Page 1 @YAMAHA SERVIIIE INHIRMATIIIN Page 2 FOREWORD

YAMAHA
- APOOO(N) 2
SERVIGE
INFORMATION
FOREWORD
This Service Information has been prepared to introduce new service and data for the XP500 (N). For
complete service information procedures it is necessary to use this Service Information together with
the following manual.
XP500 (N) SERVICE MANUAL: 5GJ1-ME1
XP500 (N)
SERVICE INFORMATION
©2000 by Yamaha Motor Co.Ltd.
First edition, September 2000
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. ltis not possible to include all the knowledge of a mechanic in one manu-
al. 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 ve-
hicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EASDOCOS
IMPORTANT INFORMATION
Particulariy important information is distinguished in this manual by the following.
A The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
À WARNING Failure to follow WARNING instructions could result in severe injury or death to
the scooter operator, a bystander or a person checking or repairing the scooter.
A CAUTION indicates special precautions that must be taken to avoid damage
to the scooter.
NOTE: A NOTE provides key information to make procedures easier or clearer.
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols ©) to © indicate the subject of each
chapter.
(1) General information
O) Specifications
(9) Periodic checks and adjustments
(4) Chassis
6) Engine
(© Cooling system
(7) Carburetor(-s)
Electrical system
(9) Troubleshooting
Symbois (9 to ( indicate the following.
© © Serviceable with engine mounted
TRBL +) rire Aid engine mu
SHTG ° (2 Lubricant
43 Special tool
@ (9 (4 Tightening torque
(3 Wear limit, clearance
Np mi (9 Engine speed
{2 Electrical data
Symbols ú8 to 63 in the exploded diagrams indi-
&1 Wheel bearing grease
@2 Lithium soap base grease
€3 Molybdenum disulfide grease
| © cate the types of lubricants and lubrication
= points.
© (8 Engine ой
(9 Gear oil
&) @ 63 ©0 Molybdenum disulfide oil
=D
& Symbols @9 1085 in the exploded diagrams indi-
cate the following:
A 64) Apply locking agent (LOCTITES)
65 Replace the part
CONTENTS
GENERAL INFORMATION
SCOOTERIDENTIFICATION ................... 000... .... 1
VERICLE IDENTIFICATION NUMBER ..................... 1
MODEL CODE ...........eerervedaosororecaorororeroerem 1
SPECIFICATIONS
GENERAL SPECIFICATIONS ,................ aa ea a es ana 2
ENGINE SPECIFICATIONS ............. iii. 3
CHASSIS SPECIFICATIONS .................. 0000. .... 11
ELECTRICAL SPECIFICATIONS ............... coven... 14
CONVERSION TABLE .............0.e.ee-enerccarocareredere, 17
TIGHTENING TORQUES ......... cc ieee, 17
GENERAL TIGHTENING TORQUES ..........ooivin 17
ENGINE TIGHTENING TORQUES in. 18
CHASSIS TIGHTENING TORQUES ...................00,00 22
LUBRICATION POINTS AND LUBRICANT TYPES ............. 24
CABLE ROUTING ..... oii eevee 25
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION EEE 38
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ... 38
XP500 (N) 2001 WIRING DIAGRAM
—1—
| GE
SCOOTER IDENTIFICATION E Se |
1-1
GENERAL INFORMATION
SCOOTER IDENTIFICATION
EA500017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped
into the right side of the frame.
EAS00018
MODEL CODE
The model code labei @ is affixed to the lug-
gage Box. This information will be needed to or-
der spare parts.
-2-
GENERAL SPECIFICATIONS |SPEC | y"
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code XP500 (N) : 5GJ1 (EUR) ...
5GJ2 (GBR)
5GJ3 (OCE)
Dimensions
Overall length 2235 mm ...
Overall width 775 mm ...
Overall height 1410 mm ...
Seat height 795 mm ...
Wheelbase 1575 mm ...
Minimum ground clearance 130 mm ...
Minimum turning radius 2800 mm ...
Weight
Wet (with oil and a full fuel tank) 205 kg ...
Dry (without oil and fuel) 197 kg ...
Maximum load (total of cargo, rider, | 183 kg ...
passenger, and accessories)
2-1
—3—
ENGINE SPECIFICATIONS |SPEC ud
ENGINE SPECIFICATIONS
item Standard Limit
Engine
Engine tipe Liquid-cooled, 4-stroke, DOHC ...
Displacement
Cylinder arrangement
Bore x stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
499 cm®
66 X 73 mm
10.1
1150 ~ 1250 r/min
35 kPa (3.5 kg/cm?)
1450 kPa (14.5 kg/cm?) at 360 r/min
Fuel
Recommended fuel
Fuel tank capacity
Regular unleaded gasoline
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure (hot)
Relief valve opening pressure
Total (including reserve) 14L ...
Engine oil
Lubrication system Dry sump ...
Recommended oil see
SAETOWSO or SAE10W40
API service SE, SF, SG type or higher
3.6L
2.8L
2.9L
150 kPa at 1200 r/min
(1.50 kgf/cm? at 1200 r/min)
450 ~ 550 kPa (4.5 ~ 5.5 kgf/cm?)
she
..
—4—
ENGINE SPECIFICATIONS |SPEC | ==
Item Standard Limit
Oil filter
Oil filter type Cartridge (paper) ...
Bypass valve opening pressure 80 ~ 120 kPa (0.8 ~ 1.2 kgf/cm?) ...
Oil pump
Oil pump type Trochoidal ...
Inner-rotor-to-outer-rotor-tip 0.04 ~ 0.12 mm 0.20 mm
clearance
Outer-rotor-to-oil-pump-housing 0.045 ~ 0.085 mm 0.15 mm
clearance
Cooling system
Radiator capacity 1.5L
Radiator cap opening pressure 107.9 — 137.3 kPa ...
(1.079 — 1.373 kgf/cm?)
Radiator core
Width 330 mm ...
Height 138 mm ...
Depth 24 mm ...
Coolant reservoir
Capacity 0.6 L ...
