Yamaha XP500 2002 Manual

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

XP500 (P) 2002. For complete service information procedures it is necessary to use this Supplementa-

ry Service Manual together with the following manual.

XP500 (N) 2001 SERVICE MANUAL: 5GJ1-AE1

XP500 (P) 2002

SUPPLEMENTARY

SERVICE MANUAL

E2001 by Yamaha Motor Co., Ltd.

First Edition, September 2001

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

WARNING

CAUTION:

EAS00002

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 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.

Designs and specifications are subject to change without notice.

EAS00005

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

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.

EAS00007

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.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter. Refer to “SYMBOLS” on the following page.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“Periodic Checks and Adjustments”), where the sub-section title(-s) appears.

(In Chapter 3, “Periodic Checks and Adjustments”, the sub-section title appears at the top of each

page, instead of the section title.)

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

24 25

2321

19 2018

16 1715

1413

11 12

GEN

INFO SPEC

ENG

CARB ELEC

COOL

CHK

ADJ

TRBL

SHTG

CHAS

EAS00008

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Carburetor(-s)

8Electrical system

9Troubleshooting

Symbols 10 to 17 indicate the following.

10 Serviceable with engine mounted

11 Filling fluid

12 Lubricant

13 Special tool

14 Tightening torque

15 Wear limit, clearance

16 Engine speed

17 Electrical data

Symbols 18 to 23 in the exploded diagrams indi-

cate the types of lubricants and lubrication

points.

18 Engine oil

19 Gear oil

20 Molybdenum disulfide oil

21 Wheel bearing grease

22 Lithium soap base grease

23 Molybdenum disulfide grease

Symbols 24 to 25 in the exploded diagrams indi-

cate the following:

24 Apply locking agent (LOCTITER)

25 Replace the part

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLANT FLOW DIAGRAMS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 16. . .

CHASSIS

FRONT FORK 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OVERHAULING THE ENGINE

CLUTCH 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVING THE CLUTCH 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBURETORS

CARBURETORS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL

ELECTRICAL COMPONENTS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ARRANGEMENT OF THE ELECTRICAL COMPONENTS

AND COUPLERS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE SWITCHES 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIGNAL SYSTEM 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM (for EUR) 28. . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE SIGNAL SYSTEM 31. . . . . . . . . . . . . . . . . . . . . . . .

XP500 2002 WIRING DIAGRAM (for EUR)

–1–

GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS/

ELECTRICAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code XP500 (P) : 5GJ5 (EUR)

5GJ7 (OCE)

SSS

ENGINE SPECIFICATIONS

Item Standard Limit

Carburetors

Model (manufacturer) 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 outlet

Pilot jet

Bypass 1

Bypass 2

Bypass 3

Pilot screw turns out

Valve seat size

Fuel level (below the line on the

float chamber)

BS30 (MIKUNI) 2

3 X5 mm

5GJ1 20

#102.5

#80

4DK4-3/5

0-OM (#910)

#85

#170

0.8

#22.5

0.8

1.0

6.5 X7.5 mm

SSS

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Hazard relay (for EUR)

Model (manufacturer)

Coil resistance

5DM (OMRON)

94.5 X115.5 Ωat 20_C

SSS

Fuses (amperage quantity)

Main fuse

Headlight fuse

Signaling system fuse

Ignition fuse

Radiator fan fuse

Hazard fuse (for EUR)

Backup fuse (odometer)

Reserve fuse

30 A 1

15 A 1

10 A 1

15 A 1

10 A 1

30 A 1

15 A 1

10 A 1

SSS

–2–

1Coolant reservoir tank

2Thermostat

3Radiator

4Water pump

5Cooling fan

6Radiator cap

COOLANT FLOW DIAGRAMS SPEC

COOLANT FLOW DIAGRAMS

–3–

F Connect the brake light switch lead through the

handlebar switch side.

G Route the throttle cables through the hole of the

handle under cover.

H Fasten the handlebar switch lead to the handlebar

using a plastic clamp.

The fastening location is the bend area on the bot-

tom of the handlebar.

I Connect the headlight sub-harness to the wirehar-

ness on top of the stay (left and right)

After making the connection, push the coupler be-

tween the front cowling and the air filter case.

1Headlight sub-harness

2Horn

3Horn (H mark on the back of the horn).

A Attach the wireharness clamp (protector terminal)

to the T stud.

B Install the wireharness to the top of the steering

after each coupler connection.

C Route the wireharness between brake hose and

upper bracket.

D Route the throttle cables between handle under

cover and upper bracket.

E Install a wireharness guide to hold down the wire-

harness.

CABLE ROUTING SPEC

CABLE ROUTING

–4–

CABLE ROUTING SPEC

J Connect the taped headlight lead coupler to the

headlight’s white marked side (left side: high beam

side).

(For UK, OCE the right side is the high beam side.)

K Fasten the headlight sub-harness. (left and right)

(For EUR)

L Connect the turn signal light. (left and right)

M Securely fasten the wire strap to the front cowling

hook to prevent it from being pulled out by the

headlight assembly. (left and right)

N Route the horn lead through the wire guide.

O After passing the horn lead through the clamp,

crimp the clamp.

P Wiring is unnecessary. (left and right) (for OCE)

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