Professional Documents
Culture Documents
xp500 PDF
xp500 PDF
OWNER’S MANUAL
XP500
XP500A
59C-28199-E1
Q Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
DECLARATION of CONFORMITY
We
Company: YAMAHA MOTOR ELECTRONICS CO., LTD.
Address: 1450-6, Mori, Mori-Machi, Shuchi-gun, Shizuoka-Ken, 437-0292 Japan
Revision record
No. Contents Date
1 To change contact person and integrate type-designation. 9 Jun. 2005
2 Version up the norm of EN60950 to EN60950-1 27 Feb. 2006
3 To change company name 1 Mar. 2007
version up of the following norm:
4 • EN300 330-2 v1.1.1 to EN300 330-2 v1.3.1 and EN300 330-2 v1.5.1 8 Jul. 2010
• EN60950-1:2001 to EN60950-1:2006/A11:2009
INTRODUCTION
EAU10113
WARNING
Please read this manual carefully and completely before operating this scooter.
EAU10200
XP500/XP500A
OWNER’S MANUAL
©2012 by Yamaha Motor Co., Ltd.
1st edition, June 2012
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
TABLE OF CONTENTS
SAFETY INFORMATION ................. 1-1 Rear view mirrors ......................... 3-25 Adjusting the engine idling
Further safe-riding points ................ 1-5 Shock absorber assembly ............ 3-26 speed ......................................... 6-16
Sidestand ..................................... 3-26 Checking the throttle grip free
DESCRIPTION .................................. 2-1 Ignition circuit cut-off system ........ 3-27 play ............................................ 6-17
Left view .......................................... 2-1 Valve clearance ............................ 6-17
Right view ........................................ 2-2 FOR YOUR SAFETY – Tires .............................................. 6-17
Controls and instruments................. 2-3 PRE-OPERATION CHECKS ............. 4-1 Cast wheels .................................. 6-19
Checking the front and rear brake
INSTRUMENT AND CONTROL OPERATION AND IMPORTANT lever free play ............................ 6-20
FUNCTIONS ....................................... 3-1 RIDING POINTS................................. 5-1 Adjusting the rear brake lock
Immobilizer system ......................... 3-1 Starting the engine ......................... 5-1 cable .......................................... 6-21
Main switch/steering lock ................ 3-2 Starting off ...................................... 5-2 Checking the rear brake lock ........ 6-21
Indicator lights and warning Acceleration and deceleration ........ 5-3 Checking the front and rear brake
lights ............................................ 3-3 Braking ........................................... 5-3 pads ........................................... 6-22
Speedometer .................................. 3-5 Tips for reducing fuel Checking the brake fluid level ....... 6-23
Tachometer .................................... 3-5 consumption ............................... 5-4 Changing the brake fluid ............... 6-24
Multi-function display ...................... 3-5 Engine break-in .............................. 5-4 Drive belt slack ............................. 6-24
Anti-theft alarm (optional) ............. 3-12 Parking ........................................... 5-5 Checking and lubricating the
Handlebar switches ...................... 3-12 cables ........................................ 6-24
Front brake lever .......................... 3-14 PERIODIC MAINTENANCE AND Checking and lubricating the
Rear brake lever ........................... 3-14 ADJUSTMENT ................................... 6-1 throttle grip and cable ................ 6-25
Rear brake lock lever .................... 3-15 Owner’s tool kit ............................... 6-2 Lubricating the front and rear
ABS (for ABS models) .................. 3-16 Periodic maintenance chart for the brake levers ............................... 6-25
Fuel tank cap ................................ 3-17 emission control system ............. 6-3 Checking and lubricating the
Fuel ............................................... 3-18 General maintenance and centerstand and sidestand ........ 6-26
Catalytic converter ........................ 3-19 lubrication chart .......................... 6-4 Checking the front fork .................. 6-26
Seat .............................................. 3-20 Removing and installing panels ..... 6-8 Checking the steering ................... 6-27
Adjusting the rider backrest .......... 3-20 Checking the spark plugs ............. 6-10 Checking the wheel bearings ........ 6-27
Helmet holder ............................... 3-21 Engine oil and oil filter cartridge ... 6-11 Battery .......................................... 6-28
Storage compartments ................. 3-22 Coolant ......................................... 6-14 Replacing the fuses ...................... 6-30
Windshield .................................... 3-24 Replacing the air filter element ..... 6-15 Replacing the headlight bulb ........ 6-32
TABLE OF CONTENTS
Tail/brake light .............................. 6-33
Replacing a front turn signal light
bulb ........................................... 6-33
Rear turn signal light bulb.............. 6-34
Replacing the license plate light
bulb ........................................... 6-34
Replacing an auxiliary light bulb ... 6-35
Troubleshooting ............................ 6-35
Troubleshooting charts ................. 6-37
SAFETY INFORMATION
EAU1026A
a training course. Beginners • Use extra caution when you are
should receive training from a cer- approaching and passing
tified instructor. Contact an autho- through intersections, since in-
1 Be a Responsible Owner rized scooter dealer to find out tersections are the most likely
As the vehicle’s owner, you are respon- about the training courses nearest places for scooter accidents to
sible for the safe and proper operation you. occur.
of your scooter. • Ride where other motorists can
Scooters are single-track vehicles. Safe Riding see you. Avoid riding in another
Their safe use and operation are de- Perform the pre-operation checks each motorist’s blind spot.
