15B-28199-E0
XP500A
OWNER’S MANUAL
XP500
DECLARATION of CONFORMITY
WeCompany: MORIC CO., LTD.Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan
Hereby declare that the product:
Kind of equipment: IMMOBILIZER
Type-designation: 5SL-00
is in compliance with following norm(s) or documents:
R&TTE Directive(1999/5/EC)EN300 330-2 v1.1.1(2001-6), EN60950-1(2001)Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Place of issue: Shizuoka, Japan
Date of issue: 1 Aug. 2002
Revolution recordNo. Contents Date
To change contact person and integrate type-designation. 9 Jun. 2005
General manager of quality assurance div.
representative name and signature
MORIC CO., LTD.1450-6 Mori-machi Shuchi-gun Shizuoka 437-0292 JAPAN Telephone +81-538-85-0757 Facsimile +81-538-85-0456
URL:http://www.moric-jp.com
1Version up the norm of EN60950 to EN60950-1 27 Feb. 20062
EAU26943
INTRODUCTION
EAU10110
Welcome to the Yamaha world of motorcycling!As the owner of the XP500/XP500A, you are benefiting from Yamaha’s vast experience and newest technology regardingthe design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XP500/XP500A. The owner’s man-ual does not only instruct you in how to operate, inspect and maintain your scooter, but also in how to safeguard yourself andothers from trouble and injury.In addition, the many tips given in this manual will help keep your scooter in the best possible condition. If you have any fur-ther questions, do not hesitate to contact your Yamaha dealer.The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
IMPORTANT MANUAL INFORMATION
EAU34111
Particularly important information is distinguished in this manual by the following notations:
NOTE:
�
This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is sub-sequently sold.
�
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the mostcurrent product information available at the time of printing, there may be minor discrepancies between your scooter and
this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
WARNING
EWA12410
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER.
*Product and specifications are subject to change without notice.
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 thescooter operator, a bystander, or a person inspecting 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:
IMPORTANT MANUAL INFORMATION
EAU10200
XP500/XP500AOWNER’S MANUAL
©2006 by Yamaha Motor Co., Ltd.1st edition, September 2006
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
...................1-1Further safe-riding points .................1-4
DESCRIPTION
...................................2-1Left view ...........................................2-1Right view .........................................2-2Controls and instruments..................2-3
INSTRUMENT AND CONTROL FUNCTIONS
........................................3-1Immobilizer system ..........................3-1Main switch/steering lock .................3-2Indicator and warning lights .............3-3Speedometer ...................................3-4Tachometer .....................................3-5Multi-function display .......................3-5Anti-theft alarm (optional) ................3-8Handlebar switches .........................3-9Front brake lever ...........................3-10Rear brake lever ............................3-10Rear brake lock lever .....................3-11ABS (for ABS models) ...................3-11Fuel tank cap .................................3-12Fuel ................................................3-13Catalytic converter .........................3-14Seat ...............................................3-14Adjusting the rider backrest ...........3-15Helmet holder ................................3-15Storage compartments ..................3-16Shock absorber .............................3-17Sidestand .......................................3-18
Ignition circuit cut-off system ......... 3-18
PRE-OPERATION CHECKS
.............. 4-1Pre-operation check list ................... 4-2
OPERATION AND IMPORTANT RIDING POINTS
.................................. 5-1Starting the engine .......................... 5-1Starting off ....................................... 5-2Acceleration and deceleration ......... 5-2Braking ............................................ 5-3Tips for reducing fuel
consumption ................................ 5-4Engine break-in ............................... 5-4Parking ............................................ 5-5
PERIODIC MAINTENANCE AND MINOR REPAIR
.................................. 6-1Owner’s tool kit ................................ 6-1Periodic maintenance and lubrication
chart ............................................. 6-3Removing and installing cowlings and
panels .......................................... 6-6Checking the spark plugs ................ 6-9Engine oil and oil filter cartridge .... 6-11Chain drive oil ............................... 6-14Coolant .......................................... 6-15Cleaning the air filter element ....... 6-17Adjusting the engine idling
speed ......................................... 6-18
Checking the throttle cable free play ............................................ 6-19
Valve clearance ............................ 6-19Tires .............................................. 6-19Cast wheels .................................. 6-21Front and rear brake lever free
play ............................................ 6-22Adjusting the rear brake lock lever
cable .......................................... 6-22Checking the front and rear brake
pads ........................................... 6-23Checking the brake fluid level ....... 6-24Changing the brake fluid ............... 6-25Checking and lubricating the throttle
grip and cable ............................ 6-25Lubricating the front and rear brake
levers ......................................... 6-26Checking and lubricating the
centerstand and sidestand ........ 6-26Checking the front fork .................. 6-27Checking the steering ................... 6-28Checking the wheel bearings ........ 6-28Battery ........................................... 6-29Replacing the fuses ...................... 6-30Replacing the headlight bulb ........ 6-32Tail/brake light ............................... 6-33Replacing a front turn signal light
bulb ............................................ 6-34Replacing a rear turn signal light
bulb ............................................ 6-34License plate light ......................... 6-35
TABLE OF CONTENTS
Replacing an auxiliary light bulb ....6-35Troubleshooting .............................6-35Troubleshooting charts ..................6-36
SCOOTER CARE AND STORAGE
...........................................7-1Matte color caution ..........................7-1Care .................................................7-1Storage ............................................7-3
SPECIFICATIONS
..............................8-1
CONSUMER INFORMATION
..............9-1Identification numbers .....................9-1
1-1
1
SAFETY INFORMATION
EAU10261
SCOOTERS ARE SINGLE TRACKVEHICLES. THEIR SAFE USE ANDOPERATION ARE DEPENDENTUPON THE USE OF PROPERRIDING TECHNIQUES AS WELL ASTHE EXPERTISE OF THE OPERA-TOR. EVERY OPERATOR SHOULDKNOW THE FOLLOWING REQUIRE-MENTS BEFORE RIDING THISSCOOTER.HE OR SHE SHOULD:
�
OBTAIN THOROUGH INSTRUC-TIONS FROM A COMPETENTSOURCE ON ALL ASPECTS OFSCOOTER OPERATION.
�
OBSERVE THE WARNINGSAND MAINTENANCE REQUIRE-MENTS IN THE OWNER’S MAN-UAL.
�
OBTAIN QUALIFIED TRAININGIN SAFE AND PROPER RIDINGTECHNIQUES.
�
OBTAIN PROFESSIONAL TECH-NICAL SERVICE AS INDICATEDBY THE OWNER’S MANUALAND/OR WHEN MADE NECES-SARY BY MECHANICAL CONDI-
TIONS.
Safe riding
�
Always make pre-operationchecks. Careful checks may helpprevent an accident.
�
This scooter is designed to carrythe operator and passenger.
�
The failure of motorists to detectand recognize scooters in traffic isthe predominating cause of auto-mobile/scooter accidents. Manyaccidents have been caused by anautomobile driver who did not seethe scooter. Making yourself con-spicuous appears to be very effec-tive in reducing the chance of thistype of accident.
Therefore:
�
Wear a brightly colored jacket.
�
Use extra caution when ap-proaching and passing throughintersections, since intersec-tions are the most likely placesfor scooter accidents to occur.
�
Ride where other motorists cansee you. Avoid riding in anothermotorist’s blind spot.
�
Many accidents involve inexperi-enced operators. In fact, many op-erators who have been involved inaccidents do not even have a cur-rent driver’s license.
�
Make sure that you are qualifiedand that you only lend yourscooter to other qualified opera-tors.
�
Know your skills and limits.Staying within your limits mayhelp you to avoid an accident.
�
We recommend that you prac-tice riding your scooter wherethere is no traffic until you havebecome thoroughly familiar withthe scooter and all of its con-trols.
�
Many accidents have been causedby error of the scooter operator. Atypical error made by the operatoris veering wide on a turn due toEXCESSIVE SPEED or undercor-nering (insufficient lean angle forthe speed).
�
Always obey the speed limit andnever travel faster than warrant-ed by road and traffic conditions.
SAFETY INFORMATION
1-2
1
�
Always signal before turning orchanging lanes. Make sure thatother motorists can see you.
�
The posture of the operator andpassenger is important for propercontrol.
�
The operator should keep bothhands on the handlebar andboth feet on the footboard duringoperation to maintain control ofthe scooter.
�
The passenger should alwayshold onto the operator, the seatstrap or grab bar, if equipped,with both hands and keep bothfeet on the passenger footrests.
�
Never carry a passenger unlesshe or she can firmly place bothfeet on the passenger footrests.
�
Never ride under the influence ofalcohol or other drugs.
�
This scooter is designed foron-road use only. It is not suitablefor off-road use.
Protective apparel
The majority of fatalities from scooteraccidents are the result of head inju-
ries. The use of a safety helmet is thesingle most critical factor in the preven-tion or reduction of head injuries.
�
Always wear an approved helmet.
�
Wear a face shield or goggles.Wind in your unprotected eyescould contribute to an impairmentof vision which could delay seeinga hazard.
�
The use of a jacket, substantialshoes, trousers, gloves, etc., is ef-fective in preventing or reducingabrasions or lacerations.
�
Never wear loose-fitting clothes,otherwise they could catch on thecontrol levers or wheels and causeinjury or an accident.
�
Never touch the engine or exhaustsystem during or after operation.They become very hot and cancause burns. Always wear protec-tive clothing that covers your legs,ankles, and feet.
�
Passengers should also observethe above precautions.
Modifications
Modifications made to this scooter not
approved by Yamaha, or the removal oforiginal equipment, may render thescooter unsafe for use and may causesevere personal injury. Modificationsmay also make your scooter illegal touse.
Loading and accessories
Adding accessories or cargo to yourscooter can adversely affect stabilityand handling if the weight distribution ofthe scooter is changed. To avoid thepossibility of an accident, use extremecaution when adding cargo or accesso-ries to your scooter. Use extra carewhen riding a scooter that has addedcargo or accessories. Here are somegeneral guidelines to follow if loadingcargo or adding accessories to yourscooter:
LoadingThe total weight of the operator, pas-senger, accessories and cargo mustnot exceed the maximum load limit.
Maximum load:
XP500 188 kg (414 lb)XP500A 183 kg (403 lb)
SAFETY INFORMATION
1-3
1
When loading within this weight limit,keep the following in mind:
�
Cargo and accessory weightshould be kept as low and close tothe scooter as possible. Make sureto distribute the weight as evenlyas possible on both sides of thescooter to minimize imbalance orinstability.
�
Shifting weights can create a sud-den imbalance. Make sure that ac-cessories and cargo are securelyattached to the scooter beforeriding. Check accessory mountsand cargo restraints frequently.
�
Never attach any large or heavyitems to the handlebar, front fork,or front fender. Such items cancreate unstable handling or a slowsteering response.
