Yamaha XP500 2001 User manual

EAS00000
XP500 (N)
SERVICE MANUAL
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.

NOTE:
CAUTION:
EAS00002 NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
andtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanu-
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
shouldhaveabasicunderstandingofmechanicsandthetechniquestorepairthesetypesofvehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.
YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallitsmodels.Modificationsandsignifi-
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.
ACAUTIONindicatesspecialprecautionsthatmustbetaken to avoid damage
to the scooter.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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26
4
5
7
3
8
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 ofeach
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.

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1
3
5
7
9
2
4
8
6
24 25
2321
19 2018
16 1715
1413
11 12
10
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 intheexplodeddiagramsindi-
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 intheexplodeddiagramsindi-
cate the following:
24 Apply locking agent (LOCTITE)
25 Replace the part

GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
CARBURETORS
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO 1
SPEC 2
3
ENG
4
COOL
5
CARB
6
CHAS
7
ELEC 8
TRBL
SHTG 9
CHK
ADJ
EAS00012 TABLE OF CONTENTS

GEN
INFO
CHAPTER 1
GENERAL INFORMATION
SCOOTER IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . .
MODEL CODE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEATURES 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT AND BALANCER SHAFT 1-2. . . . . . . . . . . . . . . . . . . . . .
CHAIN DRIVE 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWINGARM AND REAR SUSPENSION 1-3. . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY 1-4. . . . . . . . . .
REPLACEMENT PARTS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS 1-4. . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTERPINS 1-5. . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONNECTIONS 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEN
INFO

1-1
SCOOTER IDENTIFICATION GEN
INFO
EAS00015
GENERAL INFORMATION
SCOOTER IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
Thevehicleidentificationnumber 1isstamped
into the right side of the frame.
EAS00018
MODEL CODE
The model code label 2is affixed to the lug-
gageBox.Thisinformationwill be needed toor-
der spare parts.

1-2
FEATURES GEN
INFO
FEATURES
CRANKSHAFT AND BALANCER SHAFT
An integrated crankshaft of a new design is used Horizontally opposed reciprocating balancers are
used.Layoutfreefromprimaryinertialforce,secondaryinertialforce,andacoupleofforce,andsignifi-
cant vibration reduction are implemented.
CHAIN DRIVE
Thechaindriveisnewlydesigned.Anonadjustablez-stagesilentchainisused. A backlash free pivot
coaxial drive is used. The drive and the swingarm at the right are integrated to create rigidity. The rear
wheel swing system ensures high speed stability.

1-3
FEATURES GEN
INFO
SWINGARM AND REAR SUSPENSION
A newly designed swingarm is used. A pull-type monocross suspension is used. These components
are located out under the engine.

1-4
IMPORTANT INFORMATION GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
“mated” through normal wear. Mated parts
mustalwaysbereusedorreplaced as an as-
sembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disas-
sembly. This will speed up assembly and al-
low for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with greace.

1-5
IMPORTANT INFORMATION GEN
INFO
CAUTION:
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1andcotterpins. Aftertheboltornut hasbeen
tightenedtospecification,bendthelockwasher
tabs and the cotter pin ends along a flat of the
bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are vis-
ible.Wheninstallingoilseals,lubricatetheoil
seallipswithalightcoatoflithiumsoapbase
grease.Oilbearingsliberallywheninstalling,
if appropriate.
1Oil seal
Donotspin the bearing withcompressedair
because this will damage the bearing sur-
faces.
1Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2is positioned opposite
the thrust 3that the circlip receives.
4Shaft

1-6
CHECKING THE CONNECTIONS GEN
INFO
NOTE:
NOTE:
NOTE:
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
lead
coupler
connector
2. Check:
lead
coupler
connector
Moisture Dry with an air blower.
Rust/stains Connect and disconnect sev-
eral times.
3. Check:
all connections
Loose connection Connect properly.
If the pin 1on the terminal is flattened, bend it
up.
4. Connect:
lead
coupler
connector
Make sure all connections are tight.
5. Check:
continuity
(with the pocket tester)
Pocket tester
90890-03112
If there is no continuity, clean the terminals.
When checking the wire harness, perform
steps (1) to (3).
As a quick remedy, use a contact revitalizer
available at most part stores.

1-7
SPECIAL TOOLS GEN
INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
theappropriatespecialtoolsasthiswillhelpprevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Function Illustration
90890-01362
Flywheel puller
This tool is used to remove the generator
rotor.
T-handle
90890-01326
Damper rod
holder
90890-01294
T-handle
Damper rod holder
These tools are used to hold the cartridge
cylinder when loosening or tightening the
cartridge cylinder bolt.
90890-01312
Fuel level gauge
This tool is used to measure the fuel level in
the float chamber.
90890-03141
Timing light
This tool is used to check the ignition
timing.
90890-03148
Locknut wrench
This tool is used to remove the sheave or
install the secondary sheave nut.
Fork seal
driver weight
90890-01367
Adapter
90890-01372
Fork seal driver weight
Adapter
These tools are used to install the front
fork’s oil seal and dust seal.
90890-06754
Ignition checker
This tool is used to check the ignition
system components.
90890-04019
Valve spring compressor
This tool is used to remove or install the
valve assemblies.

1-8
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/Function Illustration
90890-04111
Valve guide remover (4 mm)
This tool is used to remove or install the
valve guides.
90890-04112
Valve guide installer
This tool is used to install the valve guides.
90890-04113
Valve guide reamer
This tool is used to rebore the new valve
guides.
90890-01481
Primary/secondary sheave holder
Thistoolisusedtoholdthesheave assembly
when removing or installing the primary and
secondary sheave.
90890-01701
Sheave holder
This tool is used for hold the generator
rotor when removing or installing the
generator rotor bolt, generator shaft bolt or
pickup coil rotor bolt.
90890-01304
Piston pin puller set
This tool is used to remove the piston pins.
90890-03008
Micrometer (50~75 mm)
This tool is used to measure the piston skirt
diameter.
90890-03017
Cylinder bore gauge (50~100 mm)
Thistoolisusedtomeasurethecylinderbore.
90890-03112
Pocket tester
This tool is used to check the electrical
system.

1-9
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/Function Illustration
Compression
gauge
90890-03081
Compression
gauge adapter
90890-04082
Compression gauge
These tools are used to measure engine
compression.
90890-01403
Steering nut wrench
This tool is used to loosen or tighten the
steering stem ring nuts.
90890-01469
Oil filter wrench
This tool is needed to loosen or tighten
the oil filter cartridge.
90890-03113
Engine tachometer
This tool is used to check engine speed.
90890-85505
Yamaha bond No. 1215
This sealant is used to seal two mating
surfaces (e.g., crankcase mating surfaces).
Oil pressure
gauge
90890-03153
Adapter
90890-03124
Oil pressure gauge
This tool is used to measure the engine oil
pressure.
90890-01439
Plane bearing installer/remover
This tool is used to install or remove the
bearing.
Sheave spring
compressor
90890-04134
Sheave fixed
block
90890-04135
Sheave spring compressor
Sheave fixed block
This tool is used to remove spring.
90890-01325
Radiator cap tester
This tool is used to check the cooling system.