING CHAIN GUIDES
The following procedure applies to all of the
camshaft sprockets and timing chain guides.
1. Check:
● Camshaft sprocket
More than 1/4 tooth wear “a”→ Replace the
camshaft sprockets and the timing chain as a
set.
c. Install the dowel pins and camshaft caps.
NOTE:
● Tighten
the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.
● Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the Plastigauge®.
T.
Camshaft cap bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
R.
d. Remove the camshaft caps and then measure the width of the Plastigauge® “1”.
5-10
CAMSHAFTS
b
2
a
1
b. Lock the timing chain tensioner rod “1” by setting the circlip “3” to groove“4” while pushing
the timing chain tensioner rod.
a. 1/4 tooth
b. Correct
1. Timing chain roller
2. Camshaft sprocket
2. Check:
● Timing chain guide (intake side)“1”
● Timing chain guide (exhaust side)“2”
● Timing chain guide (top side)“3”
Damage/wear → Replace the defective
part(s).
3
4
c. Push the timing chain tensioner rod “c”.
d. Make sure that the timing chain tensioner rod
comes out “d” of the timing chain tensioner
housing smoothly. If there is rough movement, replace the timing chain tensioner.
c
EAS23960
CHECKING THE TIMING CHAIN TENSIONER
The following procedure applies to the timing
chain tensioner.
1. Check:
● Timing chain tensioner
Cracks/damage → Replace.
d
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Push the timing chain tensioner rod “1” into
the timing chain tensioner housing by hand.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE:
While pushing the timing chain tensioner rod “a”,
turn it clockwise “b” with the timing chain tensioner body “2” until if stops.
EAS24000
INSTALLING THE CAMSHAFTS
1. Install:
● Intake camshaft “1”
● Exhaust camshaft “2”
5-11
CAMSHAFTS
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
2. Install:
● Dowel pins
● Intake camshaft cap “1”
● Exhaust camshaft cap “2”
● Camshaft cap bolts
2
T.
Camshaft cap bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compression stroke, align the “I” mark “a” on the A.C.
magneto rotor with the stationary pointer “b”
on the A.C. magneto cover.
ECA15B1025
CAUTION:
The camshaft cap bolts must be tightened
evenly or damage to the cylinder head, camshaft cap, and camshafts will result.
NOTE:
Lubricate the camshaft cap bolt threads with engine oil.
1
2
c. Install the timing chain onto both camshaft
sprockets, and then install the camshafts
onto the cylinder head.
NOTE:
The camshafts should be installed onto the cylinder head so that the alignment mark “c” on the
intake camshaft sprocket and the alignment
mark “d” on the exhaust camshaft sprocket align
with the cylinder head mating surface, as shown
in the illustration.
3. Install:
● Timing chain tensioner gasket New
● Timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Push the timing chain tensioner rod “1” into
the timing chain tensioner housing by hand.
NOTE:
While pushing the timing chain tensioner rod “a”,
turn it clockwise “b” with the timing chain tensioner body “2” until if stops.
ECA15B1024
CAUTION:
Do not turn the crankshaft when installing
the camshafts to avoid damage or improper
valve timing.
b
2
a
1
b. Lock the timing chain tensioner rod “1” by set-
5-12
CAMSHAFTS
ting the circlip “3” into groove“4” while pushing the timing chain tensioner rod.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Turn:
● Crankshaft (several turns counterclockwise)
5. Check:
● “I”mark “a”
Make sure that the “I” mark is aligned with the
stationary pointer “b”.
● Camshaft sprocket alignment marks “c”
● Make sure that the camshaft sprocket alignment mark is aligned with the cylinder head
mating surface “d”.
Out of alignment → Reinstall.
Refer to the installation steps above.
3
4
c. Install the timing chain tensioner to the cylinder block.
T.
Timing chain tensioner bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)
R.
EWA15B1008
WARNING
Always use a new gasket.
d. Remove the cap “5”.
5
e. Release the timing chain tensioner rod by
pushing up the timing chain guide “6” from
the hole “7”
6
6. Measure:
● Valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE” on page 3-3.
7. Install:
● Cylinder head cover gasket New
● Cylinder head cover
a
7
Cylinder head cover bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
ECA15B1034
CAUTION:
NOTE:
Do not push up the timing chain. Push up “a”
the timing chain guide “6”.
Tighten the cylinder head cover bolts in stages
and in a crisscross pattern.
f. Install the cap.
5-13
CYLINDER HEAD
EAS24100
CYLINDER HEAD
Removing the cylinder head
10 Nm (1.0 m • kg, 7.2 ft • Ib)
46 Nm (4.6 m • kg, 33 ft • Ib)
3
2
1
35 Nm (3.5 m • kg, 25 ft • Ib)
Order
1
2
3
Job/Parts to remove
Q’ty
Intake and exhaust camshafts
Cylinder head
Cylinder head gasket
Dowel pin
Remarks
Refer to “CAMSHAFTS” on page 5-6.
1
1
2
For installation, reverse the removal procedure.
5-14
CYLINDER HEAD
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS15B420a
REMOVING THE CYLINDER HEAD
1. Remove:
● Cylinder head bolts
● Cylinder head nuts
a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.
NOTE:
● Loosen
the nuts and bolts in the proper sequence as shown.
● Loosen each nut 1/2 of a turn at a time. After
all of the nuts are fully loosened, remove them.
EAS24160
CHECKING THE CYLINDER HEAD
1. Eliminate:
● Combustion chamber carbon deposits
(with a rounded scraper)
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder head
using a figure-eight sanding pattern.
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
● Spark plug bore threads
● Valve seats
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS15B422a
2. Check:
● Cylinder head
Damage/scratches → Replace.
● Cylinder head water jacket
Mineral deposits/rust → Eliminate.
3. Measure:
● Cylinder head warpage
Out of specification → Resurface the cylinder
head.
INSTALLING THE CYLINDER HEAD
1. Install:
● Dowel pins
● Cylinder head gasket New
2. Install:
● Cylinder head
NOTE:
Pass the timing chain through the timing chain
cavity.
3. Tighten:
● Cylinder head nuts “1”
T.
Warpage limit
0.03 mm (0.0012 in)
R.
5-15
Cylinder head nut
35 Nm (3.5 m•kg, 25 ft•lb)
CYLINDER HEAD
●
Cylinder head nuts “2”
T.
Cylinder head nut
46 Nm (4.6 m•kg, 33 ft•lb)
R.
●
Cylinder head bolts “3”
T.
Cylinder head bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)
R.
NOTE:
● Apply
engine oil onto the threads of the cylinder head nuts.
● Tighten the cylinder head nuts and bolts in the
proper tightening sequence as shown and
torque them in two stages.
5-16
VALVES AND VALVE SPRINGS
EAS24270
VALVES AND VALVE SPRINGS
Removing the valves and valve springs
1
2
3
4
5
6
1
2 3
7
4
5
6
7
8
8
Order
1
2
3
4
5
6
7
8
9
10
Job/Parts to remove
Q’ty
Cylinder head
Valve lifter
Valve pad
Valve cotter
Valve retainer
Valve spring
Valve stem seal
Valve spring seat
Valve guide
Intake valve
Exhaust valve
10
9
Remarks
Refer to “CYLINDER HEAD” on page 5-14.
8
8
16
8
8
8
8
8
4
4
For installation, reverse the removal procedure.
5-17
VALVES AND VALVE SPRINGS
3. Remove:
● Valve cotters “1”
EAS24280
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
“2” and the valve spring compressor attachment
“3”.
NOTE:
Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
1. Remove:
● Valve lifter “1”
● Valve pad “2”
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor attachment
90890-04114
Valve spring compressor adapter
19.5 mm
YM-04114
NOTE:
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:
● Valve sealing
Leakage at the valve seat → Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”
on page 5-20.
4. Remove:
● Upper spring seat “1”
● Valve spring “2”
● Valve stem seal “3”
● Lower spring seat “4”
● Valve “5”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent “a” into the intake and
exhaust ports.
b. Check that the valves properly seal.
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
NOTE:
There should be no leakage at the valve seat
“1”.
EAS24290
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-18
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
VALVES AND VALVE SPRINGS
remover “1”.
1. Measure:
● Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
guide.
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” Valve stem diameter “b”
Valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance (intake)
0.010–0.037 mm (0.0004–0.0015
in)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.100 mm (0.0039 in)
b. Install the new valve guide with the valve
guide installer “2” and valve guide remover
“1”.
c. After installing the valve guide, bore the valve
guide with the valve guide reamer “3” to obtain the proper valve-stem-to-valve-guide
clearance.
NOTE:
After replacing the valve guide, reface the valve
seat.
Valve guide remover (ø4)
90890-04111
Valve guide remover (4.0 mm)
YM-04111
Valve guide installer (ø4)
90890-04112
Valve guide installer (4.0 mm)
YM-04112
Valve guide reamer (ø4)
90890-04113
Valve guide reamer (4.0 mm)
YM-04113
2. Replace:
● Valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100°C (212°F) in an oven.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve guide
5-19
VALVES AND VALVE SPRINGS
place the oil seal.
Valve stem runout
Valve stem runout
0.040 mm (0.0016 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
● Carbon deposits
(from the valve face and valve seat)
4. Check:
● Valve face
Pitting/wear → Grind the valve face.
● Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem → Replace the valve.
5. Measure:
● Valve margin thickness “a”
Out of specification → Replace the valve.
EAS24300
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
● Carbon deposits
(from the valve face and valve seat)
2. Check:
● Valve seat
Pitting/wear → Replace the cylinder head.
3. Measure:
● Valve seat width “a”
Out of specification → Replace the cylinder
head.
Valve margin thickness
Valve margin thickness D (intake)
0.60–0.80 mm (0.0236–0.0315 in)
Limit
0.5 mm (0.0197 in)
Valve margin thickness D (exhaust)
0.60–0.80 mm (0.0236–0.0315 in)
Limit
0.5 mm (0.0197 in)
Valve seat width
Valve seat width C (intake)
0.90–1.10 mm (0.0354–0.0433 in)
Limit
1.6 mm (0.06 in)
Valve seat width C (exhaust)
0.90–1.10 mm (0.0354–0.0433 in)
Limit
1.6 mm (0.06 in)
6. Measure:
● Valve stem runout
Out of specification → Replace the valve.
NOTE:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
● When
installing a new valve, always replace
the valve guide.
● If the valve is removed or replaced, always re-
a. Apply Mechanic’s blueing dye (Dykem) “b”
5-20
VALVES AND VALVE SPRINGS
onto the valve face.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth between your hands.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been removed.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
● Valve face
● Valve seat
NOTE:
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from the
valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) onto
the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
j. Measure the valve seat width “b” again. If the
valve seat width is out of specification, reface
and lap the valve seat.
a. Apply a coarse lapping compound “a” to the
valve face.
ECA13790
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24310
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:
● Valve spring free length “a”
Out of specification → Replace the valve
spring.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
5-21
VALVES AND VALVE SPRINGS
Valve spring free length
Free length (intake)
35.59 mm (1.40 in)
Limit
33.81 mm (1.33 in)
Free length (exhaust)
35.59 mm (1.40 in)
Limit
33.81 mm (1.33 in)
EAS24320
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the
valve lifters.
1. Check:
● Valve lifter
Damage/scratches → Replace the valve lifters and cylinder head.
2. Measure:
● Compressed valve spring force “a”
Out of specification → Replace the valve
spring.
EAS24340
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:
● Valve stem end
(with an oil stone)
1. Installed length
Intake
91.2–104.9 N (9.3–10.7 kg,
20.5–23.6 lb) at 30.4 mm (1.2 in)
Exhaust
91.2–104.9 N (9.3–10.7 kg,
20.5–23.6 lb) at 30.4 mm (1.2 in)
3. Measure:
● Valve spring tilt “a”
Out of specification → Replace the valve
spring.
2. Lubricate:
● Valve stem “1”
● Valve stem seal “2”
(with the recommended lubricant)
Spring tilt limit
Spring tilt (intake)
2.5 °/1.6 mm
Spring tilt (exhaust)
2.5 °/1.6 mm
Recommended lubricant
Molybdenum disulfide oil
5-22
VALVES AND VALVE SPRINGS
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor attachment
90890-04114
Valve spring compressor adapter
19.5 mm
YM-04114
3. Install:
● Valve “1”
● Lower spring seat “2”
● Valve stem seal “3”
● Valve spring “4”
● Upper spring seat “5”
(into the cylinder head)
NOTE:
● Make
sure each valve is installed in its original
place.
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
● Install
the valve springs with the larger pitch “a”
facing up.
ECA13800
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
6. Lubricate:
● Valve pad
● Valve lifter
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
a. Smaller pitch
4. Install:
● Valve cotters “1”
7. Install:
● Valve pad
● Valve lifter
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
“2” and the valve spring compressor attachment
“3”.
ECA15B1026
CAUTION:
After making sure that the valve pads are fully inserted, install the valve lifter taking care
5-23
VALVES AND VALVE SPRINGS
so that the pads do not fall.
NOTE:
● The
valve lifter must move smoothly when rotated with a finger.
● Each valve lifter and valve pad must be reinstalled in its original position.
5-24
CYLINDER AND PISTONS
EAS24370
CYLINDER AND PISTONS
Removing the cylinder and pistons
4
4
2
3
5
5
6
7
8
1
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Q’ty
Cylinder head
Timing chain guide (exhaust side)
Cylinder
Cylinder gasket
Dowel pin
Piston pin clip
Piston pin
Piston
Piston ring set
Remarks
Refer to “CYLINDER HEAD” on page 5-14.
1
1
1
2
4
2
2
2
For installation, reverse the removal procedure.
5-25
CYLINDER AND PISTONS
EAS24380
REMOVING THE PISTON
The following procedure applies to all of the pistons.
1. Remove:
● Piston pin clips “1”
● Piston pin “2”
● Piston “3”
NOTE:
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
ECA13810
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
● Before
removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crankcase.
● Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set “4”.
EAS15B4256
CHECKING THE CYLINDERS AND PISTONS
The following procedure applies to all of the cylinders and pistons.
1. Check:
● Piston wall
● Cylinder wall
Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:
● Piston-to-cylinder clearance
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
2. Remove:
● Top ring
● 2nd ring
● Oil ring
5-26
CYLINDER AND PISTONS
cylinder, and replace the piston and piston
rings as a set.
Bore “C”
Bore
66.000–66.010 mm
(2.5984–2.5988 in)
Taper limit “T”
Taper limit
0.050 mm (0.0020 in)
Out of round “R”
Out of round limit
0.050 mm (0.0020 in)
“C”= maximum of D1–D6
“T”= (maximum of D1 or D2)—(maximum of
D5 or D6)
“R” = maximum of D1, D3 or D5 . minimum of
D2, D4 or D6
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24430
CHECKING THE PISTON RINGS
1. Measure:
● Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
Piston ring side clearance
Ring side clearance
0.030–0.065 mm (0.0012–0.0026
in)
Limit
0.100 mm (0.0039 in)
Ring side clearance
0.020–0.055 mm (0.0008–0.0022
in)
Limit
0.100 mm (0.0039 in)
b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
c. Measure piston skirt diameter “P” with the micrometer.
Piston size “P”
65.965–65.980 mm
(2.5970–2.5976 in)
a. 9.0 mm (0.35 in) from the bottom edge of the piston
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
2. Install:
● Piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
Piston-to-cylinder clearance =
Cylinder bore “C”
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.020 – 0.045 mm (0.0008 –
0.0018 in)
Limit: 0.15 mm (0.0059 in)
f. If out of specification, rebore or replace the
5-27
CYLINDER AND PISTONS
3. Measure:
● Piston pin bore diameter “b”
Out of specification → Replace the piston.
a. 10 mm (0.39 in)
3. Measure:
● Piston ring end gap
Out of specification → Replace the piston
ring.
Piston pin bore inside diameter
15.002–15.013 mm
(0.5906–0.5911 in)
Limit
15.043 mm (0.5922 in)
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.
Piston ring end gap
End gap (installed)
0.15–0.25 mm (0.0059–0.0098 in)
Limit
0.50 mm (0.0197 in)
End gap (installed)
0.40–0.50 mm (0.0157–0.0197 in)
Limit
0.75 mm (0.0295 in)
End gap (installed)
0.10–0.35 mm (0.0039–0.0138 in)
4. Calculate:
● Piston-pin-to-piston-pin-bore clearance
Out of specification → Replace the piston pin
and piston as a set.
EAS24440
CHECKING THE PISTON PIN
The following procedure applies to all of the piston pins.
1. Check:
● Piston pin
Blue discoloration/grooves → Replace the
piston pin and then check the lubrication system.
2. Measure:
● Piston pin outside diameter “a”
Out of specification → Replace the piston pin.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter “b” Piston pin outside diameter “a”
Piston-pin-to-piston-pin-bore
clearance
0.002–0.022 mm
(0.00008–0.00087 in)
Limit: 0.072 mm (0.0028 in)
Piston pin outside diameter
14.991–15.000 mm
(0.5902–0.5906 in)
Limit
14.971 mm (0.5894 in)
EAS24470
INSTALLING THE PISTONS AND
CYLINDERS
The following procedure applies to all of the pistons and cylinders.
1. Install:
● Top ring
● 2nd ring
● Oil ring
5-28
CYLINDER AND PISTONS
NOTE:
●
Be sure to install the top and 2nd rings so that
the manufacturers marks or numbers face up.
Cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Offset:
● Top ring
● 2nd ring
● Oil ring
Offset the piston ring end gaps as shown.
2. Install:
● Piston
● Piston pin
● Piston pin clips New
NOTE:
● Apply
engine oil onto the piston pin.
sure the arrow mark “a” on the piston
points towards the exhaust side of the engine.
● Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crankcase.
● Make
a. Top ring end
b. Upper oil ring rail end
c. Oil ring expander end
d. Lower oil ring rail end
e. 2nd ring end
f. 20 mm (0.79 in)
6. Install:
● Cylinder
● Timing chain guide (exhaust side)
NOTE:
Pass the timing chain through the timing chain
cavity.
3. Install:
● Gasket “1” New
● Dowel pins
4. Lubricate:
● Piston
● Piston rings
5-29
GENERATOR AND STARTER CLUTCH
EAS24480
GENERATOR AND STARTER CLUTCH
Removing the starter clutch and A.C. magneto rotor
7 Nm (0.7 m • kg, 5.1 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
(7)
5
7
14
1
4
3
2
7
8
6
16
18
15
17
9
13
12
4
11
30 Nm (3.0 m • kg, 22 ft • Ib)
Order
10
60 Nm (6.0 m • kg, 43 ft • Ib) + 120˚
Job/Parts to remove
Q’ty
Left side panel/lower side cover moulding/footrest board
Coolant
Engine oil
1
2
3
4
5
6
7
8
9
10
11
12
Water pump assembly
Starter coil assembly coupler
A.C. magneto cover
A.C. magneto cover gasket
Dowel pin
Oil tank
Gasket
Dowel pin
Oil strainer
Starter coil assembly
A.C. magneto rotor nut
Spacer
A.C. magneto rotor
2
1
1
2
1
1
2
1
1
1
1
1
5-30
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-19.
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-13.
Refer to “WATER PUMP” on page 6-7.
Disconnect.
GENERATOR AND STARTER CLUTCH
Removing the starter clutch and A.C. magneto rotor
7 Nm (0.7 m • kg, 5.1 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
(7)
5
7
14
1
4
3
2
7
8
6
16
18
15
17
9
13
12
4
11
30 Nm (3.0 m • kg, 22 ft • Ib)
Order
13
14
15
16
17
18
10
60 Nm (6.0 m • kg, 43 ft • Ib) + 120˚
Job/Parts to remove
Q’ty
Starter clutch
Woodruff key
Starter clutch idle gear shaft
Starter clutch idle gear
Starter clutch gear
Washer
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
1
1
1
1
1
1
For installation, reverse the removal procedure.
5-31
GENERATOR AND STARTER CLUTCH
EAS24530
REMOVING THE A.C. MAGNETO ROTOR
1. Remove:
● A.C. magneto rotor cover
NOTE:
Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
3. Remove:
● A.C. magneto rotor “1”
(with the flywheel puller set “2”)
● Woodruff key
NOTE:
● Remove
the A.C. magneto rotor “1” using the
flywheel puller.
● Center the flywheel puller over the A.C. magneto rotor. Make sure after installing the holding bolts that the clearance between the
flywheel puller and the A.C. magneto rotor is
the same everywhere. If necessary, one holding bolt maybe turned out slightly to adjust the
flywheel puller’s position.
2. Remove:
● A.C. magneto rotor nut “1”
● Spacer “2”
NOTE:
● While
holding the A.C. magneto rotor “3” with
the rotor holding tool “4”, loosen the pickup coil
rotor bolt.
● Do not allow the sheave holder to touch the
projection on the A.C. magneto rotor.
ECA15B1038
CAUTION:
Cover the crankshaft end with the box
wrench for protection.
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
EAS24570
CHECKING THE STARTER CLUTCH
1. Check:
● Starter clutch
Damage/wear → Replace.
2. Check:
● Starter clutch idle gear
● Starter clutch drive gear
5-32
GENERATOR AND STARTER CLUTCH
●
Starter clutch gear
Burrs/chips/roughness/wear → Replace the
defective part(s).
“a” in the A.C magneto rotor.
2. Tighten:
● A.C magneto rotor nut “1”
3. Check:
● Starter clutch operation
A.C magneto rotor nut
60 Nm (6.0 m•kg, 43 ft•lb)
R.
a. Install the starter clutch drive gear “1” onto
the starter clutch “2” and hold the starter
clutch.
b. When turning the starter clutch drive gear
clockwise “A”, the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and must be
replaced.
c. When turning the starter clutch drive gear
counterclockwise “B”, it should turn freely,
otherwise the starter clutch is faulty and must
be replaced.
T.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
● While
holding the generator rotor “2” with the
rotor holding tool “3”, tighten the pickup coil rotor bolt.
● Do not allow the sheave holder to touch the
projection on the A.C. magneto rotor.
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
ECA15B1039
CAUTION:
● When
tightening the A.C. magneto rotor
nut, be sure to use an F-type torque
wrench.
● After tightening the A.C. magneto rotor nut,
to the specified torque, turn the A.C. magneto rotor nut another + 120°.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24540
INSTALLING THE A.C. MAGNETO ROTOR
1. Install:
● Woodruff key
● A.C. magneto rotor “1”
● Spacer “2”
● A.C. magneto rotor nut “3”
NOTE:
When installing the pickup coil rotor, align the
pin “2” in the crankshaft sprocket with the groove
5-33
GENERATOR AND STARTER CLUTCH
3. Apply:
● Sealant
(onto the crankshaft position sensor lead
grommet)
Yamaha bond No. 1215 (Three
Bond No.1215®)
90890-85505
4. Install:
● A.C. magneto rotor cover
T.
A.C. magneto rotor cover bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
R.
NOTE:
Tighten the A.C. magneto rotor cover bolts in
stages and in a crisscross pattern.
5-34
ELECTRIC STARTER
EAS24780
ELECTRIC STARTER
Removing the starter motor
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5 Nm (0.5 m • kg, 3.6 ft • Ib)
2
1
Order
1
2
3
3
Job/Parts to remove
Q’ty
Fuel tank
Negative battery lead
Starter motor lead
Starter motor
Remarks
Refer to “FUEL TANK” on page 7-1.
1
1
1
For installation, reverse the removal procedure.
5-35
ELECTRIC STARTER
Disassembling the starter motor
3
2
5
6
4
1
7
9
8
11
10
2
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Parts to remove
Q’ty
Front bracket
O-ring
Shims
Lock washer
Oil seal
Bearing
Rear bracket
Shims
Brush holder set
Armature assembly
Starter motor yoke
Remarks
1
2
1
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly procedure.
5-36
ELECTRIC STARTER
with the pocket tester.
EAS24790
CHECKING THE STARTER MOTOR
1. Check:
● Commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
● Commutator diameter “a”
Out of specification → Replace the starter
motor.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
Limit
27.0 mm (1.06 in)
Armature coil
Commutator resistance “1”
0.0015–0.0025 Ω at 20°C (68°F)
Insulation resistance “2”
Above 1 MΩ at 20°C (68°F)
3. Measure:
● Mica undercut “a”
Out of specification → Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
b. If any resistance is out of specification, replace the starter motor.
Mica undercut (depth)
0.70 mm (0.03 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE:
5. Measure:
● Brush length “a”
Out of specification → Replace the brushes
as a set.
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
Limit
4.00 mm (0.16 in)
4. Measure:
● Armature assembly resistances (commutator
and insulation)
Out of specification → Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances
5-37
6. Measure:
● Brush spring force
Out of specification → Replace the brush
ELECTRIC STARTER
2. Connect:
● Starter motor lead
springs as a set.
Brush spring force
7.65–10.01 N (27.54–36.03 oz)
(780–1021 gf)
7. Check:
● Gear teeth
Damage/wear → Replace the gear.
8. Check:
● Bearing“1”
● Oil seal“2”
Damage/wear → Replace the defective
part(s).
EAS24800
ASSEMBLING THE STARTER MOTOR
1. Install:
● Starter motor yoke “1”
● Starter motor front cover “2”
● Starter motor rear cover “3”
NOTE:
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the front and
starter motor rear covers.
EAS24810
INSTALLING THE STARTER MOTOR
1. Install:
● Starter motor
● Starter motor bolts
T.
Starter motor bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
R.
5-38
OIL PUMP
EAS24900
OIL PUMP
Removing the oil pump
10 Nm (1.0 m • kg, 7.2 ft • Ib)
4
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
3
3
5
6
Order
2
Job/Parts to remove
Q’ty
Left side panel/lower side cover moulding/footrest board
Coolant
Engine oil
A.C. magneto cover/Starter clutch gear
1
2
3
4
5
6
Oil pump assembly
Oil pump drive chain
O-ring
Oil delivery pipe
Oil delivery pipe
Relief valve assembly
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-19.
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-13.
Refer to “GENERATOR AND STARTER
CLUTCH” on page 5-30.
1
1
2
1
1
1
For installation, reverse the removal procedure.
5-39
OIL PUMP
Disassembling the oil pump
6
3
7
5
2
4
8
9
1
5
3
2
4
Order
1
2
3
4
5
6
7
8
9
Job/Parts to remove
Q’ty
Oil pump housing
Oil pump outer rotor
Oil pump inner rotor
Pin
Dowel pin
Oil pump housing center
Washer
Oil pump cover
Oil pump driven gear
Remarks
1
2
2
2
4
1
1
1
1
For installation, reverse the removal procedure.
5-40
OIL PUMP
EAS24960
CHECKING THE OIL PUMP
1. Check:
● Oil pump drive gear “1”
● Oil pump housing “2”
● Oil pump cover “3”
Cracks/damage/wear → Replace the defective part(s).
Inner-rotor-to-outer-rotor-tip
clearance
0.040–0.120 mm (0.0016–0.0047
in)
Limit
0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance
0.045–0.085 mm (0.0018–0.0033
in)
Limit
0.155 mm (0.0061 in)
Oil-pump-housing-to-inner-and-outer-rotor clearance
0.11–0.23 mm (0.0043–0.0091 in)
Limit
0.30 mm (0.0118 in)
3. Check:
● Oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
2. Measure:
● Inner-rotor-to-outer-rotor-tip clearance “a”
● Outer-rotor-to-oil-pump-housing
clearance
“b”
● Oil-pump-housing-to-inner-rotor-and-outer-rotor clearance “c”
Out of specification → Replace the oil pump.
EAS24970
CHECKING THE RELIEF VALVE
1. Check:
● Relief valve body “1”
● Relief valve “2”
● Spring “3”
● O-ring “4”
Damage/wear → Replace the defective
part(s).
1. Inner rotor
2. Outer rotor
3. Oil pump housing
5-41
OIL PUMP
2. Install:
● Pins
● Inner rotors
EAS24980
CHECKING THE OIL DELIVERY PIPES
The following procedure applies to all of the oil
delivery pipes.
1. Check:
● Oil delivery pipe “1”
Damage → Replace.
Obstruction → Wash and blow out with compressed air.
NOTE:
When installing the inner rotor, align the pin “1”
in the oil pump shaft with the groove “a” in the inner rotor.
1
a
1
a
3. Check:
● Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-41.
EAS24990
CHECKING THE OIL STRAINER
1. Check:
● Oil strainer
Damage → Replace.
Contaminants → Clean with solvent.
EAS15B4368a
CHECKING THE OIL PUMP DRIVE CHAIN
1. Check:
● Oil pump drive chain
Cracks/stiffness → Replace the oil pump
chain, oil pump drive and driven sprocket as
a set.