AccessoriesGenuine Yamaha accessories havebeen specifically designed for use onthis scooter. Since Yamaha cannot testall other accessories that may be avail-able, you must personally be responsi-ble for the proper selection, installation
and use of non-Yamaha accessories.Use extreme caution when selectingand installing any accessories.Keep the following guidelines in mind,as well as those provided under “Load-ing” when mounting accessories.
�
Never install accessories or carrycargo that would impair the perfor-mance of your scooter. Carefullyinspect the accessory before usingit to make sure that it does not inany way reduce ground clearanceor cornering clearance, limit sus-pension travel, steering travel orcontrol operation, or obscure lightsor reflectors.
�
Accessories fitted to the handle-bar or the front fork area cancreate instability due to improperweight distribution or aerody-namic changes. If accessoriesare added to the handlebar orfront fork area, they must be aslightweight as possible andshould be kept to a minimum.
�
Bulky or large accessories mayseriously affect the stability ofthe scooter due to aerodynamic
effects. Wind may attempt to liftthe scooter, or the scooter maybecome unstable in crosswinds. These accessories mayalso cause instability whenpassing or being passed bylarge vehicles.
�
Certain accessories can dis-place the operator from his orher normal riding position. Thisimproper position limits the free-dom of movement of the opera-tor and may limit control ability,therefore, such accessories arenot recommended.
�
Use caution when adding electri-cal accessories. If electrical acces-sories exceed the capacity of thescooter’s electrical system anelectric failure could result, whichcould cause a dangerous loss oflights or engine power.
Gasoline and exhaust gas
�
GASOLINE IS HIGHLY FLAMMA-BLE:
�
Always turn the engine off whenrefueling.
SAFETY INFORMATION
1-4
1
�
Take care not to spill any gaso-line on the engine or exhaustsystem when refueling.
�
Never refuel while smoking or inthe vicinity of an open flame.
�
Never start the engine or let it runfor any length of time in a closedarea. The exhaust fumes are poi-sonous and may cause loss ofconsciousness and death within ashort time. Always operate yourscooter in an area that has ade-quate ventilation.
�
Always turn the engine off beforeleaving the scooter unattendedand remove the key from the mainswitch. When parking the scooter,note the following:
�
The engine and exhaust systemmay be hot, therefore, park thescooter in a place where pedes-trians or children are not likely totouch these hot areas.
�
Do not park the scooter on aslope or soft ground, otherwise itmay fall over.
�
Do not park the scooter near aflammable source (e.g., a kero-
sene heater, or near an openflame), otherwise it could catchfire.
�
If you should swallow any gaso-line, inhale a lot of gasoline vapor,or allow gasoline to get into youreyes, see your doctor immediate-ly. If any gasoline spills on yourskin or clothing, immediately washthe affected area with soap andwater and change your clothes.
EAU10371
Further safe-riding points
�
Be sure to signal clearly whenmaking turns.
�
Braking can be extremely difficulton a wet road. Avoid hard braking,because the scooter could slide.Apply the brakes slowly whenstopping on a wet surface.
�
Slow down as you approach a cor-ner or turn. Once you have com-pleted a turn, accelerate slowly.
�
Be careful when passing parkedcars. A driver might not see youand open a door in your path.
�
Railroad crossings, streetcar rails,iron plates on road constructionsites, and manhole covers be-come extremely slippery whenwet. Slow down and cross themwith caution. Keep the scooter up-right, otherwise it could slide outfrom under you.
�
The brake pads could get wetwhen you wash the scooter. Afterwashing the scooter, check thebrakes before riding.
�
Always wear a helmet, gloves,trousers (tapered around the cuff
SAFETY INFORMATION
1-5
1
and ankle so they do not flap), anda bright colored jacket.
�
Do not carry too much luggage onthe scooter. An overloaded scoot-er is unstable.
SAFETY INFORMATION
1-6
1
2-1
1
2
3
4
5
6
7
8
9
DESCRIPTION
EAU10410
Left view
1 2 3 4
9 8 7 6 510
1. Fuel tank cap (page 3-12)2. Rear storage compartment (page 3-16)3. Helmet holder (page 3-15)4. Grab bar (page 5-2)5. Chain drive oil filler cap (page 6-14)6. Engine oil filler cap (page 6-11)7. V-belt air filter element (left)8. Engine oil drain bolt (page 6-11)
9. Engine oil level check window (page 6-11)10. Oil filter cartridge (page 6-11)
DESCRIPTION
2-2
2
3
4
5
6
7
8
9
EAU10420
Right view
1 3 4 5
7 689
2
1. Battery (page 6-29)2. Fuses (page 6-30)3. Owner’s tool kit (page 6-1)4. Front storage compartment (page 3-16)5. Air filter element (page 6-17)6. Coolant level check window (page 6-15)7. V-belt air filter element (right)8. Centerstand (page 6-26)
9. Passenger footrest
DESCRIPTION
2-3
1
2
3
4
5
6
7
8
9
EAU10430
Controls and instruments
542 3 6 7 81
109
1. Rear brake lever (page 3-10)2. Left handlebar switches (page 3-9)3. Rear brake lock lever (page 3-11)4. Speedometer (page 3-4)5. Multi-function display (page 3-5)6. Tachometer (page 3-5)7. Right handlebar switches (page 3-9)8. Front brake lever (page 3-10)
9. Throttle grip (page 6-19)10. Main switch/steering lock (page 3-2)
3-1
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU10972
Immobilizer system
This vehicle is equipped with an immo-bilizer system to help prevent theft byre-registering codes in the standardkeys. This system consists of the fol-lowing.
�
a code re-registering key (with ared bow)
�
two standard keys (with a blackbow) that can be re-registered withnew codes
�
a transponder (which is installed inthe code re-registering key)
�
an immobilizer unit
�
an ECU
�
an immobilizer system indicatorlight (See page 3-3.)
The key with the red bow is used to reg-ister codes in each standard key. Sincere-registering is a difficult process, takethe vehicle along with all three keys toa Yamaha dealer to have them re-reg-istered. Do not use the key with the redbow for driving. It should only be usedfor re-registering the standard keys. Al-ways use a standard key for driving.
CAUTION:
ECA11820
�
DO NOT LOSE THE CODERE-REGISTERING KEY! CON-TACT YOUR DEALER IMMEDI-ATELY IF IT IS LOST! If the codere-registering key is lost, regis-tering new codes in the stan-dard keys is impossible. Thestandard keys can still be usedto start the vehicle, however ifcode re-registering is required(i.e., if a new standard key ismade or all keys are lost) the en-tire immobilizer system must bereplaced. Therefore, it is highlyrecommended to use eitherstandard key and keep the code
re-registering key in a safeplace.
�
Do not submerse any key in wa-ter.
�
Do not expose any key to exces-sively high temperatures.
�
Do not place any key close tomagnets (this includes, but notlimited to, products such asspeakers, etc.).
�
Do not place heavy items on anykey.
�
Do not grind any key or alter itsshape.
�
Do not disassemble the plasticpart of any key.
�
Do not put two keys of any im-mobilizer system on the samekey ring.
�
Keep the standard keys as wellas keys of other immobilizersystems away from this vehi-cle’s code re-registering key.
�
Keep other immobilizer systemkeys away from the main switchas they may cause signal inter-
ference.
1. Code re-registering key (red bow)2. Standard keys (black bow)
INSTRUMENT AND CONTROL FUNCTIONS
3-2
1
2
3
4
5
6
7
8
9
EAU10471
Main switch/steering lock
The main switch/steering lock controlsthe ignition and lighting systems, and isused to lock the steering.
NOTE:
Be sure to use the standard key (blackbow) for regular use of the vehicle. Tominimize the risk of losing the codere-registering key (red bow), keep it in asafe place and only use it for code
re-registering.
EAU34121
ON
All electrical circuits are supplied withpower; the meter lighting, taillight, li-cense plate light and auxiliary lights
come on, and the engine can be start-ed. The key cannot be removed.
NOTE:
The headlights come on automaticallywhen the engine is started and stay onuntil the key is turned to “OFF” or the
sidestand is moved down.
EAU10660
OFF
All electrical systems are off. The keycan be removed.
EAU10680
LOCK
The steering is locked, and all electricalsystems are off. The key can be re-moved.
To lock the steering1. Turn the handlebars all the way to
the left.2. Push the key in from the “OFF” po-
sition, and then turn it to “LOCK”while still pushing it.
3. Remove the key.
To unlock the steeringPush the key in, and then turn it to“OFF” while still pushing it.
WARNING
EWA10060
Never turn the key to “OFF” or“LOCK” while the vehicle is moving,otherwise the electrical systems willbe switched off, which may result inloss of control or an accident. Makesure that the vehicle is stopped be-fore turning the key to “OFF” or
“LOCK”.
EAU39460
(Parking)
The steering is locked, and the tail-lights, license plate light and auxiliarylights are on. The hazard lights and turnsignal lights can be turned on, but allother electrical systems are off. Thekey can be removed.The steering must be locked before thekey can be turned to “ ”.
CAUTION:
ECA11020
Do not use the parking position foran extended length of time, other-
INSTRUMENT AND CONTROL FUNCTIONS
3-3
2
3
4
5
6
7
8
9
wise the battery may discharge.
EAU11003
Indicator and warning lights
EAU11030
Turn signal indicator lights “ ” and “ ”
The corresponding indicator light flash-es when the turn signal switch ispushed to the left or right.
EAU11080
High beam indicator light “ ”
This indicator light comes on when the
high beam of the headlight is switchedon.
EAU43020
Engine trouble warning light “ ”
This warning light comes on when anelectrical circuit monitoring the engineis defective. When this occurs, have aYamaha dealer check the self-diagno-sis system.The electrical circuit of the warning lightcan be checked by turning the key to“ON”. If the warning light does not comeon for a few seconds, then go off, havea Yamaha dealer check the electricalcircuit.
NOTE:
This warning light will come on whenthe key is turned to “ON” and the startswitch is pushed, but this does not indi-
cate a malfunction.
EAU43030
ABS warning light “ ” (for ABS models)
CAUTION:
ECA10830
If the ABS warning light comes on or
1. Turn signal indicator lights “ ” and “ ”
2. High beam indicator light “ ”
3. Immobilizer system indicator light
4. Engine trouble warning light “ ”
5. Anti-lock Brake System (ABS) warning light “ ” (for ABS models)
1 2 3 4 5
ABS
ABS
INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
2
3
4
5
6
7
8
9
flashes while riding, the ABS may bedefective. If this occurs, have aYamaha dealer check the electrical
circuit.
See page 3-11 for an explanation of theABS.The electrical circuit of the warning lightcan be checked by setting the enginestop switch to “ ” and turning the keyto “ON”. The warning light should comeon for a few seconds, and then go off. Ifthe warning light does not come on orremains on, have a Yamaha dealercheck the electrical circuit.
WARNING
EWA11350
When the ABS warning light comeson or flashes while riding, the brakesystem reverts to conventional brak-ing. Therefore, be careful not tocause the wheel to lock during emer-
gency braking.