Water pump
Water pump type Single-suction centrifugal pump ...
Reduction ratio 23/19 (1.210) ...
Starting system type Electric starter
Spark plugs
Model (manufacturer) x quantity CR 7E/NGK x 2 ...
Spark plug gap 0.7 ~ 0.8 mm ...
Cylinder head
Max. warpage ... 0.10 mm
> 4 4 4 4
= +.
Y т q
-5-
ENGINE SPECIFICATIONS |SPEC „|
Item Standard Limit
Camshafts
Drive system Chain drive (left) ...
Camshaft cap inside diameter 23.000 ~ 23.021 mm ...
Camshaft journal diameter 22.967 ~ 22.980 mm ...
Camshaft-journal-to-camshaftcap 0.020 — 0.054 mm 0.08 mm
clearance
Intake camshaft lobe dimensions
Measurement À 33.252 ~ 33.352 mm 33.152 mm
Measurement B 24.956 ~ 25.056 mm 24.856 mm
Measurement C 8.196 ~ 8.396 mm ...
Exhaust camshaft lobe dimensions
Measurement A 33.252 ~ 33.352 mm 33.152 mm
Measurement B 24.956 ~ 25.056 mm 24.856 mm
Measurement C 8.19e— 8.336 mM ...
Max. camshaft runout ... 0.03 mm
—6—
ENGINE SPECIFICATIONS
SPEC | Y"
item
Standard
Limit
Timing chain
Model/number of links
Tensioning system
SCR-0409SDH/132
Automatic
Valves, valve seats, valve guides
Valve clearance (cold)
A `
Intake
Exhaust
Face Width
Valve dimensions
<
N— — — — —
kF— A—
Head Diameter
Valve head diameter A
intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-quide clearance
Intake
Exhaust
Valve stem runout
№№ Г
Ш
ИИ ИИ ИИ ИИ LLE LEEREN
Valve seat width
Intake
Exhaust
0.15 ~ 0.20 mm
0.25 ~ 0.30 mm
ze
Seat Wıdth
24.9 — 25.1 mm
21.9 — 22.1 mm
1.14 — 1.98 mm
1.14 — 1.98 mm
0.9 ~ 1.1mm
09 ~ 1.1 mm
0.6 ~ 0.8 mm
0.6 ~ 0.8 mm
3.975 ~ 3.990 mm
3.960 ~ 3.975 mm
4.000 ~ 4.012 mm
4.000 ~ 4.012 mm
0.010 — 0.037 mm
0.025 ~ 0.052 mm
0.9 ~ 1.1mm
0.9 ~ 1.1mm
Margin Thickness
1.6 mm
1.6 mm
0.5 mm
0.5 mm
3.295 mm
3.935 mm
4.05 mm
4.05 mm
0.08 mm
0.1 mm
0.04 mm
1.6 mm
1.6 mm
7 -
ENGINE SPECIFICATIONS SPEC | (=
item Standard Limit
Valve springs
Free length
Intake 35.59 mm 33.81 mm
Exhaust 35.59 mm 33.81 mm
Installed length (valve closed)
Intake 30.39 mm ...
Exhaust 30.39 mm ...
Compressed spring force
(installed)
Intake 91.1 — 104.9 N (9.3 ~ 10.7 kgf) at 30.4 mm | eee
Exhaust 91.1 — 104.9 № (9.3 ~ 10.7 kgf) at 30.4 mm | eee
Spring tilt
À *
ПОНИ
intake (inner) ... 2.5°/1.6 mm
Exhaust ... 2.5°/1.6 mm
Clockwise ...
Winding direction (top view) Clockwise ...
Intake pe
Exhaust ( )
Cylinders
Cylinder arrangement Forward-included parallel-2 cylinder ...
Bore x stroke 66.0 x 73.0 mm vee
Compression ratio 10.1 ...
Bore 66.00 — 66.01 mm ...
Max. taper ... 0.05 mm
Max. out-of-round ... 0.05 mm
—8-—
ENGINE SPECIFICATIONS |SPEC | =
Item Standard Limit
Pistons
Piston-to-cylinder clearance 0.020 — 0.045 mm 0.15 mm
Diameter D 65.965 — 65.980 mm ...
_H
Height H 9 mm ...
Piston pin bore (in the piston)
Diameter 16.002 — 16.013 mm ...
Offset 0.5 mm ...
Offset direction Intake side ...
Piston pins
Outside diameter 15.991 — 16.000 mm ...
Piston-pin-to-piston-pin-bore 0.002 — 0.022 mm 0.072 mm
clearance
Piston rings
Top ring
)_|8
|
Ring type Barrel ...
Dimensions (B x T) 0.80 x 2.45 mm ...
End gap (installed) 0.15 — 0.25 mm 0.50 mm
Ring side clearance 0.030 — 0.065 mm 0.115 mm
2nd ring
Ne
L— -
Ring type Plain РРР
Dimensions (B x T) 0.8 x 2.5 mm ...
End gap (installed) 0.4 ~ 0.5mm 0.75 mm
Ring side clearance 0.020 ~ 0.055 mm 0.105 mm
Oil ring
= |
Fe] 4 B
LT 4
Dimensions (B x T) 1.5 x 2.0 mm ...
End gap (instalied) 0.10 — 0.35 mm ...
1
a.
ENGINE SPECIFICATIONS |SPEC
Item Standard Limit
Connecting rods
Crankshaft-pin-to-big-end-bearing 0.026 — 0.050 mm ...
clearance
Bearing color code 1 = Blue 2 = Black 3 = Brown 4 = Green | eee
Crankshaft F С
Lyin
a a
E ID
Width B B 118.55 — 118.60 mm ...
Max. runout C 0.03 mm
Big end side clearance D 0.160 ~ 0.262 mm ...
Big end radial clearance E 0.026 — 0.050 mm ...
Small end free play F 0.32 ~ 0.50 mm ...
Crankshaft-journal-to-crankshaft- 0.040 — 0.082 mm ...
journal-bearing clearance
Bearing color code 1 = Blue 2 = Black 3 = Brown 4 = Green | eee
Clutch
Clutch type Wet, multiple disc automatic ...