pendent upon the use of proper riding time you use the vehicle to make sure it • Never maintain a scooter with-
techniques as well as the expertise of is in safe operating condition. Failure to out proper knowledge. Contact
the operator. Every operator should inspect or maintain the vehicle properly an authorized scooter dealer to
know the following requirements before increases the possibility of an accident inform you on basic scooter
riding this scooter. or equipment damage. See page 4-1 maintenance. Certain mainte-
He or she should: for a list of pre-operation checks. nance can only be carried out by
Obtain thorough instructions from This scooter is designed to carry certified staff.
a competent source on all aspects the operator and a passenger. Many accidents involve inexperi-
of scooter operation. The failure of motorists to detect enced operators. In fact, many op-
Observe the warnings and mainte- and recognize scooters in traffic is erators who have been involved in
nance requirements in this Own- the predominating cause of auto- accidents do not even have a cur-
er’s Manual. mobile/scooter accidents. Many rent driver’s license.
Obtain qualified training in safe accidents have been caused by an • Make sure that you are qualified
and proper riding techniques. automobile driver who did not see and that you only lend your
Obtain professional technical ser- the scooter. Making yourself con- scooter to other qualified opera-
vice as indicated in this Owner’s spicuous appears to be very effec- tors.
Manual and/or when made neces- tive in reducing the chance of this • Know your skills and limits.
sary by mechanical conditions. type of accident. Staying within your limits may
Never operate a scooter without Therefore: help you to avoid an accident.
proper training or instruction. Take • Wear a brightly colored jacket. • We recommend that you prac-
1-1
SAFETY INFORMATION
tice riding your scooter where with both hands and keep both control levers or wheels and cause
there is no traffic until you have feet on the passenger footrests. injury or an accident.
become thoroughly familiar with Never carry a passenger unless Always wear protective clothing
the scooter and all of its con- he or she can firmly place both that covers your legs, ankles, and 1
trols. feet on the passenger footrests. feet. The engine or exhaust sys-
Many accidents have been caused Never ride under the influence of tem become very hot during or af-
by error of the scooter operator. A alcohol or other drugs. ter operation and can cause burns.
typical error made by the operator This scooter is designed for A passenger should also observe
is veering wide on a turn due to ex- on-road use only. It is not suitable the above precautions.
cessive speed or undercornering for off-road use.
(insufficient lean angle for the Avoid Carbon Monoxide Poisoning
speed). Protective Apparel All engine exhaust contains carbon
• Always obey the speed limit and The majority of fatalities from scooter monoxide, a deadly gas. Breathing car-
never travel faster than warrant- accidents are the result of head inju- bon monoxide can cause headaches,
ed by road and traffic conditions. ries. The use of a safety helmet is the dizziness, drowsiness, nausea, confu-
• Always signal before turning or single most critical factor in the preven- sion, and eventually death.
changing lanes. Make sure that tion or reduction of head injuries. Carbon Monoxide is a colorless, odor-
other motorists can see you. Always wear an approved helmet. less, tasteless gas which may be
The posture of the operator and Wear a face shield or goggles. present even if you do not see or smell
passenger is important for proper Wind in your unprotected eyes any engine exhaust. Deadly levels of
control. could contribute to an impairment carbon monoxide can collect rapidly
• The operator should keep both of vision that could delay seeing a and you can quickly be overcome and
hands on the handlebar and hazard. unable to save yourself. Also, deadly
both feet on the operator foot- The use of a jacket, substantial levels of carbon monoxide can linger
rests during operation to main- shoes, trousers, gloves, etc., is ef- for hours or days in enclosed or poorly
tain control of the scooter. fective in preventing or reducing ventilated areas. If you experience any
• The passenger should always abrasions or lacerations. symptoms of carbon monoxide poison-
hold onto the operator, the seat Never wear loose-fitting clothes, ing, leave the area immediately, get
strap or grab bar, if equipped, otherwise they could catch on the fresh air, and SEEK MEDICAL TREAT-
1-2
SAFETY INFORMATION
MENT. senger, accessories and cargo must sure of your tires.
Do not run engine indoors. Even if not exceed the maximum load limit. • Never attach any large or heavy
you try to ventilate engine exhaust Operation of an overloaded vehicle items to the handlebar, front
1 with fans or open windows and could cause an accident. fork, or front fender. Such items
doors, carbon monoxide can rap- can create unstable handling or
idly reach dangerous levels. Maximum load: a slow steering response.
XP500 198 kg (437 lb)
Do not run engine in poorly venti- XP500A 194 kg (428 lb) This vehicle is not designed to
lated or partially enclosed areas pull a trailer or to be attached to
such as barns, garages, or car- When loading within this weight limit, a sidecar.
ports. keep the following in mind:
Do not run engine outdoors where Cargo and accessory weight Genuine Yamaha Accessories
engine exhaust can be drawn into should be kept as low and close to Choosing accessories for your vehicle
a building through openings such the scooter as possible. Securely is an important decision. Genuine
as windows and doors. pack your heaviest items as close Yamaha accessories, which are avail-
to the center of the vehicle as pos- able only from a Yamaha dealer, have
Loading sible and make sure to distribute been designed, tested, and approved
Adding accessories or cargo to your the weight as evenly as possible by Yamaha for use on your vehicle.
scooter can adversely affect stability on both sides of the scooter to min- Many companies with no connection to
and handling if the weight distribution of imize imbalance or instability. Yamaha manufacture parts and acces-
the scooter is changed. To avoid the Shifting weights can create a sud- sories or offer other modifications for
possibility of an accident, use extreme den imbalance. Make sure that ac- Yamaha vehicles. Yamaha is not in a
caution when adding cargo or accesso- cessories and cargo are securely position to test the products that these
ries to your scooter. Use extra care attached to the scooter before aftermarket companies produce.
when riding a scooter that has added riding. Check accessory mounts Therefore, Yamaha can neither en-
cargo or accessories. Here, along with and cargo restraints frequently. dorse nor recommend the use of ac-
the information about accessories be- • Properly adjust the suspension cessories not sold by Yamaha or
low, are some general guidelines to fol- for your load (suspension-ad- modifications not specifically recom-
low if loading cargo to your scooter: justable models only), and mended by Yamaha, even if sold and
The total weight of the operator, pas- check the condition and pres- installed by a Yamaha dealer.