NOTE:
The ABS warning light may come onwhile accelerating the engine with thescooter on its centerstand, but this
does not indicate a malfunction.
EAU38620
Immobilizer system indicator light
The electrical circuit of the indicatorlight can be checked by turning the keyto “ON”.If the indicator light does not come onfor a few seconds, then go off, have aYamaha dealer check the electrical cir-cuit.When the key is turned to “OFF” and 30seconds have passed, the indicatorlight will start flashing indicating the im-mobilizer system is enabled. After 24hours have passed, the indicator lightwill stop flashing, however the immobi-lizer system is still enabled.This model is also equipped with aself-diagnosis device for the immobiliz-er system. (See page 3-5 for an expla-nation of the self-diagnosis device.)
EAU11601
Speedometer
The speedometer shows the ridingspeed.When the key is turned to “ON”, thespeedometer needle will sweep onceacross the speed range and then returnto zero in order to test the electrical cir-cuit.
1. Speedometer
1
INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
3
4
5
6
7
8
9
EAU11872
Tachometer
The electric tachometer allows the riderto monitor the engine speed and keep itwithin the ideal power range.When the key is turned to “ON”, the ta-chometer needle will sweep onceacross the r/min range and then returnto zero r/min in order to test the electri-cal circuit.
CAUTION:
ECA10031
Do not operate the engine in the ta-chometer red zone.
Red zone: 8250 r/min and above
EAU33519
Multi-function display
WARNING
EWA12311
Be sure to stop the vehicle beforemaking any setting changes to the
multi-function display.
The multi-function display is equippedwith the following:
�
a fuel meter
�
a coolant temperature meter
�
an odometer (which shows the to-tal distance traveled)
�
two tripmeters (which show thedistance traveled since they werelast set to zero)
�
a fuel reserve tripmeter (whichshows the distance traveled sincethe bottom segment of the fuelmeter and fuel level warning indi-
1. Tachometer2. Tachometer red zone
1
2
1. Clock2. Coolant temperature meter3. Fuel meter4. Odometer/tripmeters5. “SELECT” button6. “RESET” button
123
45
6
1. V-belt replacement indicator “V-BELT”
2. Fuel level warning indicator “ ”
3. Coolant temperature warning indicator “ ”
4. Oil change indicator “OIL”
1 2 43
INSTRUMENT AND CONTROL FUNCTIONS
3-6
1
2
3
4
5
6
7
8
9
cator started flashing)
�
a self-diagnosis device
�
a clock
�
an oil change indicator
�
a V-belt replacement indicator
NOTE:
�
Be sure to turn the key to “ON” be-fore using the “SELECT” and “RE-SET” buttons.
�
When the key is turned to “ON”, allof the display segments of themulti-function display will appearone after the other and then disap-pear, in order to test the electrical
circuit.
Odometer and tripmeter modes
Pushing the “SELECT” button switchesthe display between the odometermode “ODO” and the tripmeter modes“TRIP” in the following order:ODO
→
TRIP (top)
→
TRIP (bottom)
→
ODOWhen approximately 2.8 L (0.74 USgal) (0.62 Imp.gal) of fuel remains in thefuel tank, the bottom segment of thefuel meter and fuel level warning indica-tor will start flashing, and the display will
automatically change to the fuel re-serve tripmeter mode “TRIP F” andstart counting the distance traveledfrom that point. In that case, pushingthe “SELECT” button switches the dis-play between the various tripmeter andodometer modes in the following order:TRIP F
→
TRIP (top)
→
TRIP (bottom)
→
ODO
→
TRIP F
To reset a tripmeter, select it by push-ing the “SELECT” button until “TRIP” or“TRIP F” begins flashing (“TRIP” or“TRIP F” will only flash for five sec-onds). While “TRIP” or “TRIP F” isflashing, push the “RESET” button forat least one second. If you do not resetthe fuel reserve tripmeter manually, it
will reset itself automatically and thedisplay will return to the prior mode af-ter refueling and traveling 5 km (3 mi).
NOTE:
The display cannot be changed back to“TRIP F” after pushing the “RESET”
button.
Fuel meter
With the key in the “ON” position, thefuel meter indicates the amount of fuelin the fuel tank. The display segmentsof the fuel meter disappear towards “E”(Empty) as the fuel level decreases.When the fuel level reaches the bottomsegment near “E”, the fuel level warn-ing indicator and the bottom segmentwill flash. Refuel as soon as possible.
Coolant temperature meter
With the key in the “ON” position, thecoolant temperature meter indicatesthe temperature of the coolant. Thecoolant temperature varies with chang-es in the weather and engine load. Ifthe top segment and coolant tempera-ture warning indicator flash, stop thevehicle and let the engine cool. (See
1. Fuel reserve tripmeter
1
INSTRUMENT AND CONTROL FUNCTIONS
3-7
2
3
4
5
6
7
8
9
page 6-36.)
CAUTION:
ECA10020
Do not operate the engine if it is
overheated.
Oil change indicator “OIL”
This indicator flashes at the initial 1000km (600 mi), then at 5000 km (3000 mi)and every 5000 km (3000 mi) thereafterto indicate that the engine oil should bechanged.After changing the engine oil, reset theoil change indicator. (See page 6-11.)If the engine oil is changed before theoil change indicator comes on (i.e. be-fore the periodic oil change interval hasbeen reached), the indicator must be
reset after the oil change for the nextperiodic oil change to be indicated atthe correct time. (See page 6-11.)The electrical circuit of the indicator canbe checked according to the followingprocedure.
1. Set the engine stop switch to “ ”and turn the key to “ON”.
2. Check that the indicator comes onfor a few seconds and then goesoff.
3. If the indicator does not come on,have a Yamaha dealer check theelectrical circuit.
NOTE:
The oil change indicator may flashwhen the engine is revved with thescooter on the centerstand, but this
does not indicate a malfunction.
V-belt replacement indicator “V-BELT”
This indicator flashes every 20000 km(12500 mi) when the V-belt needs to bereplaced.The electrical circuit of the indicator canbe checked according to the followingprocedure.
1. Turn the key to “ON” and makesure that the engine stop switch isset to “ ”.
2. If the indicator does not come on,have a Yamaha dealer check theelectrical circuit.
Self-diagnosis device
This model is equipped with a self-diag-nosis device for various electrical cir-cuits.If any of those circuits are defective, themulti-function display will indicate atwo-digit error code.If the multi-function display indicatessuch an error code, note the code num-ber, and then have a Yamaha dealercheck the vehicle.
CAUTION:
ECA11790
If the multi-function display indi-cates an error code, the vehicleshould be checked as soon as pos-sible in order to avoid engine dam-
age.
This model is also equipped with aself-diagnosis device for the immobiliz-er system.
INSTRUMENT AND CONTROL FUNCTIONS
3-8
1
2
3
4
5
6
7
8
9
If any of the immobilizer system circuitsare defective, the immobilizer systemindicator light will flash, and then themulti-function display will indicate atwo-digit error code when the key isturned to “ON”.
NOTE:
If the multi-function display indicates er-ror code 52, this could be caused bytransponder interference. If this error
appears, try the following.
1. Use the code re-registering key tostart the engine.
NOTE:
Make sure there are no other immobi-lizer keys close to the main switch, anddo not keep more than one immobilizerkey on the same key ring! Immobilizersystem keys may cause signal interfer-ence, which may prevent the engine
from starting.
2. If the engine starts, turn it off, andtry starting the engine with thestandard keys.
3. If one or both of the standard keysdo not start the engine, take thevehicle, the code re-registering
key and both standard keys to aYamaha dealer and have the stan-dard keys re-registered.
If the multi-function display indicatesany error codes, note the code number,and then have a Yamaha dealer checkthe vehicle.
Clock mode
To set the clock:1. Push the “SELECT” button and
“RESET” button together for atleast two seconds.
2. When the hour digits start flashing,push the “RESET” button to set thehours.
3. Push the “SELECT” button, andthe minute digits will start flashing.
4. Push the “RESET” button to setthe minutes.
5. Push the “SELECT” button andthen release it to start the clock.
EAU12331
Anti-theft alarm (optional)
This model can be equipped with anoptional anti-theft alarm by a Yamahadealer. Contact a Yamaha dealer formore information.
INSTRUMENT AND CONTROL FUNCTIONS
3-9
2
3
4
5
6
7
8
9
EAU12347
Handlebar switches
Left
Right
EAU12360
Pass switch “PASS”
Press this switch to flash the headlight.
EAU12400
Dimmer switch “ / ”
Set this switch to “ ” for the highbeam and to “ ” for the low beam.
EAU12460
Turn signal switch “ / ”
To signal a right-hand turn, push thisswitch to “ ”. To signal a left-handturn, push this switch to “ ”. When re-
leased, the switch returns to the centerposition. To cancel the turn signallights, push the switch in after it has re-turned to the center position.
EAU12500
Horn switch “ ”
Press this switch to sound the horn.
EAU12660
Engine stop switch “ / ”
Set this switch to “ ” before startingthe engine. Set this switch to “ ” tostop the engine in case of an emergen-cy, such as when the vehicle overturnsor when the throttle cable is stuck.
EAU12720
Start switch “ ”
With the sidestand up, push this switchwhile applying the front or rear brake tocrank the engine with the starter.
CAUTION:
ECA10050
See page 5-1 for starting instruc-
tions prior to starting the engine.
1. Pass switch “ ”
2. Dimmer switch “ / ”
3. Turn signal switch “ / ”
4. Horn switch “ ”
1
2
3
4
1. Engine stop switch “ / ”
2. Hazard switch “ ”
3. Start switch “ ”
1
2
3
INSTRUMENT AND CONTROL FUNCTIONS
3-10
1
2
3
4
5
6
7
8
9
EAU41700
The engine trouble warning light willcome on when the key is turned to “ON”and the start switch is pushed, but thisdoes not indicate a malfunction.
EAU12733
Hazard switch “ ”
With the key in the “ON” or “ ” posi-tion, use this switch to turn on the haz-ard lights (simultaneous flashing of allturn signal lights).The hazard lights are used in case ofan emergency or to warn other driverswhen your vehicle is stopped where itmight be a traffic hazard.
CAUTION:
ECA10061
Do not use the hazard lights for anextended length of time with the en-gine not running, otherwise the bat-
tery may discharge.
EAU12900
Front brake lever
The front brake lever is located on theright handlebar grip. To apply the frontbrake, pull this lever toward the handle-bar grip.
EAU12950
Rear brake lever
The rear brake lever is located on theleft handlebar grip. To apply the rearbrake, pull this lever toward the handle-bar grip.
1. Front brake lever
1
1. Rear brake lever
1
INSTRUMENT AND CONTROL FUNCTIONS
3-11
2
3
4
5
6
7
8
9
EAU12962
Rear brake lock lever
This vehicle is equipped with a rearbrake lock lever to prevent the rearwheel from moving while stopped attraffic signals, railroad crossings, etc.