EAS25000
ASSEMBLING THE OIL PUMP
1. Lubricate:
● Inner rotor
● Outer rotor
● Oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
5-42
CLUTCH
EAS25060
CLUTCH
Removing the clutch
65 Nm (6.5 m • kg, 47 ft • Ib)
3
2
1
Order
Job/Parts to remove
Q’ty
A.C. magneto cover
1
2
3
Remarks
Refer to “GENERATOR AND STARTER
CLUTCH” on page 5-30.
Clutch assembly nut
Clutch assembly
Washer
1
1
1
For installation, reverse the removal procedure.
5-43
CLUTCH
Disassembling the clutch
16
17
90 Nm (9.0 m • kg, 65 ft • Ib)
15
11
14
10
12
6
5
6
13
8
13
8
8
9
6
7
E
7
5
7
4
3
2
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
7
E
1
E
E
Job/Parts to remove
Q’ty
Circlip
Spring stopper plate
Clutch damper spring “2”
Pressure plate
Clutch plate “2”
Clutch damper spring “1”
Friction plate
Clutch plate “1”
Clutch spring
Thrust plate
Clutch boss nut
Primary drive gear
Bearing
Clutch boss
Collar
Weight
Clutch housing
Remarks
1
1
1
1
2
6
5
4
6
1
1
1
2
1
1
12
1
For assembly, reverse the removal procedure.
5-44
CLUTCH
EAS25070
REMOVING THE CLUTCH
1. Remove:
● Clutch assembly nut “1”
● Clutch assembly “2”
NOTE:
● Before
removal, apply “a” and “b” alignment
marks.
● While holding the clutch assembly with the rotor holding tool “3”, loosen the clutch assembly
nut.
● Align these marks during reassembly.
2. Remove:
● Spring stopper plate “1”
● Clutch damper spring 2
● Pressure plate
● Clutch plate “2”
● Friction plate
● Clutch plate 1
● Clutch damper spring 1
● Thrust plate
● Clutch springs
Rotor holding tool
90890-01235
Universal magneto & rotor holder
YU-01235
NOTE:
One to three holes “a” are drilled in the spring
stopper plate to adjust the balance of the clutch
assembly. Before removing the spring stopper
plate, make alignment marks on both the plate
and the clutch housing so that the plate can be
reinstalled in its original position.
3. Remove:
● Clutch boss nut “1”
EAS15B4001
DISASSEMBLING THE CLUTCH
1. Remove:
● Circlip “1”
NOTE:
While holding the clutch boss “2” with the clutch
holding tool “3”, loosen the clutch boss nut.
NOTE:
Install the clutch spring compressor “2” onto the
clutch assembly as shown. Then, compress the
spring, and remove the circlip.
Universal clutch holder
90890-04086
YM-91042
Clutch spring compressor
90890-01482
5-45
CLUTCH
Warpage limit
0.10 mm (0.0039 in)
1
2
3
EAS25100
CHECKING THE FRICTION PLATES
The following procedure applies to all of the friction plates.
1. Check:
● Friction plate
Damage/wear → Replace the friction plates
as a set.
2. Measure:
● Friction plate thickness
Out of specification → Replace the friction
plates as a set.
EAS25130
CHECKING THE CLUTCH SPRING PLATE
The following procedure applies to all of the
clutch springs.
1. Check:
● Clutch plate spring
Damage → Replace.
2. Measure:
● Clutch spring free height
Out of specification → Replace the clutch
plate spring.
NOTE:
Measure the friction plate at four places.
Clutch spring limit
25.4 mm (1.00 in)
Friction plate thickness
2.75–3.05 mm (0.108–0.120 in)
Wear limit
2.65 mm (0.1043 in)
3. Measure:
● Clutch damper spring 1 “b”
Out of specification → Replace the clutch
damper spring 1.
● Clutch damper spring 2 “c”
Out of specification → Replace the clutch
damper spring 2.
EAS25110
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
● Clutch plate
Damage → Replace the clutch plates as a
set.
2. Measure:
● Clutch plate warpage
(with a surface plate and thickness gauge “1”)
Out of specification → Replace the clutch
plates as a set.
5-46
CLUTCH
EAS25160
Clutch spring height “c”
4.70 mm (0.19 in)
Minimum height
4.40 mm (0.17 in)
Clutch spring height “b”
3.30 mm (0.13 in)
Minimum height
2.9 mm (0.11 in)
CHECKING THE CLUTCH BOSS
1. Check:
● Clutch boss splines
Damage/pitting/wear → Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause erratic clutch operation.
EAS25170
CHECKING THE PRESSURE PLATE
1. Check:
● Clutch boss splines
Damage/pitting/wear → Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause erratic clutch operation.
EAS25150
CHECKING THE CLUTCH HOUSING
1. Check:
● Clutch housing dogs “1”
Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause erratic clutch operation.
EAS15B4286b
CHECKING THE WEIGHT
1. Check:
● Weight
Cracks/wear/scaling/chipping → Replace.
Out of specification → Replace.
Weight outside diameter
16.0 mm (0.63 in)
Limit: 15.5 mm (0.61 in)
5-47
CLUTCH
EAS15B4586b
ASSEMBLING THE CLUTCH
1. Lubricate:
● Friction plates
● Clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Install:
● Clutch boss
● Primary drive gear
● Clutch boss nut “1”
3. Tighten:
● Clutch boss nut
T.
Clutch boss nut
90 Nm (9.0 m•kg, 65 ft•lb)
R.
NOTE:
While holding the clutch boss “2” with the clutch
holding tool “3”, tighten the clutch boss nut.
A. Engine side
Universal clutch holder
90890-04086
YM-91042
EAS15B4286c
INSTALLING THE CLUTCH
1. Install:
● Clutch assembly “1”
● Clutch assembly nut “2”
1
T.
Clutch boss nut
65 Nm (6.5 m•kg, 47 ft•lb)
R.
NOTE:
● Align
the “a” and “b” during reassembly.
● While holding the clutch assembly with the rotor holding tool “3”, tighten the clutch assembly
nut.
2
3
4. Install:
● Clutch damper spring 1 “1”
● Clutch plate 2 “2”
● Friction plate “3”
● Clutch plate 1 “4”
Rotor holding tool
90890-01235
Universal magneto & rotor holder
YU-01235
5-48
CLUTCH
5-49
V-BELT AUTOMATIC TRANSMISSION
EAS24610
V-BELT AUTOMATIC TRANSMISSION
Removing the V-belt case
7 Nm (0.7 m • kg, 5.1 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
5
4
8
3
11
12
2
10
9
11 Nm (1.1 m • kg, 8.0 ft • Ib)
7
6
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Parts to remove
Q’ty
Muffler
V-belt case cover “1”
V-belt case cover “2”
V-belt case air filter cover
V-belt case air filter element
Lead holder
V-belt case
V-belt case gasket
Bearing retainer
Bearing
Circlip
Oil seal
Bearing
(M6)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
(M8)
24 Nm (2.4 m • kg, 17 ft • Ib)
Remarks
Refer to “ENGINE REMOVAL” on page 5-1.
1
1
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
5-50
V-BELT AUTOMATIC TRANSMISSION
Removing the V-belt and primary/secondary sheave
24 Nm (2.4 m • kg, 17 ft • Ib)
13
10 Nm (1.0 m • kg, 7.2 ft • Ib)
12
15
24 Nm (2.4 m • kg, 17 ft • Ib)
10
14
11
10 Nm (1.0 m • kg, 7.2 ft • Ib)
7
89
6
1
3
2
2
1
5
90 Nm (9.0 m • kg, 65 ft • Ib)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
4
1
160 Nm (16.0 m • kg, 116 ft • Ib)
Job/Parts to remove
Q’ty
Primary sheave nut
Spacer
O-ring
Primary sheave assembly
Primary fixed sheave
Secondary sheave nut
Secondary sheave assembly
Collar
O-ring
V-belt
Right crankcase cover
V-belt case air duct joint clamp
V-belt case air duct
Plate
V-belt case air duct seal
Remarks
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
5-51
V-BELT AUTOMATIC TRANSMISSION
Disassembling the primary sheave
4
3
5
1
2
Order
1
2
3
4
5
Job/Parts to remove
Q’ty
Cam
silinder
Weight
Primary sliding sheave
Collar
Remarks
1
4
8
1
1
For installation, reverse the disassembly
procedure.
5-52
V-BELT AUTOMATIC TRANSMISSION
Disassembling the secondary sheave
9
5
8
7
1
2
3
4
6
90 Nm (9.0 m • kg, 65 ft • Ib)
Order
1
2
3
4
5
6
7
8
9
Job/Parts to remove
Q’ty
Secondary sheave spring seat nut
Upper spring seat
Compression spring
Spring seat
Secondary sliding sheave
Oil seal
O-ring
Guide pin
Secondary fixed sheave
Remarks
1
1
1
1
1
1
2
4
1
For assembly, reverse the disassembly procedure.
5-53
V-BELT AUTOMATIC TRANSMISSION
EAS24620
EAS24630
REMOVING THE PRIMARY SHEAVE
1. Remove:
● Primary sheave nut “1”
● Secondary sheave nut “2”
REMOVING THE SECONDARY SHEAVE
1. Remove:
● Secondary sheave assembly “1”
● Primary sheave assembly “2”
● V-belt “3”
NOTE:
While holding the primary and secondary
sheave with the sheave holder, loosen the nut.
NOTE:
● Before
removal, apply “a” and “b” alignment
marks.
● Align these marks during reassembly.
● Remove the primary sliding sheave, secondary sheave assembly and V-belt together.
Sheave holder
90890-01481
a
3
1
1
2
b
2. Remove:
● Primary fixed sheave “1”
2
2. Install:
● Bolts “1”
NOTE:
EAS15B4002
Insert M6 bolts (more than 45 mm (1.77 in)) into
the holes of the secondary sheave assembly,
and then tighten the bolts to open the secondary
sheave assembly.
DISASSEMBLING THE PRIMARY SHEAVE
1. Remove:
● Cam “1”
● Slider “2”
● Weight “3”
1
1
3
2
5-54
V-BELT AUTOMATIC TRANSMISSION
EAS24640
DISASSEMBLING THE SECONDARY
SHEAVE
1. Remove:
● Spring seat “1”
NOTE:
Install the sheave spring compressor “2” onto
the secondary sheave as shown. Then, compress the spring, and remove the secondary
sheave spring seat nut “1” with locknut wrench
“3”.
EAS24680
CHECKING THE PRIMARY SHEAVE
1. Check:
● Primary sliding sheave “1”
● Primary fixed sheave “2”
Cracks/damage/wear → Replace the primary
sliding sheave and primary fixed sheave as a
set.
Sheave spring compressor
90890-04134
YM-04134
Locknut wrench
90890-01348
YM-01348
Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135
EAS15B4003
CHECKING THE V-BELT CASE AIR DUCT
1. Check
● V-belt case air duct
Cracks/damage → Replace.
EAS24670
CHECKING THE V-BELT
1. Check:
● V-belt “1”
Cracks/damage/wear → Replace.
Grease/oil → Clean the primary and secondary sheave.
2. Measure:
● V-belt width “2”
Out of specification → Replace.
EAS24690
CHECKING THE PRIMARY SHEAVE
WEIGHTS
The following procedure applies to all of the primary sheave weights.
1. Check:
● Primary sheave weight
Cracks/damage/wear → Replace.
Primary sheave weight outside diameter
25.0 mm (0.98 in)
Limit
24.5 mm (0.96 in)
V-belt width
32.0 mm (1.26 in)
Limit
30.5 mm (1.20 in)
5-55
V-BELT AUTOMATIC TRANSMISSION
EAS24720
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
● Primary fixed sheave
● Primary sliding sheave
● Collar
● Weights
● Sliders
● Cam
2. Install:
● Weights “1”
● Sliders “2”
● Cam “3”
EAS24700
CHECKING THE SLIDER
1. Check:
● Slider “1”
Cracks/damage/wear → Replace.
NOTE:
Do not apply the grease inside of the primary
sheave.
1
2
3
EAS24710
CHECKING THE SECONDARY SHEAVE
1. Check:
● Secondary fixed sheave
● Secondary sliding sheave
Cracks/damage/wear → Replace the secondary fixed and sliding sheaves as a set.
2. Check:
● Torque cam groove “1”
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
3. Check:
● Guide pin “2”
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
EAS24730
ASSEMBLING THE SECONDARY SHEAVE
1. Lubricate:
● Secondary fixed sheave shaft’s outer and inner surfaces “1”
● Secondary sliding sheave’s outer and inner
surfaces “2”
● Grease nipple groove
● Oil seals New
(with the recommended lubricant)
Recommended lubricant
BEL-RAY assembly lube®
2. Install:
● Secondary sliding sheave “1”
5-56
V-BELT AUTOMATIC TRANSMISSION
T.
3. Install:
● Guide pin “2”
4. Lubricate:
● Guide pin groove “3”
● O-ring New
(with the recommended lubricant)
R.
Secondary sheave spring seat
nut
90 Nm (9.0 m•kg, 65 ft•lb)
Recommended lubricant
BEL-RAY assembly lube
EAS15B4009
5. Install:
● Spring seat “1”
● Compression spring “2”
● Upper spring seat “3”
INSTALLING THE PRIMARY SHEAVE
ASSEMBLY, SECONDARY SHEAVE
ASSEMBLY AND V-BELT
1. Install:
● V-belt case air duct joint clamp “1”
● V-belt case air duct “2”
NOTE:
● Align
the projection “a” in the V-belt case air
duct “2” with the slot “b” on the V-belt case air
duct joint clamp “1”.
● Align the projection “c” in the V-belt case air
duct joint clamp “1” with the slot “d” in the right
crankcase cover “3”.
1
b
2
3
c
a
6. Tighten:
● Secondary sheave spring seat nut
2
NOTE:
Attach the sheave spring compressor “2” onto
the secondary sheave as shown.
Then compress the spring, and tighten the secondary sheave spring seat nut “1” with locknut
wrench “3”.
Sheave spring compressor
90890-04134
YM-04134
Locknut wrench
90890-01348
YM-01348
Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135
d
2. Install:
● primary fixed sheave “1”
● V-belt “2”
● secondary sheave assembly “3”
ECA15B1004
CAUTION:
Do not allow grease to contact the V-belt, primary and secondary pulleys.
NOTE:
● When
installing the belt, screw M6 (more than
45 mm (1.77 in)) bolts “4” to spread apart the
secondary sheave and then install the belt.
Make sure the belt pullout direction is correct.
5-57
V-BELT AUTOMATIC TRANSMISSION
● Install
the V-belt and secondary sheave assembly onto the primary sheave side.
● Align the “a” and “b” during reassembly.
1
2
5. Tighten:
● Primary sheave nut “1”
Primary sheave nut
160 Nm (16.0 m•kg, 115 ft•lb)
ECA15B1005
CAUTION:
● Before
tightening the nut to remount the
primary sheave, make sure that the serrations of the cam are fitted firmly into the
serrations of the crankshaft.
Also, make sure that cam is properly seated.
● Apply grease to the thread and seat of the
primary sheave nut.
3. Tighten:
● Secondary sheave nut “1”
Recommended lubricant
Shell BT grease 3®
NOTE:
While holding the secondary sheave with the
sheave holder “2”, tighten the secondary sheave
nut “1”.
NOTE:
While holding the primary sheave with the
sheave holder “2”, tighten the primary sheave
nut “1”.
T.
Secondary sheave nut
90 Nm (9.0 m•kg, 65 ft•lb)
R.
Sheave holder
90890-01481
Sheave holder
90890-01481
2
2
1
1
4. Install:
● primary sliding sheave “1”
● O-rings
● spacer
● primary sheave nut “2”
5-58
CRANKCASE AND CRANKSHAFT
EAS25960
CRANKCASE AND CRANKSHAFT
Removing the crankshaft assembly
7
10
8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
58 Nm (5.8 m • kg, 42 ft • Ib)
5
4
10
6
11
9
3
11
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
55 Nm (5.5 m • kg, 40 ft • Ib)
1
24 Nm (2.4 m • kg, 17 ft • Ib)
Order
Job/Parts to remove
Q’ty
Engine
Cylinder head
Cylinder/piston
Starter clutch/A.C. magneto rotor
Clutch
Oil pump
Right crankcase cover
1
2
3
4
5
6
7
8
9
10
Remarks
Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “CYLINDER HEAD” on page 5-14.
Refer to “CYLINDER AND PISTONS” on
page 5-25.
Refer to “GENERATOR AND STARTER
CLUTCH” on page 5-30.
Refer to “CLUTCH” on page 5-43.
Refer to “OIL PUMP” on page 5-39.
Refer to “V-BELT AUTOMATIC TRANSMISSION” on page 5-50.
Centerstand assembly
Timing chain
Timing chain guide (intake side)
Left crankcase
Dowel pin
Crankshaft assembly
Balancer cylinder
Right crankcase
Oil strainer
Dowel pin
1
1
1
1
2
1
1
1
1
2
5-59
CRANKCASE AND CRANKSHAFT
Removing the crankshaft assembly
7
10
8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
58 Nm (5.8 m • kg, 42 ft • Ib)
5
4
10
6
11
9
3
11
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
55 Nm (5.5 m • kg, 40 ft • Ib)
1
24 Nm (2.4 m • kg, 17 ft • Ib)
Order
11
Job/Parts to remove
Q’ty
Crankshaft main journal bearing
Remarks
2
For installation, reverse the removal procedure.
5-60
CRANKCASE AND CRANKSHAFT
Removing the connecting rod
7
16 Nm (1.6 m • kg, 12 ft • Ib) + 90˚
5
3
6
2
5
8
4
3
4
4
4
1
4
3
4
1
16 Nm (1.6 m • kg, 12 ft • Ib) + 90˚
60 Nm (6.0 m • kg, 43 ft • Ib)
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Q’ty
Connecting rod
Connecting rod (balancer)
Connecting rod cap
Big end bearing
Circlip
Piston pin
Balancer piston
Crankshaft
Remarks
2
1
3
3
2
1
1
1
For installation, reverse the removal procedure.
5-61
CRANKCASE AND CRANKSHAFT
EAS25560
DISASSEMBLING THE CRANKCASE
1. Remove:
● Crankcase bolts
NOTE:
Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
2. Remove:
● Left crankcase
ECA13900
NOTE:
CAUTION:
Identify the position of each crankshaft main
journal bearing so that it can be reinstalled in its
original place.
Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves
separate evenly.
EAS26010
REMOVING THE CONNECTING RODS
The following procedure applies to all of the connecting rods.
1. Remove:
● Connecting rod “1”
● Big end bearings
3. Remove:
● Dowel pins
EAS26050
REMOVING THE CRANKSHAFT JOURNAL
BEARING
1. Remove:
● Crankshaft assembly
● Crankshaft main journal bearings “1”
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
NOTE:
Remove the main journal bearing by the plane
bearing installer “2”.
Plane bearing installer
90890-04139
EAS25580
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
5-62
CRANKCASE AND CRANKSHAFT
3. Check:
● Crankcase
Cracks/damage → Replace.
● Oil delivery passages
Obstruction → Blow out with compressed air.
Journal oil clearance (using plastigauge®)
0.040–0.082 mm (0.0016–0.0032
in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS15B4207
CHECKING THE TIMING CHAIN
1. Check:
● Timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprockets as a set.
The following procedure applies to all of the
connecting rods.
ECA13930
CAUTION:
Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing
clearance and prevent engine damage, the big
end bearings must be installed in their original positions.
c. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rod halves.
d. Install the big end upper bearing into the connecting rod and the big end lower bearing into
the connecting rod cap.
NOTE:
EAS26090
Align the projections “a” on the big end bearings
with the notches “b” in the connecting rod and
connecting rod cap.
CHECKING THE CRANKSHAFT AND
CONNECTING RODS
1. Measure:
● Crankshaft runout
Out of specification → Replace the crankshaft.
Runout limit C
0.030 mm (0.0012 in)
e. Put a piece of Plastigauge® on the crankshaft pin.
f. Assemble the connecting rod halves.
NOTE:
● Do
not move the connecting rod or crankshaft
until the clearance measurement has been
completed.
● Lubricate the bolts threads and nut seats with
molybdenum disulfide grease.
● Make sure the “Y” mark “c” on the connecting
rod faces towards the left side of the crankshaft.
● Make sure the characters “d” on both the connecting rod and connecting rod cap are
aligned.
2. Check:
● Crankshaft journal surfaces
● Crankshaft pin surfaces
● Bearing surfaces
Scratches/wear → Replace the crankshaft.
3. Measure:
● Crankshaft-pin-to-big-end-bearing clearance
Out of specification → Replace the big end
bearings.
5-63
CRANKCASE AND CRANKSHAFT
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Select:
● Big end bearings (“P ”,“P ”,“P ”)
1
2
3
NOTE:
● The
numbers “A” stamped into the crankshaft
web and the numbers “1” on the connecting
rods are used to determine the replacement
big end bearing sizes.
● “P1”,“P2”,“P3” refer to the bearings shown in
the crankshaft illustration.
g. Tighten the connecting rod nuts.
ECA15B1040
CAUTION:
● When
tightening the connecting rod nuts,
be sure to use an F-type torque wrench.
● After tightening the connecting rod nut to
the specified torque, turn the connecting
rod nut another+90°.
Refer to “INSTALLING THE CONNECTING
RODS” on page 5-67.
T.
Connecting rod nut
16 Nm (1.6 m•kg, 11 ft•lb)
R.
h. Remove the connecting rod and big end
bearings.
Refer to “REMOVING THE CONNECTING
RODS” on page 5-62.
i. Measure the compressed Plastigauge®
width “e” on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select replacement big end bearings.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
For example, if the connecting rod “P1” and
the crankshaft web “P1” numbers are “4” and
“1” respectively, then the bearing size for “P1”
is:
“P1” (connecting rod) - “P1” (crankshaft)
=
4 - 1 = 3 (brown)
5-64
CRANKCASE AND CRANKSHAFT
Bearing color code
1.Blue 2.Black 3.Brown 4.Green
m. Measure the inside diameter “b” of each journal bearing at two places.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
● Crankshaft-journal-to-crankshaft-journal
bearing clearance.
Out of specification → Replace the crankshaft journal bearings.
Crankshaft-journal-to-crankshaft-journal bearing clearance
0.04–0.082 mm (0.0016–0.0032
in)
n. If journal bearing inside diameter is “45.03”
and crankshaft journal outside diameter is
“44.98”, then the main journal oil clearance is:
Main journal oil clearance: Journal bearing
inside diameter–
Main journal outside diameter
=
45.03–44.98 = 0.05 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
The following procedure applies to all of the
journal bearing.
ECA15B1027
CAUTION:
On the journal, the larger value is used as a
basis for calculation of the oil clearance, and
on the journal bearing, the smaller value is
used.
j. Clean the surface of main journal and journal
bearings.
k. Check the bearing surface. If the bearing surface is worn or scratched, the bearings
should be replace.
If the oil clearance is out of specification, select a replacement bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Select:
● Crankshaft journal bearings (J1, J2)
NOTE:
● The
numbers “a” stamped into the crankshaft
web and the numbers “1” on the crankcase are
used to determine the replacement crankshaft
journal bearing size.
● “J1, J2” refer to the bearings shown in the
crankshaft illustration.
NOTE:
If either of the right or left journal bearing is worn
or scratched, both bearings should be replaced
as a set.
l. Measure the outside diameter “a” of each
main journal at two places. If it is out of specification, replace the crankshaft.
5-65
CRANKCASE AND CRANKSHAFT
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS25630
INSTALLING THE CRANKSHAFT MAIN
JOURNAL BEARING
1. Attach:
● Crankshaft main journal bearings
NOTE:
Attach the crankshaft main journal bearing to the
plane bearing installer “1”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. For example, if the crankcase “J1”and the
crankshaft web “J1” numbers are “4” and “2”
respectively, then the bearing size for “J1” is:
Bearing size for “J1”:
“J1” (crankcase)–
“J1” (crankshaft web) =
4–2 = (black)
Bearing color code
1.Blue,
2.Black,
4.Green
Plane bearing installer
90890-04139
2. Install:
● Crankshaft main journal bearings “2”
NOTE:
● Align
the projection “a” on the bearing with the
projection “b” on the crankcase.
● Place an iron “3” plate beneath the crankcase
and press fit until the end of the plain bearing
installer touches the iron plate.
3.Brown,
5-66
CRANKCASE AND CRANKSHAFT
EAS26150
INSTALLING THE CONNECTING RODS
1. Install:
● Big end bearings “1”
NOTE:
● Align
the projections “a” on the big end bearings with the notches “b” in the connecting rods
and connecting rod caps.
● Be sure to reinstall each big end bearing in its
original place.
4. Tighten:
● Connecting rod nuts
NOTE:
Apply molybdenum disulfide grease to the rod
cap bolt threads and nut surfaces.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EWA13390
WARNING
Replace the connecting rod bolts and nuts
with new ones.
● Clean the connecting rod bolts and nuts.
●
2. Install:
● Connecting rods
NOTE:
NOTE:
Tighten the connecting rod bolts using the following procedure.
● The
stamped “Y” mark “a” on the connecting
rods should face towards the left side of the
crankcase.
● Install each connecting rod in its original place.
b. Clean the connecting rod bolts and nuts.
c. Tighten the connecting rod nuts with a torque
wrench.
T.
Connecting rod nut
16 Nm (1.6 m•kg, 11 ft•lb) + 90°
R.
d. Put a mark “1” on the corner of the connecting rod nut “2” and the connecting rod “3”.
3. Install:
● Connecting rod cap
NOTE:
Be sure that the characters “a” on the side of the
cap and connecting rod are aligned.
e. After tightening the connecting rod nut to the
specified torque, turn the connecting rod nut
clockwise another 90°.
EWA13400
WARNING
If the connecting rod nut is tightened more
than the specified angle, do not loosen the
nut and then retighten it. Instead, replace the
5-67
CRANKCASE AND CRANKSHAFT
connecting rod bolt and nut with a new one
and perform the procedure again.
T.
R.
ECA15B1028
CAUTION:
● Tighten
Balancer piston cylinder bolt
58 Nm (5.8 m•kg, 42 ft•lb)
ECA15B1003
CAUTION:
the nut until it is at the specified an-
To avoid scratching the crankshaft and to
ease the installation procedure, apply grease
onto the oil seal lips and apply engine oil
onto each bearing.
gles.
● Do not use a torque wrench to tighten the
connecting rod nut to the specified angle.
NOTE:
On a hexagonal nut, note that the angle from
one corner to another is 90°.
EAS25700
ASSEMBLING THE CRANKCASE
1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces.
2. Apply:
● Sealant
(onto the crankcase mating surfaces)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
● Balancer connecting rod
● Connecting rod cap
Yamaha bond No. 1215 (Three
Bond No.1215®)
90890-85505
T.
Connecting rod cap
60 Nm (6.0 m•kg, 43 ft•lb)
R.
ECA15B1043
NOTE:
Do not allow any sealant to come into contact
with the oil gallery.
CAUTION:
● When
tightening the nuts be sure to use an
F-type torque wrench.
● Without pausing, tighten to full torque
specification. Apply continuous torque
57–63 Nm (5.7–6.3 m•kg, 41–45 ft•lb). Once
you reach 57 Nm (5.7 m•kg, 41 ft•lb) DO
NOT STOP TIGHTENING until final torque is
reached. If the tightening is interrupted
57–63 Nm (5.7–6.3 m•kg, 41–45 ft•lb) loosen
the nut to less than 57 Nm (5.7 m•kg, 41
ft•lb) and start again.
3. Install:
● Dowel pins
● Left crankcase
EAS15B4004
INSTALLING THE CRANKSHAFT
1. Install:
● Crankshaft assembly “1”
● Balancer piston cylinder “2”
5-68
CRANKCASE AND CRANKSHAFT
5-69
TRANSMISSION
EAS26240
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
10
9
7
8
6
9
9
10
5
4
2
9
3
1
9
12 Nm (1.2 m • kg, 8.7 ft • Ib)
Order
Job/Parts to remove
Q’ty
Left crankcase
1
2
3
4
5
6
7
8
9
10
Remarks
Refer to “CHECKING THE CRANKCASE”
on page 5-62.
Secondary shaft
Main axle
Primary driven gear
First pinion gear
Washer
Drive axle
First wheel gear
Circlip
Bearing
Oil seal
1
1
1
1
1
1
1
1
5
2
For installation, reverse the removal procedure.
5-70
TRANSMISSION
EAS26250
REMOVING THE TRANSMISSION
1. Remove:
● Left crankcase
Refer to “CRANKCASE AND CRANKSHAFT” on page 5-59.