1-3
SAFETY INFORMATION
Aftermarket Parts, Accessories, • Accessories fitted to the handle- sories exceed the capacity of the
and Modifications bar or the front fork area can scooter’s electrical system, an
While you may find aftermarket prod- create instability due to improper electric failure could result, which
ucts similar in design and quality to weight distribution or aerody- could cause a dangerous loss of 1
genuine Yamaha accessories, recog- namic changes. If accessories lights or engine power.
nize that some aftermarket accessories are added to the handlebar or
or modifications are not suitable be- front fork area, they must be as Aftermarket Tires and Rims
cause of potential safety hazards to you lightweight as possible and The tires and rims that came with your
or others. Installing aftermarket prod- should be kept to a minimum. scooter were designed to match the
ucts or having other modifications per- • Bulky or large accessories may performance capabilities and to provide
formed to your vehicle that change any seriously affect the stability of the best combination of handling, brak-
of the vehicle’s design or operation the scooter due to aerodynamic ing, and comfort. Other tires, rims, siz-
characteristics can put you and others effects. Wind may attempt to lift es, and combinations may not be
at greater risk of serious injury or death. the scooter, or the scooter may appropriate. Refer to page 6-17 for tire
You are responsible for injuries related become unstable in cross specifications and more information on
to changes in the vehicle. winds. These accessories may replacing your tires.
Keep the following guidelines in mind, also cause instability when
as well as those provided under “Load- passing or being passed by Transporting the Scooter
ing” when mounting accessories. large vehicles. Be sure to observe following instruc-
Never install accessories or carry • Certain accessories can dis- tions before transporting the scooter in
cargo that would impair the perfor- place the operator from his or another vehicle.
mance of your scooter. Carefully her normal riding position. This Remove all loose items from the
inspect the accessory before using improper position limits the free- scooter.
it to make sure that it does not in dom of movement of the opera- Point the front wheel straight
any way reduce ground clearance tor and may limit control ability, ahead on the trailer or in the truck
or cornering clearance, limit sus- therefore, such accessories are bed, and choke it in a rail to pre-
pension travel, steering travel or not recommended. vent movement.
control operation, or obscure lights Use caution when adding electri- Secure the scooter with tie-downs
or reflectors. cal accessories. If electrical acces- or suitable straps that are attached
1-4
SAFETY INFORMATION
to solid parts of the scooter, such EAU10373
and ankle so they do not flap), and
as the frame or upper front fork tri- Further safe-riding points a bright colored jacket.
ple clamp (and not, for example, to Be sure to signal clearly when Do not carry too much luggage on
1 rubber-mounted handlebars or making turns. the scooter. An overloaded scoot-
turn signals, or parts that could Braking can be extremely difficult er is unstable. Use a strong cord to
break). Choose the location for the on a wet road. Avoid hard braking, secure any luggage to the carrier
straps carefully so the straps will because the scooter could slide. (if equipped). A loose load will af-
not rub against painted surfaces Apply the brakes slowly when fect the stability of the scooter and
during transport. stopping on a wet surface. could divert your attention from the
The suspension should be com- Slow down as you approach a cor- road. (See page 1-3.)
pressed somewhat by the ner or turn. Once you have com-
tie-downs, if possible, so that the pleted a turn, accelerate slowly.
scooter will not bounce excessive- Be careful when passing parked
ly during transport. cars. A driver might not see you
and open a door in your path.
Railroad crossings, streetcar rails,
iron plates on road construction
sites, and manhole covers be-
come extremely slippery when
wet. Slow down and cross them
with caution. Keep the scooter up-
right, otherwise it could slide out
from under you.
The brake pads could get wet
when you wash the scooter. After
washing the scooter, check the
brakes before riding.
Always wear a helmet, gloves,
trousers (tapered around the cuff
1-5
DESCRIPTION
EAU10410
Left view
1 2 3 4 5 1
11 10 98 7 6
1. Battery (page 6-28) 8. Engine oil drain bolt (page 6-11)
2. V-belt air filter element (left) 9. Engine oil level check window (page 6-11)
3. Helmet holder (page 3-21) 10.Oil filter cartridge (page 6-11)
4. Rear storage compartment (page 3-22) 11.Coolant level check window (page 6-14)
5. Grab bar (page 5-2)
6. Engine oil filler cap (page 6-11)
7. Sidestand (page 3-26)
2-1
DESCRIPTION
EAU10420
Right view
1
1 2 3 4 5
8 7 6
1. Owner’s tool kit (page 6-2)
9 2. Fuel tank cap (page 3-17)
3. Air filter element (page 6-15)
4. Windshield (page 3-24)
5. Fuses (page 6-30)
6. V-belt air filter element (right)
7. Centerstand (page 6-26)
2-2
DESCRIPTION
EAU10430
6
9
7
10
12 11 8
1. Rear brake lever (page 3-14) 8. Front brake lever (page 3-14)
2. Left handlebar switches (page 3-12) 9. Throttle grip (page 6-17) 9
3. Rear brake lock lever (page 3-15) 10.Front storage compartment B (page 3-22)
4. Speedometer (page 3-5) 11.Main switch/steering lock (page 3-2)
5. Multi-function display (page 3-5) 12.Front storage compartment A (page 3-22)
6. Tachometer (page 3-5)
7. Right handlebar switches (page 3-12)
2-3
OFF
4
All electrical systems are off. The key
The main switch/steering lock controls can be removed.