To lock the rear wheel
Push the rear brake lock lever to the leftuntil it snaps into place.
To unlock the rear wheel
Push the rear brake lock lever back tothe original position.
NOTE:
�
Be sure to check that the rearwheel does not move when the
rear brake lock lever is applied.
�
To provide secure locking of therear wheel, apply the rear brake le-ver first before moving the rear
brake lock lever to the left.
WARNING
EWA12361
Never move the rear brake lock leverto the left while the vehicle is mov-ing, otherwise loss of control or anaccident may result. Make sure thatthe vehicle is stopped before mov-ing the rear brake lock lever to the
left.
EAU12991
ABS (for ABS models)
The Yamaha ABS (Anti-lock BrakeSystem) features a dual electronic con-trol system, which acts on the front andrear brakes independently. The ABSsecurely controls wheel lockup duringemergency braking on changing roadsurfaces and under various weatherconditions, thereby maximizing tire ad-hesion and performance while provid-ing a smooth braking action. The ABSis monitored by an ECU (ElectronicControl Unit), which will have recourseto manual braking if a malfunction oc-curs.
WARNING
EWA10090
�
The ABS performs best on longbraking distances.
�
On certain (rough or gravel)roads, the braking distance maybe longer with than without theABS. Therefore, always keep asufficient distance to the vehi-cle ahead to match the riding
speed.
1. Rear brake lock lever
1
INSTRUMENT AND CONTROL FUNCTIONS
3-12
1
2
3
4
5
6
7
8
9
NOTE:
�
When the ABS is activated, thebrakes are operated in the usualway. A pulsating action may be feltat the brake levers, but this doesnot indicate a malfunction.
�
This ABS has a test mode whichallows the owner to experience thepulsating at the brake levers whenthe ABS is operating. However,special tools are required, soplease consult your Yamaha deal-
er when performing this test.
EAU13174
Fuel tank cap
To remove the fuel tank cap
1. Open the lid by pulling the lever up.
2. Insert the key into the lock and turnit clockwise. The lock will be re-leased and the fuel tank cap canbe removed.
To install the fuel tank cap
1. Align the match marks, insert thefuel tank cap into the tank opening,and then push down on the cap.
2. Turn the key counterclockwise tothe original position, and then re-
1. Lid2. Opening lever
2
1
1. Fuel tank cap
1. Match marks
1
1
INSTRUMENT AND CONTROL FUNCTIONS
3-13
2
3
4
5
6
7
8
9
move it.3. Close the lid.
WARNING
EWA11260
Make sure that the fuel tank cap isproperly installed and locked in
place before riding the scooter.
EAU13211
Fuel
Make sure that there is sufficient fuel inthe tank. Fill the fuel tank to the bottomof the filler tube as shown.
WARNING
EWA10880
�
Do not overfill the fuel tank, oth-erwise it may overflow when thefuel warms up and expands.
�
Avoid spilling fuel on the hot en-
gine.
CAUTION:
ECA10070
Immediately wipe off spilled fuelwith a clean, dry, soft cloth, since
fuel may deteriorate painted surfac-
es or plastic parts.
EAU33520
CAUTION:
ECA11400
Use only unleaded gasoline. The useof leaded gasoline will cause severedamage to internal engine parts,such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been de-signed to use regular unleaded gaso-line with a research octane number of91 or higher. If knocking (or pinging) oc-curs, use a gasoline of a different brandor premium unleaded fuel. Use of un-leaded fuel will extend spark plug lifeand reduce maintenance costs.
1. Fuel tank filler tube2. Fuel level
2
1
Recommended fuel:
REGULAR UNLEADED GASOLINE ONLY
Fuel tank capacity:
14.0 L (3.70 US gal) (3.08 Imp.gal)
INSTRUMENT AND CONTROL FUNCTIONS
3-14
1
2
3
4
5
6
7
8
9
EAU13431
Catalytic converter
This model is equipped with a catalyticconverter in the exhaust system.
WARNING
EWA10860
The exhaust system is hot after op-eration. Make sure that the exhaustsystem has cooled down before do-
ing any maintenance work.
CAUTION:
ECA10700
The following precautions must beobserved to prevent a fire hazard orother damages.
�
Use only unleaded gasoline.The use of leaded gasoline willcause unrepairable damage tothe catalytic converter.
�
Never park the vehicle near pos-sible fire hazards such as grassor other materials that easilyburn.
�
Do not allow the engine to idle
too long.
EAU13932
Seat
To open the seat
1. Place the scooter on the center-stand.
2. Insert the key into the main switch,and then turn it counterclockwiseto “OPEN”.
NOTE:
Do not push inward when turning the
key.
3. Fold the seat up.
To close the seat
1. Fold the seat down, and then pushit down to lock it in place.
2. Remove the key from the mainswitch if the scooter will be left un-attended.
NOTE:
Make sure that the seat is properly se-
cured before riding.
1. Open.
1
INSTRUMENT AND CONTROL FUNCTIONS
3-15
2
3
4
5
6
7
8
9
EAU14270
Adjusting the rider backrest
The rider backrest can be adjusted tothe three different positions shown.
Adjust the backrest as follows.1. Open the seat. (See page 3-14.)2. Remove the backrest bolts.
3. Slide the backrest forward or back-ward to the desired position.
4. Install and securely tighten thebackrest bolts.
5. Close the seat.
EAU14340
Helmet holder
The helmet holder is located under theseat. A helmet holding cable is provid-ed beside the owner’s tool kit to securea helmet to the helmet holder.
To secure a helmet to the helmet holder
1. Open the seat. (See page 3-14.)2. Pass the helmet holding cable
through the buckle on the helmetstrap as shown, and then hook thecable loop over the helmet holder.
3. Securely close the seat.
1. Rider backrest
1
1. Rider backrest2. Bolt
1
2
1. Helmet holder
1
INSTRUMENT AND CONTROL FUNCTIONS
3-16
1
2
3
4
5
6
7
8
9
WARNING
EWA10160
Never ride with a helmet attached tothe helmet holder, since the helmetmay hit objects, causing loss of con-
trol and possibly an accident.
To release the helmet from the hel-met holder
Open the seat, remove the helmetholding cable from the helmet holderand the helmet, and then close theseat.
EAU14503
Storage compartments
Front storage compartment
To open the front storage compart-ment, slide the lever up, and then pullon the lever.
To close the front storage compart-ment, push the lid into the original posi-tion.
WARNING
EWA11160
Do not store heavy items in this
compartment.
Rear storage compartment
A helmet can be stored in the rear stor-age compartment under the seat. (Seepage 3-14.) To store a helmet in therear storage compartment, place thehelmet upside-down with the front fac-ing forward.
NOTE:
�
Some helmets cannot be stored inthe rear storage compartment be-cause of their size or shape.
�
Do not leave your scooter unat-
tended with the seat open.
CAUTION:
ECA10080
Keep the following points in mind
1. Storage compartment opening lever2. Lid
1
2
1. Rear storage compartment
1
INSTRUMENT AND CONTROL FUNCTIONS
3-17
2
3
4
5
6
7
8
9
when using the storage compart-ment.
�
Since the storage compartmentaccumulates heat when ex-posed to the sun, do not storeanything susceptible to heat in-side it.
�
To avoid humidity from spread-ing through the storage com-partment, wrap wet articles in aplastic bag before storing themin the compartment.
�
Since the storage compartmentmay get wet while the scooter isbeing washed, wrap any articlesstored in the compartment in aplastic bag.
�
Do not keep anything valuableor breakable in the storage com-
partment.
CAUTION:
ECA11270
Do not leave the seat open for an ex-tended period of time, otherwise thelight may cause the battery to dis-
charge.
WARNING
EWA11241
�
Do not exceed the load limit of5 kg (11 lb) for the rear storagecompartment.
�
Do not exceed the maximumload of XP500 188 kg (414 lb)XP500A 183 kg (403 lb) for the
vehicle.
EAU15090
Shock absorber
WARNING
EWA10220
This shock absorber contains highlypressurized nitrogen gas. For prop-er handling, read and understandthe following information beforehandling the shock absorber. Themanufacturer cannot be held re-sponsible for property damage orpersonal injury that may result fromimproper handling.
�
Do not tamper with or attempt toopen the gas cylinder.
�
Do not subject the shock ab-sorber to an open flame or otherhigh heat sources, otherwise itmay explode due to excessivegas pressure.
�
Do not deform or damage thegas cylinder in any way, as thiswill result in poor damping per-formance.
�
Always have a Yamaha dealer
service the shock absorber.
INSTRUMENT AND CONTROL FUNCTIONS
3-18
1
2
3
4
5
6
7
8
9
EAU15301
Sidestand
The sidestand is located on the left sideof the frame. Raise the sidestand orlower it with your foot while holding thevehicle upright.
NOTE:
The built-in sidestand switch is part ofthe ignition circuit cut-off system, whichcuts the ignition in certain situations.(See further down for an explanation of
the ignition circuit cut-off system.)
WARNING
EWA10240
The vehicle must not be ridden withthe sidestand down, or if the side-stand cannot be properly moved up(or does not stay up), otherwise thesidestand could contact the groundand distract the operator, resultingin a possible loss of control.Yamaha’s ignition circuit cut-offsystem has been designed to assistthe operator in fulfilling the respon-sibility of raising the sidestand be-fore starting off. Therefore, checkthis system regularly as describedbelow and have a Yamaha dealer re-
pair it if it does not function proper-
ly.
EAU15371
Ignition circuit cut-off system
The ignition circuit cut-off system (com-prising the sidestand switch and brakelight switches) has the following func-tions.
�
It prevents starting when the side-stand is up, but neither brake is ap-plied.
�
It prevents starting when eitherbrake is applied, but the sidestandis still down.
�
It cuts the running engine when thesidestand is moved down.
Periodically check the operation of theignition circuit cut-off system accordingto the following procedure.
WARNING
EWA10250
If a malfunction is noted, have aYamaha dealer check the system be-
fore riding.
INSTRUMENT AND CONTROL FUNCTIONS
3-19
2
3
4
5
6
7
8
9
With the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is turned on.3. Turn the key on. 4. Keep the front or rear brake applied.5. Push the start switch.Does the engine start?
With the engine still off:6. Move the sidestand up.7. Keep the front or rear brake applied.8. Push the start switch.Does the engine start?
With the engine still running:9. Move the sidestand down.Does the engine stall?
The system is OK. The scooter can be ridden.
This check is most reliable if performed witha warmed-up engine.
The sidestand switch may be defective.The scooter should not be ridden untilchecked by a Yamaha dealer.
The brake switch may be defective.The scooter should not be ridden untilchecked by a Yamaha dealer.
The sidestand switch may be defective.The scooter should not be ridden untilchecked by a Yamaha dealer.
YES NO
YES NO
NO YES
NOTE:
4-1
1
2
3
4
5
6
7
8
9
PRE-OPERATION CHECKS
EAU15592
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or lossof tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-tion, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.
WARNING
EWA11150
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.