Clutch release method Automatic
Ericti
Thickness 2.75 — 3.05 mm 2.65 mm
Plate quantity 5 ...
Friction plate
Thickness 1.8 ~ 2.0 mm ...
Plate quantity 2 ...
Max. warpage ... 1.7 mm
Clutch plate
Thickness 1.3 ~ 1.5mm
Plate quantity 4
Max. warpage ... 0.1 mm
Clutch springs
Free length 25.9 mm 25.4 mm
Spring quantity 6 ...
V-belt
V-belt width 32 Mmm 30.5 mm
y
—10—
ENGINE SPECIFICATIONS |SPEC| U="
Item Standard Limit
Transmission
Primary reduction system Spur gear/helical gear ...
Primary reduction ratio 52/32 x 36/22 (2.659) ...
Secondary reduction system Chain drive ...
Secondary reduction ratio 41/25 x 40/29 (2.262) ...
Max. main axle runout ... 0.08 mm
Max. drive axle runout ... 0.08 mm
Air filter type Dry element ...
Fuel pump
Pump type Electrical ...
Model (manufacturer)
Output pressure
3LN (MITSUBISHI)
8.3 ~ 12.3 kPa (0.83 ~ 0.123 kgf/cm?)
Carburetors
Model (manufacturer) x quantity
Throttle cable free play (at the
flange of the throttle grip)
ID mark
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet
Pilot air jet
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Pitot screw turns out
Valve seat size
Fuel level (below the line on the
float chamber)
BS30 (MIKUNI) x 2
3 ~ 5mm
5GJ1 00
#102.5
#100
4DK4-3/5
0-OM (#893)
#85
#170
0.8
#22.5
0.8
0.8
0.8
2
1.0
55 ~ 6.5 mm
...
...
— 11 —
CHASSIS SPECIFICATIONS |SPEC| u
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Diamond ...
Caster angle 28° ...
Trail 95 mm ...
Front wheel
Wheel type Cast wheel ...
Rim
Size 14 x MT3.50 ...
Material Aluminum seo
Wheel travel 120 mm ...
Wheel runout
Max. radial wheel runout ... 1 mm
Max. lateral wheel runout ... 0.5 mm
Rear wheel
Wheel type Cast wheel ...
Rim
Size 14 x MT4.50 ...
Materiai Aluminum ...
Wheel travel 120 mm ...
Wheel runout
Max. radial wheel runout ... 1 mm
Max. lateral wheel runout ... 0.5 mm
Front tire
Tire type Tubeless ...
Size 120/70-14 ...
Model (manufacturer) BRIDGESTONE HOOP BOS ...
DUNLOP D305FA ...
Tire pressure (cold)
О — 90 Ка 200 kPa (2.0 kg/cm?, 2.0 bar) ...
90 — 197 kg 225 kPa (2.25 kg/em?, 2.25 bar) ...
High-speed riding 225 kPa (2.25 kg/em?, 2.25 bar) ...
Min. tire tread depth ... 1.6 mM
2-10
7
—-12—
CHASSIS SPECIFICATIONS |SPEC | =
Item Standard Limit
Rear tire
Tire type Tubeless ...
Size 150/70-14 coe
Model (manufacturer) BRIDGESTONE HOOP B02 ...
DUNLOP D305
Tire pressure (cold)
0 — 90 kg 225 kPa (2.25 kg/cmê, 2.25 bar) ...
90 — 197 kg 250 kPa (2.50 kg/cm°, 2.50 bar) ...
High-speed riding 250 kPa (2.5 kg/em?, 2.5 bar) ...
Min. tire tread depth 1.6 mm
Front brakes
Brake type Single-disc brake ...
Operation Right-hand operation ...
Recommended fluid DOT 4 ...
Brake discs
Diameter x thickness 282 x 5 mm ...
Min. thickness ... 4.5 mm
Max. deflection ... 0.15 mm
Brake pad lining thickness 6.0 mm 0.8 mm
>
|
Master cylinder inside diameter 14 mm ...
Caliper cylinder inside diameter 30.16 mm and 33.34 mm ...
Rear brake
Brake type Single-disc brake ...
Operation Left-hand operation ...
Recommended fluid DOT 4 ...
Brake discs
Diameter Xx thickness 267 X 5mm ...
Min. thickness ... 3.5 mm
Max. deflection ... 0.15 mm
Brake pad lining thickness 8.3 mm 0.8 mm
HE
Master cylinder inside diameter 12.7 mm ...
Caliper cylinder inside diameter 38.1 mm ...
2-11
— 13 —
CHASSIS SPECIFICATION |SPEC | Ye
item Standard Limit
Front suspension
Suspension type Telescopic fork ...
Front fork type Coil spring/ oil damper ...
Front fork travel 120 mm ...
Spring
Free length 428.5 mm 419.9 mm
Spacer length 129.6 mm ...
Installed length 419.5 mm ...
Spring rate (K1)
Spring rate (K2)
Spring rate (K3)
Spring stroke (K1)
Spring stroke (K2)
Spring stroke (K3)
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the innertube,
with the inner tube fullycompressed,
and without thefork spring)
11.8 N/mm (1.2 kgf/mm)
15.7 N/mm (1.6kgf/mm)
18.6 N/mm (2 kgf/mm)
0 ~ 19 mm
19 ~ 83 mm
83 ~ 120 mm
No
Suspension oil “01” or equivalent
402 cm?
135 mm
Steering
Steering bearing type
Angular ball bearings
и”
Suspension type
Rear shock absorber assemblytype
Rear shock absorber assemblytravel
Spring
Free length
Installed length
Spring rate (K1)
Spring rate (K2)
Spring stroke (K1)
Spring stroke (K2)
Optional spring available
Standard spring preload gas/air
pressure
Swingarm (link suspension)
Coil spring/gas-oil damper
44.5 mm
190 mm
180 mm
226 N/mm (23.05 kgf/mm)
294 N/mm (29.98 kgf/mm)
0 ~ 30 mm
30.0 ~ 44.5 mm
No
4.9 kPa (0.05 kg/cm?)
ve.