the ignition and lighting systems, and is EWA10061 5
used to lock the steering. The various WARNING
positions are described below. Never turn the key to “OFF” or 6
TIP “LOCK” while the vehicle is moving.
Be sure to use the standard key (black Otherwise the electrical systems will
be switched off, which may result in 7
bow) for regular use of the vehicle. To
minimize the risk of losing the code loss of control or an accident.
re-registering key (red bow), keep it in a 8
safe place and only use it for code EAU10684
re-registering. LOCK 9
The steering is locked, and all electrical
systems are off. The key can be re-
EAU10560
moved.
ON
All electrical circuits are supplied with
To lock the steering
power; the meter lighting, taillight, li-
1. Turn the handlebars all the way to
cense plate light and auxiliary light
3-2
Turn signal indicator lights “ ” and This warning light will come on when
NOTICE
“ ” the key is turned to “ON” and the start
9 Do not use the parking position for switch is pushed, but this does not indi-
an extended length of time, other- The corresponding indicator light flash-
es when the turn signal switch is cate a malfunction.
wise the battery may discharge.
pushed to the left or right.
EAU53990
EAU11080
ABS warning light “ ” (for ABS
ABS
1 WARNING
1 1 Be sure to stop the vehicle before
making any setting changes to the
2
multi-function display. Changing
settings while riding can distract the
3 operator and increase the risk of an
2 accident.
4
4
1. Speedometer 1. Tachometer red zone 3
5 2. Tachometer
The speedometer shows the riding 2 5
speed. The electric tachometer allows the rider 1 6 7
6 When the key is turned to “ON”, the to monitor the engine speed and keep it
speedometer needle will sweep once within the ideal power range.
7 across the speed range and then return When the key is turned to “ON”, the ta-
to zero in order to test the electrical cir- chometer needle will sweep once
8 cuit. across the r/min range and then return
to zero r/min in order to test the electri- 1. Left set button
cal circuit. 2. Fuel meter
9 ECA10031 3. Fuel level warning indicator “ ”
NOTICE 4. Odometer
Do not operate the engine in the ta- 5. Coolant temperature warning indicator
“ ”
chometer red zone.
6. Coolant temperature meter
Red zone: 8250 r/min and above
7. Right set button
3-5
3-6
The temperature displayed may vary This display shows the average fuel
3-10
3-12
1 1 Hazard switch “ ”
EAU12500 With the key in the “ON” or “ ” posi-
Horn switch “ ” tion, use this switch to turn on the haz-
2 Press this switch to sound the horn. ard lights (simultaneous flashing of all
2 turn signal lights).
3 EAU12660
The hazard lights are used in case of
3 Engine stop switch “ / ” an emergency or to warn other drivers
Set this switch to “ ” before starting when your vehicle is stopped where it
4 the engine. Set this switch to “ ” to
1. Engine stop switch “ / ” might be a traffic hazard.
2. Hazard switch “ ” stop the engine in case of an emergen- ECA10061
2 2
1 1
4 4 2
2
3
5 4
3 3
4
1. Front brake lever 1. Rear brake lever
2. Brake lever position adjusting dial 2. Brake lever position adjusting dial 5
3. “ ” mark 3. “ ” mark
4. Distance between brake lever and handle- 4. Distance between brake lever and handle- 6
bar grip bar grip
The front brake lever is located on the The rear brake lever is located at the 7
right side of the handlebar. To apply the left handlebar grip. To apply the rear
front brake, pull this lever toward the brake, pull this lever toward the handle-
throttle grip. bar grip. 8
The front brake lever is equipped with a The rear brake lever is equipped with a
position adjusting dial. To adjust the position adjusting dial. To adjust the 9
distance between the front brake lever distance between the rear brake lever
and the throttle grip, turn the adjusting and the handlebar grip, turn the adjust-
dial while holding the front brake lever ing dial while holding the rear brake le-
pushed away from the throttle grip. ver pushed away from the handlebar
Make sure that the appropriate setting grip. Make sure that the appropriate
on the adjusting dial is aligned with the setting on the adjusting dial is aligned
3-14
WARNING
3 Never move the rear brake lock lever
to the left while the vehicle is mov-
ing, otherwise loss of control or an
4 accident may result. Make sure that
1. Rear brake lock lever the vehicle is stopped before mov-
5 ing the rear brake lock lever to the
This vehicle is equipped with a rear left.
brake lock lever to prevent the rear
6 wheel from moving while stopped at
traffic signals, railroad crossings, etc.
7
To lock the rear wheel
8 Push the rear brake lock lever to the left
until it snaps into place.
3-15
1. Match mark
NOTICE
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-
pairable damage to the catalytic
3-19
3-20
WARNING
Do not exceed the following loading
3-23
Windshield 2
To suit the rider’s preference, the wind- 1
1
shield height can be changed to one of
two positions. 1
2
1
1
3
3-24
3 1
1 2
4 1. Screw 1. Screw access cover
3-25
3-27
3-28
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
1 and maintenance procedures and schedules described in the Owner’s Manual.
