Yamaha XP500 User manual

2005

XP500

XP500A

5VU5-AE1

SERVICE MANUAL

EAS00000

XP500/XP500A 2005

SERVICE MANUAL

First edition, September 2004

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

EAS00002

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-

ers 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.

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 deal-

ers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EAS00005

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!

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.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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”.

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.

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.

Refer to “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.

612

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

7Fuel injection system

8Electrical system

9Troubleshooting

Symbols 0to Gindicate the following.

0Serviceable with engine mounted

AFilling fluid

BLubricant

CSpecial tool

DTightening torque

EWear limit, clearance

FEngine speed

GElectrical data

Symbols Hto Min the exploded diagrams

indicate the types of lubricants and lubrication

points.

HEngine oil

IGear oil

JMolybdenum-disulfide oil

KWheel-bearing grease

LLithium-soap- based grease

MMolybdenum-disulfide grease

Symbols Nto Oin the exploded diagrams

indicate the following.

NApply locking agent (LOCTITE®)

OReplace the part

EFG

HIJ

KLM

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

COOL

FI –+

ELEC

TRBL

SHTG

EGM

BLS M

New

EAS00012

TABLE OF CONTENTS

GENERAL INFORMATION GEN

INFO 1

SPECIFICATIONS SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS CHK

ADJ 3

CHASSIS CHAS 4

ENGINE ENG 5

COOLING SYSTEM COOL 6

FUEL INJECTION SYSTEM FI 7

ELECTRICAL SYSTEM ELEC 8

TROUBLESHOOTING TRBL

SHTG 9

–+

GEN

INFO 1

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

SCOOTER 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

INSTRUMENT FUNCTION .....................................................................1-15

IMPORTANT INFORMATION .......................................................................1-19

PREPARATION FOR REMOVAL AND DISASSEMBLY.........................1-19

REPLACEMENT PARTS.........................................................................1-19

GASKETS, OIL SEALS AND O-RINGS ..................................................1-19

LOCK WASHERS/PLATES AND COTTER PINS ...................................1-20

BEARINGS AND OIL SEALS ..................................................................1-20

CIRCLIPS ................................................................................................1-20

CHECKING THE CONNECTIONS ................................................................1-21

SPECIAL TOOLS ..........................................................................................1-22

Other manuals for XP500

This manual suits for next models

Table of contents

Other Yamaha Motorcycle manuals

Yamaha

Yamaha XJR1300V User manual

Yamaha

Yamaha FJR1300AT(C) User manual

Yamaha

Yamaha 2011 WR250FA Application guide

Yamaha

Yamaha YZ250F(W) Application guide

Yamaha

Yamaha YZF-R1P 2001-2003 User manual

Yamaha

Yamaha PW80(N) Application guide

Yamaha

Yamaha YZ450F(V) Application guide

Yamaha

Yamaha FJR1300AV User manual

Yamaha

Yamaha Moto matrix YZF-R6SC User manual

Yamaha

Yamaha XT225C User manual

Yamaha

Yamaha TW200B User manual

Yamaha

Yamaha MTN690-U User manual

Yamaha

Yamaha Venture XVZ13TFW User manual

Yamaha

Yamaha XT250 2021 User manual

Yamaha

Yamaha YZ125(V) Instruction Manual

Yamaha

Yamaha midnightstar XV1900A User manual

Yamaha

Yamaha YZ450F 2021 Application guide

Yamaha

Yamaha XV250L User manual

Yamaha

Yamaha ROAD STAN XV17ASC Manual

Yamaha

Yamaha XZ550RJ User manual

Yamaha

Yamaha 2009 YZF-R1Z User manual

Yamaha

Yamaha Royal Star XVZ13A User manual

Yamaha

Yamaha YZF600RKC User manual

Yamaha

Yamaha 2005 BT1100 Manual

Popular Motorcycle manuals by other brands

OHVALE

OHVALE GP-0 Use & maintenance

KTM

KTM 350 XCF-W USA owner's manual

HYOSUNG

HYOSUNG ST7 owner's manual

Husqvarna

Husqvarna FC 250 2016 owner's manual

Ducati

Ducati SCRAMBLER 800 Workshop manual

MOTO GUZZI

MOTO GUZZI QUOTA 1100 ES owner's manual

APRILIA

APRILIA ETV MILLE CAPONORD - PART1 02-2001 manual

KTM

KTM Freeride E-XC 2021 owner's manual

Fantic

Fantic Enduro 125 user manual

Ducati

Ducati Supersport 750 desmodue owner's manual

MV Agusta

MV Agusta 2008 F4 312RR 1078 Workshop manual

Ducati

Ducati 748 monoposto strada owner's manual

ATK

ATK 1988 250 owner's manual

Excelsior-HENDERSON

Excelsior-HENDERSON 1999 HCX Riders handbook

Triumph

Triumph Thunderbird Service manual

Ducati

Ducati 996 owner's manual

BMW

BMW MOTORRAD K 1200 R Sport Rider's manual

BMW Motorrad

BMW Motorrad G 650 GS 2007 Rider's manual