Drive chain
Model (manufacturer) 23RH303.5-82ASM (Borg warner) ...
Link quantity 82 008
Primary chain
Model (manufacturer)
Link quantity
89HV302.5RCF-66 (Borg warner)
66
2-12
— 14 —
ELECTRICAL SPECIFICATIONS | SPEC „|
ELECTRICAL SPECIFICATIONS
item Standard Limit
System voltage 12V ...
Ignition system
ignition system type T.C.l. ...
fgnition timing 10° BTDC at 1200 r/min ...
Advancer type Digital ...
Pickup coil resistance/color 189 ~ 231 Q/Gy-B ...
Transistorized coil ignition unit model | J4T120 (MITSUBISHI) ...
(manufacturer)
Ignition coils
Mode! J0313 0...
Minimum ignition spark gap 6 mm ...
Primary coil resistance 1.87 — 2.53 Q ...
Secondary coil resistance 12 ~ 18 kQ ...
Throttle position sensor standard 4 — 6 КО ...
resistance
Charging system
System type AC magneto ...
Model (manufacturer) F4T373 (MITSUBISHI) ...
Nominal output 14 V/305W at 5,000 r/min ...
Stator coil resistance 0.375 Q ...
Voltage regulator
Regulator type
Model (manufacturer)
No-load regulated voltage
Semiconductor, short circuit type
SHE50A-12 (SHINDENGEN)
14.1 — 14.9 V
Rectifier
Model SHE50A-12 ...
Rectifier capacity 18 A veo
Withstand voltage 200 V vor
Battery
Battery type GT9B-4 ...
Battery voltage/ capacity 12 V/8 Ah ...
Headlight type Halogen bulb ...
Bulbs (voltage/wattage x quantity)
Auxiliary light 12VEW x 2 ...
Tail/brake light
Turn signal light (Front)
Turn signal light (Rear)
12 V 5 W/21 W x 2
12 V 21 W/5W x 2
12V21W x 2
2-13
— 15 —
ELECTRICAL SPECIFICATIONS SPEC | y“
item Standard Limit
License plate light 12V5W x 1 ...
Meter light 12 \ 1.7 \\ х 3 ...
High beam indicator light 12V 1.7 W x 1 ...
Oil level indicator light 12 V 1.7 W x 1 ...
Turn signal indicator light 12 V 3.4W x 2 ...
Electric starting system
System type Constant mesh ...
Starter motor
Model (manufacturer) SM-13 (MITSUBA) ...
Power output 0.7 KW ...
Brushes
Overall length 12 mm 4.0 mm
Spring force 7.65 — 10.01 N (780 ~ 1021 gf) ...
Commutator resistance 0.0015 — 0.0025 Q ...
Commutator diameter 28 mm 27 mm
Mica undercut 0.7 mm ...
Starter relay
Model (manufacturer) MS5F-561 (JIDECO) ...
Amperage 180 A ...
Coil resistance 4.18 — 4.620 ...
Horn
Horn type Plain see
Model (manufacturer) x quantity YF-12 (NIKKO) x 2 ...
! ЗА eos
Flasher relay
Relay type Full-transistor ...
Model (manufacturer) FE246BH (DENSO) ...
Self-cancelling device built-in No ...
Turn signal blinking frequency
Wattage
75 ~ 95 cycles/min.
21W xX 2+34W
Fuel sender
Model (manufacturer) 5GJ (NIPPON SEIKI) ...
Resistance (Full) 4 ~10Q ...
(Empty) | 90 — 100 Q ...
Sidestand relay
Model ACA12115-1 ...
Coil resistance 70 ~ 90 Q ...
Fuel pump maximum amperage 1A ...
Fuel pump relay model ACA12115 MC2 ео
Resistance 70 ~ 90 Q ...
Thermo switch model (manufacturer)
SGH, 5GJ (NIPPON TERMOSTAT)
2-14
— 16 —
ELECTRICAL SPECIFICATIONS |SPEC| g™*
Item Standard Limit
Temperature sender
Resistance 69 at 80°C cos
22 (3 at 120°C ...
Fuses (amperage x quantity)
Main fuse 30 À x 1 ese
Headlight fuse 15A x 1 ...
Signaling system fuse 15A x 1 ...
Ignition fuse 10A x 1 ...
Radiator fan fuse 15A x 1 ...
Backup fuse (odometer) 10A x 1 ...
Reserve fuse 30A x 1 ...
15A x 1 ...
10A X 1 see
2-15
— 17 -
CONVERSION TABLE/TIGHTENING TORQUES |SPEC
CONVERSION TABLE TIGHTENING TORQUES
All specification data in this manual are
listed in SI and METRIC UNITS.
Use this table to convert METRIC unit data
to IMPERIAL unit data.
GENERAL TIGHTENING TORQUES
This chart specifies tightening torques for standard
fasteners with a standard ISO thread pitch. Tighten-
ing torque specifications for special components or
EX. assemblies are provided for each chapter of this
manual. To avoid warpage, tighten multi-fastener
METRIC MULTIPLIER IMPERIAL assemblies in a crisscross pattern and progressive
*mm x 0.03937 — **in stages until the specified tightening torque 1s
, reached. Unless otherwise specified, tightening
2mm x 0.03937 = 0.08in torque specifications require clean, dry threads.
CONVERSION TABLE Components should be at room temperature.
METRIC TO IMPERIAL
Metric unit | Multiplier | Imperial unit
mekg 7.233 — | ftelb и
Tighten- mekg 86.794 | inelb i gi
torque cmekg 0.0723 | ftelb ©
q cmekg 0.8679 | inelb |
; kg 2.205 Ib
Weight |, 0.08527 | oz
Speed km/hr 0.6214 mph
K 0.6214 i
ыы 3.281 я | A: Width across flats
Distance | т 1.094 yd . i
em o. da B: Thread diameter
mm 0.03937 | in - -
General tightening
cc (cms) 0.03527 | oz (IMP lig.) A B torques
Volume/ | cc (cm?) 0.06102 | cuein (nut) (bolt)
Capacity | It (liter) DN qt (Ihe ia) Nm mekg
i , a iq.