2. Remove:
● Secondary shaft; “1”
● Main axle“2”
● Drive axle“3”
● Primary driven gear“4”
● First wheel gear“5”
● First pinion gear
3. Measure:
● Secondary shaft runout
(with a centering device and dial gauge)
Out of specification → Replace the secondary shaft.
Maximum secondary shaft runout
0.08 mm (0.0031 in)
EAS26300
CHECKING THE TRANSMISSION
1. Measure:
● Main axle runout
(with a centering device and dial gauge)
Out of specification → Replace the main axle.
4. Check:
● Transmission gear movement
Rough movement → Replace the defective
part(s).
5. Check:
● Circlips
Bends/damage/looseness → Replace.
Main axle runout
0.08 mm (0.0031 in)
2. Measure:
● Drive axle runout
(with a centering device and dial gauge)
Out of specification → Replace the drive axle.
Drive axle runout
0.08 mm (0.0031 in)
5-71
CHAIN DRIVE TRANSMISSION
EAS24750
CHAIN DRIVE TRANSMISSION
Removing primary and secondary drive chains
23 Nm (2.3 m • kg, 17 ft • Ib)
30 Nm (3.0 m • kg, 22 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
100 Nm (10.0 m • kg, 72 ft • Ib)
14
8 7
10 9
3 2
4
11
13
6
5
1
40 Nm (4.0 m • kg, 29 ft • Ib)
12
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Order
Job/Parts to remove
Q’ty
Chain drive oil
DRIVE OIL LEVEL” on page 3-26.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY” on page 4-68.
Refer to “REAR WHEEL” on page 4-16.
Rear shock absorber
1
2
3
4
5
6
7
8
9
10
11
12
13
Remarks
Drain.
Refer to “CHECKING THE CHAIN
Rear brake caliper/rear wheel
Rear brake hose/rear brake lock lever cable
holder
Cover
Nut
Washer
Swingarm
Dowel pin
Pivot shaft
Collar
Oil seal
Bearing
Left rear footrest
Chain drive assembly
Chain drive holder assembly
5-72
1/1
1
1
1
1
2
1
1
1
1
1
1
1
CHAIN DRIVE TRANSMISSION
Removing primary and secondary drive chains
23 Nm (2.3 m • kg, 17 ft • Ib)
30 Nm (3.0 m • kg, 22 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
100 Nm (10.0 m • kg, 72 ft • Ib)
14
8 7
10 9
3 2
4
13
11
6
5
1
40 Nm (4.0 m • kg, 29 ft • Ib)
12
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Order
14
Job/Parts to remove
Q’ty
O-ring
Remarks
1
For installation, reverse the removal procedure.
5-73
CHAIN DRIVE TRANSMISSION
Removing primary and secondary drive chains
6
10
13
12
10
7
9
3
9
9
8 10
5
9
9
11
4
10
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
2
Job/Parts to remove
Q’ty
Chain drive case (outer)
Secondary drive chain
Secondary drive gear
Secondary driven gear
Middle shaft
Primary drive chain
Primary drive gear
Primary driven gear
Bearing
Oil seal
Collar
Chain drive case (inner)
Retainer
Remarks
1
1
1
1
1
1
1
1
5
4
1
1
1
For installation, reverse the removal procedure.
5-74
CHAIN DRIVE TRANSMISSION
EAS15B4006
CHECKING THE SWINGARM
1. Check:
● swingarm “1”
Damage/wear → Replace.
2. Check:
● Pivot shaft “1”
● Collar
● Bearing
● Oil seal
Damage/wear → Replace.
EAS15B4008
ASSEMBLING THE CHAIN DRIVE
ASSEMBLY
1. Install:
● Chain drive case (outer)
Chain drive case bolt
10 Nm (1.0 m E kg, 7.2 ft E lb)
NOTE:
First, tighten the chain drive case bolts that are
numbered in the illustration in the order shown,
and then tighten the unnumbered bolts in a
crisscross pattern.
EAS24760
CHECKING THE CHAIN DRIVE ASSEMBLY
1. Check:
● Primary drive chain “1”
● Secondary drive chain “2”
Damage/stiffness → Replace the drive chain
and its respective gears as a set.
2. Check:
● Primary/secondary drive gear “3”
● Primary/secondary driven gear “4”
● Secondary drive gear “5”
● Secondary driven gear “6”
Damage/wear → Replace the respective
drive gears and respective drive chains as a
set.
3
1
4
2
EAS24770
INSTALLING THE CHAIN DRIVE
1. Install:
● Chain drive assembly
● Swingarm
● Pivot shaft
● Washer
● Nut
5-75
CHAIN DRIVE TRANSMISSION
2. Tighten:
● Swingarm bolt
T.
Swingarm bolt
40 Nm (4.0 m•kg, 29 ft•lb)
R.
3. Adjust:
● Pivot shaft
● Nut
T.
R.
Pivot shaft
7 Nm (0.7 m•kg, 5.1 ft•lb)
Nut
100 Nm (10.0 m•kg, 72 ft•lb)
NOTE:
● With
your fingers, screw in the pivot shaft until
it touches the collar and then tighten the pivot
shaft to the tightening torque.
● Tighten the nut to the tightening torque.
● Install the shock absorber and rear wheel after
the swingarm is installed.
4. Fill:
● Chain drive oil
5. Check:
● Chain drive oil level
Refer to “CHECKING THE CHAIN DRIVE
OIL LEVEL” on page 3-26.
5-76
CHAIN DRIVE TRANSMISSION
5-77
COOLING SYSTEM
RADIATOR .................................................................................................... 6-1
CHECKING THE RADIATOR.................................................................. 6-3
CHECKING THE OIL COOLER .............................................................. 6-3
INSTALLING THE OIL COOLER AND RADIATOR ................................ 6-3
THERMOSTAT .............................................................................................. 6-5
CHECKING THE THERMOSTAT............................................................ 6-6
INSTALLING THE THERMOSTAT ASSEMBLY ..................................... 6-6
WATER PUMP............................................................................................... 6-7
DISASSEMBLING THE WATER PUMP.................................................. 6-9
CHECKING THE WATER PUMP ............................................................ 6-9
ASSEMBLING THE WATER PUMP........................................................ 6-9
INSTALLING THE WATER PUMP .......................................................... 6-11
1
2
3
4
5
6
7
8
9
RADIATOR
EAS26380
RADIATOR
Removing the radiator
6
7
3
9
5
2
8
14
10 Nm (1.0 m • kg, 7.2 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
17
15
16
4
18
11
63 Nm (6.3 m • kg, 45 ft • Ib)
17 Nm (1.7 m • kg, 12 ft • Ib)
Order
12
Job/Parts to remove
13
10
Q’ty
Leg shield/footrest board/inner fender
Engine oil
Coolant
1
2
3
4
5
6
7
8
9
10
11
12
13
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-13.
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-19.
Coolant reservoir hose
Coolant reservoir
Cooling system air bleed hose
Oil cooler outlet hose
Radiator inlet hose
Thermostat outlet hose
Coolant pipe
Fast idle outlet hose
Radiator outlet hose
Radiator fan motor coupler
Radiator filler neck
Radiator filler hose
Stay
1
1
1
1
1
1
1
1
1
1
1
1
1
6-1
Disconnect.
Disconnect.
Disconnect.
Disconnect.
RADIATOR
Removing the radiator
6
7
3
9
5
2
8
14
10 Nm (1.0 m • kg, 7.2 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
17
15
16
4
18
11
63 Nm (6.3 m • kg, 45 ft • Ib)
17 Nm (1.7 m • kg, 12 ft • Ib)
Order
14
15
16
17
18
12
Job/Parts to remove
13
10
Q’ty
Radiator
Radiator fan
Oil filter cartridge
Oil cooler inlet hose
Oil cooler
1
1
1
1
1
Remarks
Disconnect.
For installation, reverse the removal procedure.
6-2
RADIATOR
EAS26390
CHECKING THE RADIATOR
1. Check:
● Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radiator.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin,
flat-head screwdriver.
b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
● Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” on page 8-29.
EAS15B4458
CHECKING THE OIL COOLER
1. Check:
● Oil cooler
Cracks/damage → Replace.
2. Check:
● Oil cooler inlet hose
● Oil cooler outlet hose
Cracks/damage/wear → Replace.
2. Check:
● Radiator hoses
● Radiator pipes
Cracks/damage → Replace.
3. Measure:
● Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Radiator cap opening pressure
107.9–137.3 kPa (15.6–19.9 psi)
(1.08–1.37 kgf/cm2)
EAS26400
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester “1” and radiator
cap tester adapter “2” to the radiator cap “3”.
T.
Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01
Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-33984
INSTALLING THE OIL COOLER AND
RADIATOR
1. Clean:
● Mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
● O-ring
● Oil cooler “1”
● Oil cooler bolt “2”
Oil cooler bolt
63 Nm (6.3 m•kg, 45 ft•lb)
R.
●
Oil filter cartridge
T.
Oil filter cartridge
17 Nm (1.7 m•kg, 12 ft•lb)
R.
Oil filter wrench
90890-01469
Oil filter wrench
YM-01469
6-3
RADIATOR
NOTE:
Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01
Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-33984
● Before
installing the oil cooler, lubricate the oil
cooler bolt with engine oil.
● Make sure that the O-ring is positioned properly.
● Align the projection “a” on the oil cooler with
the slot “b” in the crankcase.
b. Apply 100 kPa (1.0 kg/cm2, 14.22 psi) of
pressure.
c. Measure the indicated pressure with the
gauge.
2
b
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
● Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
1
3. Fill:
● Cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-19.
● Crankcase
(with the specified amount of the recommended engine oil)
Refer to “CHANGING THE ENGINE OIL” on
page 3-13.
4. Check:
● Cooling system
Leaks → Repair or replace any faulty part.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the radiator cap tester “1” to the radiator.
1
6-4
THERMOSTAT
EAS26440
THERMOSTAT
Removing the thermostat assembly
18 Nm (1.8 m • kg, 13 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
2
5
3
6
4
Order
Job/Part
Q’ty
Center cover/side cover
Coolant
1
2
3
4
5
6
Thermostat outlet hose
Coolant temperature sensor coupler
Coolant temperature sensor
Copper washer
Thermostat cover
Thermostat
1
1
1
1
1
1
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-19.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
6-5
THERMOSTAT
EAS26450
CHECKING THE THERMOSTAT
1. Check:
● Thermostat
Does not open at 70.5–73.5°C (159–164°F)
→ Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
● Thermostat housing cover
Cracks/tears → Replace.
EAS26480
INSTALLING THE THERMOSTAT
ASSEMBLY
1. Install:
● Thermostat
● Thermostat cover
T.
Bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat “1” in a container “2”
filled with water.
b. Slowly heat the water.
c. Place a thermometer “3” in the coolant.
d. While stirring the water “4”, observe the thermostat and thermometer’s indicated temperature.
NOTE:
Install the thermostat with its breather hole “a”
facing forward.
NOTE:
If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious
overheating or overcooling.
a
2. Install:
● Copper washer
● Coolant temperature sensor New
T.
Coolant temperature sensor
18 Nm (1.8 m•kg, 13 ft•lb)
R.
3. Fill the coolant with the specified amount.
● Cooling system
Refer to “CHANGING THE COOLANT” on
page 3-19.
4. Check:
● Cooling system
Leaks → Repair or replace the faulty part.
5. Measure:
● Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
A. Fully close
B. Fully open
6-6
WATER PUMP
EAS26500
WATER PUMP
Removing the water pump
1
4
3
2
10
5
6
9
7
10 Nm (1.0 m • kg, 7.2 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
8
Order
Job/Parts to remove
Q’ty
Left upper side cover moulding/left footrest
board
Coolant
1
2
3
4
5
6
7
8
9
10
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-19.
V-belt case air filter element clamp joint
V-belt case air filter element (left)
Generator cover protector cover
Generator cover protector
Oil cooler inlet hose
Coolant hose
Radiator outlet hose
Water pump inlet pipe
Water pump outlet pipe
Water pump assembly
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
6-7
WATER PUMP
Disassembling the water pump
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
6
7
8
5
2
4
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Order
Job/Parts to remove
Q’ty
Remarks
NOTE:
It is not necessary to remove the impeller
shaft, unless the coolant level is extremely low
or coolant contains engine oil.
1
2
3
4
5
6
7
8
Water pump housing cover
O-ring
Circlip
Impeller shaft
Water pump seal
Bearing
Oil seal
Water pump housing
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly procedure.
6-8
WATER PUMP
4. Remove:
● Rubber damper holder “1”
● Rubber damper “2”
(from the impeller, with a thin, flat-head
screwdriver)
EAS26510
DISASSEMBLING THE WATER PUMP
1. Remove:
● Water pump seal “1”
NOTE:
Remove the water pump seal from the inside of
the water pump housing.
NOTE:
Do not scratch the impeller shaft.
a. Water pump housing
EAS26550
CHECKING THE WATER PUMP
1. Check:
● Water pump housing cover “1”
● Water pump housing “2”
● Impeller shaft “3”
● Water pump seal “4”
● Oil seal “5”
● Rubber damper
● Rubber damper holder
Cracks/damage/wear → Replace.
2. Remove:
● Oil seal “1”
(with a thin, flat-head screwdriver)
NOTE:
Remove the oil seal from the outside of the water pump housing.
3. Remove:
● Bearing “1”
NOTE:
Remove the bearing from inside of the water
pump housing.
EAS26570
ASSEMBLING THE WATER PUMP
1. Install:
● Oil seal “1”
(to the water pump housing)
NOTE:
● Install
the oil seal with a socket that matches its
outside diameter.
● Before installing the oil seal, apply tap water or
coolant onto its outer surface.
Installed depth of oil seal “a”
11.5 mm (0.45 in)
6-9
WATER PUMP
a
1
2. Install:
● Bearing “1”
A. Push down
3. Install:
● Water pump seal “1” New
ECA15B1029
4. Install:
● Rubber damper “1” New
● Rubber damper holder “2” New
CAUTION:
NOTE:
Never apply oil or grease onto the water
pump seal surface.
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
NOTE:
● Install
the water pump seal with the special
tools.
● Before installing the water pump seal, apply
Yamaha bond No.1215 or Sealant (Quick GasketR) “2” to the water pump housing “3”.
Mechanical seal installer
90890-04078
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driver
90890-04058
Bearing driver 40 mm
YM-04058
Yamaha bond No. 1215 (Three
Bond No.1215®)
90890-85505
5. Measure:
● Tilt
Out of specification → Repeat steps (3) and
(4).
ECA15B1030
CAUTION:
Make sure that the rubber damper and rubber damper holder are flush with the impeller.
Maximum impeller shaft tilt
0.15 mm (0.006 in)
6-10
WATER PUMP
1. Straightedge
2. Impeller
EAS26600
INSTALLING THE WATER PUMP
1. Install:
● Water pump assembly
T.
Water pump assembly bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
R.
NOTE:
Align the projection “a” at the oil pump shaft and
water pump shaft groove “b”.
a
b
2. Fill:
● Cooling
system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-19.
3. Check:
● Cooling system
Leaks → Repair or replace any faulty part.
4. Measure:
● Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
6-11
FUEL SYSTEM
FUEL TANK................................................................................................... 7-1
REMOVING THE FUEL TANK ................................................................ 7-2
REMOVING THE FUEL PUMP ............................................................... 7-2
INSTALLING THE FUEL PUMP.............................................................. 7-2
INSTALLING THE FUEL TANK............................................................... 7-2
THROTTLE BODIES ..................................................................................... 7-4
CHECKING THE INJECTORS ................................................................ 7-7
CHECKING THE THROTTLE BODIES................................................... 7-7
CHECKING THE PRESSURE REGULATOR OPERATION ................... 7-7
ADJUSTING THE THROTTLE POSITION SENSOR.............................. 7-7
1
2
3
4
5
6
7
8
9
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank
4 Nm (0.4 m • kg, 2.9 ft • Ib)
5
10 Nm (1.0 m • kg, 7.2 ft • Ib)
2
3
6
8
7
9
1
4
10
Order
Job/Parts to remove
Q’ty
Strage box
1
2
3
4
5
6
7
8
9
10
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Fuel pump coupler
Fuel hose connector cover
Fuel hose
Fuel tank breather hose
Fuel pump bracket
Fuel pump
Fuel pump gasket
Fuel tank cap
Fuel overflow tray/fuel over flow hose
Fuel tank
1
1
1
1
1
1
1
1
1/1
1
For installation, reverse the removal procedure.
7-1
FUEL TANK
EAS26710
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
● Fuel hose connector cover “1”
3. Disconnect:
● Fuel hose “2”
● Fuel pump coupler “3”
● Fuel tank breather hose “4”
INSTALLING THE FUEL PUMP
1. Install:
● Fuel pump gasket New
● Fuel pump
● Fuel pump bracket
T.
EAS26630
Fuel pump bracket bolt
4 Nm (0.4 m•kg, 2.9 ft • lb)
R.
NOTE:
ECA15B1031
● Do
not damage the installation surfaces of the
fuel tank when installing the fuel pump.
● Always use a new fuel pump gasket.
● Align the projection “a” on the fuel pump with
the projection in the fuel tank.
● Tighten the bolts to the specified torque in the
proper tightening sequence as shown.
● Install the fuel pump in the direction shown in
the illustration.
CAUTION:
● Be
sure to disconnect the fuel hose by
hand. Do not forcefully disconnect the
hose with tools.
● Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hoses, since there may be fuel remaining in it.
● Do not disconnect the fuel hose except the
fuel hose connector of the fuel pump feeding side.
a
NOTE:
Before removing the hoses, place a few rags in
the area under where it will be removed.
6
1
FWD
4
3
4
5
2
2
EAS15B4013
INSTALLING THE FUEL TANK
1. Install:
● Fuel tank
3
1
Fuel tank bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
4. Remove:
● Fuel tank
NOTE:
Tighten the bolts to the specified torque in the
proper tightening sequence as shown.
EAS26640
REMOVING THE FUEL PUMP
1. Remove:
● Fuel pump bracket
● Fuel pump
● Fuel pump gasket
4
2
ECA14720
CAUTION:
FWD
● Do
not drop the fuel pump or give it a
strong shock.
● Do not touch the base section of the fuel
sender.
1
3
2. Connect:
● Fuel hose
7-2
FUEL TANK
Fuel breather hose
● Fuel pump coupler
●
ECA15B1032
CAUTION:
● Be
sure to connect the fuel hose by hand.
Do not forcefully connect the hose with
tools.
● When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose holders are in the correct position, otherwise the fuel hose will not be
properly installed.
3. Install:
● Fuel pump connector cover
7-3
THROTTLE BODIES
EAS26970
THROTTLE BODIES
Removing the throttle bodies
10 Nm (1.0 m • kg, 7.2 ft • Ib)
13
9
11
12
12 Nm (1.2 m • kg, 8.7 ft • Ib)
11
14
14
11
11
2
15
10
4
3
5
15
3
7
4
8
1
6
10 Nm (1.0 m • kg, 7.2 ft • Ib)
9 Nm (0.9 m • kg, 6.5 ft • Ib)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Job/Parts to remove
Q’ty
Footrest board
Leg shield
Inner fender
Air vent hose
Crankcase breather hose
Silencer joint clamp
Throttle body joint clamp
Silencer
Throttle cable
Fast idle inlet hose
Fast idle outlet hose
Throttle position sensor coupler
Throttle body assembly
Fuel injector coupler
Intake air pressure sensor coupler
Intake air pressure sensor
Fuel injector (with fuel hose)
Intake manifold
1
1
2
2
1
2
1
1
1
1
2
1
1
2
2
7-4
Remarks
Disconnect.
Loosen.
Loosen.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
THROTTLE BODIES
Removing the throttle bodies
10 Nm (1.0 m • kg, 7.2 ft • Ib)
13
9
11
12
12 Nm (1.2 m • kg, 8.7 ft • Ib)
11
14
14
11
11
2
15
10
4
3
5
15
3
7
4
8
1
6
10 Nm (1.0 m • kg, 7.2 ft • Ib)
9 Nm (0.9 m • kg, 6.5 ft • Ib)
Order
Job/Parts to remove
Q’ty
Remarks
For installation, reverse the removal procedure.
7-5
THROTTLE BODIES
Disassembling the throttle bodies
1
3
2
2
4
Order
Job/Parts to remove
Q’ty
Remarks
NOTE:
Before disassembling the throttle body, make
sure to note the number of times the air screw
is turned out from the seated position to its set
position.
1
2
3
4
Throttle position sensor
Fast idle plunger
Idle adjust screw
Air screw
1
1
1
2
For installation, reverse the removal procedure.
7-6
THROTTLE BODIES
EAS26980
CHECKING THE INJECTORS
1. Check:
● Injectors
Damage → Replace.
1
3
2
d. Set the main switch to “ON” and the engine
stop switch to “ ”.
e. Start the engine.
f. Measure the fuel pressure.
Out of specification → Check the fuel hose
connection or replace the fuel pump.
EAS26990
CHECKING THE THROTTLE BODIES
1. Check:
● Throttle bodies
Cracks/damage → Replace the throttle bodies as a set.
2. Check:
● Fuel passages
Obstructions → Clean.
Fuel pressure
240–260 kPa (240–2.60 kg/cm2,
34.2–37.0 psi)
g. Turn the main switch to “OFF”.
h. Remove the pressure gauge and fuel pressure adapter.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
a. Wash the throttle bodies in a petroleumbased solvent.
Do not use any caustic carburetor cleaning
solution.
b. Blow out all of the passages with compressed air.
Before removing the special tools, place a few
rags in the area under where it will be removed.
i. Install the fuel hose.
j. Install the fuel hose connector cover, fuel
tank cover and seat.
Refer to “GENERAL CHASSIS” on page 4-1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS27010
EAS27020
CHECKING THE PRESSURE REGULATOR
OPERATION
1. Check:
● Pressure regulator operation
ADJUSTING THE THROTTLE POSITION
SENSOR
NOTE:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the fuel tank.
Refer to “FUEL TANK” on page 7-1.
b. Disconnect the negative pressure hose “1”
from the pressure regulator at the hose joint.
c. Connect the pressure gauge “2” and adapter
“3” to the fuel injection pipe.
Before adjusting the throttle position sensor, the
engine idling speed should be properly adjusted.
1. Check:
● Throttle position sensor
Refer to “CHECKING THE THROTTLE POSITION SENSOR” on page 8-119.
2. Adjust:
● Throttle position sensor angle
Pressure gauge
90890-03153
Fuel pressure adapter
90890-03181
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the main switch to “ON”.
b. Connect the throttle position sensor coupler.
c. Connect the pocket tester to the throttle position sensor as shown.
7-7
THROTTLE BODIES
Tester positive probe
Yellow “1”
Negative tester probe
Black/Blue “2”
2
1
d. Measure the throttle position sensor voltage.
e. Loosen the throttle position sensor screws
“3”.
f. Adjust the throttle position sensor angle so
that the voltage is within the specified range.
Throttle position sensor voltage
(closed position)
0.63–0.73V (Yellow–Black/Blue )
g. After adjusting the throttle position sensor angle, tighten the throttle position sensor
screws.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-8
THROTTLE BODIES
7-9
ELECTRICAL SYSTEM
IGNITION SYSTEM ....................................................................................... 8-1
CIRCUIT DIAGRAM ................................................................................ 8-1
TROUBLESHOOTING ............................................................................ 8-3
ELECTRIC STARTING SYSTEM .................................................................. 8-5
CIRCUIT DIAGRAM ................................................................................ 8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................ 8-9
TROUBLESHOOTING ............................................................................ 8-13
CHARGING SYSTEM.................................................................................... 8-15
CIRCUIT DIAGRAM ................................................................................ 8-15
TROUBLESHOOTING ............................................................................ 8-17
LIGHTING SYSTEM ...................................................................................... 8-19
CIRCUIT DIAGRAM ................................................................................ 8-19
TROUBLESHOOTING ............................................................................ 8-21
SIGNALING SYSTEM ................................................................................... 8-23
CIRCUIT DIAGRAM ................................................................................ 8-23
TROUBLESHOOTING ............................................................................ 8-25
COOLING SYSTEM....................................................................................... 8-29
CIRCUIT DIAGRAM ................................................................................ 8-29
TROUBLESHOOTING ............................................................................ 8-31
FUEL INJECTION SYSTEM.......................................................................... 8-33
CIRCUIT DIAGRAM ................................................................................ 8-33
ECU SELF-DIAGNOSTIC FUNCTION.................................................... 8-35
FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS
OPERATION CONTROL)...................................................................... 8-35
TROUBLESHOOTING METHOD............................................................ 8-38
DIAGNOSTIC MODE .............................................................................. 8-38
TROUBLESHOOTING DETAILS ............................................................ 8-45
IMMOBILIZER SYSTEM................................................................................ 8-57
CIRCUIT DIAGRAM ................................................................................ 8-57
GENERAL INFORMATION ..................................................................... 8-59
PART REPLACEMENT AND KEY CODE REGISTRATION
REQUIREMENTS.................................................................................. 8-59
TROUBLESHOOTING ............................................................................ 8-62
SELF-DIAGNOSIS FAULT CODE INDICATION..................................... 8-62
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A) .......................................... 8-65
CIRCUIT DIAGRAM ................................................................................ 8-65
ABS COMPONENTS CHART ................................................................. 8-67
ABS CONNECTOR LOCATION CHART ................................................ 8-69
ECU (ABS) AND FAIL-SAFE RELAY CHART ........................................ 8-71
1
2
3
4
5
6
7
8
9
[D-1] MAINTENANCE OF THE ECU (ABS) ............................................ 8-72
[D-2] MAINTENANCE OF THE ABS FAIL-SAFE RELAY ....................... 8-72
[D-3] MAINTENANCE OF THE FRONT WHEEL SENSOR AND
SENSOR ROTOR ................................................................................. 8-73
[D-5] MAINTENANCE OF THE HYDRAULIC UNIT ................................ 8-73
ABS TROUBLESHOOTING OUTLINE.................................................... 8-75
BASIC INSTRUCTION FOR TROUBLESHOOTING .............................. 8-76
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 8-77
[A] ABS MALFUNCTION CHECK USING THE ABS WARNING
LIGHT .................................................................................................... 8-78
[B] DETAILED ABS MALFUNCTION CHECK......................................... 8-78
[B-1] THE ABS WARNING LIGHT DOES NOT COME ON..................... 8-78
[B-2] THE ABS WARNING LIGHT REMAINS ON................................... 8-78
[B-3] THE ABS WARNING LIGHT FLASHES ......................................... 8-78
[B-4] MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS
(PAST MALFUNCTION)........................................................................ 8-79
[B-5] MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS
(PRESENT MALFUNCTION) ................................................................ 8-80
[C] DETERMINING THE CAUSE AND LOCATION OF THE
MALFUNCTION..................................................................................... 8-82
[C-1] ONLY THE ABS WARNING LIGHT DOES NOT COME ON
WHEN THE MAIN SWITCH IS SET TO “ON” ....................................... 8-82
[C-2] ABS WARNING LIGHT AND ALL OTHER INDICATORS DO
NOT COME ON..................................................................................... 8-82
[C-3] ABS WARNING LIGHT FLASHES ................................................. 8-83
[C-4] ABS WARNING LIGHT FLASHES EVERY 0.5 SECOND.............. 8-83
[C-5] DIAGNOSIS BY THE MALFUNCTION CODE ............................... 8-83
[D-6-4] DELETING THE MALFUNCTION CODE .................................... 8-93
[D-6-6] DELETE FUNCTION TEST......................................................... 8-94
[D-6] FINAL CHECK ................................................................................ 8-95
ELECTRICAL COMPONENTS...................................................................... 8-97
CHECKING THE SWITCHES ................................................................. 8-101
CHECKING THE BULBS AND BULB SOCKETS ................................... 8-105
CHECKING THE FUSES ........................................................................ 8-106
CHECKING AND CHARGING THE BATTERY....................................... 8-107
CHECKING THE RELAYS ...................................................................... 8-110
CHECKING THE TURN SIGNAL/HAZARD RELAY................................ 8-111
CHECKING THE DIODE ......................................................................... 8-112
CHECKING THE SPARK PLUG CAPS................................................... 8-112
CHECKING THE IGNITION COIL ........................................................... 8-113
CHECKING THE SPARK PLUG GAP..................................................... 8-113
CHECKING THE CRANKSHAFT POSITION SENSOR.......................... 8-114
CHECKING THE LEAN ANGLE SENSOR.............................................. 8-114
CHECKING THE STARTER MOTOR OPERATION ............................... 8-115
CHECKING THE STATOR COIL ............................................................ 8-115
CHECKING THE CHARGING VOLTAGE ............................................... 8-116
CHECKING THE HORN.......................................................................... 8-116
CHECKING THE FUEL SENDER ........................................................... 8-117
CHECKING THE SPEED SENSOR ........................................................ 8-117
CHECKING THE RADIATOR FAN MOTOR ........................................... 8-118
CHECKING THE COOLANT TEMPERATURE SENSOR....................... 8-118
CHECKING THE THROTTLE POSITION SENSOR ............................... 8-119
CHECKING THE INTAKE AIR PRESSURE SENSOR ........................... 8-120
CHECKING THE INTAKE AIR TEMPERATURE SENSOR .................... 8-120
CHECKING THE V-BELT RESET COUPLER ........................................ 8-121
IGNITION SYSTEM
EAS27090
IGNITION SYSTEM
EAS27110
CIRCUIT DIAGRAM
8-1
IGNITION SYSTEM
1. Crankshaft position sensor
4. Main switch
13. Ignition fuse
16. Battery
17. Main fuse
21. Starting circuit cut-off relay 1
26. Engine stop switch
29. Sidestand switch
30. ECU (engine)
31. Ignition coil
32. Spark plug
40. Lean angle sensor
8-2
IGNITION SYSTEM
EAS27140
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
NOTE:
Before troubleshooting, remove the following part(s):
1.Battery cover
2.Rear cover
3.Front cowling
4.Leg shield
5.Footrest board
6.Inner fender
1. Check the fuses.
(Main and ignition)
Refer to “CHECKING THE FUSES” on
page 8-106.