EWA11151
WARNING
2
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
3 this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
4 ITEM CHECKS PAGE
• Check fuel level in fuel tank.
5 • Refuel if necessary.
Fuel • Check fuel line for leakage. 3-18
• Check fuel tank breather hose and overflow hose for obstructions, cracks or
6 damage, and check hose connections.
• Check oil level in engine.
Engine oil • If necessary, add recommended oil to specified level. 6-11
7 • Check vehicle for oil leakage.
• Check coolant level in reservoir.
Coolant • If necessary, add recommended coolant to specified level. 6-14
8 • Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
9 • Check brake pads for wear.
Front brake • Replace if necessary. 6-20, 6-22, 6-23
• Check fluid level in reservoir.
• If necessary, add specified brake fluid to specified level.
• Check hydraulic system for leakage.
4-1
4-2
NOTICE
If the above warning light, indicator
light, or indicators do not come on
initially when the key is turned to
“ON”, or if a warning light, indicator
5-1
pages 3-3, 3-5, 3-8, 3-9 or 3-11 for the NOTICE Starting off
corresponding warning light, indica- For maximum engine life, never ac- 1. While pulling the rear brake lever
tor light or indicator circuit check. celerate hard when the engine is with your left hand and holding the
cold! grab bar with your right hand, push
For ABS models: the scooter off the centerstand.
The ABS warning light should come on 2
when the main switch is turned to “ON” 1
and then go off after traveling at a 3
speed of 10 km/h (6 mi/h) or higher.
ECA17680
NOTICE 4
If the ABS warning light does not
come on and then go off as ex- 5
plained above, see page 3-3 for the
indicator light circuit check. 6
2. Close the throttle completely. 1. Grab bar
3. Start the engine by pushing the 2. Sit astride the seat, and then ad- 7
start switch while applying the front just the rear view mirrors.
or rear brake. 3. Switch the turn signals on.
If the engine does not start, re- 8
4. Check for oncoming traffic, and
lease the start switch, wait a few then slowly turn the throttle grip (on
seconds, and then try again. Each the right) in order to take off. 9
starting attempt should be as short 5. Switch the turn signals off.
as possible to preserve the bat-
tery. Do not crank the engine more
than 10 seconds on any one at-
tempt.
5-2
1 (b) WARNING
Avoid braking hard or suddenly
(especially when leaning over to
2
one side), otherwise the scooter
(a) may skid or overturn.
3 Railroad crossings, streetcar
rails, iron plates on road con-
4 struction sites, and manhole
covers become extremely slip- Rear
The speed can be adjusted by opening pery when wet. Therefore, slow
5 and closing the throttle. To increase the down when approaching such
speed, turn the throttle grip in direction areas and cross them with cau-
6 (a). To reduce the speed, turn the throt- tion.
tle grip in direction (b). Keep in mind that braking on a
7 wet road is much more difficult.
Ride slowly down a hill, as brak-
ing downhill can be very diffi-
8 cult.
1. Close the throttle completely.
9 2. Apply both front and rear brakes
simultaneously while gradually in-
creasing the pressure.
5-3
your riding style. Consider the following between 0 and 1600 km (1000 mi). For NOTICE
tips to reduce fuel consumption: this reason, you should read the follow- Keep the engine speed out of
2
Avoid high engine speeds during ing material carefully. the tachometer red zone.
acceleration. Since the engine is brand new, do not If any engine trouble should oc-
Avoid high engine speeds with no put an excessive load on it for the first cur during the engine break-in 3
load on the engine. 1600 km (1000 mi). The various parts in period, immediately have a
Turn the engine off instead of let- the engine wear and polish themselves Yamaha dealer check the vehi- 4
ting it idle for an extended length of to the correct operating clearances. cle.
time (e.g., in traffic jams, at traffic During this period, prolonged full-throt-
tle operation or any condition that might 5
lights or at railroad crossings).
result in engine overheating must be
avoided. 6
EAU36531
7
0–1000 km (0–600 mi)
Avoid prolonged operation above 4100 8
r/min. NOTICE: After 1000 km (600
mi) of operation, the engine oil must 9
be changed, and the oil filter car-
tridge or element replaced.[ECA11282]
5-4
Parking
When parking, stop the engine, and
1 then remove the key from the main
switch.
EWA10311
2 WARNING
Since the engine and exhaust
3 system can become very hot,
park in a place where pedestri-
4 ans or children are not likely to
touch them and be burned.
Do not park on a slope or on soft
5 ground, otherwise the vehicle
may overturn, increasing the
6 risk of a fuel leak and fire.
Do not park near grass or other
7 flammable materials which
might catch fire.