It (titer) gal (IMP liq.) 10 mm | 6mm 6 0.6
kg/mm Ib/in
Centigrade 9/5 + 32 Fahrenheit 14 mm 10 mm 30 3.0
o °F
Ce CD 18mm | 12mm | 55 55
19mm | 14 mm 85 8.5
22 mm 16 mm 130 13.0
2-16
— 18 —
TIGHTENING TORQUES |SPEC| y“
ENGINE TIGHTENING TORQUES
Tigntening
Item Part name Thread Q'ty torque Remarks
Nm | mekg
Spark plug — M10 2 12.5 | 1.25
Cylinder head cover Bolt M6 10 10 1.0
Camshaft cap Bolt M6 12 10 | 1.0
Cylinder head and cylinder body Nut M9 4 | 35 | 35 —«
Cylinder head and cylinder body Nut M9 2 | 46 | 4.6 —C
Cylinder head and cylinder body Bolt M6 2 10 | 1.0
Cylinder head (exhaust pipe) Stud bolt M8 4 15 1.5
Cylinder body Bolt M6 1 10 | 1.0
Cylinder head (Al System) Stud bolt M6 4 7 0.7
Connecting rod cap Nut M7 4 {See NOTE*1
Connecting rod cap (balancer) Nut M9 2 60 | 6.0
Cylinder (balancer) Bolt M10 4 58 | 5.8
Generator rotor Nut M18 1 |See NOTE? —
Chain tensioner Bolt M6 2 10 | 1.0
Chain tensioner cap bolt Bolt M6 1 10 1.0
Chain guide (intake side) Bolt M6 2 10 1.0
Water pump housing cover Bolt M6 2 10 1.0
Water pump assembly Bolt M6 2 10 | 1.0
Coolant pipe Bolt M6 2 10 | 1.0
Thermostat cover Bolt M6 2 10 | 1.0
Oil pump assembly Bolt M6 3 10 | 1.0
Oil strainer assembly Bolt M6 2 10 | 1.0
Oil cooler assembly Bolt M20 1 63 | 6.3
Oil filter - M20 1 17 | 1.7
Oil delivery pipe Bolt M6 1 10 | 1.0
Carburetor intake manifold Bolt M6 4 10 | 1.0
Silencer assembly Bolt M6 2 8.5 | 0.85
Air filter case assembly Bolt M6 3 8.5 | 0.85
Exhaust pipe Nut M8 4 20 | 2.0
2-17
—19—
TIGHTENING TORQUES |SPEC| g™
Tightening
Item Part name Thre м d Qty | torque Remarks
Nm | mekg
Muffler Nut M10 1 48 4.8
Muffler protector Bolt M6 3 7 | 0.7 q
A.l.System pipe Nut M6 4 10 | 1.0
A.l.System reed valve assembly Bolt M6 3 10 | 1.0
Air cut valve assembly Bolt M6 1 7 0.7
Crankcase Bolt M6 13 | 10 | 1.0
Crankcase Bolt M8 8 24 | 2.4
Engine oil drain boit Bolt M14 1 43 | 4.3
Engine oil sub tank cover Bolt M6 7 10 1.0
Stator coil base Screw M6 3 12 | 12 -
Timing plug Plug M16 1 8 0.8
Generator cover Bolt M6 19 10 | 1.0
Belt drive cover Bolt M6 4 10 | 1.0
Belt drive cover Bolt M8 6 24 | 2.4
Plate Bolt M6 3 10 | 1.0
Crankcase cover Bolt M8 2 24 | 2.4
Protector cover Bolt M6 3 7 0.7
Belt drive filter Bolt M6 2 7 0.7
Starter clutch Bolt M8 3 30 | 3.0
Clutch boss nut Nut M36 1 90 | 9.0
Clutch housing assembly Nut M16 1 65 | 6.5
Chian drive holder assembly Bolt M8 3 30 | 3.0
Chian drive drain bolt Bolt M12 1 20 | 2.0
Chian drive caes (outer) Bolt M6 18 10 | 1.0
Chian drive case cover Bolt M6 2 7 0.7
Stopper Bolt M5 8 6 0.6
Primary sheave assembly Nut M20 1 160 ¡ 16
Secondary sheave spring seat Nut M36 1 90 | 9.0 =D
Secondary sheave assembly Nut M18 1 90 | 9.0 «ED
2-18
— 20 —
TIGHTENING TORQUES |SPEC | y“
Tightening
item Part name Thread Qty torque Remarks
Nm | mekg
Primary bearing cover plate Screw M6 1 10 | 1.0 ©
Secondary bearing cover piate Screw M6 1 12 | 12 q
Stator coil assembly Bolt M6 3 10 | 1.0 Cd
Pickup coil Bolt M5 2 7 | 07 <<
Starter motor Bolt M6 2 10 | 1.0
Thermo switch — M18 2 18 1.8
Thermo unit — PT 1/8 1 8 0.8
_Ignitor unit Screw M6 2 3 0.3
NOTE:
*1: After tightening to 16 Nm (1.6 mekg), tighten another 90°.
*2: After tightening to 60 Nm (6,0 mekg), tighten another 120°.
