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2007 XP500
Yamaha 2007 XP500 Manuals
Manuals and User Guides for Yamaha 2007 XP500. We have
1
Yamaha 2007 XP500 manual available for free PDF download: Service Manual
Yamaha 2007 XP500 Service Manual (450 pages)
Brand:
Yamaha
| Category:
Scooter
| Size: 19.49 MB
Table of Contents
Table of Contents
7
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
11
Outline of Fi System
11
Fi System
12
Outline of Anti-Lock Brake System (Xp500A)
13
Multi-Function Display
24
Important Information
27
Preparation for Removal and Disassembly
27
Replacement Parts
27
Gaskets, Oil Seals and O-Rings
27
Lock Washers/Plates and Cotter Pins
27
Bearings and Oil Seals
27
Circlips
28
Checking the Connections
29
Special Tools
30
Specifications
37
General Specifications
38
Engine Specifications
39
Chassis Specifications
46
Electrical Specifications
49
Tightening Torques
52
General Tightening Torque Specifications
52
Engine Tightening Torques
52
Chassis Tightening Torques
56
Lubrication Points and Lubricant Types
58
Engine
58
Chassis
59
Lubrication System Chart and Diagrams
62
Engine Oil Lubrication Chart
62
Lubrication Diagrams
64
Cooling System Diagrams
70
Cable Routing
72
Periodic Checks and Adjustments
103
Periodic Maintenance
105
General Maintenance and Lubrication Chart
105
Introduction
105
Adjusting the Valve Clearance
107
Synchronizing the Throttle Bodies
109
Adjusting the Exhaust Gas Volume
111
Adjusting the Engine Idling Speed
112
Adjusting the Throttle Cable Free Play
112
Checking the Spark Plugs
113
Checking the Ignition Timing
114
Measuring the Compression Pressure
115
Checking the Engine Oil Level
116
Changing the Engine Oil
117
Measuring the Engine Oil Pressure
118
Cleaning the Air Filter Element
119
Cleaning the V-Belt Case Air Filter Element
120
Checking the Throttle Body Joints and Intake Manifolds
120
Checking the Fuel Hoses and Fuel Tank Breather Hose
121
Checking the Cylinder Head Breather Hose
121
Checking the Exhaust System
121
Checking the Coolant Level
122
Checking the Cooling System
122
Changing the Coolant
123
Engine
107
Chassis
126
Checking the Brake Fluid Level
126
Checking the Front Brake Pads
126
Checking the Rear Brake Pads
126
Checking the Front Brake Hoses
127
Checking the Rear Brake Hose
127
Adjusting the Rear Brake Lock Lever Cable
127
Bleeding the Hydraulic Brake System (Xp500)
128
Checking the Chain Drive Oil Level
130
Changing the Chain Drive Oil
130
Checking and Adjusting the Steering Head
131
Checking the Front Fork
133
Checking the Tires
133
Checking the Wheels
135
Checking and Lubricating the Cables
135
Lubricating the Levers
135
Lubricating the Sidestand
135
Lubricating the Centerstand
135
Electrical System
136
Checking and Charging the Battery
136
Checking the Fuses
136
Chassis
139
General Chassis
141
Front Wheel
146
Removing the Front Wheel (Xp500)
150
Removing the Front Wheel (XP500A)
150
Checking the Front Wheel
150
Maintenance of the Front Wheel Sensor and Sensor Rotor (Xp500A)
151
Adjusting the Front Wheel Static Balance
152
Installing the Front Wheel (Xp500)
153
Installing the Front Wheel (XP500A)
154
Rear Wheel
156
Removing the Rear Wheel (Xp500)
159
Removing the Rear Wheel (XP500A)
159
Checking the Rear Wheel
159
Checking the Rear Wheel Drive Hub
159
Maintenance of the Rear Wheel Sensor and Sensor Rotor
159
Adjusting the Rear Wheel Static Balance
159
Installing the Rear Wheel (Xp500A)
159
Front Brake
161
Introduction
166
Checking the Front Brake Discs
166
Replacing the Front Brake Pads
167
Removing the Front Brake Calipers
168
Disassembling the Front Brake Calipers
169
Checking the Front Brake Calipers
169
Assembling the Front Brake Calipers
170
Installing the Front Brake Calipers
170
Removing the Front Brake Master Cylinder
171
Checking the Front Brake Master Cylinder
171
Assembling the Front Brake Master Cylinder
172
Installing the Front Brake Master Cylinder
172
Rear Brake
174
Introduction
179
Checking the Rear Brake Disc