PRE-OPERATION CHECKS
4-2
2
3
4
5
6
7
8
9
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
Fuel
�
Check fuel level in fuel tank.
�
Refuel if necessary.
�
Check fuel line for leakage.3-13
Engine oil
�
Check oil level in engine.
�
If necessary, add recommended oil to specified level.
�
Check vehicle for oil leakage.6-11
Chain drive oil
�
Check vehicle for oil leakage. 6-14
Coolant
�
Check coolant level in reservoir.
�
If necessary, add recommended coolant to specified level.
�
Check cooling system for leakage.6-15
Front brake
�
Check operation.
�
If soft or spongy, have Yamaha dealer bleed hydraulic system.
�
Check brake pads for wear.
�
Replace if necessary.
�
Check fluid level in reservoir.
�
If necessary, add recommended brake fluid to specified level.
�
Check hydraulic system for leakage.
6-23, 6-24
Rear brake
�
Check operation.
�
If soft or spongy, have Yamaha dealer bleed hydraulic system.
�
Check brake pads for wear.
�
Replace if necessary.
�
Check fluid level in reservoir.
�
If necessary, add recommended brake fluid to specified level.
�
Check hydraulic system for leakage.
6-23, 6-24
Throttle grip
�
Make sure that operation is smooth.
�
Check cable free play.
�
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.
6-19, 6-25
PRE-OPERATION CHECKS
4-3
1
2
3
4
5
6
7
8
9
Wheels and tires
�
Check for damage.
�
Check tire condition and tread depth.
�
Check air pressure.
�
Correct if necessary.
6-19, 6-21
Brake levers
�
Make sure that operation is smooth.
�
Lubricate lever pivoting points if necessary.6-26
Centerstand, sidestand
�
Make sure that operation is smooth.
�
Lubricate pivots if necessary.6-26
Chassis fasteners
�
Make sure that all nuts, bolts and screws are properly tightened.
�
Tighten if necessary.—
Instruments, lights, signals and switches
�
Check operation.
�
Correct if necessary.—
Sidestand switch
�
Check operation of ignition circuit cut-off system.
�
If system is defective, have Yamaha dealer check vehicle.3-18
ITEM CHECKS PAGE
5-1
2
3
4
5
6
7
8
9
OPERATION AND IMPORTANT RIDING POINTS
EAU15970
WARNING
EWA11250
�
Become thoroughly familiarwith all operating controls andtheir functions before riding.Consult a Yamaha dealer re-garding any control or functionthat you do not thoroughly un-derstand.
�
Never start the engine or oper-ate it in a closed area for anylength of time. Exhaust fumesare poisonous, and inhalingthem can cause loss of con-sciousness and death within ashort time. Always make surethat there is adequate ventila-tion.
�
For safety, always start the en-gine with the centerstand down.
�
When the centerstand is downand the engine is idling, keepyour hands and feet away from
the rear wheel.
EAU36510
Starting the engine
CAUTION:
ECA10250
See page 5-4 for engine break-in in-structions prior to operating the ve-
hicle for the first time.
In order for the ignition circuit cut-offsystem to enable starting, the side-stand must be up.
WARNING
EWA10290
�
Before starting the engine,check the function of the igni-tion circuit cut-off system ac-cording to the proceduredescribed on page 3-18.
�
Never ride with the sidestand
down.
1. Turn the key to “ON” and makesure that the engine stop switch isset to “ ”.
CAUTION:
ECA15020
The following warning lights, indica-tor light and indicators should comeon for a few seconds, then go off.
�
Engine trouble warning light
�
ABS warning light (for ABSmodels)
�
Immobilizer system indicatorlight
�
V-belt replacement indicator
�
Oil change indicatorIf a warning light, indicator light orindicator does not go off, see page3-3 or 3-5 for the correspondingwarning light, indicator light or indi-
cator circuit check.
2. Close the throttle completely.3. Start the engine by pushing the
start switch while applying the frontor rear brake.
NOTE:
If the engine does not start, release thestart switch, wait a few seconds, andthen try again. Each starting attemptshould be as short as possible to pre-serve the battery. Do not crank the en-gine more than 10 seconds on any one
attempt.
CAUTION:
ECA11040
For maximum engine life, never ac-celerate hard when the engine is
OPERATION AND IMPORTANT RIDING POINTS
5-2
1
2
3
4
5
6
7
8
9
cold!
EAU16760
Starting off NOTE:
Before starting off, allow the engine to
warm up.
1. While pulling the rear brake leverwith your left hand and holding thegrab bar with your right hand, pushthe scooter off the centerstand.
2. Sit astride the seat, and then ad-just the rear view mirrors.
3. Switch the turn signal on.4. Check for oncoming traffic, and
then slowly turn the throttle grip (onthe right) in order to take off.
5. Switch the turn signal off.
EAU16780
Acceleration and deceleration
The speed can be adjusted by openingand closing the throttle. To increase thespeed, turn the throttle grip in direction(a). To reduce the speed, turn the throt-tle grip in direction (b).
1. Grab bar
1(a)
(b)
OPERATION AND IMPORTANT RIDING POINTS
5-3
2
3
4
5
6
7
8
9
EAU16792
Braking
1. Close the throttle completely.2. Apply both front and rear brakes
simultaneously while gradually in-creasing the pressure.
Front
Rear
WARNING
EWA10300
�
Avoid braking hard or suddenly(especially when leaning over toone side), otherwise the scootermay skid or overturn.
�
Railroad crossings, streetcarrails, iron plates on road con-struction sites, and manholecovers become extremely slip-pery when wet. Therefore, slowdown when approaching suchareas and cross them with cau-tion.
�
Keep in mind that braking on awet road is much more difficult.
�
Ride slowly down a hill, as brak-ing downhill can be very diffi-
cult.
OPERATION AND IMPORTANT RIDING POINTS
5-4
1
2
3
4
5
6
7
8
9
EAU16820
Tips for reducing fuel consumption
Fuel consumption depends largely onyour riding style. Consider the followingtips to reduce fuel consumption:
�
Avoid high engine speeds duringacceleration.
�
Avoid high engine speeds with noload on the engine.
�
Turn the engine off instead of let-ting it idle for an extended length oftime (e.g., in traffic jams, at trafficlights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important periodin the life of your engine than the periodbetween 0 and 1600 km (1000 mi). Forthis reason, you should read the follow-ing material carefully.Since the engine is brand new, do notput an excessive load on it for the first1600 km (1000 mi). The various parts inthe engine wear and polish themselvesto the correct operating clearances.During this period, prolonged full-throt-tle operation or any condition that mightresult in engine overheating must beavoided.
EAU36530
0–1000 km (0–600 mi)
Avoid prolonged operation above4000 r/min.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above6000 r/min.
CAUTION:
ECA11281
After 1000 km (600 mi) of operation,
the engine oil must be changed, andthe oil filter cartridge or element re-
placed.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-mally.
CAUTION:
ECA10310
�
Keep the engine speed out ofthe tachometer red zone.
�
If any engine trouble should oc-cur during the engine break-inperiod, immediately have aYamaha dealer check the vehi-
cle.
OPERATION AND IMPORTANT RIDING POINTS
5-5
2
3
4
5
6
7
8
9
EAU17212
Parking
When parking, stop the engine, andthen remove the key from the mainswitch.
WARNING
EWA10310
�
Since the engine and exhaustsystem can become very hot,park in a place where pedestri-ans or children are not likely totouch them.
�
Do not park on a slope or on softground, otherwise the vehicle
may overturn.
CAUTION:
ECA10380
Never park in an area where thereare fire hazards such as grass or
other flammable materials.
6-1
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17280
Safety is an obligation of the owner. Pe-riodic inspection, adjustment and lubri-cation will keep your vehicle in thesafest and most efficient condition pos-sible. The most important points of in-spection, adjustment, and lubricationare explained on the following pages.The intervals given in the periodicmaintenance and lubrication chartshould be simply considered as a gen-eral guide under normal riding condi-tions. However, DEPENDING ON THEWEATHER, TERRAIN, GEOGRAPHI-CAL LOCATION, AND INDIVIDUALUSE, THE MAINTENANCE INTER-VALS MAY NEED TO BE SHORT-ENED.
WARNING
EWA10320
If you are not familiar with mainte-nance work, have a Yamaha dealer
do it for you.
WARNING
EWA10330
This scooter is designed for use onpaved roads only. If this scooter is
operated in abnormally dusty, mud-dy or wet conditions, the air filter el-ement should be cleaned orreplaced more frequently, otherwiserapid engine wear may result. Con-sult a Yamaha dealer for proper
maintenance intervals.
EAU17390
Owner’s tool kit
The owner’s tool kit is located under theseat. (See page 3-14.)The service information included in thismanual and the tools provided in theowner’s tool kit are intended to assistyou in the performance of preventivemaintenance and minor repairs. How-ever, additional tools such as a torquewrench may be necessary to performcertain maintenance work correctly.
NOTE:
If you do not have the tools or experi-ence required for a particular job, have
1. Helmet holding cable2. Owner’s tool kit
2
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
2
3
4
5
6
7
8
9
a Yamaha dealer perform it for you.
WARNING
EWA10350
Modifications not approved byYamaha may cause loss of perfor-mance and render the vehicle un-safe for use. Consult a Yamahadealer before attempting any chang-
es.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
1
2
3
4
5
6
7
8
9
EAU17706
Periodic maintenance and lubrication chart NOTE:
�
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-stead.
�
From 50000 km, repeat the maintenance intervals starting from 10000 km.
�
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km) ANNUAL CHECK1 10 20 30 40
1 *
Fuel line
�
Check fuel hoses for cracks or damage.
√ √ √ √ √
2
Spark plugs
�
Check condition.
�
Clean and regap.
√ √
�
Replace.
√ √
3 *
Valves
�
Check valve clearance.
�
Adjust.Every 40000 km
4
Air filter element
�
Clean.
√ √
�
Replace.
√ √
5 *
V-belt case air filter ele-ments
�
Clean.
√ √
�
Replace.
√ √
6 *
Front brake
�
Check operation, fluid level and vehicle for fluid leak-age.
√ √ √ √ √ √
�
Replace brake pads. Whenever worn to the limit
7 *
Rear brake
�
Check operation, fluid level and vehicle for fluid leak-age.
√ √ √ √ √ √
�
Replace brake pads. Whenever worn to the limit
8
Rear brake lock
�
Check operation.
�
Adjust.
√ √ √ √ √ √
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
2
3
4
5
6
7
8
9
9 *
Brake hoses
�
Check for cracks or damage.
√ √ √ √ √
�
Replace. Every 4 years
10
*
Wheels
�
Check runout and for damage.
√ √ √ √
11
*
Tires
�
Check tread depth and for damage.
�
Replace if necessary.
�
Check air pressure.
�
Correct if necessary.
√ √ √ √ √
12
*
Wheel bearings
�
Check bearing for looseness or damage.