2-19
. 91 —
TIGHTENING TORQUES | SPEC v= |
Crankcase tightening seguence:
© ® © 3 9 10
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2)
21 20 19
1D —- 6) M8 Bolt
9 — 21 M6 Bolt
2-20
—_ 22 —
TIGHTENING TORQUES |SPEC | g™
CHASSIS TIGHTENING TORQUES
Tightening
Item Thread size torque Remarks
Nm mekg
Upper bracket pinch boit M8 30 3.0
Steering stem nut M22 110 11.0
Lower ring nut M25 19 1.9 | See NOTE
Front fork cap bolt 45 4.5
Handlebar upper holder M8 23 2.3
Brake hose union bolt M10 30 3.0
Brake master cylinder holder M6 10 1.0
Master cylinder reservoir cap M4 1 0.1
Handlebar grip end M16 26 2.6
Engine mounting
Front mounting nut (upper) M12 87 8.7
Front mounting bolt (lower) M10 48 4.8
Front wheel axle shaft M14 59 5.9
Front wheel axle shaft pinch bolt M8 20 2.0
Rear wheel axle nut M14 104 10.4
Rear wheel axle shaft pinch bolt M8 17 1.7
Front brake caliper bracket M10 27 2.7
Front brake caliper bolt M10 40 4.0
Front brake disc M6 18 1.8
Rear brake caliper bracket M10 27 2.7
Rear brake caliper bolt M10 40 4.0
Rear brake disc M6 18 1.8
Brake caliper bleed screw M7 6 0.6
Swingarm and pivot shaft M22 7 0.7
Pivot shaft and lock nut M22 100 10.0
Chain drive and swingarm M10 40 4.0
Rear shock absorber (front) M12 67 6.7
Rear shock absorber (rear) M16 52 5.2
2-21
-23—
TIGHTENING TORQUES |SPEC| g"=
Tightening
Нет Thread size torque Remarks
Nm mekg
Fuel tank M6 10 1.0
Fuel sender M5 4 0.4
Grab bar M8 15 1.5
Seat lock M6 7 0.7
Box M6 10 1.0
Cover and panel M8 15 1.5
Cover and panel M6 7 0.7
Windshield M5 0.4 0.04
Coolant reservoir tank M6 4 0.4
Mainstand bracket M10 55 55
Mainstand M10 55 5.5
Sidestand (bolt and frame) M10 8 0.8
Sidestand (bolt and nut) M10 40 4.0
Rear footrest M8 23 2.3
NOTE:
1. First, tighten the ring nut to approximately 52 Nm (5.2 mekg) with a torque wrench, then loosen the
ring nut completely.
2. Retighten the ring nut fo specification.
2-22
— 24 —
LUBRICATION POINTS AND LUBRICANT TYPES |SPEC y
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point Lubricant
Oil seal lips «>
O-rings “ED
Bearing and bushes —«С]
Crankshaft pins —C
Piston surfaces —C
Piston pins —C
Balancer surface —C
Connecting rod bolts and nuts
—@
Crankshaft journals
—@
Camshaft lobs
—@
Camshaft journals
|
—"Q
Camshaft cap
Valve stems (intake and exhaust)
=
Valve stem ends (intake and exhaust)
—C
Cylinder head nut
—Q
Oil pump shaft
—Q
Oil pump rotors (inner and outer)
|
— Gl
Oil pump housing
Oil cooler union bolt
Starter clutch idle gear inner surface
Starter clutch
Drive axle spline
Drive sprocket
334044
Primary sheave spacer
Shell BT grease 3®
Primary sheave nut
Shell BT grease 3%
Secondary sheave nut
;
Secondary sheave
BEL-RAY
assembly lube?
Swingarm pivot shaft bearing aC
Belt drive cover bearing =i |
Crankcase mating surface УАМАНА Всп
A.C. magneto lead УАМАНА опа
2-23
— 25 -
CABLE ROUTING |SPEC| ==
CABLE ROUTING
3 Headlight lead Connect the brake light switch from the handiebar
Horn (H mark on the back of the horn). switch side wiring.
Route the throttie cables through the hoie of the
Attach the wireharness clamp (protector handle under cover.
terminal) to the T stud. Fasten the handlebar switch lead to the handiebar
Install the wireharness to the top of the steering using a plastic clamp.
after each coupler connection. The fastening location is the bend area on the
Route the wircharness between brake hose and bottom of the handlebar.
upper bracket. [1] Connect the headlight sub-harness to the
[D] Route the throttle cables between handle under wireharness on top of the stay (left and right)
cover and upper bracket. After making the connection, push the coupler
[E] Install a wireharness guide to hold down the between the front cowling and the air filter case.
wireharness.
— 26 —
CABLE ROUTING
SPEC
Connect the taped headlight lead coupler to the
headlight's white marked side (left side: high beam
side).
(For UK, the right side is the high beam side.)
Fasten the headlight sub-harness.
Connect the turn signal light.
[M Securely fasten the wire strap to the front cowling
hook to prevent it from being pulled out by the
headlight assembly.
[NI Route the horn lead through the wire guide.
[O] After passing the horn lead through the clamp,
crimp the clamp.
.. 97 —
CABLE ROUTING |SPEC y
(1) Rectifier/ regulator
(2) Starting circuit cut-off relay
(3) Pump relay
(4) Flasher relay
(5) Fuel pump
(6) Main switch
(7) Meter assembly
(8) Horn lead
(9) Ignition coil
10 Battery negative lead
(1) Frame
42) Seat lock cable
13 Starter motor lead
14 Wirenamess
15 Fuel hose
18) Sub harness
17
18
Fan motor lead
V-belt reset coupler
The wireharness pass-through is change.
Fasten the starter motor lead, battery negative lead
and seat lock cable {right side) to the frame with a
plastic clamp.
Fasten the starter motor lead and battery negative
lead to the frame with a clamp.
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— 28 —
CABLE ROUTING |SPEC | (=
[D] Fasten the starter motor lead, battery negative Use the clamp on the back of the frame to hold the
lead, V-belt reset coupler, and seat lock cable to side stand switch lead and fan motor lead.
the frame with a plastic band. [1] Connect the wireharness (wire taped area) to the
Position the band clasp on the bottom of the frame side T stud.
frame and face the band end to the outside. After connecting the main switch lead, push it
[E] Fasten the fuel sender lead and fuel pump lead between the seat lock cable adjustment area and
to the frame with a plastic clamp. the frame.
Place the wireharness and seat lock cable in the Through the main switch lead between frame and
frame holder. seat lock cable.
Through the seat lock cable between After connecting the wireharness and meter lead,
wireharness and frame. use a plastic clamp to connect them to stay 1.
[M] Connect to the headiight sub harness (left and
right)
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— 29 —
CABLE ROUTING |SPEC | y"
[N] Fasten the headlight sub harness with a plastic Through the wireharness to the frame wireharness
clamp. holder.