179
Replacing the Rear Brake Pads
179
Removing the Rear Brake Caliper
181
Disassembling the Rear Brake Caliper
181
Checking the Rear Brake Caliper
182
Assembling the Rear Brake Caliper
182
Installing the Rear Brake Caliper
183
Removing the Rear Brake Master Cylinder
184
Checking the Rear Brake Master Cylinder
184
Assembling the Rear Brake Master Cylinder
185
Installing the Rear Brake Master Cylinder
185
ABS (Anti-Lock Brake System)
187
Removing the Hydraulic Unit
188
Checking the Hydraulic Unit
188
Installing the Hydraulic Unit
189
Hydraulic Unit Operation Test
189
Trial Run
192
Handlebar
193
Removing the Handlebars
195
Checking the Handlebar
195
Installing the Handlebar
195
Front Fork
197
Removing the Front Fork Legs
199
Disassembling the Front Fork Legs
199
Checking the Front Fork Legs
200
Assembling the Front Fork Legs
201
Installing the Front Fork Legs
203
Steering Head
204
Removing the Lower Bracket
206
Checking the Steering Head
206
Installing the Steering Head
207
Rear Shock Absorber Assembly
208
Handling the Rear Shock Absorber
209
Disposing of a Rear Shock Absorber
209
Removing the Rear Shock Absorber Assembly
209
Checking the Rear Shock Absorber Assembly
209
Installing the Rear Shock Absorber Assembly
209
Engine
211
Engine Removal
215
Installing the Engine
218
Camshafts
219
Removing the Camshafts
221
Checking the Camshafts
222
Checking the Timing Chain Guides
223
Checking the Timing Chain Tensioner
224
Installing the Camshafts
224
Cylinder Head
227
Removing the Cylinder Head
228
Checking the Cylinder Head
228
Installing the Cylinder Head
228
Valves and Valve Springs
231
Removing the Valves
231
Checking the Valves and Valve Guides
231
Checking the Valve Seats
233
Checking the Valve Springs
234
Checking the Valve Lifters
235
Installing the Valves
235
Cylinder and Pistons
239
Removing the Piston
239
Checking the Cylinders and Pistons
239
Checking the Piston Rings
240
Checking the Piston Pin
241
Installing the Pistons and Cylinders
241
Generator and Starter Clutch
243
Removing the A.C. Magneto Rotor
245
Checking the Starter Clutch
245
Installing the A.C. Magneto Rotor
246
Electric Starter
248
Checking the Starter Motor
250
Assembling the Starter Motor
251
Installing the Starter Motor
251
Oil Pump
252
Checking the Oil Pump
254
Checking the Relief Valve
254
Checking the Oil Delivery Pipes
255
Checking the Oil Strainer
255
Checking the Oil Pump Drive Chain
255
Assembling the Oil Pump
255
Clutch
256
Removing the Clutch
258
Disassembling the Clutch
258
Checking the Friction Plates
259
Checking the Clutch Plates
259
Checking the Clutch Spring Plate
259
Checking the Clutch Housing
260
Checking the Clutch Boss
260
Checking the Pressure Plate
260
Checking the Weight
260
Assembling the Clutch
261
Installing the Clutch
261
V-Belt Automatic Transmission
263
Removing the Primary Sheave
267
Removing the Secondary Sheave
267
Disassembling the Primary Sheave
267
Disassembling the Secondary Sheave
268
Checking the V-Belt
268
Checking the Primary Sheave
268
Checking the V-Belt Case Air Duct
268
Checking the Primary Sheave Weights
268
Checking the Slider
269
Checking the Secondary Sheave
269
Assembling the Primary Sheave
269
Assembling the Secondary Sheave
269
Installing the Primary Sheave Assembly, Secondary Sheave Assembly and V-Belt
270
Crankcase and Crankshaft
272
Disassembling the Crankcase
275
Removing the Crankshaft Journal Bearing
275
Removing the Connecting Rods
275
Checking the Crankcase
275
Checking the Timing Chain
276
Checking the Crankshaft and Connecting Rods
276
Installing the Crankshaft Main Journal Bearing
279
Installing the Connecting Rods
280
Installing the Crankshaft
281
Assembling the Crankcase
281
Transmission
283
Removing the Transmission
284
Checking the Transmission
284
Chain Drive Transmission
285
Checking the Swingarm
288
Checking the Chain Drive Assembly
288
Assembling the Chain Drive Assembly
288
Cooling System
291
Radiator
292
Checking the Oil Cooler
294
Checking the Radiator
294
