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
All rights reserved.
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.

1
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 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.

22
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 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 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
0.8
0.8
2
1.0
6.5 X7.5 mm
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Hazard relay (for EUR)
Model (manufacturer)
Coil resistance
5DM (OMRON)
94.5 X115.5 Ωat 20_C
SSS
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
15 A 1
10 A 1
15 A 1
10 A 1
10 A 1
30 A 1
15 A 1
10 A 1
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
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)

–5–
17 Fan motor lead
18 V-belt reset coupler
19 Box 1
A Fasten the starter motor lead, battery negative lead
and seat lock cable (left side) to the frame with a
plastic clamp.
B Fasten the starter motor lead and battery negative
lead to the frame with a plastic clamp.
1Rectifier/regulator
2Starting circuit cut-off relay
3Pump relay
4Flasher relay
5Fuel pump
6Main switch
7Meter assembly
8Horn lead
9Ignition coil
10 Battery negative lead
11 Frame
12 Seat lock cable
13 Starter motor lead
14 Wireharness
15 Fuel hose
16 Sub harness
CABLE ROUTING SPEC

–6–
G Through the seat lock cable between wireharness
and frame.
H Use the clamp on the back of the frame to hold the
side stand switch lead and fan motor lead.
I Connect the wireharness (wire taped area) to the T
stud of frame.
J After connecting the main switch lead, push it be-
tween the seat lock cable adjustment area and the
frame.
K Through the main switch lead between frame and
seat lock cable.
L After connecting the wireharness and meter lead,
use a plastic clamp to connect them to stay 1.
M Connect to the headlight sub harness (left and
right)
C Fasten the starter motor lead, battery negative
lead, V-belt reset coupler, and seat lock cable to the
frame with a plastic band.
Position the band clasp on the bottom of the frame
and face the band end to the outside.
D Fasten the fuel sender lead and fuel pump lead to
the frame with a plastic clamp.
Route the fuel sender lead through the back of the
fuel pipe and pass it through the clamp from the
backward of vehicle. (Cross the leads in the
clamp.)
E Place the wireharness and seat lock cable in the
frame holder.
F After adjusting the adjustment nut, attach the front
and rear parts of the boot tightly. After placing the
boot, install the fuel hose to the frame guide.
CABLE ROUTING SPEC

–7–
T Through the wireharness to the frame wireharness
holder.
U Route the wireharness and regulator lead through
the frame wire holder.
Place the regulator lead under the wireharness.
V Fasten the lead of relay together with the wirehar-
ness to the frame. Direct the band’s combined sec-
tion toward the box side.
W After making the connections, push the couplers
into the space inside the frame above the mud-
guard.
X To the tail/brake light.
Y Insert the tail/brake light cuplers between the wire-
harness and the seat lock cable (left side).
Z To the starter relay.
N Fasten the headlight sub-harness to the stay 1
with a plastic clamp.
O Fasten the igniter lead to the stay 1 with a plastic
clamp. When fastening them using a plastic
clamp, make sure not to cross the branch leads.
P Fasten the horn lead with a clamp.
Q Fasten the fan motor lead, sidestand switch
lead, and thermo switch lead to the frame with a
plastic clamp.
R Use a plastic band to connect the wireharness
and relay lead to the frame.
Position the band clasp on the bottom of the
frame and face the band end to the outside.
S Insert the seat lock cable and the cylinder
mounting rubber into the frame stay.
CABLE ROUTING SPEC

–8–
AA After connecting the left headlight sub-harness
and wireharness (by matching the coupler col-
ors), fold back the lead facing to the right and in-
sert it into the air filter case rib.
AB Fasten the coolant reservoir hose to the stay with
a plastic clamp.
AC Route the ignition coil lead through the inside of
the bracket.
AD Route the seat lock cable through the frame
bracket side.
AE Install the band’s fastened part between frame
and box1.
CABLE ROUTING SPEC

–9–
A Route the wireharness through the frame guide.
At this time, place the protector (for the handle cov-
er inner side) on the bottom side.
B Fasten the rear brake hose and vacuum hose with
a plastic clamp.
The fastening position is 0 to 5 m from edge of the
frame bracket.
C Pass the wireharness by the outside of the rear
footrest mounting boss.
(When mounting the rear footrest, do not catch or
pinch the A.C. magneto lead in the bracket.)
1Air vent pipe
2Air vent hose
3Vacuum hose
4A.C. magneto lead
5Sidestand switch
6Thermo switch lead
7Throttle cable (accelerate side)
8Stay 1
CABLE ROUTING SPEC