[O] Fasten the igniter lead to the stay with a plastic Route the wireharness and regulator lead through
clamp. the frame wire holder.
[P] Fasten the horn lead with a clamp. Place the regulator lead under the wireharness.
[Q] Fasten the fan motor lead, sidestand switch The V-belt reset coupler position is change.
lead, and thermo switch lead to the frame with a [WM After making the connections, push the couplers
plastic clamp. into the space inside the frame above the
[Rl Use a plastic band to connect the wireharness mudguard.
and relay lead to the frame. To the tail/brake light.
Position the band clasp on the bottom of the Insert the tail/brake light cuplers between the
frame and face the band end to the outside. wireharness and the seat lock cable (left side).
Insert the seat lock cable and the cylinder To the starter relay.
mounting rubber into the frame stay.
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— 30 —
CABLE ROUTING
SPEC
After connecting the left headlight sub-harness
and wireharness (by matching the coupler
colors), foid back the lead facing to the right and
insert it into the air filter case rib.
Fasten the coolant reservoir hose to the stay with
a plastic clamp.
Route the ignition coll lead through the inside of
the bracket.
Route the seat lock cable through the frame
bracket side.
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SPEC
CABLE ROUTING y
(1) Arr vent hose
(2) Vacuum hose
(3) A.C. magneto lead
(4) Sidestand switch
(5) Fan motor lead
(6) Thermo switch lead
(7) Stay 1
Route the wireharness through the frame guide.
At this time, place the protector (for the handle
cover inner side) on the bottom side.
Fasten the rear brake hose and vacuum hose with
a plastic clamp.
The fastening position ts 0 to 5 m from edge of the
frame bracket.
Pass the wireharness by the outside of the rear
footrest mounting boss.
(When mounting the rear footrest, do not catch or
pinch the A.C. magneto lead in the bracket.)
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— 32 —
CABLE ROUTING |SPEC | y“
[D] Fasten the wireharness to the frame with a Use this as a reference when adjusting the throttle
plastic clamp. cable.
[E] Fasten the wireharness to the frame with a After adjusting the throttle cables, make sure the
plastic clamp. rubber cap is insert connectly.
Pass the box light lead by the front of the frame
back stay pipe.
Fasten the sidestand switch lead to the frame
with a plastic clamp.
When adjusting the throttie cable, completely
tighten the hut on the throttle cable return side.
[1] Through the speed sensor lead to the lead
holder.
Through the speed sensor lead between front
brake caliper and front brake caliper mounting
bolt.
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2-36
— 33 —
CABLE ROUTING |SPEC| g™=
(1) Fuel hose
(2) Battery negative lead
(3) Seat lock
(4) Starter motor iead
(5) Fuse box
(6) Battery
(7) Battery positive lead
(8) Fuel sender
(9) Breather hose
19 Lean angle cut-off switch lead
17) Wirehamess
12 Seat lock cable
Route the wireharness against the stay wire guide.
Fasten the wireharness branch wiring to the frame
with a plastic clamp.
Fasten the wireharness to the frame with a plastic
clamp.
[D] Connect the black wire on the outside of the seat
lock cable to the right seat lock.
[E] Install the starter relay to the mad guard.
Fasten the wireharness, battery positive lead and
seat lock cable to the mad guard with a clamp.
Connect the gray wire on the outside of the seat
lock cable to the left seat lock.
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2-37
. 34 —
SPEC | ==
CABLE ROUTING
Install the box light to the box 1.
[1] Fasten the auto choke leads (left and right) and
throttle position sensor lead to the frame with a
clamp.
Leave some slack in the lead wires so that when
the vacuum hose is install it does not press
against them.
Fasten the auto choke leads (left and right) to the
frame with a plastic clamp.
Pass the auto choke lead (right side) and throttle
position sensor lead by the front bottom side of
the vacuum hose.
Route the thermo switch lead through the guide.
[M] Insert the air vent hose through the hole on the
left side of the frame bracket.
[N] Route the wireharness through the guide.
[O] Place the speed sensor lead between the ribs of
the air filter case.
[P] Fasten the lean angle cut-off switch lead to the stay
(2 locations). Face the end of the band downward.
[Q] Hang the wireharness and seat lock cable on the
wire holder on the back of the fuel pump
attachment stay.
[R] Fasten the battery negative lead and the starter
motor lead to the frame,
[S] Route the battery negative lead and the fuse box
lead from the box opening to the bottom of the
Cross pipe.
Pass the black seat lock cable beneath the battery
negative lead and starter motor lead and out to the
inside of the frame.
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2-38
— 35 —
Align the plastic clamp with the white tape on the
wireharness and fasten the wireharness to the
frame.
Fasten the wireharness to the seat lock cable.
W Pass the wireharnesses past the outside of the
frame bracket.
Apply silicone when inserting the starter relay.
Fasten the wireharness to the frame with a
plastic clamp.
Use a plastic band to hold the auto choke leads
(left and right), throttie position sensor lead, and
rear brake hose in a loose bandie. (The band
should be loose enough so that it can be turned.)
Pull the band end to the bottom.
CABLE ROUTING
spec] om
Pass the speed sensor lead under the stay and
cross pipe and then over the brake hose guide.
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2-39
— 36 —
CABLE ROUTING [SPEC | =
(1) Vacuum hose
(2) Rear brake hose
(3) Switch assembly lead
4)
(5) Throttle position sensor lead
Auto choke lead
(6) Fan motor lead
(9) Sidestand switch lead
с
Air vent hose
Drain hoses
Thermo switch lead
High tension code
Route the throttle cable through the cable holder.
into the handle cover.
Route the main switch lead through over the seat
lock cable.
[D] Fasten the sidestand switch lead and thermo
switch lead to the frame with a plastic clamp.
Fasten the carburetor air vent hose to the frame
with a plastic clamp.
Fasten the carburetor air vent hose and drain
hoses (2 hoses) to the frame.
Drop the carburetor drain hose.