√ √ √ √
13
*
Steering bearings
�
Check bearing play and steering for roughness.
√ √ √ √ √
�
Lubricate with lithium-soap-based grease. Every 20000 km
14
*
Chassis fasteners
�
Make sure that all nuts, bolts and screws are properly tightened.
√ √ √ √ √
15
Sidestand, centerstand
�
Check operation.
�
Lubricate.
√ √ √ √ √
16
*
Sidestand switch
�
Check operation.
√ √ √ √ √ √
17
*
Front fork
�
Check operation and for oil leakage.
√ √ √ √
18
*
Shock absorber assem-bly
�
Check operation and shock absorber for oil leakage.
√ √ √ √
19
*
Fuel injection
�
Adjust engine idling speed and synchronization.
√ √ √ √ √ √
20
Engine oil
�
Change. (See pages 3-5 and 6-11.)
√
When the oil change indicator flashes (every 5000 km)
�
Check oil level and vehicle for oil leakage. Every 5000 km
√
21
Engine oil filter cartridge
�
Replace.
√ √ √
22
*
Cooling system
�
Check coolant level and vehicle for coolant leakage.
√ √ √ √ √
�
Change. Every 3 years
23
Chain drive oil
�
Check vehicle for oil leakage.
�
Change.
√ √ √ √
24
*
V-belt
�
Replace.When the V-belt replacement indicator flashes (every
20000 km)
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km) ANNUAL CHECK1 10 20 30 40
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
1
2
3
4
5
6
7
8
9
EAU18670
NOTE:
�
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
�
Hydraulic brake service
�
Regularly check and, if necessary, correct the brake fluid level.
�
Every two years replace the internal components of the brake master cylinders and calipers, and change the brakefluid.
�
Replace the brake hoses every four years and if cracked or damaged.
25
*
Front and rear brake switches
�
Check operation.
√ √ √ √ √ √
26
Moving parts and cables
�
Lubricate.
√ √ √ √ √
27
*
Throttle grip housing and cable
�
Check operation and free play.
�
Adjust the throttle cable free play if necessary.
�
Lubricate the throttle grip housing and cable.
√ √ √ √ √
28
*
Lights, signals and switches
�
Check operation.
�
Adjust headlight beam.
√ √ √ √ √ √
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km) ANNUAL CHECK1 10 20 30 40
PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
2
3
4
5
6
7
8
9
EAU18712
Removing and installing cowlings and panels
The cowlings and panels shown needto be removed to perform some of themaintenance jobs described in thischapter. Refer to this section each timea cowling or panel needs to be re-moved and installed.
EAU33422
Cowling A
To remove the cowling1. Remove the rear view mirrors by
removing the nuts.
2. Remove the cowling screws.
To install the cowling1. Place the cowling in the original
position, and then install thescrews.
2. Install the rear view mirrors by in-stalling the nuts.
Cowling B
To remove the cowling1. Remove panels C and E. (See
page 6-7.)
1. Panel D2. Cowling B3. Panel E4. Cowling C5. Panel F
1
23
4
5
1. Panel A2. Panel B3. Panel C4. Cowling A
4
3
1
2
1. Screw2. Nut
21
2
PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
1
2
3
4
5
6
7
8
9
2. Remove the cowling screws andbolts.
3. Unhook the cowling from the hold-er at the bottom.
4. Unhook the front of the cowling bypushing it up, and then pull thecowling out.
To install the cowling1. Place the cowling in the original
position, and then install thescrews and bolts.
2. Install panels C and E.
Cowling C
To remove the cowling1. Remove the battery cover by re-
moving the screws.
2. Remove the cowling bolts, andthen pull the cowling off.
To install the cowling1. Place the cowling in the original
position, and then install the bolts.2. Install the battery cover by install-
ing the screws.
EAU33431
Panels A and D
To remove one of the panels1. Remove panel C (right side) or
panel E (left side).
2. Remove the panel screws.
1. Bolt2. Screw
1
2
1. Bolt2. Screw
1
2
1. Screw
1 1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
2
3
4
5
6
7
8
9
3. Pull outward on the front of thepanel.
To install the panelPlace the panel in the original position,and then install the screws.
Panel B
To remove the panelRemove the panel screws, and thenpull outward on the areas shown.
To install the panelPlace the panel in the original position,and then install the screws.
Panels C and E
To remove one of the panelsPull the floorboard mat off, and then re-move the panel screws.
To install the panelPlace the panel in the original position,install the screws, and then place thefloorboard mat back.
Panel F
To remove the panelRemove the panel screws.
1. Screw
11
1. Screw
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
1
2
3
4
5
6
7
8
9
To install the panelPlace the panel in the original position,and then install the screws.
EAU19593
Checking the spark plugs
The spark plugs are important enginecomponents, which are easy to check.Since heat and deposits will cause anyspark plug to slowly erode, the sparkplugs should be removed and checkedin accordance with the periodic mainte-nance and lubrication chart. In addition,the condition of the spark plugs can re-veal the condition of the engine.
To remove a spark plug
1. Remove cowling B. (Seepage 6-6.)
2. Remove the spark plug cover bypulling it out as shown.
3. Remove the spark plug cap.
4. Remove the spark plug as shownwith the spark plug wrench includ-ed in the owner’s tool kit.
1. Screw
1
1. Spark plug cover
1
1. Spark plug cap
1. Spark plug wrench
1
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
2
3
4
5
6
7
8
9
To check the spark plugs
1. Check that the porcelain insulatoraround the center electrode oneach spark plug is a medi-um-to-light tan (the ideal colorwhen the vehicle is ridden normal-ly).
2. Check that all spark plugs installedin the engine have the same color.
NOTE:
If any spark plug shows a distinctly dif-ferent color, the engine could be oper-ating improperly. Do not attempt todiagnose such problems yourself. In-stead, have a Yamaha dealer check
the vehicle.
3. Check each spark plug for elec-trode erosion and excessive car-bon or other deposits, and replaceit if necessary.
To install a spark plug
1. Measure the spark plug gap with awire thickness gauge and, if nec-
essary, adjust the gap to specifica-tion.
2. Clean the surface of the spark pluggasket and its mating surface, andthen wipe off any grime from thespark plug threads.
3. Install the spark plug with thespark plug wrench, and then tight-en it to the specified torque.
NOTE:
If a torque wrench is not available wheninstalling a spark plug, a good estimateof the correct torque is 1/4–1/2 turnpast finger tight. However, the sparkplug should be tightened to the speci-
fied torque as soon as possible.
4. Install the spark plug cap.5. Place the spark plug cover in the
original position as shown, andthen install the cowling.
Specified spark plug:
NGK/CR7E
1. Spark plug gap
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
1
Tightening torque:
Spark plug:12.5 Nm (1.25 m·kgf, 9 ft·lbf)
1. Spark plug cover
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
1
2
3
4
5
6
7
8
9
EAU19854
Engine oil and oil filter cartridge
The engine oil level should be checkedbefore each ride. In addition, the oilmust be changed and the oil filter car-tridge replaced at the intervals speci-fied in the periodic maintenance andlubrication chart.
To check the engine oil level
1. Place the vehicle on the center-stand.
CAUTION:
ECA11290
The engine must be cold before pro-ceeding with the oil level check, oth-erwise the check will result in a false
reading.
NOTE:
Make sure that the vehicle is positionedstraight up when checking the oil level.A slight tilt to the side can result in a
false reading.
2. Start the engine, warm it up for twominutes, and then turn it off.
3. Wait two minutes until the oil set-
tles, and then check the oil levelthrough the check window locatedat the bottom-left side of the crank-case.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-mum level mark, add sufficient oilof the recommended type to raiseit to the correct level.
To change the engine oil (with or without oil filter cartridge replace-ment)
1. Start the engine, warm it up forseveral minutes, and then turn itoff.
2. Place an oil pan under the engineto collect the used oil.
3. Remove the engine oil filler capand drain bolt to drain the oil fromthe crankcase.
1. Engine oil level check window2. Maximum level mark3. Minimum level mark
132
1. Engine oil filler cap
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
2
3
4
5
6
7
8
9
NOTE:
Skip steps 4–6 if the oil filter cartridge is
not being replaced.
4. Remove the oil filter cartridge withan oil filter wrench.
NOTE:
An oil filter wrench is available at a
Yamaha dealer.
5. Apply a thin coat of engine oil tothe O-ring of the new oil filter car-tridge.
NOTE:
Make sure that the O-ring is properly
seated.
6. Install the new oil filter cartridge,and then tighten it to the specifiedtorque with a torque wrench.
7. Install the engine oil drain bolt, andthen tighten it to the specifiedtorque.
8. Add the specified amount of therecommended engine oil, and theninstall and tighten the oil filler cap.
1. Engine oil drain bolt
1
1. Oil filter wrench2. Oil filter cartridge
21
1. Torque wrench
Tightening torque:
Oil filter cartridge:17 Nm (1.7 m·kgf, 12.3 ft·lbf)
Tightening torque:
Engine oil drain bolt:43 Nm (4.3 m·kgf, 31.1 ft·lbf)
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
1
2
3
4
5
6
7
8
9
CAUTION:
ECA11620
�
In order to prevent clutch slip-page (since the engine oil alsolubricates the clutch), do notmix any chemical additives. Donot use oils with a diesel speci-fication of “CD” or oils of a high-er quality than specified. Inaddition, do not use oils labeled“ENERGY CONSERVING II” orhigher.
�
Make sure that no foreign mate-
rial enters the crankcase.
9. Start the engine, and then let it idlefor several minutes while checkingit for oil leakage. If oil is leaking, im-mediately turn the engine off andcheck for the cause.
10. Turn the engine off, and then
check the oil level and correct it ifnecessary.
11. Reset the oil change indicator ac-cording to the following procedure.
To reset the oil change indicator
1. Turn the key to “ON”.2. Hold the “OIL CHANGE” button
pushed for two to eight seconds.
3. Release the “OIL CHANGE” but-ton, and the oil change indicatorwill go off.
NOTE:
If the engine oil is changed before theoil change indicator comes on (i.e. be-fore the periodic oil change interval hasbeen reached), the indicator must be
reset after the oil change for the nextperiodic oil change to be indicated atthe correct time. To reset the oil changeindicator before the periodic oil changeinterval has been reached, follow theabove procedure, but note that the indi-cator will come on for 1.4 seconds afterreleasing the “OIL CHANGE” button,
otherwise repeat the procedure.
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replace-ment:
2.80 L (2.96 US qt) (2.46 Imp.qt)With oil filter cartridge replacement:
2.90 L (3.07 US qt) (2.55 Imp.qt)
1. “OIL CHANGE” button
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
2
3
4
5
6
7
8
9
EAU19994
Chain drive oil
The chain drive oil should be changedas follows at the intervals specified inthe periodic maintenance and lubrica-tion chart.
1. Remove panel F. (See page 6-6.)2. Place an oil pan under the chain
drive case to collect the used oil.3. Remove the oil filler cap and drain
bolt to drain the oil from the chaindrive case.