NG→
Replace the fuse(s).
OK↓
2. Check the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-107.
NG→
● Clean
the battery terminals.
or replace the battery.
● Recharge
OK↓
3. Check the spark plug.
Refer to “CHECKING THE SPARK
PLUGS” on page 3-9.
NG→
Re-gap or replace the spark plug.
OK→
Ignition system is OK.
NG→
Replace the spark plug caps.
NG→
Replace the ignition coils.
NG→
Replace the crankshaft position sensor.
NG→
Replace the main switch.
NG→
Replace the right handlebar switch.
OK↓
4. Check the spark plug gap.
Refer to “CHECKING THE SPARK
PLUG GAP” on page 8-113.
NG↓
5. Check the spark plug cap.
Refer to “CHECKING THE SPARK
PLUG CAPS” on page 8-112.
OK↓
6. Check the ignition coils.
Refer to “CHECKING THE IGNITION
COIL” on page 8-113.
OK↓
7. Check the crankshaft position sensor.
Refer to “CHECKING THE CRANKSHAFT POSITION SENSOR” on page
8-114.
OK↓
8. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
OK↓
9. Check the engine stop switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
OK↓
8-3
IGNITION SYSTEM
10. Check the sidestand switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
NG→
Replace the sidestand switch.
NG→
Replace the starting circuit cut-off relay 1.
NG→
Replace the lean angle sensor.
NG→
Properly connect or repair the ignition system’s
wiring
OK↓
11. Check the starting circuit cut-off relay
1 (Diode).
Refer to “CHECKING THE RELAYS”
on page 8-110.
OK↓
12. Check the lean angle sensor.
Refer to “CHECKING THE LEAN
ANGLE SENSOR” on page 8-114.
OK↓
13. Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-1.
OK↓
Replace the ECU.
8-4
ELECTRIC STARTING SYSTEM
EAS27160
ELECTRIC STARTING SYSTEM
EAS27170
CIRCUIT DIAGRAM
XP500
8-5
ELECTRIC STARTING SYSTEM
4. Main switch
11. Signaling system fuse
13. Ignition fuse
16. Battery
17. Main fuse
18. Starter relay
19. Starter motor
20. Diode
21. Starting circuit cut-off relay 1
25. Start switch
26. Engine stop switch
28. Front brake light switch
29. Sidestand switch
57. Rear brake light switch
8-6
ELECTRIC STARTING SYSTEM
XP500A
8-7
ELECTRIC STARTING SYSTEM
4. Main switch
12. Signaling system fuse
14. Ignition fuse
17. Battery
19. Main fuse
20. Starter relay
21. Starter motor
22. Diode
23. Starting circuit cut-off relay 2
24. Starting circuit cut-off relay 1
28. Start switch
29. Engine stop switch
31. Front brake light switch
32. Sidestand switch
65. Rear brake light switch
8-8
ELECTRIC STARTING SYSTEM
EAS27180
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the
starter motor can only operate if at least one of the following conditions is met:
● A brake lever is pulled to the handlebar (the brake light switch is closed) and the side-stand is up (the
sidestand switch is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the
starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay
is closed and the engine can be started by pressing the starter switch.
8-9
ELECTRIC STARTING SYSTEM
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Engine stop switch
6. Starting circuit cut-off relay 1
7. Sidestand switch
8. Signaling system fuse
9. Front brake switch
10. Rear brake switch
11. Start switch
12. Starter relay
13. Starter motor
8-10
ELECTRIC STARTING SYSTEM
8-11
ELECTRIC STARTING SYSTEM
1. Battery
2. Main fuse
3. Main switch
4. Signaling system fuse
5. Ignition fuse
6. Engine stop switch
7. Starting circuit cut-off relay 1
8. Front brake switch
9. Rear brake switch
10. Sidestand switch
11. Starting circuit cut-off relay 2
12. Start switch
13. Starter relay
14. Starter motor
8-12
ELECTRIC STARTING SYSTEM
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
NOTE:
Before troubleshooting, remove the following part(s):
1.Front cowling
2.Leg shield
3.Fotrest board
4.Fuel tank
1. Check the fuses.
(Main and ignition)
Refer to “CHECKING THE FUSES” on
page 8-106.
NG→
Replace the fuse(s).
OK↓
2. Check the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-107.
NG→
● Clean
the battery terminals.
or replace the battery.
● Recharge
OK↓
3. Check the starter motor operation.
Refer to “CHECKING THE STARTER
MOTOR OPERATION” on page 8-115.
OK→
Starter motor is OK. Perform the electric starter
system trouble shooting, starting with step 5.
NG→
Repair or replace the starter motor.
NG→
Replace the starting circuit cut-off relay 1.
NG→
Replace the starting circuit cut-off relay 1.
NG→
Replace the starting circuit cut-off relay 2
(XP500A).
NG→
Replace the starter relay.
NG→
Replace the main switch.
NG→
Replace the right handlebar switch.
NG↓
4. Check the starter motor.
Refer to “CHECKING THE STARTER
MOTOR” on page 5-37.
OK↓
5. Check the starting circuit cut-off relay
1.
Refer to “CHECKING THE RELAYS”
on page 8-110.
OK↓
6. Check the starting circuit cut-off relay
1 (Diode).
Refer to “CHECKING THE RELAYS”
on page 8-110.
OK↓
7. Check the starting circuit cut-off relay
2 (XP500A).
Refer to “CHECKING THE RELAYS”
on page 8-110.
OK↓
8. Check the starter relay.
Refer to “CHECKING THE RELAYS”
on page 8-110.
OK↓
9. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
OK↓
10. Check the engine stop switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
8-13
ELECTRIC STARTING SYSTEM
OK↓
11. Check the sidestand switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
NG→
Replace the sidestand switch.
NG→
Replace the brake light switch.
NG→
Replace the right handlebar switch.
NG→
Properly connect or repair the starting system’s
wiring
OK↓
12. Check the brake light switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
OK↓
13. Check the start switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
OK↓
14. Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-5.
OK↓
The starting system circuit is OK.
8-14
CHARGING SYSTEM
EAS27200
CHARGING SYSTEM
EAS27210
CIRCUIT DIAGRAM
8-15
CHARGING SYSTEM
2. AC magneto
3. Rectifier/regulator
16. Battery
17. Main fuse
8-16
CHARGING SYSTEM
EAS27220
TROUBLESHOOTING
The battery is not being charged.
NOTE:
Before troubleshooting, remove the following part(s):
1.Rear cover
2.Battery cover
3.Left side cover moulding
4.Left side cover
1. Check the fuse.
(Main)
Refer to “CHECKING THE FUSES” on
page 8-106.
NG→
Replace the fuse.
OK↓
2. Check the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-107.
NG→
● Clean
the battery terminals.
or replace the battery.
● Recharge
OK↓
3. Check the stator coil.
Refer to “CHECKING THE STATOR
COIL” on page 8-115.
NG→
Replace the stator assembly.
OK→
Charging voltage is OK.
NG→
Properly connect or repair the charging system’s
wiring.
OK↓
4. Check the charging voltage.
Refer to “CHECKING THE CHARGING VOLTAGE” on page 8-116.
NG↓
5. Check the entire charging system’s
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-15.
OK↓
Replace the rectifier/regulator.
8-17
CHARGING SYSTEM
8-18
LIGHTING SYSTEM
EAS27240
LIGHTING SYSTEM
EAS27250
CIRCUIT DIAGRAM
8-19
LIGHTING SYSTEM
4. Main switch
6. Strage box light switch
7. Strage box light
10. Back-up fuse
11. Signal fuse
12. Headlight fuse
15. Lighting system fuse
16. Battery
17. Main fuse
30. ECU (engine)
51. Headlight relay
53. Pass switch
54. Dimmer switch
61. Tail/brake light
62. Licence plate light
66. Auxiliary light
67. Headlight (high beam)
68. Headlight (low beam)
78. Meter light
79. High beam indicator light
8-20
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight, strage box light, license
light or meter light.
NOTE:
Before troubleshooting, remove the following part(s):
1.Battery cover
2.Rear cover
3.Front cowling
4.Handlebar cover
1. Check the each bulbs and bulb sockets condition.
Refer to “CHECKING THE BULBS
AND BULB SOCKETS” on page
8-105.
NG→
Replace the bulb(s) and bulb socket(s).
NG→
Replace the fuse(s).
OK↓
2. Check the fuses.
(Main, headlight, backup and lighting
system)
Refer to “CHECKING THE FUSES” on
page 8-106.
OK↓
3. Check the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-107.
NG→
● Clean
the battery terminals.
or replace the battery.
● Recharge
OK↓
4. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
NG→
Replace the main switch.
NG→
Replace the left handlebar switch.
NG→
Replace the left handlebar switch.
NG→
Replace the headlight relay.
NG→
Replace the strage box light switch.
NG→
Properly connect or repair the lighting system’s
wiring.
OK↓
5. Check the dimmer switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
OK↓
6. Check the pass switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
OK↓
7. Check the headlight relay.
Refer to “CHECKING THE RELAYS”
on page 8-110.
OK↓
8. Check the strage box light switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
OK↓
9. Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-19.
OK↓
Replace the ECU.
8-21
LIGHTING SYSTEM
8-22
SIGNALING SYSTEM
EAS27270
SIGNALING SYSTEM
EAS27280
CIRCUIT DIAGRAM
8-23
SIGNALING SYSTEM
4. Main switch
10. Backup fuse (storage box light, immobilizer
unit and meter assembly)
11. Signaling system fuse
15. Lighting system fuse
16. Battery
17. Main fuse
23. Fuel pump
27. Hazard switch
28. Front brake light switch
30. ECU (engine)
41. Speed sensor
49. Turn signal/hazard relay
50. Horn
55. Horn switch
56. Turn signal switch
57. Rear brake light switch
59. Rear turn signal light (right)
60. Rear turn signal light (left)
61. Tail/brake light
63. Front turn signal light (right)
64. Front turn signal light (left)
69. V-belt replacement reset coupler
72. Multi-function display
73. Speedometer
74. Tachometer
75. Engine oil change indicator light
76. V-belt replacement indicator light
77. Engine trouble warning light
80. Right turn signal indicator light
81. Left turn signal indicator light
8-24
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
● Any of the following fail to light: turn signal light, brake light or an indicator light.
● The horn fails to sound.
● The speedometer fails to operate.
● The V-belt replacement indicator fails to come on.
● The fuel meter(meter assembly) fails to operate.
NOTE:
Before troubleshooting, remove the following part(s):
1.Battery cover
2.Rear cover
3.Front cowling
4.Handlebar cover
1. Check the fuses.
(Main, ignition, signaling, backup and
lighting system)
Refer to “CHECKING THE FUSES” on
page 8-106.
NG→
Replace the fuse(s).
OK↓
2. Check the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-107.
NG→
● Clean
the battery terminals.
or replace the battery.
● Recharge
OK↓
3. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
NG→
Replace the main switch.
NG→
Properly connect or repair the signaling system’s
wiring.
NG→
Replace the left handlebar switch.
NG→
Replace the horn.
NG→
Properly connect or repair the signaling system’s
wiring.
OK↓
4. Check the entire signaling system’s
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-23.
OK↓
This circuit is OK.
CHECK THE SIGNALING SYSTEM
The horn fails to sound.
1. Check the horn switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
OK↓
2. Check the horn.
Refer to “CHECKING THE HORN” on
page 8-116.
OK↓
3. Check the entire signaling system’s
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-23.
OK↓
This circuit is OK.
8-25
SIGNALING SYSTEM
The tail/brake light fails to come on.
1. Check the tail/brake light bulb and
socket.
Refer to “CHECKING THE BULBS
AND BULB SOCKETS” on page
8-105.
NG→
Replace the tail/brake light bulb, socket or both.
NG→
Replace the brake light switch.
NG→
Properly connect or repair the signaling system’s
wiring.
OK↓
2. Check the brake light switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
OK↓
3. Check the entire signaling system’s
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-23.
OK↓
This circuit is OK.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal/turn signal indicator light bulb and socket.
Refer to “CHECKING THE BULBS
AND BULB SOCKETS” on page
8-105.
NG→
Replace the turn signal indicator light bulb, socket
or both.
NG→
Replace the left handlebar switch.
NG→
Replace the right handlebar switch.
NG→
The turn signal relay is faulty and must be
replaced.
NG→
Properly connect or repair the signaling system’s
wiring.
OK↓
2. Check the turn signal switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
OK↓
3. Check the hazard switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
OK↓
4. Check the turn signal/hazard relay.
Refer to “CHECKING THE RELAYS”
on page 8-110.
OK↓
5. Check the entire signaling system’s
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-23.
OK↓
This circuit is OK.
The V-belt replacement indicator fails to come on.
1. Check the V-belt replacement indicator
reset coupler.
Refer to “CHECKING THE V-BELT
RESET COUPLER” on page 8-121.
NG→
OK↓
8-26
Replace the V-belt replacement indicator reset
coupler.
SIGNALING SYSTEM
2. Check the entire signaling system’s
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-23.
NG→
Properly connect or repair the signaling system’s
wiring.
NG→
Replace the fuel pump assembly.
NG→
Properly connect or repair the signaling system’s
wiring.
OK↓
Replace the meter assembly.
The fuel meter fails to come.
1. Check the fuel sender.
Refer to “CHECKING THE FUEL
SENDER” on page 8-117.
OK↓
2. Check the entire signaling system’s
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-23.
OK↓
Replace the meter assembly.
The speedometer fails to operate.(XP500)
1. Check the speed sensor.
Refer to “CHECKING THE SPEED
SENSOR” on page 8-117.
NG→
Replace the speed sensor.
NG→
Properly connect or repair the signaling system’s
wiring.
OK↓
2. Check the entire signaling system’s
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-23.
OK↓
Replace the meter assembly or ECU.
8-27
SIGNALING SYSTEM
8-28
COOLING SYSTEM
EAS27300
COOLING SYSTEM
EAS27310
CIRCUIT DIAGRAM
8-29
COOLING SYSTEM
4. Main switch
13. Ignition fuse
14. Radiator fan motor fuse
16. Battery
17. Main fuse
30. ECU (engine)
33. Coolant temperature sensor
47. Radiator fan motor relay
48. Radiator fan motor
72. Multi-function display
8-30
COOLING SYSTEM
EAS27320
TROUBLESHOOTING
NOTE:
Before troubleshooting, remove the following part(s):
1.Battery cover
2.Rear cover
3.Footrest board
4.Leg shield
5.Inner fender
1. Check the fuses.
(Main, ignition and radiator fan motor)
Refer to “CHECKING THE FUSES” on
page 8-106.
NG→
Replace the fuse(s).
NG→
● Clean the
● Recharge
NG→
Replace the main switch.
NG→
Replace the radiator fan motor.
NG→
Replace the radiator fan motor relay.
NG→
Replace the coolant temperature sensor.
NG→
Properly connect or repair the cooling system’s
wiring.
OK↓
2. Check the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-107.
battery terminals.
or replace the battery.
OK↓
3. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
OK↓
4. Check the radiator fan motor.
Refer to “CHECKING THE RADIATOR FAN MOTOR” on page 8-118.
OK↓
5. Check the radiator fan motor relay.
Refer to “CHECKING THE RELAYS”
on page 8-110.
OK↓
6. Check the coolant temperature sensor.
Refer to “CHECKING THE COOLANT
TEMPERATURE SENSOR” on page
8-118.
OK↓
7. Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-29.
OK↓
Replace the ECU or meter assembly.
8-31
COOLING SYSTEM
8-32
FUEL INJECTION SYSTEM
EAS27330
FUEL INJECTION SYSTEM
EAS27340
CIRCUIT DIAGRAM
8-33
FUEL INJECTION SYSTEM
1. Crankshaft position sensor
4. Main switch
9. Electrical fuel injection fuse
12. Headlight fuse
13. Ignition fuse
16. Battery
17. Main fuse
21. Starter circuit cut-off relay 1
22. Fuel injection system relay
23. Fuel pump
26. Engine stop switch
29. Sidestand switch
30. ECU (engine)
31. Ignition coil
32. Spark plug
33. Coolant temperature sensor
34. Intake air temperature sensor
35. Fuel injector #1
36. Fuel injector #2
37. Intake air pressure sensor
38. O2 sensor
39. Throttle position sensor
40. Lean angle sensor
41. Speed sensor
47. Radiator fan motor relay
51. Headlight relay
72. Multi-function display
8-34
FUEL INJECTION SYSTEM
EAS27350
ECU SELF-DIAGNOSTIC FUNCTION
The ECU (engine) is equipped with a self-diagnostic function in order to ensure that the fuel injection
system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert
the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault
code is stored in the memory of the ECU (engine).
● To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes when the start switch is being pushed to start the engine.
● If a malfunction is detected in the system by the self-diagnostic function, the ECU (engine) provides
an appropriate substitute characteristic operation, and alerts the rider of the detected malfunction by
illuminating the engine trouble warning light.
● After the engine has been stopped, the lowest fault code number appears on the clock LCD. Once a
fault code has been displayed, it remains stored in the memory of the ECU (engine) until it is deleted.
Engine trouble warning light indication and FI system operation
Warning light
indication
Flashing*
Remains on
ECU (engine)
operation
FI operation
Vehicle operation
Warning provided when
unable to start engine
Operation stopped
Cannot be operated
Malfunction detected
Operated with substitute
characteristics in accordance with the description of the malfunction
Can or cannot be operated depending on the
fault code
* The warning light flashes when any one of the conditions listed below is present and the start switch is pushed:
12:
Crankshaft position sensor
41:
Lean angle sensor
(open or short-circuit)
19:
Sidestand switch
(open circuit in the wire to the ECU (engine))
50:
ECU (engine) internal malfunction
(faulty ECU (engine) memory)
30:
Lean angle sensor
(latch up detected)
Checking for a defective engine trouble warning light bulb
The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned to
“ON” and when the start switch is being pushed. If the warning light does not come on under these conditions, the warning light bulb may be defective.
EAS27382
FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL)
If the ECU (engine) detects an abnormal signal from a sensor while the vehicle is being driven, the ECU
(engine) illuminates the engine trouble warning light and provides the engine with alternate operating
instructions that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU (engine) processes the specified values
that are programmed for each sensor in order to provide the engine with alternate operating instructions
8-35
FUEL INJECTION SYSTEM
that enable the engine to continue to operate or stop operating, depending on the conditions.
The ECU (engine) takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value, and the other in which the ECU (engine) directly operates an actuator. Details on the
fail-safe actions are given in the table below.
Self-Diagnostic Function
Fault code
No.
Item
Symptom
Able /
unable to
start
Able /
unable to
drive
12
Crankshaft position sen- No normal signals are received from
sor
the crankshaft position sensor.
Unable
Unable
13
Intake air pressure sensor
(open or short circuit)
Intake air pressure sensor-open or
short circuit detected.
Able
Able
14
Intake air pressure sensor
(pipe system)
Intake air pressure sensor-pipe system malfunction (clogged or detached
hose).
Able
Able
15
Throttle position sensor
(open or short circuit)
Throttle position sensor-open or short
circuit detected.
Able
Able
16
Throttle position sensor
(stuck)
The throttle position sensor is stuck.
Able
Able
19
Sidestand switch
(open circuit wire harness to ECU (engine))
Open circuit is detected in the input
line from the sidestand switch to the
ECU (engine).
Unable
Unable
21
Coolant temperature
sensor
Coolant temperature sensor-open or
short circuit detected.
Able
Able
22
Intake air temperature
sensor
Intake air temperature sensor-open or
short circuit detected.
Able
Able
24
O2 sensor
No normal signal is received from the
O2 sensor.
Able
Able
30
Lean angle sensor
Latch up detected.
No normal signal is received from the
lean angle sensor.
Unable
Unable
33
Ignition coil
(faulty ignition)
Malfunction detected in the primary
wire of the ignition coil.
Unable
Unable
37
FID valve (stuck fully
open)
Engine speed is high when the engine
is idling.
Able
Able
41
Lean angle sensor
(open or short circuit)
Lean angle sensor-open or short circuit detected.
Unable
Unable
43
Fuel system voltage
(monitor voltage)
The ECU (engine) is unable to monitor the battery voltage
(an open circuit in the line to the ECU
(engine)).
Able
Able
44
Error in writing the
amount of CO adjustment on EEPROM
Error is detected while reading or writing on EEPROM (CO adjustment
Able
value).
Able
46
Vehicle system power
supply
(Monitoring voltage)
Power supply to the fuel injection sys- Able
tem is not normal.
Able
50
ECU (engine) internal
malfunction
(memory check error)
Faulty ECU (engine) memory. (When
this malfunction is detected in the
ECU (engine), the fault code number
might not appear on the meter.)
Unable
8-36
Unable
FUEL INJECTION SYSTEM
Communication error with the meter
Fault code
No.
Item
Symptom
Able /
unable to
start
Able /
unable to
drive
Er-1
ECU (engine) internal
malfunction
(output signal error)
No signals are received from the ECU
(engine).
Unable
Unable
Er-2
ECU (engine) internal
malfunction
(output signal error)
No signals are received from the ECU
(engine) within the specified duration.
Unable
Unable
Er-3
ECU (engine) internal
malfunction
(output signal error)
Data from the ECU (engine) cannot
be received correctly.
Unable
Unable
Er-4
ECU (engine) internal
malfunction
(input signal error)
Non-registered data has been
received from the meter.
Unable
Unable
8-37
FUEL INJECTION SYSTEM
If malfunction the sensors or actuators, repair
or replace it.
If not malfunction the sensors and actuators,
check and repair the engine inner parts.
EAS27400
TROUBLESHOOTING METHOD
The engine operation is not normal and the
engine trouble warning light comes on.
1. Check:
● Fault code number
EAS27431
DIAGNOSTIC MODE
Setting the diagnostic mode
1. Turn the main switch to “OFF” and set the engine stop switch to “ ”.
2. Disconnect the wire harness coupler from the
fuel pump.
3. Simultaneously press and hold the “SELECT”“1” and “RESET”“2” buttons, turn the
main switch to “ON”, and continue to press
the buttons for 8 seconds or more.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the fault code number displayed on
the meter.
b. Identify the system with the malfunction. Refer to “Self-Diagnostic Function table”.
c. Identify the probable cause of malfunction.
Refer to “Diagnostic monitoring code table”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Checking and repair the probable case of
malfunction.
Fault code No. YES
Fault code No. NO
Check and repair. Refer
to “TROUBLESHOOTING DETAILS” on page
8-45.
Monitor the operation of
the sensors and actuators in the diagnostic
mode. Refer to “Sensor
operation table”.
Check and repair. Refer
to “TROUBLESHOOTING DETAILS” on page
8-45.
1
NOTE:
● All
displays on the meter disappear except the
clock and tripmeter displays.
● “dIAG” appears on the clock LCD.
3. Perform ECU (engine) reinstatement action.
Refer to “Reinstatement method” of table in
“TROUBLESHOOTING DETAILS” on page
8-45.
4. Turn the main switch to “OFF” and back to
“ON”, then check the fault code number is not
displayed.
4. Press the “SELECT” button to select the CO
adjustment mode “CO” or the diagnostic
monitoring mode “dIAG”.
5. After selecting “dIAG”, simultaneously press
the “SELECT” and “RESET” buttons for 2
seconds or more to execute the selection.
6. Set the engine stop switch to “ ”.
7. Select the diagnostic code number that applies to the item that was verified with the fault
code number by pressing the “SELECT” and
“RESET” buttons.
NOTE:
If other fault code displayed, repeat steps (1) to
(4) until all fault code number is not displayed.
5. The Malfunction history is stored even if the
main switch is turned OFF. The malfunction
history must be erased in the diagnostic
mode. Refer to “Sensor operation table (Diagnostic code No.62)”.
The engine operation is not normal but the
engine trouble warning light does not come
on.
1. Check the operation of following sensors and
actuators in the Diagnostic mode. Refer to
“Sensor operation table”.
2
NOTE:
The diagnostic code number appears on the
clock LCD (01–70).
● To decrease the selected diagnostic code
number, press the “RESET” button. Press the
“RESET” button for 1 second or longer to automatically decrease the diagnostic code numbers.
● To increase the selected diagnostic code number, press the “SELECT” button. Press the
“SELECT” button for 1 second or longer to automatically increase the diagnostic code num-
01: Throttle position sensor (throttle angle)
30: Ignition coil
36: Injector #1
37: Injector #2
8-38
FUEL INJECTION SYSTEM
bers.
01
70
1
70
01
8. Verify the operation of the sensor or actuator.
● Sensor operation
The data representing the operating conditions of the sensor appears on the trip LCD.
● Actuator operation
Set the engine stop switch to “ ” to operate
the actuator.
NOTE:
If the engine stop switch is set to “
“OFF”, and then set it to “ ” again.
9. Turn the main switch to “
agnostic mode.
”, set it to
” to cancel the di-
8-39
FUEL INJECTION SYSTEM
Diagnostic code table
Fault
code
No.
Symptom
Probable cause of malfunction
Diagnostic
code No.
Open or short circuit in wire harness.
Defective crankshaft position sensor.
● Malfunction in pickup rotor.
● Malfunction in ECU (engine).
● Improperly installed sensor.
—
Open or short circuit in wire sub lead.
● Open or short circuit in wire harness.
● Defective intake air pressure sensor.
● Malfunction in ECU (engine).
03
Intake air pressure sensor hose is
detached, clogged, kinked, or pinched.
● Malfunction of the intake air pressure sensor in the intermediate electrical potential.
● Malfunction in ECU (engine).
03
Open or short circuit in wire sub lead.
Open or short circuit in wire harness.
● Defective throttle position sensor.
● Malfunction in ECU (engine).
● Improperly installed throttle position sensor.
01
●
12
No normal signals are
received from the crankshaft
position sensor.
13
Intake air pressure sensor-open or short circuit
detected.
●
●
●
14
Intake air pressure sensor-pipe system malfunction
(clogged or detached hose).
●
●
15
Throttle position sensor-open
or short circuit detected.
16
Stuck throttle position sensor
detected.
●
19
Open circuit is detected in the
input line from the sidestand
switch to the ECU (engine).
●
●
●
Stuck throttle position sensor.
Malfunction in ECU (engine).
01
Open or short circuit in wire harness.
Malfunction in ECU (engine).
20
Open or short circuit in wire harness.
Defective coolant temperature sensor.
● Malfunction in ECU (engine).
● Improperly installed coolant temperature
sensor.
06
Open or short circuit in wire harness.
Defective intake temperature sensor.
● Malfunction in ECU (engine).
● Improperly installed intake air temperature
sensor.
05
Open or short circuit in wire harness.
Defective O2 sensor.
● Malfunction in ECU (engine).
● Improperly installed O2 sensor.
—
The vehicle has overturned.
Defective lean angle sensor.
● Malfunction in ECU (engine).
● Improperly installed lean angle sensor.
08
●
21
Coolant temperature sensor-open or short circuit
detected.
●
●
22
Intake air temperature sensor-open or short circuit
detected.
24
No normal signal is received
from the O2 sensor.