5-5
WARNING
Periodic inspection, adjustment, and lu- Turn off the engine when performing Emission controls not only function to
brication will keep your vehicle in the maintenance unless otherwise ensure cleaner air, but are also vital to
safest and most efficient condition pos- specified. proper engine operation and maximum
sible. Safety is an obligation of the vehi- A running engine has moving performance. In the following periodic
2
cle owner/operator. The most important parts that can catch on body maintenance charts, the services relat-
points of vehicle inspection, adjust- parts or clothing and electrical ed to emissions control are grouped
ment, and lubrication are explained on parts that can cause shocks or separately. These services require 3
the following pages. fires. specialized data, knowledge, and
The intervals given in the periodic Running the engine while ser- equipment. Maintenance, replacement, 4
maintenance charts should be simply vicing can lead to eye injury, or repair of the emission control devic-
considered as a general guide under burns, fire, or carbon monoxide es and systems may be performed by
normal riding conditions. However, de- any repair establishment or individual 5
poisoning – possibly leading to
pending on the weather, terrain, geo- death. See page 1-2 for more in- that is certified (if applicable). Yamaha
graphical location, and individual use, formation about carbon monox- dealers are trained and equipped to 6
the maintenance intervals may need to ide. perform these particular services.
be shortened. EWA15460 7
EWA10321
WARNING
WARNING
Brake discs, calipers, drums, and 8
Failure to properly maintain the ve-
linings can become very hot during
hicle or performing maintenance ac-
use. To avoid possible burns, let
tivities incorrectly may increase 9
brake components cool before
your risk of injury or death during
touching them.
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
6-1
1
1
2
3 2
4
1. Helmet holding cable
5 2. Owner’s tool kit
6-2
TIP
The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.
From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). 2
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
3
EAU46910
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOB
ANNUAL 5
1000 km 10000 km 20000 km 30000 km 40000 km CHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Check fuel hoses for cracks or 6
1 * Fuel line
damage.
• Check condition.
7
2 * Spark plugs • Clean and regap.
• Replace.
• Check valve clearance.
3 * Valves
• Adjust.
Every 40000 km (24000 mi) 8
• Adjust engine idling speed and
4 * Fuel injection
synchronization. 9
6-3
6-4
6-6
TIP
Engine air filter and V-belt air filters
• This model’s engine air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with
compressed air to avoid damaging it. 2
• The engine air filter element needs to be replaced and the V-belt air filter elements need to be serviced more frequent-
ly when riding in unusually wet or dusty areas.
Hydraulic brake service 3
• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid
levels and fill the reservoirs as required. 4
• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
5
• Replace the brake hoses every four years and if cracked or damaged.
6-7
EAU52011
2
5
6 Panel A
6-8
1
2 2
1
3
2
1. Screw 1. Screw 4
To install the panel
2. Panel B 2. Panel C
Place the panel in the original position,
and then install the quick fastener. 5
To install the panel To install the panel
Place the panel in the original position, Place the panel in the original position,
and then install the screws. and then install the screws. 6
Panel C Panel D 7
6-9
3 1
6-12
4. Insert a new air filter element into 2. Check the engine idling speed
Engine idling speed:
the air filter case. NOTICE: Make and, if necessary, adjust it to spec- 1100–1300 r/min
5
sure that the air filter element is ification by turning the idle adjust-
properly seated in the air filter ing screw. To increase the engine
6 TIP
case. The engine should never idling speed, turn the screw in di-
If the specified idling speed cannot be
be operated without the air filter rection (a). To decrease the en-
obtained as described above, have a
7 element installed, otherwise the gine idling speed, turn the screw in
Yamaha dealer make the adjustment.
piston(s) and/or cylinder(s) may direction (b).
become excessively worn.[ECA10481] 3. Install the panel.
8
5. Install the air filter case cover by in-
stalling the screws.
9
6. Install the panel.
6-16
6-18
6-19
1
8
Adjusting the rear brake lock turn the adjusting nut in direction (b). Checking the rear brake lock
cable WARNING! If proper adjustment The rear brake lock must be checked at
Rear brake lock cable adjustment may cannot be obtained as described, the intervals specified in the periodic
be required if the rear brake lock lever have a Yamaha dealer make this ad- maintenance and lubrication chart.
does not hold properly. When the rear justment.[EWA16150] 1. Adjust the rear brake lock cable.
2
brake lock lever is not in use, the rear Check that the rear brake lock is re- 2. Apply the rear brake lock, and then
brake lock cable length should mea- leased, and then make sure that the pushing the vehicle for properly
sure 43–45 mm (1.69–1.77 in) at the rear wheel could rotate smoothly. locks the rear brake lock. 3
rear brake caliper. 3. The rear brake lock caliper is pro-
vided with a wear indicator, which 4
allows you to check the rear brake
lock pads. To check the rear brake
lock pads, check the position of the 5
(a) indicator while applying the rear
brake lock lever. If the indicator 6
has passed the wear indicator
groove, have a Yamaha dealer 7
(b) 2 check the rear brake lock.
1
4. Make sure that there is no tears
1. Adjusting nut and cracks on the rubber boot. 8
2. Rear brake lock cable length
9
Periodically check the rear brake lock
cable length and, if necessary, adjust it
as follows.
To increase the rear brake lock cable
length, turn the adjusting nut at the rear
brake caliper in direction (a). To de-
6-21
Changing the brake fluid Drive belt slack Checking and lubricating the
Have a Yamaha dealer change the The drive belt slack should be checked cables
1 brake fluid at the intervals specified in and adjusted by a Yamaha dealer at The operation of all control cables and
the TIP after the periodic maintenance the intervals specified in the periodic the condition of the cables should be
and lubrication chart. In addition, have maintenance and lubrication chart. checked before each ride, and the ca-
2
the oil seals of the master cylinders and bles and cable ends should be lubricat-
calipers as well as the brake hoses re- ed if necessary. If a cable is damaged
3 placed at the intervals listed below or or does not move smoothly, have a
whenever they are damaged or leak- Yamaha dealer check or replace it.