–10–
K Use this as a reference when adjusting the throttle
cable.
D Fasten the wireharness to the frame with a plastic
clamp.
E Pass the box light lead by the front of the frame
back stay pipe.
F When tightening the leg shield stay 3, pull the gap
of half-pierce and the hole to the arrow mark and
tighten the bolt.
G Fasten the sidestand switch lead to the frame with
a plastic clamp.
Route the sidestand switch lead through the out-
side of the air vent pipe.
H When adjusting the throttle cable, completely tight-
en the hut on the throttle cable return side.
I Through the speed sensor lead to the lead holder.
J Through the speed sensor lead between front
brake caliper and front brake caliper mounting bolt.
CABLE ROUTING SPEC

–11–
A Route the wireharness against the stay wire guide.
B Fasten the wireharness branch wiring to the frame
with a plastic clamp.
C Fasten the wireharness to the frame with a plastic
clamp.
D Connect the black seat lock cable to the right seat
lock.
E Install the starter relay to the mad guard.
F Fasten the wireharness, battery positive lead and
seat lock cable to the mad guard with a clamp.
G Connect the gray seat lock cable to the left seat
lock.
1Fuel hose
2Battery negative lead
3Seat lock
4Starter motor lead
5Fuse box
6Battery
7Battery positive lead
8Fuel sender
9Breather hose
10 Lean angle cut-off switch lead
11 Wireharness
12 Seat lock cable
CABLE ROUTING SPEC

–12–
N Route the wireharness through the guide.
O Place the speed sensor lead between the ribs of
the air filter case.
P Fasten the lean angle cut-off switch lead to the stay
(2 locations). Face the end of the band downward.
Q Hang the wireharness and seat lock cable on the
wire holder.
R Fasten the battery negative lead and the starter
motor lead to the frame with a plastic clamp.
S Route the battery negative lead and the fuse box
lead from the box opening to the bottom of the
cross pipe.
T Pass the black seat lock cable beneath the battery
negative lead and starter motor lead and out to the
inside of the frame.
H Install the box light to the box 1.
I Fasten the auto choke leads (left and right) and
throttle position sensor lead to the frame with a
clamp.
Leave some slack in the lead wires so that when
the vacuum hose is install it does not press against
them.
J Fasten the auto choke leads (left and right) to the
frame with a plastic clamp.
K Pass the auto choke lead (right side) and throttle
position sensor lead by the front bottom side of the
vacuum hose.
L Route the thermo switch lead through the guide.
M Insert the air vent hose through the hole on the left
side of the frame bracket.
Align the white paint mark with the end face of hole.
CABLE ROUTING SPEC

–13–
AA Pass the speed sensor lead under the stay and
cross pipe and then over the brake hose guide.
AB Route the lean angle cut-off switch lead through
the back of the mirror stay (cross pipe).
AC Route the fuse box lead above the starter motor
lead.
AD Route the battery positive lead through the under
the seat lock cable.
AE To the switch on the seat hinge.
U Align the plastic clamp with the white tape on the
wireharness and fasten to the frame.
V Fasten the wireharness and seat lock cable to the
frame with a plastic clamp.
W Pass the wireharnesses past the outside of the
frame bracket.
X Apply silicone grease when inserting the starter
relay.
Y Fasten the wireharness to the frame with a plastic
clamp.
Z Use a plastic band to hold the auto choke leads (left
and right), throttle position sensor lead, and rear
brake hose in a loose bandle. (The band should be
loose enough so that it can be moved.)
Pull the band end to the bottom.
CABLE ROUTING SPEC

–14–
A Route the throttle cable through the cable holder.
B Into the handle cover.
C Route the main switch lead through over the seat
lock cable.
D Fasten the sidestand switch lead and thermo
switch lead to the frame with a plastic clamp.
E Fasten the carburetor air vent hose to the frame
with a plastic clamp.
F Fasten the carburetor air vent hose and drain
hoses (2 hoses) to the frame with a plastic clamp.
When fastening with a clamp, there should be no
deformation and twist of pipes.
G Drop the carburetor drain hose.
1Rear brake hose
2Vacuum hose
3Switch assembly lead
4Auto choke lead
5Throttle position sensor lead
6Fan motor lead
7Air vent pipe
8Drain hoses
9Sidestand switch lead
10 Thermo switch lead
11 Spark plug lead #2
12 Hazard relay (for EUR)
CABLE ROUTING SPEC