30
Latch up detected.
No normal signal is received
from the lean angle sensor.
●
●
●
●
●
8-40
FUEL INJECTION SYSTEM
Fault
code
No.
Symptom
Probable cause of malfunction
Diagnostic
code No.
Open or short circuit in wire harness.
Malfunction in ignition coil.
● Malfunction in ECU (engine).
● Malfunction in a component of ignition
cut-off circuit system.
30
Stuck the FID valve (when fully open).
Malfunction in ECU (engine).
01
●
●
33
Malfunction detected in the
primary wire of the ignition
coil.
37
Faulty the FID valve.
41
Lean angle sensor-open or
short circuit detected.
The ECU is unable to monitor
the battery voltage
(an open circuit in the line to
the ECU (engine)).
●
43
Error is detected while reading or writing on EEPROM
(CO adjustment value).
●
44
Malfunction in ECU (engine). (The CO
adjustment value is not properly written on
or read from the internal memory).
60
46
Power supply to the fuel injec- Malfunction in the charging system. Refer to
tion system is not normal.
“CHARGING SYSTEM” on page 8-15.
—
50
Faulty ECU (engine) memory.
(When this malfunction is
detected in the ECU (engine),
the fault code number might
not appear on the meter.)
Er-1
No signals are received from
the ECU.
Er-2
No signals are received from
the ECU (engine) within the
specified duration.
Er-3
Data from the ECU (engine)
cannot be received correctly.
Er-4
Non-registered data has been
received from the meter.
●
●
●
Open or short circuit in wire harness.
Defective lean angle sensor.
● Malfunction in ECU (engine).
08
Open circuit in wire harness.
Malfunction in ECU (engine).
● Defective fuel injection system relay.
50
●
●
●
Malfunction in ECU (engine). (The program
and data are not properly written on or read
—
from the internal memory.)
Open or short circuit in communication line.
—
Malfunction in meter unit.
● ECU (engine) is defective
●
●
Open or short circuit in communication line.
—
Malfunction in meter unit.
● ECU (engine) is defective
●
●
Open or short circuit in communication line.
—
Malfunction in meter unit.
● ECU (engine) is defective
●
●
Open or short circuit in communication line.
—
● Malfunction in meter unit.
● ECU (engine) is defective
●
8-41
FUEL INJECTION SYSTEM
Sensor operation table
Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to
“DIAGNOSTIC MONITORING MODE”.
Diagnos
tic
monitori
ng code
No.
01
Item
Meter display
Checking method
Throttle angle
●
Fully closed position
(15–16)
Check with throttle fully
closed.
●
Fully opened position
(97–102)
Check with throttle fully open.
03
Pressure difference
(atmospheric pressure-intake
air pressure)
Displays the intake air pressure. Turn On the engine stop
switch, then operate the throttle while pressing the start
switch. (If the display value
changes, the performance is
OK.)
05
Intake air temperature
Displays the intake air temperature.
Compare the actually measured intake air temperature
with the meter display value.
(*2)
06
Coolant temperature
Displays the coolant temperature.
Compare the actually measured coolant temperature
with the meter display value.
07
Vehicle speed pulse
0–999
Check that the number
changes (integrating) when
the rear wheels are rotated.
08
Lean angle sensor
09
20
60
●
Upright
0.4–1.4 V
●
Overturned
3.8–4.2 V
Fuel system voltage
(battery voltage)
Approximately 12.0 V
Sidestand switch
●
Stand retracted
ON
●
Stand extended
OFF
Remove the lean angle sensor and incline it more than 65
degrees.
Compare with the actually
measured battery voltage. (If
the battery voltage is lower,
perform recharging.)
Turn ON/OFF the Sidestand
switch.
EEPROM fault code display
—
●
No fault
00
●
Fault detected
01 or 02 (Fault detection cylinder)
●
(If both cylinders are defective, the display alternates
every two seconds.)
8-42
FUEL INJECTION SYSTEM
Diagnos
tic
monitori
ng code
No.
61
Item
Meter display
Malfunction history code display
—
●
No history
00
●
History exists
12-50 (Fault detection code)
●
62
70
Checking method
(If code numbers more
than one are detected, the
display alternates every
two seconds to show all the
detected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
Malfunction history code erasure
●
No history
00
—
●
History exists
00–17 (Memory numbers of the
fault detection)
To erase the history, turn ON
the engine stop switch.
00–255
—
Control number
*1 If it is not possible to check the intake temperature, use the ambient temperature as reference (use
the compared values for reference).
Actuator operation table
Diagnos
tic
monitori
ng code
No.
30
36
37
50
Item
Actuation
Checking method
Ignition coil
Actuates the ignition coil for five
times every second.
Illuminates the engine trouble
warning light.
Injector #1
Actuates the injector #1 for five
times every second.
Illuminates the engine trouble
warning light.
Check the operating sound of
the injector #1 five times.
Injector #2
Actuates the injector #2 for five
times every second.
Illuminates the engine trouble
warning light.
Check the operating sound of
the injector #2 five times.
Fuel injection system relay
Actuates the fuel injection system relay for five times every
second.
Illuminates the engine trouble
warning light.
(The engine trouble warning
light is OFF when the relay is
ON, and the engine trouble
warning light is ON when the
relay is OFF).
Check the operating sound of
the fuel injection system relay
five times.
8-43
Check the spark five times.
●
Connect an ignition
checker.
FUEL INJECTION SYSTEM
Diagnos
tic
monitori
ng code
No.
51
52
57
Item
Actuation
Checking method
Radiator fan motor relay
Actuates the radiator fan motor
relay for five cycles every
five-second. (ON 2 seconds,
OFF 3 seconds)
Illuminates the engine trouble
warning light.
Check the operating sound of
the Radiator fan motor relay
five times.
Headlight relay
Actuates the headlight relay for
five times every five-second.
(ON 2 seconds, OFF 3 seconds)
Illuminates the engine trouble
warning light.
Check the operating sound of
the headlight relay five times.
Grip warmer relay
Actuates the grip warmer relay.
(the light is off when the relay is
off, and the light is on when the
relay is on)
Illuminates the engine trouble
warning light.
Check the operating sound of
the grip warmer relay 1 time.
8-44
FUEL INJECTION SYSTEM
EAS27471
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the meter. Check and service
the items or components that are the probable cause of the malfunction following the order given.
After the check and service of the malfunctioning part has been completed, reset the meter display according to the reinstatement method.
Fault code No.:
Code number displayed on the meter when the engine failed to work normally. Refer to “Self-Diagnostic
Function table”.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC
MODE” on page 8-38.
Fault code No.
12
Symptom
No normal signals are received from the crankshaft position
sensor.
Diagnostic code No.
Order Item/components and probable cause
Check or maintenance job
Reinstatement
method
1
Installed condition of crankshaft position
sensor
Check the installed area for looseness or pinching.
Cranking the
engine.
2
Connected state of connector
●
Crankshaft position sensor coupler
● Main wire harness ECU (engine)
coupler
●
Check the coupler for any pins
that may have pulled out.
● Check the locking condition of
the coupler.
● If there is a malfunction, repair it
and connect it securely.
Repair or replace if there is an
open or short circuit.
● Between the sensor coupler
and ECU coupler.
(Black/Yellow–Black/Yellow)
(Black/Blue–Black/Blue)
3
Open or short circuit in wire harness.
●
4
Defective crankshaft position sensor.
●
Replace if defective.
Refer to “CHECKING THE
CRANKSHAFT POSITION SENSOR” on page 8-114.
8-45
FUEL INJECTION SYSTEM
Fault code No.
13
Diagnostic code No.
Symptom
Intake air pressure sensor-open or short circuit detected.
03
Intake air pressure sensor
Order Item/components and probable cause
Check or maintenance job
1
●
Connected state of connector
Intake air pressure sensor coupler
● Main wire harness ECU (engine)
coupler
●
Reinstatement
method
Check the coupler for any pins Cranking the
engine.
that may have pulled out.
● Check the locking condition of
the coupler.
● If there is a malfunction, repair it
and connect it securely.
Repair or replace if there is an
open or short circuit.
● Between sensor coupler and
ECU coupler
(Black/Blue–Black/Blue)
(Pink/White–Pink/White)
(Blue–Blue)
2
Open or short circuit in wire harness.
●
3
Defective intake air pressure sensor
●
Execute the diagnostic monitoring mode. (Code No.03)
● Replace if defective.
Refer to “CHECKING THE INTAKE AIR PRESSURE SENSOR”
on page 8-120.
8-46
FUEL INJECTION SYSTEM
Fault code No.
14
Diagnostic code No.
Symptom
Intake air pressure sensor-pipe system malfunction (clogged or
detached hose).
03
Intake air pressure sensor
Order Item/components and probable cause
Check or maintenance job
Reinstatement
method
1
Intake air pressure sensor hose
●
Check the Intake air pressure
sensor hose condition.
● Repair or replace the sensor
hose.
Starting the
engine and operating it at idle.
2
Intake air pressure sensor malfunction at
intermediate electrical potential.
●
3
Connected state of connector
●
Intake air pressure sensor coupler
● Main wire harness ECU (engine)
coupler
●
4
Defective intake air pressure sensor
Check and repair the connection.
● Replace it if there is a malfunction.
Check the coupler for any pins
that may have pulled out.
● Check the locking condition of
the coupler.
● If there is a malfunction, repair it
and connect it securely.
Execute the diagnostic monitoring mode. (Code No.03)
● Replace if defective.
Refer to “CHECKING THE INTAKE AIR PRESSURE SENSOR”
on page 8-120.
●
8-47
FUEL INJECTION SYSTEM
Fault code No.
15
Diagnostic code No.
Symptom
Throttle position sensor-open or short circuit detected.
01
Throttle position sensor
Order Item/components and probable cause
Check or maintenance job
Reinstatement
method
1
Installed condition of throttle position sensor.
●
Check the installed area for
looseness or pinching.
● Check that is installed in the
specified position.
Turning the main
switch ON.
2
Connected state of connector
●
Throttle position sensor coupler
● Main wire harness ECU (engine)
coupler
●
Check the coupler for any pins
that may have pulled out.
● Check the locking condition of
the coupler.
● If there is a malfunction, repair it
and connect it securely.
Repair or replace if there is an
open or short circuit.
● Between sensor coupler and
ECU (engine) coupler
(Black/Blue–Black/Blue)
(Yellow–Yellow)
(Blue–Blue)
3
Open or short circuit in wire harness.
●
4
Throttle position sensor lead wire open circuit output voltage check.
●
Check for open circuit and
replace the throttle position sensor.
(Black/Blue–Yellow)
Open circuit item
Output voltage
Ground wire open 5 V
circuit
Output wire open 0 V
circuit
Power supply
wire open circuit
5
Defective throttle position sensor.
0V
Execute the diagnostic monitoring mode. (Code No.01)
● Replace if defective.
Refer to “CHECKING THE
THROTTLE POSITION SENSOR”
on page 8-119.
●
8-48
FUEL INJECTION SYSTEM
Fault code No.
16
Diagnostic monitoring
code No.
Symptom
Stuck throttle position sensor detected.
01
Throttle position sensor
Order Item/components and probable cause
Check or maintenance job
Reinstatement
method
1
Installed condition of throttle position sensor.
●
Check the installed area for
looseness or pinching.
● Check that is installed in the
specified position.
Reinstated by
starting the
engine, operating it at idle, and
then racing it.
2
Defective throttle position sensor.
●
Fault code No.
19
Diagnostic code No.
Execute the diagnostic monitoring mode. (Code No.01)
● Replace if defective.
Refer to “CHECKING THE
THROTTLE POSITION SENSOR”
on page 8-119.
Symptom
Open circuit is detected in the input line from the sidestand
switch to the ECU (engine).
20
Sidestand switch
Order Item/components and probable cause
Check or maintenance job
Reinstatement
method
1
●
Check the coupler for any pins
that may have pulled out.
● Check the locking condition of
the coupler.
● If there is a malfunction, repair it
and connect it securely.
Reinstated by
retracting the sidestand.
Reinstated by
reconnecting the
wiring.
Connected state of connector
●
Main wire harness ECU (engine)
coupler
Repair or replace if there is an
open or short circuit.
● Between ECU (engine) and sidestand switch
(Light green–Light green)
2
Open or short circuit in wire harness.
●
3
Defective sidestand switch
●
Execute the diagnostic monitoring mode. (Code No.20)
● Replace if defective.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
8-49
FUEL INJECTION SYSTEM
Fault code No.
21
Diagnostic code No.
Symptom
Coolant temperature sensor-open or short circuit detected.
06
Coolant temperature sensor
Order Item/components and probable cause
Check or maintenance job
Reinstatement
method
1
Installed condition of coolant temperature
sensor
Check the installed area for looseness or pinching.
Turning the main
switch ON.
2
Connected state of connector
●
Coolant temperature sensor coupler
● Main wire harness ECU (engine)
coupler
●
Check the coupler for any pins
that may have pulled out.
● Check the locking condition of
the coupler.
● If there is a malfunction, repair it
and connect it securely.
Repair or replace if there is an
open or short circuit.
● Between sensor coupler and
ECU coupler
(Black/Blue–Black/Blue)
(Green/Red–Green/Red)
3
Open or short circuit in wire harness.
●
4
Defective coolant temperature sensor.
●
Execute the diagnostic monitoring mode. (Code No.06)
● Replace if defective.
Refer to “CHECKING THE COOLANT TEMPERATURE SENSOR”
on page 8-118.
8-50
FUEL INJECTION SYSTEM
Fault code No.
22
Diagnostic code No.
Symptom
Intake air temperature sensor-open or short circuit detected.
05
Intake air temperature sensor
Order Item/components and probable cause
Check or maintenance job
Reinstatement
method
1
Installed condition of intake air temperature sensor
Check the installed area for looseness or pinching.
Turning the main
switch ON.
2
Connected state of connector
●
Intake air temperature sensor coupler
● Main wire harness ECU (engine)
coupler
●
Check the coupler for any pins
that may have pulled out.
● Check the locking condition of
the coupler.
● If there is a malfunction, repair it
and connect it securely.
Repair or replace if there is an
open or short circuit.
● Between sensor coupler and
ECU coupler
(Black/Blue–Black/Blue)
(Brown/White–Brown/White)
3
Open or short circuit in wire harness.
●
4
Defective intake air temperature sensor.
●
Execute the diagnostic monitoring mode. (Code No.05)
● Replace if defective.
Refer to “CHECKING THE INTAKE AIR TEMPERATURE SENSOR” on page 8-120.
8-51
FUEL INJECTION SYSTEM
Fault code No.
24
Diagnostic code No.
Symptom
No normal signal is received from the O2 sensor.
—
Order Item/components and probable cause
Check or maintenance job
1
Installed condition of O2 sensor
Check the installed area for looseness or pinching.
2
Connected state of connector
O2 sensor coupler
● Main wire harness ECU (engine)
coupler
●
3
Open or short circuit in wire harness.
Reinstatement
method
As the returning
method start
method, start and
● Check the coupler for any pins
warm up the
engine until the
that may have pulled out.
coolant tempera● Check the locking condition of
ture rises over
the coupler.
60°C (40°F).
● If there is a malfunction, repair it Then, maintain
the engine speed
and connect it securely.
at 2000 r/min to
3000 r/min until
● Repair or replace if there is an
the warning light
open or short circuit.
goes off.
● Between sensor coupler and
When the warning light goes off,
ECU coupler
the reset opera(Black/Blue–Black/Blue)
tion is finished.
(Gray/Green–Gray/Green)
(Red/Blue–Red/Blue)
(Black–Black)
4
Check fuel pressure
Refer to “CHECKING THE PRESSURE REGULATOR OPERATION”
on page 7-7.
5
Defective O2 sensor
Replace if defective.
Fault code No.
30
Diagnostic code No.
Symptom
Latch up detected.
No normal signal is received from the lean angle sensor.
08
Lean angle sensor
Order Item/components and probable cause
Check or maintenance job
1
The vehicle has overturned.
Raise the vehicle upright.
2
Installed state of the lean angle sensor.
3
Defective lean angle sensor.
Reinstatement
method
Turning the main
switch ON (howCheck the installed direction and
ever, the engine
condition of the sensor.
cannot be
restarted unless
● Execute the diagnostic monitor- the main switch is
ing mode. (Code No.08)
first turned OFF).
Replace if defective.
Refer to “CHECKING THE LEAN
ANGLE SENSOR” on page 8-114.
●
8-52
FUEL INJECTION SYSTEM
Fault code No.
33
Diagnostic code No.
Symptom
Malfunction detected in the primary wire of the ignition coil.
30
Ignition coil
Order Item/components and probable cause
Check or maintenance job
1
●
Connected state of connector
Ignition coil primary side coupler
(Orange)
● Main wire harness ECU (engine)
coupler
●
Check the coupler for any pins Starting the
engine and operthat may have pulled out.
ating it at idle.
● Check the locking condition of
the coupler.
● If there is a malfunction, repair it
and connect it securely.
Repair or replace if there is an
open or short circuit.
● Between ignition coil coupler
and ECU coupler
(Orange–Orange)
(Red/Black–Red/Black)
2
Open or short circuit in wire harness.
●
3
Defective ignition coil
●
Fault code No.
37
Diagnostic monitoring
code No.
Reinstatement
method
Execute the diagnostic monitoring mode. (Code No.30)
● Replace if defective.
Refer to “CHECKING THE IGNITION COIL” on page 8-113.
Symptom
Engine speed is high when the engine is idling.
01
Throttle position sensor
Order Item/components and probable cause
Check or maintenance job
1
Stuck FID valve detected.
●
2
Defective throttle fully closed.
Check the throttle body.
Refer to “THROTTLE BODIES” on
page 7-4.
Reinstatement
method
Reinstated by
starting the
engine and operating it at idle for
about 5 minutes.
● Check the throttle body.
Do not turn the
Refer to “THROTTLE BODIES” on throttle grip.
page 7-4.
8-53
FUEL INJECTION SYSTEM
Fault code No.
41
Diagnostic code No.
Symptom
Lean angle sensor-open or short circuit detected.
08
Lean angle sensor
Order Item/components and probable cause
Check or maintenance job
1
●
Connected state of connector
Lean angle sensor coupler
● Main wire harness ECU (engine)
coupler
●
Check the coupler for any pins Reinstated immediately when it
that may have pulled out.
becomes normal.
● Check the locking condition of
the coupler.
● If there is a malfunction, repair it
and connect it securely.
Repair or replace if there is an
open or short circuit.
● Between sensor coupler and
ECU coupler
(Black/Blue–Black/Blue)
(Yellow/Green–Yellow/Green)
(Blue–Blue)
2
Open or short circuit in wire harness.
●
3
Defective lean angle sensor
●
Fault code No.
43
Diagnostic code No.
Reinstatement
method
Execute the diagnostic monitoring mode. (Code No.08)
● Replace if defective.
Symptom
The ECU (engine) is unable to monitor the battery voltage.
50
Fuel injection system relay
Order Item/components and probable cause
Check or maintenance job
1
●
Connected state of connector
Fuel injection system relay coupler
● Main wire harness ECU (engine)
coupler
●
Reinstatement
method
Check the coupler for any pins Starting the
engine and operthat may have pulled out.
ating it at idle.
● Check the locking condition of
the coupler.
● If there is a malfunction, repair it
and connect it securely.
2
Defective fuel injection system relay
Replace if defective.
3
Open or short circuit in the wire harness.
●
4
Malfunction or open circuit in fuel injection
system relay
●
Repair or replace if there is an
open or short circuit.
● Between the fuse box coupler
and ECU coupler
(Red/Blue–Red/Blue)
● Between the fuse box coupler
and battery terminal
(Red–Red)
Execute the diagnostic monitoring mode. (Code No. 50)
● Replace if defective.
● If there is no malfunction with
the fuel injection system relay,
replace the ECU (engine).
8-54
FUEL INJECTION SYSTEM
Fault code No.
44
Diagnostic code No.
Symptom
Error is detected while reading or writing on EEPROM (CO
adjustment value).
60
EEPROM improper cylinder indication
Order Item/components and probable cause
Check or maintenance job
1
●
Malfunction in ECU (engine)
Reinstatement
method
Execute the diagnostic monitor- Turning the main
switch ON
ing mode. (Code No. 60)
● Check the faulty cylinder. (If
there are multiple cylinders, the
number of the faulty cylinders
appears alternately at 2-second intervals.)
● Readjust the CO of the displayed cylinder.
Refer to “ADJUSTING THE EXHAUST GAS VOLUME” on page
3-7.
● Replace ECU (engine) if defective.
8-55
FUEL INJECTION SYSTEM
Fault code No.
46
Diagnostic monitoring
code No.
Symptom
Power supply to the FI system relay is not normal.
—
—
Order Item/components and probable cause
Check or maintenance job
1
●
Connected state of connector.
●
Main wire harness ECU (engine)
coupler
Check the coupler for any pins Starting the
engine and operthat may have pulled out.
ating it at idle.
● Check the locking condition of
the coupler.
● If there is a malfunction, repair it
and connect it securely.
Replace or change the battery
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 8-107.
2
Faulty battery
●
3
The malfunction of the rectifier/regulator
●
4
Open or short circuit in wire harness.
●
Fault code No.
50
Diagnostic code No.
Reinstatement
method
Replace if defective.
Refer to “CHARGING SYSTEM”
on page 8-15.
Repair or replace if there is an
open or short circuit.
● Between battery terminal and
main switch coupler
(Red–Red)
● Between main switch coupler
and fuse box coupler
(Brown/Blue–Brown/Blue)
● Between fuse box coupler and
ECU (engine) coupler
(Red/White–Red/White)
Symptom
Faulty ECU (engine) memory. (When this malfunction is
detected in the ECU (engine), the fault code number might not
appear on the meter.)
—
—
Order Item/components and probable cause
Check or maintenance job
Reinstatement
method
1
Replace the ECU (engine).
Turning the main
switch ON
Malfunction in ECU (engine)
8-56
IMMOBILIZER SYSTEM
EAS27640
IMMOBILIZER SYSTEM
EAS27650
CIRCUIT DIAGRAM
8-57
IMMOBILIZER SYSTEM
4. Main switch
5. Immobilizer unit
10. Backup fuse (storage box light, immobilizer
unit and meter assembly)
13. Ignition fuse
16. Battery
17. Main fuse
30. ECU (engine)
71. Immobilizer system indicator light
72. Multi-function meter
8-58
IMMOBILIZER SYSTEM
EAS27671
GENERAL INFORMATION
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 (installed in the red key bow)
● an immobilizer unit
● the ECU
● an immobilizer system indicator light
The key with the red bow is used to register codes in each standard key. Do not use the key with the
red bow for driving. It should only be used for re-registering new codes in the standard keys. The immobilizer system cannot be operated with a new key until the key registered with a code. If you lose the
code re-registering key, the ECU and main switch (equipped with the immobilizer unit) need to be replaced.
Therefore, always use a standard key for driving. (See caution below.)
NOTE:
Each standard key is registered during production, therefore re-registering at purchase is not necessary.
ECA14971
CAUTION:
● DO
NOT LOSE THE CODE RE-REGISTERING KEY! 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 (e.g., 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 for driving, and to keep the code re-registering key
in a safe place.
● Do not submerse the keys in water.
● Do not expose the keys to excessively high temperatures.
● Do not place the keys close to magnets (this includes, but is not limited to, products such as
speakers, etc.).
● Do not place heavy items on the keys.
● Do not grind the keys or alter their shape.
● Do not disassemble the key bows.
● Do not put two keys of any immobilizer system on the same key ring.
● Keep the standard keys as well as other immobilizer system keys away from the code re-registering key.
● Keep other immobilizer system keys away from the main switch as they may cause signal interference.
EAS27691
PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS
In the course of use, you may encounter the following cases where replacement of parts and registration of code re-registering/standard keys are required.
NOTE:
Each standard key is registered during production, therefore re-registering at purchase is not necessary.
8-59
IMMOBILIZER SYSTEM
Parts to be replaced
Main switch/
immobilizer unit
Main Immobilize
switch
r unit
√
√
Immobilizer unit is
defective
√
√
Code re-registering
key and standard keys
Code re-registering
key and standard keys
Code re-registering
key and standard keys
√
√
Key registration
requirement
New standard key
√
ECU is defective
Main switch is defective
ECU
Accessory
lock* and
key
√
Standard key is lost
All keys have been lost
(including code re-registering key)
Standard
key
√
Accessory lock* is
defective
√
√
Code re-registering
key and standard keys
√
Not required
* Accessory locks mean the seat lock and fuel tank cap.
Code re-registering key registration:
When the immobilizer unit or ECU is replaced, the code re-registering key must be registered to the
unit.
To register a code re-registering key:
1. Turn the main switch to “ON” with the code re-registering key.
NOTE:
Check that the immobilizer system indicator light comes on for one second, then goes off. When the
immobilizer system indicator light goes off, the code re-registering key has been registered.
2. Check that the engine can be started.
3. Register the standard key, following the instructions in the section below.
Standby mode:
To enable the immobilizer system, turn the ignition key to “OFF”. 30 seconds later, the indicator light
will start flashing continuously in the standby flashing mode pattern for up to 24 hours. After that time,
the indicator light will stop flashing, but the immobilizer system is still enabled.
Standby mode
d. LED off
e. Standby mode on
f. Standby mode off
a. Main switch “ON”
b. Main switch “OFF”
c. LED on
Standard key registration:
Standard key registration is required when a standard key is lost and needs to be replaced, or when
8-60
IMMOBILIZER SYSTEM
the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
NOTE:
Do not start the engine with a standard key that has not been registered. If the main switch is turned
“ON” with a standard key that has not been registered, the immobilizer system indicator light flashes to
indicate fault code “52”. (Refer to “SELF-DIAGNOSIS FAULT CODE INDICATION” on page 8-62).
1. Check that the immobilizer system indicator light signals the standby mode.
2. Using the code re-registering key, turn the main switch to “ON”, then “OFF”, and then remove the
key within 5 seconds.
3. Insert the first standard key to be registered into the main switch, then turn the key to “ON” within 5
seconds to activate the key registration mode.
NOTE:
The existing standard key code is erased from the memory when the key registration mode is activated.
When the key registration mode is activated, the immobilizer system indicator light flashes rapidly.
4. While the indicator light is flashing, turn the main switch to “OFF”, remove the key, and within 5 seconds, insert the second standard key to be registered into the main switch.
NOTE:
If he immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered,
the registration mode is deactivated. If this occurs, the second standard key cannot be registered, and
steps 2 to 4 need to be repeated to register both standard keys.
5. Turn the main switch to “ON”.
NOTE:
When the indicator light goes off, the registration is complete.
6. Check that the engine can be started with the two registered standard keys.
Standard key registration
a.
b.
c.
d.
e.
f.
g.
h. Second standard key
i. Registration mode
Main switch “ON”
Main switch “OFF”
LED on
LED off
Less than 5.0 s
Code re-registering key
First standard key
A. Registration of the second standard key is
complete.
B. Immobilizer system indicator light stops
flashing when the registration of the second
standard key is complete.
Voiding the standard key code:
If a standard key has been lost, it is possible to disable its use by re-registering the remaining standard
key. Standard key registration erases the stored standard key code from the memory, thus disabling
the lost standard key.To re-register, refer to “Standard key registration”.
8-61
IMMOBILIZER SYSTEM
Standard key code voiding method
a.
b.
c.
d.
e.
f.
g. Remaining standard key
h. Registration mode
Main switch “ON”
Main switch “OFF”
LED on
LED off
Less than 5.0 s
Code re-registering key
A. If the immobilizer system indicator light
stops flashing 5 seconds after the first standard key is registered, the second standard
key cannot be registered.
EAS27701
TROUBLESHOOTING
When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor
flashes.
1. Check the fuses.
(Main, ignition and backup)
Refer to “CHECKING THE FUSES” on
page 8-106.
NG→
Replace the fuse(s).
OK↓
2. Check the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-107.
NG→
● Clean
the battery terminals.
● Recharge or replace the battery.
OK↓
3. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-101.
NG→
Replace the main switch/immobilizer unit.
NG→
Properly connect or repair the immobilizer system
wiring.
OK↓
4. Check the entire immobilizer system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-57.
OK↓
● Check
the condition of the each immobilizer system circuits.
● Refer to “SELF-DIAGNOSIS FAULT
CODE INDICATION” on page 8-62.
EAS27721
SELF-DIAGNOSIS FAULT CODE INDICATION
When a system failure occurrs, the error code number is indicated in the LCD display of meter and the
immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error
code.