O
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- 37 —
CABLE ROUTING |SPEC
(©
Fasten the rear end of the carburetor air vent [NM] Route the left carburetor drain hose through the
hose to the frame with a plastic clamp. (The outside of the left high tension cable.
distance from the end of clamp to the frame must
range from 0 to 5 mm.)
[1] Bundle the auto choke leads (left and right) and
the throttle position sensor lead with a plastic
clamp.
Fasten the rear brake hose and vacuum hose
with a plastic clamp.
Faster the rear brake hose to the stay 1 with a
plastic clamp.
Pass the right carburetor drain hose and air vent
hose between the right and left high tension
cables.
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2-41
INTRODUCTION/PERIODIC MAINTENANCE
AND LUBRICATION INTERVALS
— 38 —
CHK
ADJ
QA
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the 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 {echnicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
ODOMETER READING (x 1,000 km) | ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1 10 | 20 | 30 | 40 | CHECK
1 Fuel line » Check fuel hoses and vacuum hose f ks or da
(See page 3-29) eck fue uy 56 tor cracks or damage м м’ м \ м
Fuel filter
2 (See page 3-29) + Check condition. м’ м
+ Check condition
3 Spark plugs * Clean and regap. У У
(See page 3-18)
« Replace м Vv
+ Check valve clearance
4 Valves (See page 3-8) Ad Every 40,000 km
» Adjust
5 Air tilter element * Clean. V Vv
(See page 3-27) * Replace J /
V-belt case air filter + Clean \ Vv
6 elements
(See page 3-28) = Replace м
Front brake + Check operation, fluid level and vehicle for fluid leakage. v4 \ v4 \У Vv v4
7 (See page 3-36)
(See page 3-37) » Repalce brake pads Whenever worn to the limit
Rear brake » Check operation, fluid level and vehicle for fluid leakage v | \” | Vv | м | V | Vv
8 (See page 3-36)
(See page 3-37) » Replace brake pads. Whenever worn to the mit
(See page 3-37) + Replace Every 4 years
10 Wheels (See page 3-47) | + Check runout and for damage A Vv \” Vv
« Check tread depth and for damage
* Replace if necessary.
u Tires (See page 3-45) + Check air pressure У У У У
+ Correct If necessary
Wheel bearings
12 (See page 4-4) » Check beanng for looseness or damage М \’ м” va
13 Steering bearings * Check beanng play and steenng for roughness м м Vv м Vv
(Ses page 3-40) * Lubncate with ithum-soap-based grease. Every 20,000 km
Chassis fasteners * Маке sure that alf nuts, bolts and screws are properiy
14 {See page 2-21) tightened У ый У v У
Sidestand/centerstand | » Check operation
15 (See page 3-48) » Lubnicate. v У У У У
Sldestand switch
16 (See page 8-9) + Check operation \ \ м Vv м м
17 Front fork + Check operation and for oil leakage Vv м v4 м
{See page 3-43)
Rear shock absorber » Check operation and shock absorber for oil leakage v4 м Vv V
18 assembiy * Lubnicate the pivoting points with kthium-soap-based
(See page 3-49) grease. 4 У
Carburetors
19 (See page 3-15) + Adjust engine idling speed and synchronization М A Vv \ VS v4
3-1
— 39 —
PERIODIC MAINTENANCE
AND LUBRICATION INTERVALS
CHK
ADJ
Q
ODOMETER READING ( x 1,000 К
NO. MEM CHECK OR MAINTENANCE JOB п) | ANNUAL
1 10 | 20 | 30 | 40 | CHECK
\’ 4,000 km after mitral 1,000 km
Engine oli
20 (See page 3-23) » Change When the oil change indicator light comes on
(every 5,000 km)
Engine oil filter
21 cartridge « Repalce. м Vv ММ
{See page 3-23)
22 Cooling system » Check coolant level and vehicle for coolant leakage V \” Vv v4 Vv
{See page 3-32) * Change. Every 3 years
Chain drive oil
23 (See page 3-39) Chano vehicte for oll leakage. / y №, №
(See page 3-40)
, When the V-Belt replacement indication light comes
24 V-belt (See page 5-48) Replace. on {every 20,000 km)
Front and rear brake
25 switches + Check operation Vv м va м’ м м
(See page 8-9)
Moving parts and .
26 cables (See page 3-48) Lubricate. V iv v |v \
Lights, signals and
switches + Check operation
7 (See page 3-57) * Adjust headhght beam, У У У У v Y
(See page 3-58)
ЕАМОЗ541
NOTE:
e The air filter needs more frequent service if
® Hydraulic brake service
* Regularly check and, if necessary, correct the brake fluid level.
* Every two years replace the internal com
change the brake fluid.
you are riding in unusually wet or dusty areas.
ponents of the brake master cylinder and caliper, and
* Replace the brake hoses every four years and if cracked or damaged.
3-2
XP500 (N) WIRING DIAGRAM (for OCE)
(1) Pickup coil Left handlebar switch
(2) A.C. magneto Pass switch
(3) Rectifier/regulator Dimmer switch
(4) Box light switch Horn switch
Turn signal switch
Rear brake light switch
Horn
Flasher relay
Headlight (Hi)
Headlight (Low)
48 Auxiliary light
Front tum signal light (Left)
Front turn signal light (Right)
Rear turn signal light (Left)
= Grip warmer switch (OPTION) 63 Water temperature gauge
Grip warmer relay (OPTION) ) Fuel gauge
= Grip warmer (OPTION) Thermo unit (Water temperature)
DC outlet fuse Fuel level sender
DC outlet 67 Fuse box
Thermo switch (Fan) Backup fuse
Radiator fan motor 69 Signal fuse
Right handlebar switch 79 Headlight fuse
Start switch 77 Ignition fuse
Engine stop switch
Front brake light switch
XP500(N) 2001 (for OCE)
WIRING DIAGRAM
D Brown/Green
3 Brown/Red
€) Brown/Yellow
O Brown/White
© Green/Red
O Green/Yellow
COLOR CODE
@ sa“
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a Dark green
® Green
Ss Gray
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№ Y ellowHed
© Black/White
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