Installing the Oil Cooler and Radiator
294
Thermostat
296
Checking the Thermostat
297
Installing the Thermostat Assembly
297
Water Pump
298
Disassembling the Water Pump
300
Checking the Water Pump
300
Assembling the Water Pump
300
Installing the Water Pump
302
Fuel System
303
Fuel Tank
304
Installing the Fuel Pump
305
Installing the Fuel Tank
305
Removing the Fuel Pump
305
Removing the Fuel Tank
305
Throttle Bodies
307
Checking the Injectors
310
Checking the Throttle Bodies
310
Checking the Pressure Regulator Operation
310
Adjusting the Throttle Position Sensor
310
Electrical System
313
Ignition System
316
Circuit Diagram
316
Troubleshooting
318
Electric Starting System
320
Circuit Diagram
320
Starting Circuit Cut-Off System Operation
324
Troubleshooting
328
Charging System
330
Circuit Diagram
330
Troubleshooting
332
Lighting System
334
Circuit Diagram
334
Troubleshooting
336
Signaling System
338
Circuit Diagram
338
Troubleshooting
340
Cooling System
344
Circuit Diagram
344
Troubleshooting
346
Fuel Injection System
348
Circuit Diagram
348
Ecu Self-Diagnostic Function
350
Fail-Safe Actions (Substitute Characteristics Operation Control)
350
Troubleshooting Method
353
Diagnostic Mode
353
Troubleshooting Details
360
Immobilizer System
372
Circuit Diagram
372
General Information
374
Part Replacement and Key Code Registration Requirements
374
Troubleshooting
377
Self-Diagnosis Fault Code Indication
377
Abs (Anti-Lock Brake System) (Xp500A)
380
Circuit Diagram
380
Abs Components Chart
382
Abs Connector Location Chart
384
Ecu (Abs) and Fail-Safe Relay Chart
386
[D-1] Maintenance of the Ecu (Abs)
387
[D-2] Maintenance of the Abs Fail-Safe Relay
387
[D-3] Maintenance of the Front Wheel Sensor and
388
[D-5] Maintenance of the Hydraulic Unit
388
Specifications
388
Abs Troubleshooting Outline
390
Basic Instruction for Troubleshooting
391
Basic Process for Troubleshooting
392
[A] Abs Malfunction Check Using the Abs Warning Light
393
[B] Detailed Abs Malfunction Check
393
[B-1] the Abs Warning Light Does Not Come on
393
[B-2] the Abs Warning Light Remains on
393
[B-3] the Abs Warning Light Flashes
393
[B-4] Malfunction Check by the Abs Self Diagnosis (Past Malfunction)
394
[B-5] Malfunction Check by the Abs Self Diagnosis (Present Malfunction)
395
[C] Determining the Cause and Location of the Malfunction
397
[C-1] Only the Abs Warning Light Does Not Come on When the Main Switch Is Set to "On
397
[C-2] Abs Warning Light and All Other Indicators Do Not Come on
397
[C-3] Abs Warning Light Flashes
398
[C-4] Abs Warning Light Flashes Every 0.5 Second
398
[C-5] Diagnosis by the Malfunction Code
398
[D-6-4] Deleting the Malfunction Code
408
[D-6-6] Delete Function Test
409
[D-6] Final Check
410
Electrical Components
412
Checking the Switches
416
Checking the Bulbs and Bulb Sockets
420
Checking the Fuses
421
Checking and Charging the Battery
422
Checking the Relays
425
Checking the Turn Signal/Hazard Relay
426
Checking the Diode
427
Checking the Spark Plug Caps
427
Checking the Ignition Coil
428
Checking the Spark Plug Gap
428
Checking the Crankshaft Position Sensor
429
Checking the Lean Angle Sensor
429
Checking the Starter Motor Operation
430
Checking the Stator Coil
430
Checking the Charging Voltage
431
Checking the Horn
431
Checking the Fuel Sender
432
Checking the Speed Sensor
432
Checking the Radiator Fan Motor
433
Checking the Coolant Temperature Sensor
433
Checking the Throttle Position Sensor
434
Checking the Intake Air Pressure Sensor
435
Checking the Intake Air Temperature Sensor
435
Checking the V-Belt Reset Coupler
436
Troubleshooting
437
Troubleshooting
438
General Information
438
Starting Failure/Hard Starting
438
Incorrect Engine Idling Speed
438
Poor Medium-And-High-Speed Performance
439
Faulty Clutch
439
Overheating
439
Overcooling
440
Poor Braking Performance
440
Faulty Front Fork Legs
440
Unstable Handling
440
Faulty Lighting or Signaling System
440
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