8-62
IMMOBILIZER SYSTEM
Fault code
Part
Symptom
Cause
Action
51
IMMOBILIZER
UNIT
Code cannot be transmitted between the
key and immobilizer
unit.
●
Radio wave interference caused by
objects around the
keys and antennas.
● Immobilizer unit malfunction.
● Key malfunction.
●
Keep magnets,
metal objects,
and other immobilizer system keys
away form the
keys and antennas.
● Replace the main
switch/immobilizer unit.
● Replace the key.
52
IMMOBILIZER
UNIT
Codes between the
key and immobilizer
unit do not match.
●
Signal received from
other transponder
(failed to recognize
code after ten consecutive attempts).
● Signal received from
unregistered standard
key.
●
53
IMMOBILIZER
UNIT
Codes cannot be
transmitted between
the ECU and the
immobilizer unit.
Noise interference or disconnected lead/cable.
Place the immobilizer unit at least
50 mm away from
the transponder
of other vehicles.
● Register the standard key.
Check the wire
harness and con● Interference due to
nector.
radio wave noise.
● Replace the main
● Disconnected commuswitch/immobinication harness.
lizer unit.
● Immobilizer unit mal● Replace the ECU.
function.
●
ECU malfunction.
Register the code
re-registering key.
● Interference due to
● Check the wire
radio wave noise.
harness and con● Disconnected communector.
nication harness.
● Replace the main
● Immobilizer unit malswitch/immobifunction.
lizer unit.
● ECU failure.
● Replace the ECU.
(The ECU or immobilizer
unit was replaced with a
used unit from another
vehicle.)
54
IMMOBILIZER
UNIT
Codes transmitted
between the ECU and
the immobilizer unit do
not match.
Noise interference or disconnected lead/cable.
●
55
IMMOBILIZER
UNIT
Key code registration
malfunction.
Same standard key was
attempted to be registered
two consecutive times.
Register another
standard key.
8-63
IMMOBILIZER SYSTEM
Fault code
56
Part
ECU
Symptom
Cause
Undefinition code is
received.
Noise interference or disconnected lead/cable.
Immobilizer system indicator light fault code indication
Digit of 10 : Cycles of “1” sec. ON and 1.5 sec. OFF.
Digit of “1” : Cycles of 0.5 sec. ON and 0.5 sec. OFF.
Example: fault code 52
8-64
Action
Check the wire
harness and connector.
● Replace the main
switch/immobilizer unit.
● Replace the ECU.
●
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
EAS28790
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
EAS27730
CIRCUIT DIAGRAM
8-65
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
4. Main switch
9. ABS control unit fuse
12. Signaling system fuse
17. Battery
18. ABS motor fuse
19. Main fuse
23. Starting circuit cut-off relay 2
24. Starting circuit cut-off relay 1
28. Start switch
29. Engine stop switch
31. Front brake light switch
32. ECU (engine)
44. ABS test coupler
45. ECU (ABS)
46. Front wheel sensor
47. Rear wheel sensor
48. Fail-safe relay
58. Hydraulic unit
65. Rear brake light switch
69. Tail/brake light
72. Multi-function display
90. ABS warning light
8-66
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
EAS27740
ABS COMPONENTS CHART
8-67
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
1. ABS warning light
2. Fail-safe relay
3. Electronic control unit (ECU)
4. Hydraulic unit
5. Rear disc rotor
6. Rear brake caliper
7. Rear wheel sensor
8. Front brake caliper
9. Front wheel sensor
10. Front disc rotor
8-68
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
EAS27750
ABS CONNECTOR LOCATION CHART
1
3
4
2
6
7
5
8-69
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
1.
2.
3.
4.
5.
6.
7.
ABS test coupler
ECU (ABS) coupler
Front wheel sensor coupler
Fail-safe relay coupler
Hydraulic unit coupler
Rear wheel sensor coupler
Multi-function coupler
8-70
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
EAS27760
ECU (ABS) AND FAIL-SAFE RELAY CHART
Removing the ECU (ABS) and fail-safe relay
2
1
3
7 Nm (0.7 m • kg, 5.1 ft • Ib)
5
4
4
Order
Job/Parts to remove
Q’ty
Front cowling
1
2
3
4
5
Fail-safe relay coupler
Fail-safe relay
Upper ECU (ABS) bracket
ECU (ABS) coupler
ECU (ABS)
1
1
1
1
1
8-71
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Disconnect.
Disconnect.
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
EAS27770
[D-1] MAINTENANCE OF THE ECU (ABS)
Checking the ECU (ABS)
1. Check:
● Terminals “1” of the ECU (ABS)
Cracks/damages → Replace ECU (ABS)
● Terminals “2” of the ECU (ABS) coupler
Connection
defective,
contaminated,
come-off → Correct or clean.
Solenoid relay resistance
150–450 Ω
Tester reading is “∞”. → Replace the fail-safe
relay.
NOTE:
If the ECU (ABS) couplers are clogged with mud
or dirt, clean with compressed air.
●
EAS15B4014
[D-2] MAINTENANCE OF THE ABS
FAIL-SAFE RELAY
CHECKING THE FAIL-SAFE RELAY
1. Check:
● Solenoid relay for continuity
Connect the pocket tester (Ω×1) to the terminals.
Check for continuity between terminals “3”
and “4” of the solenoid relay.
Positive tester probe Terminal →“3”
Negative tester probe Terminal →“4”
Tester reading is “∞”. → Replace the fail-safe
relay.
● Check for continuity between terminals “7”
and “8” of the solenoid relay.
Positive tester probe Terminal →“7”
Negative tester probe Terminal →“8”
Connect the positive battery terminal to terminal “7” and the negative battery terminal to
terminal “8”, and then check for continuity between terminals “4” and “5” of the solenoid relay.
Positive tester probe → Terminal “4”
Negative tester probe → Terminal “5”
Tester reading is “∞”. → Replace the fail-safe
relay.
a. Fail-safe relay
b. ABS motor relay
c. Solenoid relay
2. Check:
● ABS motor relay for continuity
Connect the pocket tester (.Ω×1) to the terminals of the ABS motor relay.
Check for continuity between terminals “1”
and “6” of the ABS motor relay.
Positive tester probe Terminal
Negative tester probe Terminal
Tester reading is “∞”. →Replace the fail-safe
relay.
ABS motor relay resistance
50–150 Ω
8-72
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
Connect the positive battery terminal to terminal “6” and the negative battery terminal to
terminal “1”, and then check for continuity between terminals “2” and “5” of the ABS motor
relay.
Positive tester probe → Terminal “2”
Negative tester probe → Terminal “5”
Tester reading is “∞”. → Replace the fail-safe
relay.
● When connecting the battery and the ABS
motor relay terminals, be careful not to
short-circuit the positive and negative battery
terminals.
EAS15B4887d
●
[D-5] MAINTENANCE OF THE HYDRAULIC
UNIT
ECA15B1006
CAUTION:
Do not remove the hydraulic unit to check
the resistance of the solenoid valves and the
ABS motor for continuity.
Checking the resistance of the solenoid
valves and ABS motor for continuity
ECA15B1007
CAUTION:
When check the hydraulic unit solenoid relay
and ABS motor, do not remove the brake
hoses.
1. Measure:
● Resistance of the solenoid valve (front)
Connect a pocket tester (Ω× 1) to the terminals of the solenoid valve (front).
Positive tester probe → Terminal “1”
Negative tester probe → Terminal “2”
Solenoid valve resistance
2.96–3.20 at 20 °C (68 °F)
Out of specification Replace the hydraulic
unit.
EAS15B4887b
[D-3] MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR
CHECKING THE FRONT WHEEL SENSOR
AND SENSOR ROTOR
Refer to “CHECKING THE FRONT WHEEL
SENSOR AND SENSOR ROTOR (XP500A)”.
2. Measure:
● Resistance of the solenoid valve (rear)
Connect the pocket tester (Ω× 1) to the terminals of solenoid valve (rear).
Positive tester probe → Terminal “4”
Negative tester probe → Terminal “3”
EAS15B4887c
[D-4] MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR
CHECKING THE REAR WHEEL SENSOR
AND SENSOR ROTOR
Refer to “CHECKING THE FRONT WHEEL
SENSOR AND SENSOR ROTOR (XP500A)”.
Solenoid valve resistance
2.96–3.20 at 20 °C (68 °F)
Out of specification → Replace the hydraulic
unit.
3. Check:
● ABS motor for continuity
Connect the pocket tester (Ω× 1) to the terminals of the ABS motor coupler.
8-73
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
Positive tester probe Terminal “1”
Negative tester probe Terminal “2”
There is continuity.
No continuity → Replace the hydraulic unit.
8-74
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
EAS27790
ABS TROUBLESHOOTING OUTLINE
This section describes the troubleshooting about ABS in details. Read carefully this service manual before repairing various malfunctions, understand and perform the service.
Electronic control unit (ECU) has the self diagnostic function. When failures occur in the system, the
ABS warning light on the meter assembly indicates a malfunction.
Troubleshooting mentioned below describes the cause pursuing and service method according to the
indication by the maltifunction display. For troubleshooting other than these items, perform by following
the normal service method.
EWA13880
WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer. (Refer to “[D-6] FINAL
CHECK”.)
ABS warning light goes on and the ABS condition
● When the ABS warning light keeps going on → It works as a normal brake.
● Detecting the malfunction by means of the ABS self diagnostic function.
● Light goes on and off at the time of starting → ABS operation is normal.
● ABS warning light goes on for 2 seconds every time the main switch is turned on and goes off afterward.
● When the ABS warning light flashes → ABS operation is normal.
● Brake switch is defective or improperly adjusted.
● Rear wheel is racing.
● Continuous riding on extremely uneven roads.
● Defective starter motor monitor.
● Other defective
Self diagnosis and services
The ECU (ABS) has a self diagnostic function. By utilizing this function, quick and secure services are
possible. Previously occurred error phenomenon can be checked since it also installs the memory for
storing malfunction history.
“In case malfunctions are detected”
It is disabled to call the malfunction code by using the malfunction display since the ABS warning light
already goes on. Connect the test coupler adapter to the test connector, connect a pocket tester to the
terminal of light green lead and check by its pointing needle movement.
Refer to “[B-5] MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PRESENT MALFUNCTION)” on page 8-80.
“In case any malfunctions are not detected”
The multifunction display indicates all the malfunction codes recorded in the ECU (ABS). You can
check it by using a pocket tester. Note everything if more than two items of malfunction codes are recorded.
“Deleting the malfunction code”
When the malfunction service is finished, check the normal operation of vehicle then delete the malfunction code(Refer to “[D-6] FINAL CHECK” on page 8-95). By deleting the malfunction code memory,
it is possible to pursue the cause correctly if the next defective phenomenon occurred.
Self diagnosis by ECU (ABS)
ECU (ABS) performs the static check for whole system when the main switch is turned on. It is also possible
to check the malfunction while riding. It is possible to check the recorded malfunction data by using a pocket
tester or the maltifunction display of meter by setting the ECU (ABS) to the self diagnostic mode since all
malfunctions which has been once detected are recorded.
Differences between the normal handling and services on a vehicle
should be taken not to damage components by shocks and pulling too much since the ABS components are precisely adjusted.
● ECU (ABS), HU, Wheel sensors and fail-safe relay cannot be disassembled.
● Care
8-75
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
● Malfunction
history in ECU (ABS) is recorded. Delete it when the service is finished. (This is because
the past malfunction contents will be redundantly displayed when the same malfunction occurred
again.)
EAS27800
BASIC INSTRUCTION FOR TROUBLESHOOTING
EWA14030
WARNING
● Execute
● Use
the troubleshooting on each malfunction from [A] to [D] in sequence.
the sufficiently charged regular batteries only.
[A] Malfunction check by the ABS warning light
[B] Detail check of malfunction
Results by self diagnosis are displayed by the multifunction display or a pocket tester according to the
ECU’s operation.
[C] Supposing the malfunction cause and position
Find the malfunction cause by reasoning the place and situation where it occurred.
[D] ABS system services
Execute the final check after disassembly and assembly.
EWA14040
WARNING
Perform the troubleshooting [A] → [B] → [C] → [D] in order. Be sure to follow the order since it
results in the wrong diagnosis if the order is differently taken or omitted.
8-76
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
EAS27810
BASIC PROCESS FOR TROUBLESHOOTING
8-77
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
NOTE:
Do not delete the malfunction code during the troubleshooting procedures. Be sure to delete it when
the service is finished.
EWA14050
WARNING
Always execute the “final check” when the components related to ABS are checked and serviced.
EAS27830
[A] ABS MALFUNCTION CHECK USING THE ABS WARNING LIGHT
Turn the main switch to “ON”. (Do not start the engine.)
1. The ABS warning light does not come on. [B-1]
2. The ABS warning light remains on. [B-2]
3. The ABS warning light flashes. [B-3]
4. The ABS warning light comes on for 2 seconds, then goes off. [B-4]
EAS15B3008
[B] DETAILED ABS MALFUNCTION CHECK
EAS15B3009
[B-1] THE ABS WARNING LIGHT DOES NOT COME ON
Do other indicators operate normally?
1. Yes [C-1]
2. No [C-2]
EAS15B3010
[B-2] THE ABS WARNING LIGHT REMAINS ON
NOTE:
Check following the steps in sequence.
1. Battery voltage low
Charge, inspect or replace the battery.
2. Malfunction codes displayed. Check the malfunction codes using the ABS test coupler adaptor.
Perform troubleshooting corresponding to the malfunction codes. [B-5]
3. Wire harness, ECU (ABS) and meter coupler are disconnected.
Connect the coupler securely until a “click” sound is heard.
4. Check the disconnection between the ECU (ABS) and meter (ABS warning light).
Check the conductivity of the wire harness and repair or replace the failure part.
5. Meter circuit malfunction
Check by the following procedures.
● Remove the ECU (ABS) and connect the ABS test coupler adaptor.
● Connect the white/red lead from the test coupler adaptor to the GND terminal and set the main
switch to “ON”.
● Does the ABS warning light go off?
● Yes → Replace the ECU (ABS).
● No → Replace the meter.
EAS15B3031
[B-3] THE ABS WARNING LIGHT FLASHES
NOTE:
Check the battery voltage before proceeding.
Check the test coupler located in the front cowling. Is the T/C terminal ground?
1. Yes → Disconnect the grounding lead from the T/C terminal and install the protective cap onto the
test coupler.
8-78
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
NOTE:
When the test coupler adaptor is connected to test coupler, the T/C terminal is grounded.
2. No → [C-3]
Arrangement and the function of test couplers
● ECU becomes the malfunction diagnostic mode when the T/C terminal is grounded.
● Malfunction code which the ECU generated in the malfunction diagnostic mode (rise and fall of voltage) is output at the T/F terminal.
● ABS warning light terminal is used when checking the ABS warning light circuit.
● To ground the T/C terminal, connect the test coupler adapter “A” with the test coupler. Before connecting, check if the battery is sufficiently charged.
3. Grounding (black)
4. ABS warning light terminal (white/red)
1. T/C terminal (sky-blue)
2. T/F terminal (light green)
EAS27860
[B-4] MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PAST MALFUNCTION)
Check the location of test coupler “1”. Remove the protective cap and connect the ABS test coupler
adapter “2” to the test coupler. The T/C terminal (sky-blue) is now connected to the ground.
1
1
2
● Indicate
the malfunction code (Example: malfunction code 11)
8-79
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
warning light flashes every 0.5 second for more than 6 seconds. → [C-4, C-5]
If the ABS warning light flashes every 0.5 second, the malfunction code of a past malfunction has not
been stored in the memory of the ECU (ABS). If a malfunction code is displayed on the multifunction
display, the ABS warning light flashes. Make sure that the customer understands the possible conditions when the ABS warning light comes on.
● ABS
ECA15B1033
CAUTION:
● When
checking for ABS malfunctions, the odometer and bottom tripmeter are not displayed.
checking for fuel injection system malfunctions or adjusting the exhaust gas volume,
the ABS malfunction codes are not displayed.
● When
EAS27870
[B-5] MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PRESENT MALFUNCTION)
NOTE:
Before proceeding to read the part of “Arrangement and the function of test coupler”.
Remove the side cowling (right) and check the location of test coupler. Connect the test coupler adapter
with the test coupler in order to ground the T/C terminal (sky-blue). (Figure-“A”)
Set the range of pocket tester to DC 20 V. Connect the negative (-) terminal of tester to the T/F terminal
(light green) and positive (+) terminal to the positive (+) terminal of battery. (Figure-“B”) Read the tester
indication. (Figure-“C”)
NOTE:
Read the code through this means so that the “current mulfunction” code is not indicated on the meter.
8-80
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
1.
2.
3.
4.
5.
6.
7. ABS warning light terminal (white/red)
8. Test coupler adapter
9. (Light green)
10. (Black)
11. (White/red)
ABS test coupler
Lock plate
Protective cap
Grounding
T/C terminal
T/F terminal
As an example, “10 digits/1 digit pattern” of tester reading is shown below.
8-81
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
C. Time (second)
A. This example is the pattern which shows
malfunction code 12.
B. This example is the pattern which shows
malfunction code 21.
EAS15B3011
[C] DETERMINING THE CAUSE AND LOCATION OF THE MALFUNCTION
EAS15B3012
[C-1] ONLY THE ABS WARNING LIGHT DOES NOT COME ON WHEN THE MAIN SWITCH IS SET
TO “ON”
NOTE:
Check following the steps in sequence.
1. Visual check
● Check the ABS fuse.
Determine the cause of the blown fuse and repair. Replace with a new fuse. (Refer to “CHECKING
THE FUSES” in chapter 3.)
● Check the wire harness (ABS system circuit) couplers.
Check that the wire harness (ABS system circuit) couplers are securely connected.
● Check the connection of the wire harness (ABS system circuit) to the ECU (ABS).
Check that the wire harness (ABS system circuit) is securely connected to the ECU (ABS).
2. Confirmation using the test coupler adaptor
● Connect the test coupler adaptor to the test coupler. (Refer to “[B-5] ABS malfunction check using
the ABS self-diagnosis (present malfunction)”.)
● Ground the warning light terminal (white/red) of the test coupler adaptor or connect the warning light
terminal to the negative battery terminal.
If the ABS warning light comes on, the wire harness (ABS system circuit) may be disconnected.
If the ABS warning light does not come on, the ABS warning light lead may be disconnected or the
contact of the ABS warning light may be defective.
● Remove the ECU (ABS) coupler and check the ECU (ABS) coupler and test coupler adaptor ends
of the white/red lead for continuity.
If there is continuity, the ECU (ABS) is defective. → Replace the ECU (ABS). (Refer to “[D-1] Maintenance of the ECU (ABS)”.)
If there is no continuity, the warning light circuit in the wire harness (ABS system circuit) is defective.
Disconnection or short → Correct. (Refer to “CIRCUIT DIAGRAM”.)
EAS15B3013
[C-2] ABS WARNING LIGHT AND ALL OTHER INDICATORS DO NOT COME ON
NOTE:
Check following the steps in sequence.
1. Check the power supply system.
● Check that the battery is connected correctly.
8-82
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
Check the battery voltage. (Refer to “CHECKING AND CHARGING THE BATTERY” on page
8-107.)
● Check if the main fuse or signal fuse is blown. If the main fuse is blown, determine the cause and
repair.
Replace with a new fuse. (Refer to “CHECKING THE FUSES” on page 8-106.)
2. Check the connections.
● Check that the main fuse coupler is securely connected.
● Check that the main switch coupler is securely connected.
● Check that the meter assembly coupler is securely connected. (Refer to “ABS CONNECTOR LOCATION CHART” on page 8-69.)
When these checks are finished, return to [A] and check the ABS again.
●
EAS15B3014
[C-3] ABS WARNING LIGHT FLASHES
With the engine off, check the front and rear brake switches.
Check if the brake light comes on when the front or rear brake is applied.
1. The light does not come on for only one brake.
→ The corresponding brake switch connector is disconnected. (Refer to “CIRCUIT DIAGRAM”.)
→ The corresponding brake switch is defective.
2. The light does not come on for either brake.
→ The wire harness (ABS system circuit) may be disconnected or the fuse may be blown. Check
the fuse and make sure the wire harness (ABS system circuit) (brown lead) is connected to the power source end of the brake switch. (Refer to “CIRCUIT DIAGRAM”.)
3. The brake light comes on.
→ The wire harness (ABS system circuit) couplers may be disconnected.
4. Adjust the rear brake switch to the specified setting.
EAS15B3015
[C-4] ABS WARNING LIGHT FLASHES EVERY 0.5 SECOND
If the ABS warning light flashes every 0.5 second, the malfunction code of a past malfunction has not
been stored in the memory of the ECU (ABS). If a malfunction code is displayed on the multifunction
display, the ABS warning light flashes. Make sure that the customer understands the possible conditions when the ABS warning light comes on.
1. Voltage drop
For the ABS to operate correctly, the voltage should be always higher than the specified voltage. If
the voltage drops to lower than 10 V, the ABS warning light comes on and the ABS does not operate.
When the voltage recovers to higher than 10 V, the ABS operates. However, the magneto, battery
and rectifier/regulator must be checked. Follow the regular procedures for service of the power supply system.
2. ABS is stopped by the ECU (ABS)
The ECU (ABS) may stop the ABS operation if it is exposed to extremely strong electromagnetic
waves or static electricity.
When the ECU (ABS) is no longer exposed to the electromagnetic waves, static electricity, and the
ABS warning light is not flashing, there is no effect on the operation of the ABS. Explain to the customer that the ABS will operate normally.
EAS27880
[C-5] DIAGNOSIS BY THE MALFUNCTION CODE
Malfunction codes are used to determine the malfunctions that have occurred. (Refer to “[B-4] MALFUNCTION CHECK BY THE ABS SELF-DIAGNOSIS (PAST MALFUNCTION)” and “[B-5] MALFUNCTION CHECK BY THE ABS SELF-DIAGNOSIS (PRESENT MALFUNCTION)”.) The
malfunction codes are explained in the following table.
NOTE:
Record all of the malfunction codes displayed and check the check points.
8-83
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
Malfunction
code
Problem
Front wheel sensor signal is not
received properly.
11*
Rear wheel sensor signal is not
received properly.
12
Malfunction
code 11
Installation of the rear wheel
sensor
● Rear wheel sensor lead and
coupler
● ABS wireharness circuit
● Rear wheel sensor rotor
Malfunction
code 12
●
Wheel sensor installation
Wheel sensor housings
● Wheel sensor rotors
No continuity in the front (15) or rear
(16) wheel sensor circuits
●
Disconnection and short-circuit of
hydraulic unit solenoid
●
Disconnection is detected between
the battery and ECU (ABS) system.
●
21
31
33
Installation of the front wheel
sensor
● Front wheel sensor lead and
coupler
● ABS wireharness circuit
● Front wheel sensor rotor
●
15 (front)
16 (rear)
Reference
●
Incorrect signal is detected by the
front (13) or rear (14) wheel sensor.
13 (front)
14 (rear)
32
Check point
●
Continuity of sensor circuits
ABS wireharness circuit
● Connection of sensor coupler
●
Malfunction
codes 13
(front wheel)
and 14 (rear
wheel)
Malfunction
codes 15
(front wheel
sensor) and
16 (rear wheel
sensor)
Wire harness circuit
Hydraulic unit solenoid coupler
● Hydraulic unit solenoid
● Battery terminal is disconnect
Malfunction
code 21
Fuse (ABS motor)
ABS wireharness circuit
(between the battery and ECU
(ABS))
● ECU (ABS) coupler
Malfunction
code 31
●
●
Circuit malfunction of ECU (ABS) is
detected.
Upstream side of the solenoid relay
●
Defective operation of the ABS motor
is detected. (ABS motor stops and will
not rotate.)
●
●
Wire harness circuit
Replace the ECU (ABS).
ABS wireharness circuit
ABS motor coupler
● Fail-safe relay
● ABS motor circuit
● ABS motor fuse
●
8-84
Malfunction
code 32
Malfunction
code 33
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
Malfunction
code
34
41
42
51
52
Present
malfunction (test
always
indicates
12 V)
Problem
Check point
Fail-safe relay
● ABS wireharness circuit
● ABS motor circuit
Defective operation of the ABS motor
is detected. (ABS motor keeps running and will not stop.)
●
Front wheel will not recover from the
locking tendency even though the signal is continuously transmitted from
the ECU (ABS) to release the hydraulic state (when the battery voltage is
normal).
●
Rear wheel will not recover from the
locking tendency even though the signal is continuously transmitted from
the ECU (ABS) to release the hydraulic state (when the battery voltage is
normal).
●
Front wheel will not recover from the
locking tendency even though the signal is continuously transmitted from
the ECU (ABS) to release the hydraulic state (when the battery voltage is
low).
●
Rear wheel will not recover from the
locking tendency even though the signal is continuously transmitted from
the ECU (ABS) to release the hydraulic state (when the battery voltage is
low).
●
ECU (ABS) may be malfunctioning
●
Brake dragging
Hydraulic unit operation test 2
[D-6-3-2]
● Front wheel brake line
Reference
Malfunction
code 34
●
Brake dragging
Hydraulic unit operation test 2
[D-6-3-2]
● Rear wheel brake line
Malfunction
code 41
●
Brake dragging
Hydraulic unit operation test 2
[D-6-3-2]
● Front wheel brake line
● Battery voltage
Malfunction
code 42
●
Brake dragging
Hydraulic unit operation test 2
[D-6-3-2]
● Rear wheel brake line
● Battery voltage
Malfunction
code 51
●
ABS wireharness circuit (test
coupler circuits)
● ECU (ABS) (Replace)
Malfunction
code 52
Maintenance
of the ECU
(ABS)
[D-1]
* Malfunction code 11 is indicated if the rear wheel rotates for more than 20 seconds with the front wheel stopped.
NOTE:
Malfunction code 15 (front wheel sensor) or 16 (rear wheel sensor) is displayed if a defective connection to either the front or rear sensor is detected whether or not the vehicle is ridden.
Malfunction code 11 (Front wheel sensor signal is not received properly.)
Turn the main switch to “OFF”, then back to “ON” after removing the test coupler adapter.
1. ABS warning light remains on.
→ Defective connection in the front wheel sensor circuit.
● Front wheel sensor coupler is disconnected. → [D-3]
8-85
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
Front wheel sensor lead or internal circuit is broken. → [D-3]
● Wire harness (ABS) sensor circuit is broken. → (Refer to “CIRCUIT DIAGRAM” on page 8-65.)
● ECU (ABS) coupler terminal is disconnected. → [D-1]
2. ABS warning light goes on for 2 seconds then goes off.
● With the front wheel stopped, the rear wheel was rotated for more than 20 seconds. This is not a
malfunction.
● Signal is not generated at the front wheel sensor.
● Front wheel sensor is not installed properly. → [D-3]
● Front wheel sensor rotor is defective. → [D-3]
● Front wheel sensor circuit is short-circuited.
● Front wheel sensor or lead is short-circuited. → [D-3]
● Wire harness (ABS) sensor circuit is short-circuited. → (Refer to “CIRCUIT DIAGRAM” on page
8-65.)
● Front wheel sensor output drops.
● Sensor signal output may drop due to failure on bearings, wheel axle, wheel or sensor housing of
front wheel. Check these components when installed for looseness, distortion, and bends.
Malfunction code 12 (Rear wheel sensor signal is not received properly.)
Turn the main switch to “OFF”, then back to “ON” after removing the test coupler adapter.
1. ABS warning light remains on.
→ Defective connection in the rear wheel sensor circuit.
● Rear wheel sensor coupler is disconnected. → [D-4]
● Rear wheel sensor lead or internal circuit is broken. → [D-4]
● Wire harness (ABS) sensor circuit is disconnected. → (Refer to “CIRCUIT DIAGRAM” on page
8-65.)
● ECU (ABS) coupler terminal is disconnected. → [D-1]
2. ABS warning light goes on for 2 seconds then goes off.
● With the rear wheel stopped, the front wheel was rotated at a speed faster than 11 km/h. This is not
a malfunction.
● Signal is not generated at the rear wheel sensor.
● Rear wheel sensor is not installed properly. → [D-4]
● Rear wheel sensor rotor is defective. → [D-4]
● Rear wheel sensor circuit is short-circuited.
● Rear sensor or lead is short-circuited. → [D-4]
● Wire harness (ABS) sensor circuit is short-circuited. → (Refer to “CIRCUIT DIAGRAM” on page
8-65.)
● Rear wheel sensor output drops.
● Sensor signal output may drop due to failure of the bearing, wheel, or brake caliper bracket of the
rear wheel. Check these components when installed for looseness, distortion, and bends.