4. Install the chain drive oil drain bolt,and then tighten it to the specifiedtorque.
5. Add the specified amount of therecommended oil.
6. Wipe the dipstick clean, insert itinto the oil filler hole (withoutscrewing it in), and then remove itto check the oil level.
NOTE:
The chain drive oil should be betweenthe minimum and maximum level
marks.
7. If the chain drive oil is below theminimum level mark, add sufficientoil of the recommended type toraise it to the correct level.
8. Insert the dipstick into the oil fillerhole, and then tighten the oil fillercap.
CAUTION:
ECA15010
�
Make sure that no foreign mate-rial enters the chain drive case.
�
Make sure that no oil gets on the
tire or wheel.
9. Check the chain drive case for oilleakage. If leakage is found, checkfor the cause.
1. Chain drive oil filler cap2. Chain drive oil drain bolt
1
2
Tightening torque:
Chain drive oil drain bolt:20 Nm (2.0 m·kgf, 14.5 ft·lbf)
Recommended chain drive oil:
See page 8-1.
Oil quantity:
0.70 L (0.74 US qt) (0.62 Imp.qt)
1. Maximum level mark2. Minimum level mark
1
2
PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
1
2
3
4
5
6
7
8
9
10. Install the panel.
EAU20070
Coolant
The coolant level should be checkedbefore each ride. In addition, the cool-ant must be changed at the intervalsspecified in the periodic maintenanceand lubrication chart.
EAU42831
To check the coolant level
1. Place the vehicle on a level sur-face and hold it in an upright posi-tion.
NOTE:
�
The coolant level must be checkedon a cold engine since the levelvaries with engine temperature.
�
Make sure that the vehicle is posi-tioned straight up when checkingthe coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level throughthe check window.
NOTE:
The coolant should be between the
minimum and maximum level marks.
3. If the coolant is at or below theminimum level mark, lift up theright floorboard mat as shown.
4. Remove the coolant reservoir cov-
1. Maximum level mark2. Minimum level mark3. Coolant level check window
1. Right floorboard mat
3
12
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
2
3
4
5
6
7
8
9
er by removing the screw.
5. Open the reservoir cap, add cool-ant to the maximum level mark,and then close the reservoir cap.
CAUTION:
ECA10471
�
If coolant is not available, usedistilled water or soft tap waterinstead. Do not use hard wateror salt water since it is harmfulto the engine.
�
If water has been used insteadof coolant, replace it with cool-ant as soon as possible, other-wise the cooling system will notbe protected against frost andcorrosion.
�
If water has been added to the
coolant, have a Yamaha dealercheck the antifreeze content ofthe coolant as soon as possible,otherwise the effectiveness of
the coolant will be reduced.
WARNING
EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
6. Install the coolant reservoir coverby installing the screw.
7. Place the right floorboard mat inthe original position.
NOTE:
�
The radiator fan is automaticallyswitched on or off according to thecoolant temperature in the radia-tor.
�
If the engine overheats, see page
6-36 for further instructions.
1. Coolant reservoir cover2. Screw
12
1. Coolant reservoir cap
Coolant reservoir capacity (up to the maximum level mark):
0.35 L (0.37 US qt) (0.31 Imp.qt)
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
1
2
3
4
5
6
7
8
9
EAU21121
Cleaning the air filter element
The air filter element should be cleanedat the intervals specified in the periodicmaintenance and lubrication chart.Clean the air filter element more fre-quently if you are riding in unusuallywet or dusty areas.
1. Remove cowling A. (Seepage 6-6.)
2. Remove the windshield by remov-ing the screws.
3. Remove the panel shown by re-moving the screws.
4. Remove the air filter case cover byremoving the screws, and then pullthe air filter element out.
5. Lightly tap the air filter element toremove most of the dust and dirt,and then blow the remaining dirtout with compressed air as shown.If the air filter element is damaged,replace it.
6. Insert the air filter element into the
1. Screw
1
1
1. Screw2. Panel
1. Air filter case cover2. Screw
1 1
2
1
2 2
1. Air filter element
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
2
3
4
5
6
7
8
9
air filter case.
CAUTION:
ECA10480
�
Make sure that the air filter ele-ment is properly seated in theair filter case.
�
The engine should never be op-erated without the air filter ele-ment installed, otherwise thepiston(s) and/or cylinder(s) may
become excessively worn.
7. Install the air filter case cover by in-stalling the screws.
8. Place the panel in the original po-sition, and then install the screws.
9. Install the windshield and the cowl-ing.
EAU33481
Adjusting the engine idling speed
The engine idling speed must bechecked and, if necessary, adjusted asfollows at the intervals specified in theperiodic maintenance and lubricationchart.The engine should be warm beforemaking this adjustment.
NOTE:
The engine is warm when it quickly re-
sponds to the throttle.
1. Remove panel B. (See page 6-6.)2. Check the engine idling speed
and, if necessary, adjust it to spec-ification by turning the idle adjust-ing screw. To increase the engineidling speed, turn the screw in di-rection (a). To decrease the en-gine idling speed, turn the screw indirection (b).
NOTE:
If the specified idling speed cannot beobtained as described above, have a
Yamaha dealer make the adjustment.
3. Install the panel.
1. Idle adjusting screw
Engine idling speed:
1100–1300 r/min
1(a)(b)
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
1
2
3
4
5
6
7
8
9
EAU21382
Checking the throttle cable free play
The throttle cable free play should mea-sure 3.0–5.0 mm (0.12–0.20 in) at thethrottle grip. Periodically check thethrottle cable free play and, if neces-sary, have a Yamaha dealer adjust it.
EAU21401
Valve clearance
The valve clearance changes with use,resulting in improper air-fuel mixtureand/or engine noise. To prevent thisfrom occurring, the valve clearancemust be adjusted by a Yamaha dealerat the intervals specified in the periodicmaintenance and lubrication chart.
EAU33600
Tires
To maximize the performance, durabil-ity, and safe operation of your vehicle,note the following points regarding thespecified tires.
Tire air pressure
The tire air pressure should be checkedand, if necessary, adjusted before eachride.
WARNING
EWA10500
�
The tire air pressure must bechecked and adjusted on coldtires (i.e., when the temperatureof the tires equals the ambienttemperature).
�
The tire air pressure must be ad-justed in accordance with theriding speed and with the totalweight of rider, passenger, car-go, and accessories approved
for this model.
1. Throttle cable free play
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
2
3
4
5
6
7
8
9
WARNING
EWA11200
Because loading has an enormousimpact on the handling, braking,performance and safety characteris-tics of your vehicle, you should keepthe following precautions in mind.
�
NEVER OVERLOAD THE VEHI-CLE! Operation of an overload-ed vehicle may result in tiredamage, loss of control, or se-vere injury. Make sure that the
total weight of rider, passenger,cargo, and accessories doesnot exceed the specified maxi-mum load for the vehicle.
�
Do not carry along looselypacked items, which can shiftduring a ride.
�
Securely pack the heaviestitems close to the center of thevehicle and distribute theweight evenly on both sides.
�
Adjust the tire air pressure withregard to the load.
�
Check the tire condition and air
pressure before each ride.
Tire inspection
The tires must be checked before eachride. If the center tread depth reachesthe specified limit, if the tire has a nail orglass fragments in it, or if the sidewall iscracked, have a Yamaha dealer re-place the tire immediately.
NOTE:
The tire tread depth limits may differfrom country to country. Always comply
with the local regulations.
Tire air pressure (measured on cold tires):
0–90 kg (0–198 lb):
Front:225 kPa (33 psi) (2.25 kgf/cm
2
)Rear:
250 kPa (36 psi) (2.50 kgf/cm
2
)
XP500 90–188 kg (198–414 lb)XP500A 90–183 kg (198–403 lb):
Front:225 kPa (33 psi) (2.25 kgf/cm
2
)Rear:
280 kPa (41 psi) (2.80 kgf/cm
2
)
Maximum load*:
XP500 188 kg (414 lb)XP500A 183 kg (403 lb)
* Total weight of rider, passenger, car-go and accessories
1. Tire sidewall2. Tire tread depth
Minimum tire tread depth (front and rear):
1.6 mm (0.06 in)
1
2
PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
1
2
3
4
5
6
7
8
9
Tire information
This model is equipped with tubelesstires.
WARNING
EWA10470
�
Have a Yamaha dealer replaceexcessively worn tires. Besidesbeing illegal, operating the vehi-cle with excessively worn tiresdecreases riding stability andcan lead to loss of control.
�
The replacement of all wheeland brake related parts, includ-ing the tires, should be left to aYamaha dealer, who has thenecessary professional knowl-
edge and experience.
EAU21960
Cast wheels
To maximize the performance, durabil-ity, and safe operation of your vehicle,note the following points regarding thespecified wheels.
�
The wheel rims should be checkedfor cracks, bends or warpage be-fore each ride. If any damage isfound, have a Yamaha dealer re-place the wheel. Do not attempteven the smallest repair to thewheel. A deformed or crackedwheel must be replaced.
�
The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced. Anunbalanced wheel can result inpoor performance, adverse han-dling characteristics, and a short-ened tire life.
�
Ride at moderate speeds afterchanging a tire since the tire sur-face must first be “broken in” for itto develop its optimal characteris-tics.
Front tire:
Size:120/70R14 M/C 55H
Manufacturer/model:DUNLOP/D252FBRIDGESTONE/TH01F
Rear tire:
Size:160/60R15 M/C 67H
Manufacturer/model:DUNLOP/D252BRIDGESTONE/TH01R
PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
2
3
4
5
6
7
8
9
EAU33453
Front and rear brake lever free play
Front
Rear
There should be no free play at thebrake lever ends. If there is free play,have a Yamaha dealer inspect the
brake system.
WARNING
EWA14211
A soft or spongy feeling in the brakelever can indicate the presence of airin the hydraulic system. If there is airin the hydraulic system, have aYamaha dealer bleed the system be-fore operating the vehicle. Air in thehydraulic system will diminish thebraking performance, which may re-sult in loss of control and an acci-
dent.
EAU33473
Adjusting the rear brake lock lever cable
Rear brake lock lever cable adjustmentmay be required if the rear brake locklever does not hold properly. When therear brake lock lever is not in use, therear brake lock lever cable lengthshould measure 45 mm to 47 mm (1.77in to 1.85 in) at the rear brake caliper.Periodically check the rear brake locklever cable length and, if necessary,adjust it as follows.To increase the rear brake lock levercable length, turn the adjusting nut atthe rear brake caliper in direction (a).
1. Adjusting nut2. Rear brake lock lever cable length
2 1
(b)
(a)
PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
1
2
3
4
5
6
7
8
9
To decrease the rear brake lock levercable length, turn the adjusting nut indirection (b).
WARNING
EWA10650
If proper adjustment cannot be ob-tained as described, have a Yamaha
dealer make this adjustment.