4 ing. WARNING! Damage to the outer
Oil seals: Replace every two housing of cables may result in in-
years. ternal rusting and cause interfer-
5 Brake hoses: Replace every four ence with cable movement. Replace
years. damaged cables as soon as possi-
6 ble to prevent unsafe condi-
tions.[EWA10711]
7
Recommended lubricant:
Yamaha Chain and Cable Lube or
8 engine oil
6-24
6-25
6-26
6-27
6-28
6-30
6-31
6-33
1 1
3
6-34
WARNING
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from water
6-35
6-36
Troubleshooting charts
2. Compression
There is compression. Check the ignition. 4
Operate the electric starter.
Have a Yamaha dealer
There is no compression.
check the vehicle.
5
3. Ignition 6
Wipe off with a dry cloth and correct the
Wet Operate the electric starter.
spark plug gaps, or replace the spark plugs.
Remove the spark plugs
and check the electrodes. 7
The engine does not start.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
8
4. Battery The engine turns over
The battery is good.
quickly. The engine does not start.
Operate the electric starter.
9
Have a Yamaha dealer
Check the battery lead connections, check the vehicle.
The engine turns over
and have a Yamaha dealer charge
slowly.
the battery if necessary.
6-37
WARNING
1 Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
Place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the de-
2
tent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap
while turning it counterclockwise, and then remove the cap.
3
4
There is Have a Yamaha dealer check
The coolant level is low. leakage. and repair the cooling system.
5 Check the cooling system
for leakage.
There is
Add coolant. (See TIP.)
Wait until the Check the coolant level in the no leakage.
6 engine has cooled. reservoir and radiator.
The coolant level Start the engine. If the engine overheats again, have a
is OK. Yamaha dealer check and repair the cooling system.
7
8
TIP
9 If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
6-38
SPECIFICATIONS
Dimensions: EAU50916
Engine oil: Spark plug(s):
Overall length: Recommended brand: Manufacturer/model:
2200 mm (86.6 in) YAMALUBE NGK/CR7E
Overall width: Type: Spark plug gap:
775 mm (30.5 in) SAE 10W-30 or 10W-40 0.7–0.8 mm (0.028–0.031 in)
Overall height: Recommended engine oil grade: Clutch:
1420/1475 mm (55.9/58.1 in) API service SG type or higher, JASO stan- Clutch type: 2
Seat height: dard MA Wet, multiple-disc automatic
800 mm (31.5 in) Engine oil quantity: Transmission:
Wheelbase: Without oil filter cartridge replacement: Primary reduction ratio: 3
1580 mm (62.2 in) 2.70 L (2.85 US qt, 2.38 Imp.qt) 1.000
Ground clearance: With oil filter cartridge replacement: Final drive:
125 mm (4.92 in) 2.90 L (3.07 US qt, 2.55 Imp.qt) Belt 4
Minimum turning radius: Cooling system: Secondary reduction ratio:
2800 mm (110.2 in) Coolant reservoir capacity (up to the maxi- 6.034 (52/32 x 36/22 x 59/26)
Weight: mum level mark): Transmission type: 5
Curb weight: 0.27 L (0.29 US qt, 0.24 Imp.qt) V-belt automatic
XP500 217 kg (478 lb) Radiator capacity (including all routes): Chassis:
XP500A 221 kg (487 lb) 1.50 L (1.59 US qt, 1.32 Imp.qt) 6
Frame type:
Engine: Air filter: Diamond
Engine type: Air filter element: Caster angle: 7
Liquid cooled 4-stroke, DOHC Oil-coated paper element 25.00
Cylinder arrangement: Fuel: Trail:
Inline 2-cylinder Recommended fuel: 92 mm (3.6 in) 8
Displacement: Regular unleaded gasoline (Gasohol (E10) Front tire:
530 cm3 acceptable) Type:
Bore stroke: Fuel tank capacity: Tubeless 9
68.0 73.0 mm (2.68 2.87 in) 15.0 L (3.96 US gal, 3.30 Imp.gal) Size:
Compression ratio: Fuel reserve amount: 120/70R15 M/C 56H
10.90 : 1 3.0 L (0.79 US gal, 0.66 Imp.gal) Manufacturer/model:
Starting system: Fuel injection: DUNLOP/GPR-100F
Electric starter Throttle body: Manufacturer/model:
Lubrication system: ID mark: BRIDGESTONE/BT011F
Dry sump 59C1 00
8-1
SPECIFICATIONS
Rear tire: Rim size: Wheel travel:
Type: 15M/C x MT3.50 116.0 mm (4.57 in)
Tubeless Rear wheel: Electrical system:
Size: Wheel type: Ignition system:
1 160/60R15 M/C 67H Cast wheel TCI
Manufacturer/model: Rim size: Charging system:
DUNLOP/GPR-100L 15M/C x MT5.00 AC magneto
2
Manufacturer/model: Front brake: Battery:
BRIDGESTONE/BT012R Type: Model:
3 Loading: Dual disc brake YTZ12S
Maximum load: Operation: Voltage, capacity:
XP500 198 kg (437 lb) Right hand operation 12 V, 11.0 Ah
4 XP500A 194 kg (428 lb) Specified brake fluid: Headlight:
* (Total weight of rider, passenger, cargo DOT 4 Bulb type:
and accessories) Rear brake: Halogen bulb
5 Tire air pressure (measured on cold Type: Bulb voltage, wattage quantity:
tires): Single disc brake Headlight:
Loading condition: Operation: 12 V, 55.0 W 2
6 Left hand operation
0–90 kg (0–198 lb) Tail/brake light:
Front: Specified brake fluid: LED
7 225 kPa (2.25 kgf/cm2, 33 psi) DOT 4 Front turn signal light:
Rear: Front suspension: 12 V, 21.0 W 2
250 kPa (2.50 kgf/cm2, 36 psi) Type: Rear turn signal light:
8 Loading condition: Telescopic fork 12 V, 21.0 W 2
XP500 90–198 kg (198–437 lb) Spring/shock absorber type: Auxiliary light:
XP500A 90–194 kg (198–428 lb) Coil spring/oil damper 12 V, 5.0 W 1
9 Front: Wheel travel: License plate light:
225 kPa (2.25 kgf/cm2, 33 psi) 120.0 mm (4.72 in) 12 V, 5.0 W 1
Rear: Rear suspension: Meter lighting:
280 kPa (2.80 kgf/cm2, 41 psi) Type: LED
Front wheel: Swingarm High beam indicator light:
Wheel type: Spring/shock absorber type: LED
Cast wheel Coil spring/gas-oil damper Turn signal indicator light:
LED x 2
8-2
SPECIFICATIONS
Engine trouble warning light:
LED
ABS warning light:
XP500A LED
Immobilizer system indicator light:
LED
Fuses:
2
Main fuse:
40.0 A
Headlight fuse: 3
20.0 A
Signaling system fuse:
15.0 A 4
Ignition fuse:
7.5 A
Parking lighting fuse: 5
10.0 A
Radiator fan fuse:
15.0 A 6
Fuel injection system fuse:
7.5 A
ABS control unit fuse: 7
XP500A 5.0 A
ABS motor fuse:
8
XP500A 30.0 A
ABS solenoid fuse:
XP500A 20.0 A 9
Backup fuse:
7.5 A
8-3
CONSUMER INFORMATION
EAU48612 EAU26410 EAU26500
9-1
INDEX
A Front and rear brake pads, checking ...... 6-22 R
ABS (for ABS models) .............................3-16 Front fork, checking................................. 6-26 Rear brake lock cable, adjusting..............6-21
ABS warning light (for ABS models) ..........3-3 Fuel ......................................................... 3-18 Rear brake lock, checking .......................6-21
Acceleration and deceleration ...................5-3 Fuel consumption, tips for reducing .......... 5-4 Rear brake lock lever...............................3-15
Air filter element, replacing ......................6-15 Fuel tank cap........................................... 3-17 Rear view mirrors.....................................3-25
Anti-theft alarm (optional) ........................3-12 Fuses, replacing...................................... 6-30 Rider backrest, adjusting .........................3-20
Auxiliary light bulb, replacing ...................6-35 H S
B Handlebar switches ................................. 3-12 Safe-riding points .......................................1-5
Battery .....................................................6-28 Hazard switch.......................................... 3-13 Safety information......................................1-1
Brake fluid, changing ...............................6-24 Headlight bulb, replacing......................... 6-32 Seat .........................................................3-20
Brake fluid level, checking .......................6-23 Helmet holder .......................................... 3-21 Shock absorber assembly .......................3-26
Brake lever, front .....................................3-14 High beam indicator light........................... 3-3 Sidestand .................................................3-26
Brake lever, rear ......................................3-14 Horn switch ............................................. 3-13 Spark plugs, checking..............................6-10
Brake levers, lubricating ..........................6-25 I Specifications.............................................8-1
Braking ......................................................5-3 Identification numbers ............................... 9-1 Speedometer .............................................3-5
C Ignition circuit cut-off system ................... 3-27 Starting off .................................................5-2
Cables, checking and lubricating .............6-24 Immobilizer system ................................... 3-1 Starting the engine.....................................5-1
Care...........................................................7-1 Immobilizer system indicator light ............. 3-4 Start switch ..............................................3-13
Catalytic converter...................................3-19 Indicator lights and warning lights ............. 3-3 Steering, checking ...................................6-27
Centerstand and sidestand, checking L Storage ......................................................7-3
and lubricating .......................................6-26 License plate light bulb, replacing ........... 6-34 Storage compartments ............................3-22
Coolant ....................................................6-14 M T
D Main switch/steering lock .......................... 3-2 Tachometer................................................3-5
Dimmer switch .........................................3-13 Maintenance and lubrication, periodic....... 6-4 Tail/brake light .........................................6-33
Drive belt slack ........................................6-24 Maintenance, emission control system ..... 6-3 Throttle grip and cable, checking and
E Matte color, caution................................... 7-1 lubricating ..............................................6-25
Engine break-in .........................................5-4 Model label ................................................ 9-1 Throttle grip free play, checking...............6-17
Engine idling speed .................................6-16 Multi-function display................................. 3-5 Tires .........................................................6-17
Engine oil and oil filter cartridge ..............6-11 P Tool kit .......................................................6-2
Engine stop switch...................................3-13 Panels, removing and installing ................ 6-8 Troubleshooting .......................................6-35
Engine trouble warning light ......................3-3 Parking ...................................................... 5-5 Troubleshooting charts ............................6-37
F Part locations ............................................ 2-1 Turn signal indicator lights .........................3-3
Front and rear brake lever free play, Pass switch ............................................. 3-13 Turn signal light bulb (front), replacing ....6-33
checking ................................................6-20 Turn signal switch ....................................3-13
INDEX
V
Valve clearance .......................................6-17
Vehicle identification number .....................9-1
W
Wheel bearings, checking........................6-27
Wheels .....................................................6-19
Windshield ...............................................3-24