●
NOTE:
If the vehicle is ridden on extremely uneven roads continuously, the ABS warning light may flash and
malfunction code 11 or 12 may be recorded depending on the condition.
Malfunction code 13 (front wheel) and malfunction code 14 (rear wheel) (Incorrect signal is
detected by the front (13) or rear (14) wheel sensor.)
1. The wheel sensors or sensor rotors are not properly installed.
● Installation of the front or rear wheel sensor
● Check that the wheel sensor is properly installed in the housing. → [D-3, 4]
● Check if there is looseness between the housing and the front wheel. → [D-3, 4]
● Check if there is looseness rear brake caliper bracket and the rear wheel. → [D-3, 4]
● Installation of the front or rear wheel sensor rotor
● Check that the sensor rotor is correctly pressed in the front wheel. → [D-3, 4]
● Check that the sensor rotor is correctly install to the rear wheel. → [D-3, 4]
● Check the rotor and inside the rotor housing for foreign materials. → [D-3, 4]
2. Teeth surfaces of the sensor rotors are defective.
8-86
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
Check for flaws on the teeth surfaces of the front or rear wheel sensor rotors.
Also, check for any foreign materials. → [D-3, 4]
3. Sensor output has dropped.
● Sensor signal output may drop due to failure of the bearings, wheel axle, rear brake caliper bracket
wheel or sensor housing of (front) the front or rear wheel. Check these components when installed
for looseness, distortion, and bends.
Malfunction code 15 (front wheel sensor) and malfunction code 16 (rear wheel sensor) (No
continuity in the front or rear wheel sensor circuits.)
Broken front or rear wheel sensor circuit is detected.
● Front or rear wheel sensor coupler is broken. → [D-3, 4]
● Front or rear wheel sensor or lead is broken. → [D-3, 4]
● Front or rear wheel sensor circuit is broken. → (Refer to “CIRCUIT DIAGRAM”.)
● Wire harness (ABS system circuit) is disconnected from the ECU (ABS) coupler terminal. → [D-1]
●
NOTE:
● Check
that both the front and rear wheel sensor couplers are connected securely.
the vehicle is ridden after malfunction code 15 (front wheel sensor) or 16 (rear wheel sensor) is displayed, the malfunction code will be overwritten from 15 to 11 (front wheel sensor signal) or from 16
to 12 (rear wheel sensor signal).
● If
Malfunction code 21 (Disconnection and short-circuit of hydraulic unit solenoid.)
1. Hydraulic unit solenoid coupler
● Check if the hydraulic unit solenoid coupler terminal is disconnected. (Refer to “ABS CONNECTOR
LOCATION CHART” on page 8-69.)
2. Hydraulic unit solenoid
● Check the front and rear wheel solenoids for continuity → [D-5]
● Check the insulation of all solenoid terminals and the negative battery terminal. → [D-5]
3. Wire harness (ABS)
● Check the hydraulic unit solenoid circuits for continuity. (See the illustration below.)
1.
2.
3.
4.
5.
6.
7.
8.
9.
ECU (ABS)
White/Brown
Red
Red
Front solenoid
Rear solenoid
White/Blue
Green
Fail-safe relay
*Continuity between: “A”–“B”, “A”–“C”, “D”–“G”, “E”–“F”
● Check the insulation of the hydraulic unit solenoid circuits and the negative battery terminal.
4. Battery
● Battery terminal is disconnected
Malfunction code 31 (Disconnection is detected between the fail-safe relay and the hydraulic
unit solenoid.)
NOTE:
Check following the steps in sequence.
1. ABS motor fuse
● Check if the ABS motor fuse beside the battery is blown.
2. Hydraulic unit solenoid coupler
8-87
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
Check if the hydraulic unit solenoid coupler located in the front cowling is connected properly.
3. Wire harness (ABS system circuit)
● Check the pink/white leads between the ECU (ABS) and the fail-safe relay for continuity. (Refer to
“CIRCUIT DIAGRAM”.)
● ECU (ABS) coupler terminal (pink/white) is disconnected. → [D-1]
● Check the red leads between “1” and “2”, and between “1” and “3” of the hydraulic unit solenoid circuits for continuity.
●
4. Front solenoid
5. Rear solenoid
6. Fail-safe relay
1. Red
2. Red
3. Red
4. Fale-safe relay
● Check if the fail-safe relay operates correctly. → [D-2]
5. Wire harness
● Check for continuity between the red terminal of the fail-safe relay coupler and the positive battery
terminal.
● Remove the ABS fuse and check for continuity between the brown/white “1”lead of the fail-safe relay
coupler and the ABS fuse“2”. (See the illustration below.)
2
1. Check for continuity between these two points
8-88
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
Malfunction code 32 (Circuit malfunction of ECU (ABS) is detected. Upstream side of the solenoid relay.)
NOTE:
Check following the steps in sequence.
1. Fail-safe relay
● Check if the fail-safe relay operates correctly. → [D-2]
2. Wire harness (ABS system circuit)
● Disconnect the couplers from the fail-safe relay and the ECU (ABS), and then check the insulation
of the fail-safe relay coupler between the red and red terminals.
Malfunction code 33 (Defective operation of the ABS motor is detected. [ABS motor stops and
will not rotate.])
NOTE:
Check following the steps in sequence.
1. ABS motor fuse
● Check if the ABS motor fuse beside the battery is blown.
2. Fail-safe relay
● Check if the fail-safe relay operates correctly. → [D-2]
3. Wire harness
● Remove the fail-safe relay and the ABS motor fuse, and then check for continuity between the red
(Refer to “ABS CONNECTOR LOCATION CHART” on page 8-69 in fail-safe relay coupler drawing.)
terminal of the wire harness (ABS) and the wire harness (ABS) end (terminal A shown in the illustration) of the ABS motor fuse terminal in the side of the stay. (Refer to “ABS CONNECTOR LOCATION CHART” on page 8-69.)
1
2
2. Terminal B
1. Terminal A
Check for continuity between the positive battery terminal and the battery end of the ABS motor fuse
terminal (terminal B shown in the above illustration).
● Remove the ECU (ABS) and the fail-safe relay from the wire harness (ABS), and then check for continuity between the white/black lead terminals of ECU (ABS) coupler and the red/white lead terminals of ABS motor coupler.
Malfunction code 34 (Defective operation of the ABS motor is detected. [ABS motor keeps
running and will not stop.])
●
NOTE:
Check following the steps in sequence.
1. ABS motor
● Check if the ABS motor coupler located in the front cowling is connected properly.
● Check the ABS motor for continuity. → [D-5]
2. Wire harness (ABS)
● Remove the ABS motor coupler and check for continuity between the black/white terminal of the
ABS motor coupler of the wire harness (ABS) and the negative battery terminal.
● Remove the ECU (ABS) coupler and check for continuity between the red/white terminal of the ECU
8-89
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
(ABS) coupler and the red/white terminal of the ABS motor coupler. → [D-1]
● Remove the fail-safe relay and check for continuity between the red/white terminal of the ABS motor
coupler of the wire harness (ABS) and the positive battery terminal.
3. Fail-safe relay
● Check if the fail-safe relay operates correctly. → [D-2]
Malfunction code 41 (Front wheel will not recover from the locking tendency even though the
signal is continuously transmitted from the ECU (ABS) to release the hydraulic state [when
the battery voltage is normal].)
NOTE:
Check following the steps in sequence.
1. Rotation of the front wheel
● Check that there is no brake disc drag on the front wheel and make sure it rotates smoothly.
● Check the front wheel axle for loose bearings and bends, and the brake disc for distortion.
2. Brake master cylinder and brake caliper
● Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever
is operated and that the pressure decreases when the lever is released.
3. Brake fluid
● Visually check the brake fluid in the brake master cylinder reservoir and the fluid for water, foreign
materials, solidification and contamination.
● Check for air in the brake hose lines.
4. Brake hose lines
● Check the brake hose lines for kinks and deterioration.
EWA15B3005
WARNING
Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the
brake hose lines.
●
Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic
unit and to the front brake caliper from the hydraulic unit are correct.
EWA15B3006
WARNING
The front brake will not function properly if the connections are reversed.
● Front brake hose “1” outlet: to the front brake caliper
● Front brake hose “2” inlet: from the front brake master cylinder
NOTE:
● If
the front brake hose inlet and outlet connections are reversed on the hydraulic unit, the brake lever
is pulled to full stroke without responding and will be pushed back slowly without pulsating when the
final check in [D-6] is performed.
● If the front and rear brake hose connections are reversed on the hydraulic unit, the pulsating action in
the right hand brake lever and left hand brake lever will be performed in the reverse order when the
final check in [D-6] is performed.
2
1
8-90
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
5. Hydraulic unit solenoid coupler terminal
● Check if the front and rear hydraulic unit solenoid coupler terminals (hydraulic unit and wire harness
[ABS]) are reversed.
Terminal color
Solenoid side
Wire harness side (ABS)
Front
Red, Green
Red, White
Rear
Red, White
Red, Green
6. Hydraulic unit
If the malfunction is not corrected after performing steps 1 to 5, replace the hydraulic unit. Be sure
to connect the brake hoses and couplers correctly and securely. Check the hydraulic unit operation.
(Refer to “[D-6] FINAL CHECK” on page 8-95.)
Malfunction code 42 (Rear wheel not recover from the locking tendency even though the signal is continuously transmitted from the ECU (ABS) to release the hydraulic state [when the
battery voltage is normal].)
Check the following:
1. Rotation of the rear wheel
● Check that there is no brake drag on the rear wheel and make sure it rotates smoothly.
● Check for brake disc distortion.
2. Brake master cylinder and brake caliper
● Check that the brake fluid pressure is correctly transmitted to the brake disc when the left hand brake
lever is operated and that the pressure decreases when the lever is released.
3. Brake fluid
● Visually check the brake fluid in the brake master cylinder reservoir and check the fluid for water,
foreign materials, solidification and contamination.
● Check for air in the brake hose lines.
4. Brake hose lines
● Check the brake hose lines for kinks and deterioration (particularly between the hydraulic unit and
the rear brake caliper).
EWA15B3005
WARNING
Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the
brake hose lines.
●
Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic
unit and to the rear brake caliper from the hydraulic unit are correct.
EWA15B3007
WARNING
The rear brake will not function properly if the connections are reversed.
● Rear brake hose “1” outlet: to the rear brake caliper
● Rear brake hose “2” inlet: from the rear brake master cylinder
NOTE:
● If
the rear brake hose inlet and outlet connections are reversed on the hydraulic unit, the left hand
brake lever is pulled to full stroke without responding and will be pushed back slowly without pulsating
when the final check is performed.
● If the front and rear brake hose connections are reversed on the hydraulic unit, the pulsating action in
the right hand brake lever and left hand brake lever will be performed in the reverse order when the
final check is performed.
8-91
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
1
2
5. Hydraulic unit solenoid coupler terminal
● Check if the front and rear hydraulic unit solenoid coupler terminals (hydraulic unit and wire harness
[ABS]) are reversed.
Terminal color
Solenoid side
Wire harness side (ABS)
Front
Red, green
Red, white
Rear
Red, white
Red, green
6. Hydraulic unit
If the malfunction is not corrected after performing steps 1 to 5, replace the hydraulic unit. Be sure
to connect the brake hose lines and couplers correctly and securely. Check the hydraulic unit operation. (Refer to “[D-6] FINAL CHECK” on page 8-95.)
Malfunction code 51 (Front wheel will not recover from the locking tendency even though the
signal is continuously transmitted from the ECU (ABS) to release the hydraulic state [when
the battery voltage is low].))
Check the following:
1. Rotation of the front wheel
Refer to “Malfunction code 41”.
2. Brake master cylinder and brake caliper
Refer to “Malfunction code 41”.
3. Brake fluid
Refer to “Malfunction code 41”.
4. Brake hose lines
Refer to “Malfunction code 41”.
5. Hydraulic unit solenoid coupler terminals
Refer to “Malfunction code 41”.
6. Hydraulic unit
Refer to “Malfunction code 41”.
7. Battery voltage
Measure the battery voltage.
Malfunction code 52 (Rear wheel will not recover from the locking tendency even though the
signal is continuously transmitted from the ECU (ABS) to release the hydraulic state [when
the battery voltage is low].)
Check the following:
1. Rotation of the rear wheel
Refer to “Malfunction code 42”.
2. Brake master cylinder and brake caliper
Refer to “Malfunction code 42”.
3. Brake fluid
Refer to “Malfunction code 42”.
8-92
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
4. Brake hose lines
Refer to “Malfunction code 42”.
5. Hydraulic unit solenoid coupler terminals
Refer to “Malfunction code 42”.
6. Hydraulic unit
Refer to “Malfunction code 42”.
7. Battery voltage
Measure the battery voltage.
EAS15B3036
[D-6-4] DELETING THE MALFUNCTION CODE
1. Connect the test coupler adapter “1” to the test coupler “2”. Refer to “[B-5] MALFUNCTION CHECK
BY THE ABS SELF DIAGNOSIS (PRESENT MALFUNCTION)”
2
1
2. Turn the main switch on.
● The multifunction display indicates previously recorded malfunction codes.
NOTE:
The ABS error code is not displayed during the diagnosis of the fuel injection.
3. Turn the engine stop switch off.
ECA15B3026
CAUTION:
If the starter switch is pushed without turning the engine stop switch off, it may damage the
starting motor gears or other parts, therefore be sure to turn it off.
4. Push the starter switch “2” more than 10 times in 4 seconds to delete the malfunction codes.
NOTE:
The multifunction meter display switches to the ODO/TRIP display and the ABS warning light flashes
in 0.5 second intervals when the malfunction codes are deleted.
1
2
5. Turn the main switch off.
6. Turn the main switch on again.
● Check that the ABS warning light goes on for 2 seconds, then goes out for 3 seconds and starts
flashing.
8-93
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
a.
b.
c.
d.
e.
f.
g.
h.
ABS warning light
ON
Main switch on
Main switch off
Flashing
2 seconds
3 seconds
0.5 seconds
7. Turn the main switch off.
8. Disconnect the test coupler adaptor from the test coupler and install the protective cap onto the test
coupler.
NOTE:
Do not forget to install the protective cap onto the test coupler.
ECA15B3027
CAUTION:
Since the ECU (ABS) remains in the memory until the malfunction code is deleted, always delete
the malfunction code when the service work is finished.
EAS15B3038
[D-6-6] DELETE FUNCTION TEST
1. Place the vehicle on the centerstand.
2. Set the main switch to “OFF”.
3. Connect the test coupler adapter to the test coupler.
4. Set the main switch to “ON”.
5. Check:
● ECU (ABS) voltage
Connect the pocket tester (DC 20 V) to the ECU (ABS) coupler.
Tester positive probe → Brown/White “1”
Tester negative probe → Black “2”
Battery voltage
Higher than 12.8 V
Lower than 12.8 V → Charge or replace the battery.
8-94
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
6. Check:
● ECU (ABS)-to-start-switch-lead continuity
Connect the pocket tester (Ω × 1) to the ECU (ABS) coupler and start switch coupler.
Tester positive probe → Green/White “1” (ECU (ABS))
Tester negative probe → Green/White “2” (start switch)
No continuity → Replace or repair the wire harness.
7. Check:
● ECU (ABS) voltage
Connect the pocket tester (DC 20 V) to the ECU (ABS) coupler.
Tester positive probe → White/Blue “2”
Tester negative probe → Black “1”
Push the start switch.
Start switch ON: less than 1 V
Start switch OFF: more than 12 V
Out of specification → Replace the handlebar switch.
8. If the above-mentioned check are within specification, replace the ECU (ABS).
EAS15B3016
[D-6] FINAL CHECK
Checking procedures
1. Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-22.
2. Check the wheel sensor housings and wheel sensors for proper installation.
Refer to “FRONT WHEEL” on page 4-6 and “REAR WHEEL” on page 4-16.
3. Perform hydraulic unit operation test “1” or “2”.
Refer to “HYDRAULIC UNIT OPERATION TEST” on page 4-49.
4. Delete the malfunction codes.
Refer to “[D-6-4] DELETING THE MALFUNCTION CODE” on page 8-93.
5. Perform a trial run.
Refer to “TRIAL RUN” on page 4-52.
8-95
ABS (ANTI-LOCK BRAKE SYSTEM) (XP500A)
8-96
ELECTRICAL COMPONENTS
EAS27970
ELECTRICAL COMPONENTS
22
21
1
2
3
20
4
5
19
6
7
18
17
16
8
9
10
15
14
12
13
8-97
11
ELECTRICAL COMPONENTS
1. Front brake light switch
2. Rear brake light switch
3. Turn signal/hazard relay
4. Starting circuit cut-off relay 1
5. Starting circuit cut-off relay 2 (XP500A)
6. Battery
7. Fuse box
8. Main fuse
9. Starter relay
10. Rectifier/regulator
11. Sidestand switch
12. Crankshaft position sensor
13. Stator coil
14. Radiator fan
15. Speed sensor (XP500)
16. Throttle position sensor
17. Ignition coil
18. Horn
19. Lean angle sensor
20. Fuel injection system relay
21. Headlight relay
22. Radiator fan motor relay
8-98
ELECTRICAL COMPONENTS
3
2
5
4
1
6
13
7
12
9
8
10
11
8-99
ELECTRICAL COMPONENTS
1. ECU (ABS) (XP500A)
2. Fail-safe relay (XP500A)
3. Main switch/immobilizer unit
4. Intake air pressure sensor
5. Coolant temperature sensor
6. ABS motor fuse
7. Fuel pump
8. Rear wheel sensor (XP500A)
9. O2 sensor
10. Hydraulic unit (XP500A)
11. Front wheel sensor (XP500A)
12. Intake air temperature sensor
13. ECU (engine)
8-100
ELECTRICAL COMPONENTS
EAS27980
CHECKING THE SWITCHES
9
8
2
1
Y L/B G
R/Y Y
–
PASS
Br/R
R
Br/L
3
L/W B
R Br/L Br/R
ON
OFF
P
–
10
R/W R/B
Ch Br/W Dg
11
NR
N
NL
4
Ch Br/W DgL/Y Br/L
B/Y
5
L/Y
12
P B
–
Br
Br/W P B
L/B R/Y
Y G L/Y
Dg Ch B/Y
G/Y
Dg Br/W Ch
Br/L L/Y
(BLACK)
(BLUE)
6
B B
(BLUE)
7
13
R L/G
8-101
G/Y R/B R/W
L/W B Br
(BROWN)
ELECTRICAL COMPONENTS
1. Pass switch
2. Dimmer switch
3. Turn signal switch
4. Horn switch
5. Rear brake light switch
6. Sidestand switch
7. Storage box light switch
8. Main switch
9. Start switch
10. Engine stop switch
11. Hazard switch
12. Front brake light switch
13. Fuse
8-102
ELECTRICAL COMPONENTS
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECA14370
CAUTION:
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
checking for continuity, switch back and forth between the switch positions a few times.
● Before
● When
The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustration similar to the one on the left.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row in the switch illustration.
NOTE:
“
” indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the respective switch position).
The example illustration on the left shows that:
There is continuity between black and black/white when the switch is set to “OFF”.
There is continuity between red, brown/blue and brown/red when the switch is set to “ON”.
8-103
ELECTRICAL COMPONENTS
8-104
ELECTRICAL COMPONENTS
EAS27990
CHECKING THE BULBS AND BULB
SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continuity between the terminals.
Damage/wear → Repair or replace the bulb,
bulb socket or both.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb, bulb
socket or both.
Types of bulbs
The bulbs used on this vehicle are shown in the
illustration on the left.
● Bulbs “A” and “B” are used for the headlights
and usually use a bulb holder that must be detached before removing the bulb. The majority
of these types of bulbs can be removed from
their respective socket by turning them counterclockwise.
● Bulbs “C” is used for turn signal and tail/brake
lights and can be removed from the socket by
pushing and turning the bulb counterclockwise.
● Bulbs “D” and “E” are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out.
1. Remove:
● Bulb
EWA13320
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
ECA14380
CAUTION:
● Be
sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in
the coupler.
● Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb, and the luminous flux will be adversely affected. If the headlight bulb gets soiled,
thoroughly it with a cloth moistened with alcohol or lacquer thinner.
2. Check:
● Bulb (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“2”, and check the continuity.
b. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“3”, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the condition of the bulbs
The following procedure applies to all of the
bulbs.
8-105
ELECTRICAL COMPONENTS
2. Check:
● Fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω × 1”.
Checking the condition of the bulb sockets
The following procedure applies to all of the bulb
sockets.
1. Check:
● Bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
b. If the pocket tester indicates “∞”, replace the
fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Replace:
● Blown fuse
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
A
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any of
the readings indicate no continuity, replace
the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
B
EAS28000
CHECKING THE FUSES
The following procedure applies to all of the fuses.
ECA13680
CAUTION:
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:
● Grab bar
● Rear cover
● Battery cover
Refer to “GENERAL CHASSIS” on page 4-1.
A. XP500
B. XP500A
d. If the fuse immediately blows again, check
the electrical circuit.
8-106
ELECTRICAL COMPONENTS
Fuses
Amperage
rating
Q’ty
Main
30A
1
Headlight
15A
1
Signal
20A
(XP500)
15A
(XP500A)
1
Ignition
10A
1
Radiator fan motor
15A
1
Hazard
10A
1
Fuel injection
10A
1
Backup
10A
1
ABS motor (XP500A)
30A
1
ABS control unit (XP500A)
5A
1
Backup fuse (storage box
light, immobilizer unit, and
meter assembly)
10A
1
Reserve
30A
1
Reserve
20A
(XP500)
1
Reserve
15A
1
Reserve
10A
1
Reserve
5A
(XP500A)
1
and contain electrolyte which is made of poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
● Wear protective eye gear when handling or
working near batteries.
● Charge batteries in a well-ventilated area.
● Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
● DO NOT SMOKE when charging or handling batteries.
● KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
● Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
● Skin — Wash with water.
● Eyes — Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
● Drink large quantities of water or milk followed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical attention.
ECA13660
CAUTION:
● This
EWA13310
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or using a fuse with the wrong amperage rating
may cause extensive damage to the electrical system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
● Battery cover
● Rear cover
● Grab bar
Refer to “GENERAL CHASSIS” on page 4-1.
EAS28030
CHECKING AND CHARGING THE BATTERY
EWA13290
WARNING
Batteries generate explosive hydrogen gas
is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery performance will deteriorate.
● Charging time, charging amperage and
charging voltage for an MF battery are different from those of conventional batteries.
The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by measuring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:
● Battery cover
Refer to “GENERAL CHASSIS” on page 4-1.
8-107
ELECTRICAL COMPONENTS
2. Disconnect:
● Battery leads
(from the battery terminals)
5. Charge:
● Battery
(refer to the appropriate charging method illustration)
ECA13640
CAUTION:
EWA13300
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”.
WARNING
Do not quick charge a battery.
ECA13670
2
CAUTION:
1
● Never
remove the MF battery sealing caps.
not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause battery overheating and battery plate damage.
● If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
● When charging a battery, be sure to remove
it from the vehicle. (If charging has to be
done with the battery mounted on the vehicle, disconnect the negative battery lead
from the battery terminal.)
● To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
● Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
● Make sure the battery charger lead clips are
in full contact with the battery terminal and
that they are not shorted. A corroded battery charger lead clip may generate heat in
the contact area and a weak clip spring may
cause sparks.
● If the battery becomes hot to the touch at
any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot
batteries can explode!
● As shown in the following illustration, the
open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has
been completed. Therefore, wait 30 minutes after charging is completed before
measuring the open-circuit voltage.
● Do
3. Remove:
● Battery
4. Check:
● Battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery terminals.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe →
positive battery terminal
Negative tester probe →
negative battery terminal
NOTE:
● The
charge state of an MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive battery terminal is disconnected).
● No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in
the charts and the following example.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20–30%
Charging method using a variable-current
(voltage) charger
a. Measure the open-circuit voltage prior to
charging.
NOTE:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Voltage should be measured 30 minutes after
8-108
ELECTRICAL COMPONENTS
the machine is stopped.
b. Connect a charged and AMP meter to the
battery and start charging.
NOTE:
c. Make sure that the current is higher than the
standard charging current written on the battery.
NOTE:
Set the charging voltage at 16–17 V.If the setting
is lower, charging will be insufficient. If too high,
the battery will be over-charged.
If the current is lower than the standard charging
current written on the battery, This type of battery charger cannot charge the MF battery. A
variable voltage charger is recommended.
c. Make sure that the current is higher than the
standard charging current written on the battery.
d. Charge the battery until the battery’s charging voltage is 15 V.
NOTE:
If the current is lower than the standard charging
current written on the battery, set the charging
voltage adjust dial at 20–24 V and monitor the
amperage for 3–5 minutes to check the battery.
NOTE:
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
Reach the standard charging current
Battery is good.
Does not reach the standard charging
current
Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. Adjust the voltage so that the current is at the
standard charging level.
e. Set the time according to the charging time
suitable for the open-circuit voltage.
Refer to “Battery condition checking steps”.
f. If charging requires more than 5 hours, it is
advisable to check the charging current after
a lapse of 5 hours. If there is any change in
the amperage, readjust the voltage to obtain
the standard charging current.
g. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
6. Install:
● Battery
7. Connect:
● Battery leads
(to the battery terminals)
ECA13630
CAUTION:
First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
1
2
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant voltage
charger
a. Measure the open-circuit voltage prior to
charging.
NOTE:
8. Check:
● Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
● Battery terminals
Voltage should be measured 30 minutes after
the machine is stopped.
b. Connect a charger and AMP meter to the battery and start charging.
Recommended lubricant
Dielectric grease
10.Install:
● Battery cover
8-109
ELECTRICAL COMPONENTS
Refer to “GENERAL CHASSIS” on page 4-1.
Result
Continuity → OK
No continuity → Replace.
EAS28040
CHECKING THE RELAYS
Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect, replace the relay.
Starting circuit cut-off relay 2 (XP500A)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester (Ω× 1) and battery
(12 V) to the relay terminal as shown.
Check the relay operation.
Out of specification → Replace.
1.
2.
3.
4.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Result
Continuity → OK
No continuity → Replace.
Radiator fan motor relay
1.
2.
3.
4.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Relay operation
Continuity/No continuity
(between “3” to “4”)
Starting circuit cut-off relay 1
1.
2.
3.
4.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Result
Continuity → OK
No continuity → Replace.
1.
2.
3.
4.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
8-110
ELECTRICAL COMPONENTS
Headlight relay
1.
2.
3.
4.
b. Turn the main switch to “ON”.
c. Measure the turn signal/hazard relay input
voltage.
Positive battery terminal
Negative battery terminal
Tester positive probe
Negative tester probe
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
● Turn signal/hazard relay output voltage
Out of specification → Replace.
Result
Continuity → OK
No continuity → Replace.
Turn signal/hazard relay output
voltage
DC 12 V
EAS15B1010
CHECKING THE TURN SIGNAL/HAZARD
RELAY
1. Check:
● Turn signal/hazard relay input voltage
Out of specification → The wiring circuit from
the main switch to the turn signal/hazard relay coupler is faulty and must be repaired.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
turn signal/hazard relay terminal as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Turn signal/hazard relay input
voltage
DC 12 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Positive tester probe
Brown/White “1”
Negative tester probe
Ground
a. Connect the pocket tester (DC 20 V) to the
turn signal/hazard relay terminal as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe
Brown “1”
Negative tester probe
Ground
b. Turn the main switch to “ON”.
c. Measure the turn signal/hazard relay output
voltage.
8-111
ELECTRICAL COMPONENTS
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28050
CHECKING THE DIODE
1. Check:
● Starting circuit cut-off relay 1 diode
Out of specification → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Continuity
Positive tester
Black “1”
Negative tester
green “2”
No continuity
Positive tester
Black “2”
Negative tester
green “1”
NOTE:
When you switch the positive and negative
tester probes, the readings in the above chart
will be reversed.
probe → Red/
probe → Light
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28070
probe → Red/
probe → Light
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the starting circuit cut-off relay 1
from the wire harness.
b. Connect the pocket tester (Ω× 1) to the starting circuit cut-off relay 1 as shown.
c. Check the starting circuit cut-off relay 1 diode
for continuity.
Positive tester probe
Light green “1”
Negative tester probe
Red/Black “2”
CHECKING THE SPARK PLUG CAPS
The following procedure applies to all of the
spark plug caps.
1. Check:
● Spark plug cap resistance
Out of specification → Replace.
Resistance
10.0 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the spark plug cap from the spark
plug lead.
b. Connect the pocket tester (Ω × 1k) to the
spark plug cap as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
d. Check the starting circuit cut-off relay diode
for no continuity.
