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
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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
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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)