Positive tester probe
Red/Black “1”
Negative tester probe
Light green “2”
c. Measure the spark plug cap resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-112
ELECTRICAL COMPONENTS
EAS28080
CHECKING THE IGNITION COIL
1. Check:
● Primary coil resistance
Out of specification → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Primary coil resistance
1.87–2.53 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil connectors from
the ignition coil terminals.
b. Connect the pocket tester (Ω × 1) to the ignition coil as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Negative tester probe
Spark plug lead
Positive tester probe
Spark plug lead
c. Measure the secondary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28080b
CHECKING THE SPARK PLUG GAP
1. Check:
● Ignition spark gap
Out of specification → Replace.
Positive tester probe
Red/Black
Negative tester probe
Orange (gray)
Minimum ignition spark gap
6 mm (0.24 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c. Measure the primary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
● Secondary coil resistance
Out of specification → Replace.
a. Disconnect the spark plug cap “1” from the
spark plug.
b. Connect the ignition checker/dynamic spark
tester “2” as shown.
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
Secondary coil resistance
12.00–18.00 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the ignition coil.
b. Connect the pocket tester (Ω × 1k) to the ignition coil as shown.
c. Set the main switch to “ON”.
d. Measure the ignition spark gap “a”.
8-113
ELECTRICAL COMPONENTS
1. Spark plug gap
e. Crank the engine by pushing the starter
switch and gradually increase the spark gap
until a misfire occurs.
b. Measure the crankshaft position sensor resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28130
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28120
CHECKING THE CRANKSHAFT POSITION
SENSOR
1. Disconnect:
● Crankshaft position sensor coupler
(from the wire harness)
2. Check:
● Crankshaft position sensor resistance
Out of specification → Replace the crankshaft position sensor.
Crankshaft position sensor resistance
189–231 Ω (Gy-B)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE LEAN ANGLE SENSOR
1. Remove:
● Lean angle sensor
(from the bracket.)
2. Check:
● Lean angle sensor out put voltage
Out of specification → Replace.
Lean angle sensor out put voltage
Less than 45° “a”: 0.4–1.4 V
More than 45° “b”: 3.8–4.2 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the lean angle sensor coupler to the
wireharness.
b. Connect the pocket tester (DC 20 V) to the
lean angle sensor coupler as shown.
a. Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Tester positive probe
Blue “1”
Negative tester probe
Yellow/Green “2”
Positive tester probe
Gray “1”
Negative tester probe
Black “2”
8-114
ELECTRICAL COMPONENTS
c. When turn the lean angle sensor to 45°.
d. Measure the lean angle sensor out put voltage.
b. Check the starter motor operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28150
CHECKING THE STATOR COIL
1. Disconnect:
● Stator coil coupler
(from the wire harness)
2. Check:
● Stator coil resistance
Out of specification → Replace the stator coil.
Stator coil resistance
0.22–0.26 kΩ at 20 °C (68 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS15B1011
CHECKING THE STARTER MOTOR
OPERATION
1. Check:
● Starter motor operation
Does not operate → Perform the electric
starting system troubleshooting, starting with
step 4.
Refer to “TROUBLESHOOTING” on page
8-13.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1) to the stator
coil coupler as shown.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive battery terminal “1” and
starter motor lead “2” with a jumper lead “3”.
EWA13810
WARNING
●A
wire that is used as a jumper lead must
have at least the same capacity of the battery lead, otherwise the jumper lead may
burn.
● This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.
8-115
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe
White “1”
Negative tester probe
White “2”
Positive tester probe
White “1”
Negative tester probe
White “3”
Positive tester probe
White “2”
Negative tester probe
White “3”
ELECTRICAL COMPONENTS
b. Measure the stator coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28170
CHECKING THE CHARGING VOLTAGE
1. Check:
● Charging voltage
Out of specification → Correct the stator coil
condition.
Refer to “CHECKING THE STATOR COIL”
on page 8-115.
c. Start the engine and let it run at approximately 5000 r/min.
d. Measure the charging voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28180
CHECKING THE HORN
1. Check:
● Horn voltage
Out of specification → Properly connect or repair the signaling system’s wiring.
Horn voltage
12V
Rectifier/regulator input voltage
above 14 V at 5000 r/min
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
Make sure the battery is fully charged.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (20V DC) to the
horn terminal.
a. Set the digital tachometer to the ignition coil
of cylinder #1.
b. Connect the pocket tester (AC 20 V) to the
battery terminal as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Digital tachometer
90890-06760
YU-39951-B
Tester positive probe
Brown “1”
Negative tester probe
Ground
1
Positive tester probe
Positive battery terminal
Negative tester probe
Nagative battery terminal
b. Turn the main switch to “ON”.
c. Measure the voltage (DC 12 V) of brown at
the horn coupler.
8-116
ELECTRICAL COMPONENTS
Positive tester probe
Green “1”
Negative tester probe
Black “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
● Operation of the horn
The horn fails to sound → check the step (3).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the horn coupler at the horn.
b. Connect a jumper lead “1” to the brown terminal in the horn coupler and the horn terminal.
2
B
B
G R/L
1
1
A
1
c. Turn the main switch to “ON”.
d. Check that the horn does sound.
B
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28230
CHECKING THE FUEL SENDER
1. Remove:
● Fuel pump
(from the fuel tank)
2. Disconnect:
● Fuel sender coupler
(from the wire harness)
3. Check:
● Fuel sender resistance
Out of specification → Replace.
b. Measure the fuel sender resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28240
Fuel sender resistance (up position F “A”)
19–21Ω at 20°C (68°F)
Fuel sender resistance (down position E “B”)
137–143Ω at 20°C (68°F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω× 1) to the fuel
sender terminal as shown.
CHECKING THE SPEED SENSOR
1. Check:
● Speed sensor output voltage
Out of specification → Replace.
Output voltage reading cycle
0 V–5 V–0 V–5 V–0 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
speed sensor coupler (wire harness side) as
shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
8-117
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
ELECTRICAL COMPONENTS
Tester positive probe
White “1”
Negative tester probe
Black/Blue “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28260
CHECKING THE COOLANT TEMPERATURE
SENSOR
1. Remove:
● Coolant temperature sensor
Refer to “THERMOSTAT” on page 6-5.
EWA14130
WARNING
● Handle
the coolant temperature sensor
with special care.
● Never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor is dropped, replace it.
b. Turn the main switch to “ON”.
c. Elevate the rear wheel and slowly rotate it.
d. Measure the voltage (5 V) of White and black/
blue. With each full rotation of the rear wheel,
the voltage reading should cycle from 0 V to
5 V to 5 V to 0 V.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28250
2. Check:
● Coolant temperature sensor resistance
Out of specification → Replace.
Coolant temperature sensor resistance
2.32–2.59 kΩ at 20 °C (68 °F)
0.310–0.326 kΩ at 80 °C (176 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω× 1k) to the coolant temperature sensor “1” as shown.
CHECKING THE RADIATOR FAN MOTOR
1. Check:
● Radiator fan motor
Faulty/rough movement → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the radiator fan motor coupler
from the wire harness.
b. Connect the battery (DC 12 V) as shown.
Positive tester probe
Blue “1”
Negative tester probe
Black “2”
c. Measure the radiator fan motor movement.
8-118
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Tester positive probe
Green/Red
Negative tester probe
Black/Blue
ELECTRICAL COMPONENTS
Tester positive probe
Blue “1”
Negative tester probe
Black/Blue “2”
2
b. Immerse the coolant temperature sensor in a
container filled with coolant “2”.
NOTE:
Make sure the coolant temperature sensor terminals do not get wet.
c. Place a thermometer “3” in the coolant.
d. Slowly heat the coolant, and then let it cool to
the specified temperature indicated in the table.
e. Check the coolant temperature sensor for
continuity at the temperatures indicated in the
table.
3
1
d. Measure the throttle position sensor resistance.
Out of specification → Replace the throttle
position sensor.
Maximum throttle position sensor
resistance
4.0–6.0 kΩ at 20 °C (68 °F)
(Blue–Black/Blue )
e. Connect the pocket tester to the throttle position sensor as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28300
CHECKING THE THROTTLE POSITION
SENSOR
1. Check:
● Throttle position sensor
Tester positive probe
Yellow “1”
Negative tester probe
Black/Blue “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the throttle position sensor coupler from the throttle position sensor.
b. Remove the throttle position sensor from the
throttle body.
c. Connect the pocket tester (Ω× 1k) to the
throttle position sensor as shown.
2
3
1
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
f. While slowly opening the throttle, check that
the throttle position sensor resistance is within the specified range.
Resistance does not change or it changes
8-119
ELECTRICAL COMPONENTS
abruptly → Replace the throttle position sensor.
The slot is worn or broken → Replace the
throttle position sensor.
NOTE:
Check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide-open throttle) may
differ slightly from those specified.
Throttle position sensor resistance
(0.52–0.9)–(4.0–6.0) kΩ at 20 °C
(68 °F) (Yellow–Black/Blue )
b. Turn the main switch to “ON”.
c. Measure the intake air pressure sensor output voltage.
g. Install the throttle position sensor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28420
EAS28410
CHECKING THE INTAKE AIR
TEMPERATURE SENSOR
EWA14110
CHECKING THE INTAKE AIR PRESSURE
SENSOR
1. Check:
● Intake air pressure sensor output voltage
Out of specification → Replace.
WARNING
● Handle
Intake air pressure sensor output
voltage
2.21–2.69 V at 20°C (68°F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
the intake air temperature sensor
with special care.
● Never subject the intake air temperature
sensor to strong shocks. If the intake air
temperature sensor is dropped, replace it.
1. Check:
● Intake air temperature sensor voltage
Out of specification → Replace.
a. Connect the pocket tester (DC 20 V) to the intake air pressure sensor coupler (wire harness side) as shown.
Intake air temperature sensor
voltage
13.3kPa (0.13 kgf/cm2, 1.85 psi):
1.0 V
Intake air temperature sensor
voltage
120.0kPa (1.2 kgf/cm2, 17.1S
psi):
4.2 V
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Tester positive probe
Brown/White “1”
Negative tester probe
Black/Blue “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20V) to the intake air temperature sensor terminal as
shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
8-120
ELECTRICAL COMPONENTS
Tester positive probe
Pink/White “1”
Negative tester probe
Black/Blue “2”
1
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Set the main switch to “ON”.
c. Measure the intake air temperature sensor
voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
● Intake air temperature sensor
2. Check:
● V-belt reset coupler voltage
Out of specification → Replace.
V-belt reset coupler voltage
12V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (20V DC) to the
meter assembly coupler (wire harness side)
as shown.
EAS15B3019
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
CHECKING THE V-BELT RESET COUPLER
1. Check:
● V-belt replacement indicator reset coupler for
continuity
No continuity → Replace
Tester positive probe
Light green “1”
Negative tester probe
Black/White “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1) to the
V-belt replacement indicator reset coupler as
shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Tester positive probe
Black “1”
Negative tester probe
Black “2”
1 2
b. Turn the main switch to “ON”.
c. Measure the voltage of gray “1” and black “2”
at the meter assembly coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-121
TROUBLESHOOTING
TROUBLESHOOTING................................................................................... 9-1
GENERAL INFORMATION ..................................................................... 9-1
STARTING FAILURE/HARD STARTING................................................ 9-1
INCORRECT ENGINE IDLING SPEED .................................................. 9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......................... 9-2
FAULTY CLUTCH ................................................................................... 9-2
OVERHEATING ...................................................................................... 9-2
OVERCOOLING...................................................................................... 9-3
POOR BRAKING PERFORMANCE........................................................ 9-3
FAULTY FRONT FORK LEGS................................................................ 9-3
UNSTABLE HANDLING .......................................................................... 9-3
FAULTY LIGHTING OR SIGNALING SYSTEM ...................................... 9-3
1
2
3
4
5
6
7
8
9
TROUBLESHOOTING
Faulty battery
2. Fuse(s)
● Blown, damaged or incorrect fuse
● Improperly installed fuse
3. Spark plug(s)
● Incorrect spark plug gap
● Incorrect spark plug heat range
● Fouled spark plug
● Worn or damaged electrode
● Worn or damaged insulator
● Faulty spark plug cap
4. Ignition coil(s)
● Cracked or broken ignition coil body
● Broken or shorted primary or secondary coils
● Faulty spark plug lead
5. Ignition system
● Faulty ECU (engine)
● Faulty crankshaft position sensor
6. Switches and wiring
● Faulty main switch
● Faulty engine stop switch
● Broken or shorted wiring
● Faulty front, rear or both brake light switches
● Faulty start switch
● Faulty sidestand switch
● Improperly grounded circuit
● Loose connections
● Faulty lean angle sensor
7. Starting system
● Faulty starter motor
● Faulty starter relay
● Faulty starting circuit cut-off relay
● Faulty starter clutch
EAS28450
●
TROUBLESHOOTING
EAS28460
GENERAL INFORMATION
NOTE:
The following guide for troubleshooting does not
cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this
manual for checks, adjustments, and replacement of parts.
EAS28480
STARTING FAILURE/HARD STARTING
Engine
1. Cylinder(s) and cylinder head(s)
● Loose spark plug
● Loose cylinder head or cylinder
● Damaged cylinder head gasket
● Damaged cylinder gasket
● Worn or damaged cylinder
● Incorrect valve clearance
● Improperly sealed valve
● Incorrect valve-to-valve-seat contact
● Incorrect valve timing
● Faulty valve spring
● Seized valve
2. Piston(s) and piston ring(s)
● Improperly installed piston ring
● Damaged, worn or fatigued piston ring
● Seized piston ring
● Seized or damaged piston
3. Air filter
● Improperly installed air filter
● Clogged air filter element
4. Crankcase and crankshaft
● Improperly assembled crankcase
● Seized crankshaft
Fuel system
1. Fuel tank
● Empty fuel tank
● Clogged fuel tank cap breather hole
● Deteriorated or contaminated fuel
● Clogged or damaged fuel hose
2. Fuel pump
● Faulty fuel pump
● Faulty fuel pump relay
3. Throttole body
● Deteriorated or contaminated fuel
● Sucked-in air
Electrical system
1. Battery
● Discharged battery
EAS28500
INCORRECT ENGINE IDLING SPEED
Engine
1. Cylinder(s) and cylinder head(s)
● Incorrect valve clearance
● Damaged valve train components
2. Air filter
● Clogged air filter element
Fuel system
1. Throttle body
● Damaged or loose throttle body joint
● Improperly synchronized throttle bodies
● Improperly adjusted engine idling speed (idle
adjust screw)
● Improper throttle cable free play
● Flooded throttle body
Electrical system
1. Battery
● Discharged battery
● Faulty battery
9-1
TROUBLESHOOTING
2. Spark plug(s)
● Incorrect spark plug gap
● Incorrect spark plug heat range
● Fouled spark plug
● Worn or damaged electrode
● Worn or damaged insulator
● Faulty spark plug cap
3. Ignition coil(s)
● Faulty spark plug lead
4. Ignition system
● Faulty ECU (engine)
● Faulty crankshaft position sensor
Bent, damaged or worn clutch shoe
Poor speed performance
1. V-belt
● Oil or grease on the V-belt
2. Primary pulley weight(s)
● Faulty operation
● Worn primary pulley weight
3. Primary fixed sheave
● Worn primary fixed sheave
4. Primary sliding sheave
● Worn primary sliding sheave
5. Secondary fixed sheave
● Worn secondary fixed sheave
6. Secondary sliding sheave
● Worn secondary sliding sheave
●
EAS28510
POOR MEDIUM-AND-HIGH-SPEED
PERFORMANCE
Refer to “STARTING FAILURE/HARD STARTING” on page 9-1.
Engine
1. Air filter
● Clogged air filter element
Fuel system
1. Fuel pump
● Faulty fuel pump
EAS28600
OVERHEATING
Engine
1. Clogged coolant passages
● Cylinder head(s) and piston(s)
● Heavy carbon buildup
2. Engine oil
● Incorrect oil level
● Incorrect oil viscosity
● Inferior oil quality
Cooling system
1. Coolant
● Low coolant level
2. Radiator
● Damaged or leaking radiator
● Faulty radiator cap
● Bent or damaged radiator fin
3. Water pump
● Damaged or faulty water pump
● Thermostat
● Thermostat stays closed
● Oil cooler
● Clogged or damaged oil cooler
● Hose(s) and pipe(s)
● Damaged hose
● Improperly connected hose
● Damaged pipe
● Improperly connected pipe
Fuel system
1. Throttle body
● Damaged or loose throttle body joint
2. Air filter
● Clogged air filter element
Chassis
1. Brake(s)
● Dragging brake
Electrical system
1. Spark plug(s)
EAS28580
FAULTY CLUTCH
Engine operates but vehicle will not move
1. V-belt
● Bent, damaged or worn V-belt
● Slipping V-belt
2. Primary pulley cam and primary pulley slider
● Damaged or worn primary pulley cam
● Damaged or worn primary pulley slider
3. Clutch spring(s)
● Damaged clutch spring
4. Transmission gear(s)
● Damaged transmission gear
Clutch slips
1. Clutch shoe spring(s)
● Damaged, loose or worn clutch shoe spring
2. Clutch shoe(s)
● Damaged or worn clutch shoe
3. Primary sliding sheave
● Seized primary sliding sheave
Poor starting performance
1. V-belt
● V-belt slips
● Oil or grease on the V-belt
2. Primary sliding sheave
● Faulty operation
● Worn pin groove
● Worn pin
3. Clutch shoe(s)
9-2
TROUBLESHOOTING
Incorrect spark plug gap
● Incorrect spark plug heat range
2. Ignition system
● Faulty ECU (engine)
3. Front fork leg(s)
● Uneven oil levels (both front fork legs)
● Unevenly tensioned fork spring (both front
fork legs)
● Broken fork spring
● Bent or damaged inner tube
● Bent or damaged outer tube
4. Swingarm
● Worn bearing or bushing
● Bent or damaged swingarm
5. Rear shock absorber assembly(-ies)
● Faulty rear shock absorber spring
● Leaking oil or gas
6. Tire(s)
● Uneven tire pressures (front and rear)
● Incorrect tire pressure
● Uneven tire wear
7. Wheel(s)
● Incorrect wheel balance
● Deformed cast wheel
● Damaged wheel bearing
● Bent or loose wheel axle
● Excessive wheel runout
8. Frame
● Bent frame
● Damaged steering head pipe
● Improperly installed bearing race
●
EAS28610
OVERCOOLING
Cooling system
1. Thermostat
● Thermostat stays open
EAS28620
POOR BRAKING PERFORMANCE
● Worn brake pad
● Worn brake disc
● Air in hydraulic brake system
● Leaking brake fluid
● Faulty brake caliper kit
● Faulty brake caliper seal
● Loose union bolt
● Damaged brake hose
● Oil or grease on the brake disc
● Oil or grease on the brake pad
● Incorrect brake fluid level
EAS28660
FAULTY FRONT FORK LEGS
Leaking oil
● Bent, damaged or rusty inner tube
● Cracked or damaged outer tube
● Improperly installed oil seal
● Damaged oil seal lip
● Incorrect oil level (high)
● Loose damper rod assembly bolt
● Damaged damper rod assembly bolt copper
washer
● Cracked or damaged cap bolt O-ring
Malfunction
● Bent or damaged inner tube
● Bent or damaged outer tube
● Damaged fork spring
● Worn or damaged outer tube bushing
● Bent or damaged damper rod
● Incorrect oil viscosity
● Incorrect oil level
EAS28710
FAULTY LIGHTING OR SIGNALING SYSTEM
Headlight does not come on
● Wrong headlight bulb
● Too many electrical accessories
● Hard charging
● Incorrect connection
● Improperly grounded circuit
● Poor contacts (main or light switch)
● Burnt-out headlight bulb
Headlight bulb burnt out
● Wrong headlight bulb
● Faulty battery
● Faulty rectifier/regulator
● Improperly grounded circuit
● Faulty main switch
● Faulty light switch
● Headlight bulb life expired
Tail/brake light does not come on
● Wrong tail/brake light bulb
● Too many electrical accessories
● Incorrect connection
● Burnt-out tail/brake light bulb
Tail/brake light bulb burnt out
● Wrong tail/brake light bulb
● Faulty battery
EAS28670
UNSTABLE HANDLING
1. Handlebar
● Bent or improperly installed handlebar
2. Steering head components
● Improperly installed upper bracket
● Improperly installed lower bracket
(improperly tightened ring nut)
● Bent steering stem
● Damaged ball bearing or bearing race
9-3
TROUBLESHOOTING
● Incorrectly
adjusted rear brake light switch
● Tail/brake light bulb life expired
Turn signal does not come on
● Faulty turn signal switch
● Faulty turn signal relay
● Burnt-out turn signal bulb
● Incorrect connection
● Damaged or faulty wire harness
● Improperly grounded circuit
● Faulty battery
● Blown, damaged or incorrect fuse
Turn signal blinks slowly
● Faulty turn signal relay
● Faulty main switch
● Faulty turn signal switch
● Incorrect turn signal bulb
Turn signal remains lit
● Faulty turn signal relay
● Burnt-out turn signal bulb
Turn signal blinks quickly
● Incorrect turn signal bulb
● Faulty turn signal relay
● Burnt-out turn signal bulb
Horn does not sound
● Improperly adjusted horn
● Damaged or faulty horn
● Faulty main switch
● Faulty horn switch
● Faulty battery
● Blown, damaged or incorrect fuse
● Faulty wire harness
9-4
EAS28740
WIRING DIAGRAM
2007 XP500 WIRING DIAGRAM
1.Crankshaft position sensor
2.A.C. magneto
3.Rectifier/regulator
4.Main switch
5.Immobilizer unit
6.Storage box light switch
7.Storage box light
8.Fuse box
9.Fuel injection system fuse
10.Backup fuse (storage box
light, immobilizer unit and
meter assembly)
11.Signaling system fuse
12.Headlight fuse
13.Ignition fuse
14.Radiator fan motor fuse
15.Lighting system fuse
16.Battery
17.Main fuse
18.Starter relay
19.Starter motor
20.Diode
21.Starting circuit cut-off relay 1
22.Fuel injection system relay
23.Fuel pump
24.Right handlebar switch
25.Start switch
26.Engine stop switch
27.Hazard switch
28.Front brake light switch
29.Sidestand switch
30.ECU (engine)
31.Ignition coil
32.Spark plug
33.Coolant temperature sensor
34.Intake air temperature sensor
35.Fuel injector #1
36.Fuel injector #2
37.Intake air pressure sensor
38.O2 sensor
39.Throttle position sensor
40.Lean angle cut-off switch
41.Speed sensor
42.Grip warmer switch (optional)
43.Grip warmer relay (optional)
44.Grip warmer (optional)
45.Auxiliary DC jack fuse
46.Auxiliary DC jack
47.Radiator fan motor relay
48.Radiator fan motor
49.Turn signal/hazard relay
50.Horn
51.Headlight relay
52.Left handlebar switch
53.Pass switch
54.Dimmer switch
55.Horn switch
56.Turn signal switch
57.Rear brake light switch
58.Tail/brake light assembly
59.Rear turn signal light (right)
60.Rear turn signal light (left)
61.Tail/brake light
62.Licence plate light
63.Front turn signal light (right)
64.Front turn signal light (left)
65.Headlight assembly
66.Auxiliary light
67.Headlight (high beam)
68.Headlight (low beam)
69.V-belt replacement indicator
reset coupler
70.Meter assembly
71.Immobilizer system indicator
light
72.Multi-function display
73.Speedometer
74.Tachometer
75.Engine oil change indicator
light
76.V-belt replacement indicator
light
77.Engine trouble warning light
78.Meter light
79.High beam indicator light
80.Right turn signal indicator
light
81.Left turn signal indicator light
82.Anti-theft alarm (optional)
2007 XP500A WIRING DIAGRAM
1.Crankshaft position sensor
2.A.C. magneto
3.Rectifier/regulator
4.Main switch
5.Immobilizer unit
6.Storage box light switch
7.Storage box light
8.Fuse box
9.ABS control unit fuse
10.Fuel injection system fuse
11.Backup fuse (storage box
light, immobilizer unit and
meter assembly)
12.Signaling system fuse
13.Headlight fuse
14.Ignition fuse
15.Radiator fan motor fuse
16.Lighting system fuse
17.Battery
18.ABS motor fuse
19.Main fuse
20.Starter relay
21.Starter motor
22.Diode
23.Starting circuit cut-off relay 2
24.Starting circuit cut-off relay 1
25.Fuel injection system relay
26.Fuel pump
27.Right handlebar switch
28.Start switch
29.Engine stop switch
30.Hazard switch
31.Front brake light switch
32.Sidestand switch
33.ECU (engine)
34.Ignition coil
35.Spark plug
36.Coolant temperature sensor
37.Intake air temperature sensor
38.Fuel injector #1
39.Fuel injector #2
40.Intake air pressure sensor
41.O2 sensor
42.Throttle position sensor
43.Lean angle cut-off switch
44.ABS test coupler
45.ECU (ABS)
46.Front wheel sensor
47.Rear wheel sensor
48.Fail-safe relay
49.Hydraulic unit
50.Grip warmer switch (optional)
51.Grip warmer relay (optional)
52.Grip warmer (optional)
53.Auxiliary DC jack fuse
54.Auxiliary DC jack
55.Radiator fan motor relay
56.Radiator fan motor
57.Turn signal/hazard relay
58.Horn
59.Headlight relay
60.Left handlebar switch
61.Pass switch
62.Dimmer switch
63.Horn switch
64.Turn signal switch
65.Rear brake light switch
66.Tail/brake light assembly
67.Rear turn signal light (right)
68.Rear turn signal light (left)
69.Tail/brake light
70.Licence plate light
71.Front turn signal light (right)
72.Front turn signal light (left)
73.Headlight assembly
74.Auxiliary light
75.Headlight (high beam)
76.Headlight (low beam)
77.V-belt replacement indicator
reset coupler
78.Meter assembly
79.Immobilizer system indicator
light
80.Multi-function display
81.Speedometer
82.Tachometer
83.Engine oil change indicator
light
84.V-belt replacement indicator
light
85.Engine trouble warning light
86.Meter light
87.High beam indicator light
88.Right turn signal indicator
light
89.Left turn signal indicator light
90.ABS warning light
91.Anti-theft alarm (optional)
EAS28750
COLOR CODE
B
Black
Br
Brown
Ch
Chocolate
Dg
Dark green
G
Green
Gy
Gray
L
Blue
O
Orange
P
Pink
R
Red
Sb
Sky blue
W
White
Y
Yellow
B/G
Black/Green
B/L
Black/Blue
B/R
Black/Red
B/W
Black/White
B/Y
Black/Yellow
Br/G
Brown/Green
Br/L
Brown/Blue
Br/R
Brown/Red
Br/W
Brown/White
G/B
Green/Black
G/R
Green/Red
G/W
Green/White
G/Y
Green/Yellow
Gy/G
Gray/Green
Gy/R
Gray/Red
L/B
Blue/Black
L/R
Blue/Red
L/W
Blue/White
L/Y
Blue/Yellow
O/B
Orange/Black
P/W
Pink/White
R/B
Red/Black
R/G
Red/Green
R/L
Red/Blue
R/W
Red/White
R/Y
Red/Yellow
Sb/W
Sky blue/White
W/B
White/Black
W/R
White/Red
W/Y
White/Yellow
Y/B
Yellow/Black
Y/G
Yellow/Green
Y/L
Yellow/Blue
Y/R
Yellow/Red
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
XP500 2007
WIRING DIAGRAM
XP500 2007
SCHÉMA DE CÂBLAGE
XP500 2007
SCHALTPLAN
SCHEMA ELETTRICO
XP500 2007
DIAGRAMA ELÉCTRICO DE LA
XP500 2007
XP500A 2007
WIRING DIAGRAM
XP500A 2007
SCHÉMA DE CÂBLAGE
XP500A 2007
SCHALTPLAN
SCHEMA ELETTRICO
XP500A 2007
DIAGRAMA ELÉCTRICO DE LA
XP500A 2007
XP500 2007
WIRING DIAGRAM
XP500 2007
SCHÉMA DE CÂBLAGE
XP500 2007
SCHALTPLAN
SCHEMA ELETTRICO
XP500 2007
DIAGRAMA ELÉCTRICO DE LA
XP500 2007
XP500A 2007
WIRING DIAGRAM
XP500A 2007
SCHÉMA DE CÂBLAGE
XP500A 2007
SCHALTPLAN
SCHEMA ELETTRICO
XP500A 2007
DIAGRAMA ELÉCTRICO DE LA
XP500A 2007