EAU22390
Checking the front and rear brake pads
The front and rear brake pads must bechecked for wear at the intervals spec-ified in the periodic maintenance andlubrication chart.
EAU22430
Front brake pads
Each front brake pad is provided withwear indicator grooves, which allowyou to check the brake pad wear with-out having to disassemble the brake.To check the brake pad wear, checkthe wear indicator grooves. If a brakepad has worn to the point that the wear
indicator grooves have almost disap-peared, have a Yamaha dealer replacethe brake pads as a set.
EAU22493
Rear brake pads
1. Remove the rear brake caliper byremoving the bolts.
2. Check each rear brake pad fordamage and measure the liningthickness. If a brake pad is dam-aged or if the lining thickness isless than 0.8 mm (0.03 in), have aYamaha dealer replace the brakepads as a set.
3. Install the rear brake caliper by in-
1. Brake pad wear indicator groove
11
1. Bolt2. Lining thickness
1
2
PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
2
3
4
5
6
7
8
9
stalling the bolts, then tighteningthem to the specified torque.
CAUTION:
ECA12822
Do not apply the rear brake or rearbrake lock after the brake caliperhas been removed, otherwise thebrake caliper piston will be forced
out.
EAU22710
Checking the brake fluid level
Front brake
Rear brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-ing it to become ineffective.Before riding, check that the brake fluidis above the minimum level mark andreplenish if necessary. A low brake fluidlevel may indicate worn brake padsand/or brake system leakage. If thebrake fluid level is low, be sure to checkthe brake pads for wear and the brakesystem for leakage.Observe these precautions:
�
When checking the fluid level,make sure that the top of the brakefluid reservoir is level.
�
Use only the recommended qualitybrake fluid, otherwise the rubberseals may deteriorate, causingleakage and poor braking perfor-mance.
�
Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor braking performance.
�
Be careful that water or dust doesnot enter the brake fluid reservoir
Tightening torque:
Brake caliper bolt:40 Nm (4.0 m·kgf, 28.9 ft·lbf)
1. Minimum level mark
1. Minimum level mark
1
1
Recommended brake fluid:
DOT 4
PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
1
2
3
4
5
6
7
8
9
when refilling. Water will signifi-cantly lower the boiling point of thefluid and may result in vapor lock,and dirt may clog the ABS hydrau-lic unit valves.
�
Brake fluid may deteriorate paint-ed surfaces or plastic parts. Al-ways clean up spilled fluidimmediately.
�
As the brake pads wear, it is nor-mal for the brake fluid level to grad-ually go down. However, if thebrake fluid level goes down sud-denly, have a Yamaha dealercheck the cause.
EAU22730
Changing the brake fluid
Have a Yamaha dealer change thebrake fluid at the intervals specified inthe NOTE after the periodic mainte-nance and lubrication chart. In addition,have the oil seals of the master cylin-ders and calipers as well as the brakehoses replaced at the intervals listedbelow or whenever they are damagedor leaking.
�
Oil seals: Replace every twoyears.
�
Brake hoses: Replace every fouryears.
EAU23111
Checking and lubricating the throttle grip and cable
The operation of the throttle grip shouldbe checked before each ride. In addi-tion, the cable should be lubricated atthe intervals specified in the periodicmaintenance chart.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
2
3
4
5
6
7
8
9
EAU23171
Lubricating the front and rear brake levers
Front brake lever
Rear brake lever
The pivoting points of the front and rearbrake levers must be lubricated at theintervals specified in the periodic main-
tenance and lubrication chart.
EAU23211
Checking and lubricating the centerstand and sidestand
The operation of the centerstand andsidestand should be checked beforeeach ride, and the pivots and met-al-to-metal contact surfaces should belubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-pur-pose grease)
PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
1
2
3
4
5
6
7
8
9
WARNING
EWA10740
If the centerstand or sidestand doesnot move up and down smoothly,have a Yamaha dealer check or re-
pair it.
EAU23271
Checking the front fork
The condition and operation of the frontfork must be checked as follows at theintervals specified in the periodic main-tenance and lubrication chart.
To check the condition
WARNING
EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
Check the inner tubes for scratches,damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-face and hold it in an upright posi-tion.
2. While applying the front brake,push down hard on the handlebarsseveral times to check if the frontfork compresses and reboundssmoothly.
CAUTION:
ECA10590
If any damage is found or the frontfork does not operate smoothly,have a Yamaha dealer check or re-
pair it.
Recommended lubricant:
Lithium-soap-based grease (all-pur-pose grease)
PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
2
3
4
5
6
7
8
9
EAU23280
Checking the steering
Worn or loose steering bearings maycause danger. Therefore, the operationof the steering must be checked as fol-lows at the intervals specified in the pe-riodic maintenance and lubricationchart.
1. Place a stand under the engine toraise the front wheel off theground.
WARNING
EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the frontfork legs and try to move them for-ward and backward. If any freeplay can be felt, have a Yamahadealer check or repair the steering.
EAU23290
Checking the wheel bearings
The front and rear wheel bearings mustbe checked at the intervals specified inthe periodic maintenance and lubrica-tion chart. If there is play in the wheelhub or if the wheel does not turnsmoothly, have a Yamaha dealer checkthe wheel bearings.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
1
2
3
4
5
6
7
8
9
EAU23411
Battery
This model is equipped with asealed-type (MF) battery, which doesnot require any maintenance. There isno need to check the electrolyte or toadd distilled water.
To access the battery
1. Open the seat. (See page 3-14.)2. Remove the battery cover by re-
moving the screws.
To charge the battery
Have a Yamaha dealer charge the bat-tery as soon as possible if it seems tohave discharged. Keep in mind that thebattery tends to discharge more quicklyif the vehicle is equipped with optionalelectrical accessories.
WARNING
EWA10760
�
Electrolyte is poisonous anddangerous since it contains sul-furic acid, which causes severeburns. Avoid any contact withskin, eyes or clothing and al-ways shield your eyes whenworking near batteries. In caseof contact, administer the fol-
lowing FIRST AID.
�
EXTERNAL: Flush with plentyof water.
�
INTERNAL: Drink large quan-tities of water or milk and im-mediately call a physician.
�
EYES: Flush with water for 15minutes and seek promptmedical attention.
�
Batteries produce explosive hy-drogen gas. Therefore, keepsparks, flames, cigarettes, etc.,away from the battery and pro-vide sufficient ventilation whencharging it in an enclosedspace.
�
KEEP THIS AND ALL BATTER-IES OUT OF THE REACH OF
CHILDREN.
To store the battery
1. If the vehicle will not be used formore than one month, remove thebattery, fully charge it, and thenplace it in a cool, dry place.
2. If the battery will be stored for morethan two months, check it at leastonce a month and fully charge it if
1. Screw2. Battery cover
1
2
1. Battery
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
2
3
4
5
6
7
8
9
necessary.3. Fully charge the battery before in-
stallation.4. After installation, make sure that
the battery leads are properly con-nected to the battery terminals.
CAUTION:
ECA10630
�
Always keep the batterycharged. Storing a dischargedbattery can cause permanentbattery damage.
�
To charge a sealed-type (MF)battery, a special (constant-volt-age) battery charger is required.Using a conventional batterycharger will damage the battery.If you do not have access to asealed-type (MF) battery charg-er, have a Yamaha dealer
charge your battery.
EAU36543
Replacing the fuses
The main fuse box is located beside thebattery and can be accessed as fol-lows:
1. Open the seat. (See page 3-14.)2. Remove the battery cover. (See
page 6-29.)3. Disconnect the negative battery
lead, and then lift the battery asshown.
For non-ABS models
For ABS models
The fuse box, which contains the fusesfor the individual circuits, is located un-der the battery cover and can be ac-cessed as follows.
1. Open the seat. (See page 3-14.)2. Remove the battery cover.
If a fuse is blown, replace it as follows.1. Turn the key to “OFF” and turn off
the electrical circuit in question.2. Remove the blown fuse, and then
install a new fuse of the specified
1. Negative battery lead2. Fuse box3. Battery4. Parking lighting fuse
1
2
4
3
1. Negative battery lead2. Fuse box 3. Battery 4. ABS motor fuse (for ABS models)5. ABS control unit fuse (for ABS models)6. Parking lighting fuse7. Spare fuse
1
32
4
7
6
5
PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
1
2
3
4
5
6
7
8
9
amperage.
NOTE:
To access the main fuse, remove the
main fuse box cover as shown.
For non-ABS models For ABS models
1. Main fuse2. Spare main fuse3. Main fuse box cover
2
1
3
1. Signaling system fuse2. Headlight fuse3. Ignition fuse4. Radiator fan fuse5. Fuel injection system fuse6. Backup fuse (for odometer and clock)7. Spare fuse
7
123456
1. Signaling system fuse2. Headlight fuse3. Ignition fuse4. Radiator fan fuse5. Fuel injection system fuse6. Backup fuse (for odometer and clock)7. Spare fuse
7
123456
PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
2
3
4
5
6
7
8
9
CAUTION:
ECA10640
Do not use a fuse of a higher amper-age rating than recommended toavoid causing extensive damage tothe electrical system and possibly a
fire.
3. Turn the key to “ON” and turn on
the electrical circuit in question tocheck if the device operates.
4. If the fuse immediately blowsagain, have a Yamaha dealercheck the electrical system.
EAU23760
Replacing the headlight bulb
This model is equipped with a quartzbulb headlight. If the headlight bulbburns out, replace it as follows.
1. Disconnect the headlight coupler,and then remove the bulb cover.
2. Unhook the headlight bulb holder,and then remove the defectivebulb.
Specified fuses:
Main fuse: 30.0 A
Headlight fuse: 15.0 A
Signaling system fuse: XP500 20.0 AXP500A 15.0 A
Ignition fuse: 10.0 A
Parking lighting fuse: 10.0 A
Radiator fan fuse: 15.0 A
Fuel injection system fuse: 10.0 A
ABS control unit fuse: XP500A 5.0 A
ABS motor fuse: XP500A 30.0 A
Backup fuse: 10.0 A
1. Headlight coupler2. Headlight bulb cover
12
PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
1
2
3
4
5
6
7
8
9
WARNING
EWA10790
Headlight bulbs get very hot. There-fore, keep flammable products awayfrom a lit headlight bulb, and do nottouch the bulb until it has cooled
down.
3. Place a new headlight bulb into po-sition, and then secure it with thebulb holder.
CAUTION:
ECA10660
Do not touch the glass part of theheadlight bulb to keep it free fromoil, otherwise the transparency ofthe glass, the luminosity of the bulb,
and the bulb life will be adversely af-fected. Thoroughly clean off any dirtand fingerprints on the headlightbulb using a cloth moistened with al-
cohol or thinner.
4. Install the headlight bulb cover,and then connect the coupler.
5. Have a Yamaha dealer adjust theheadlight beam if necessary.
EAU43040
Tail/brake light
If the tail/brake light does not come on,have a Yamaha dealer check its electri-cal circuit or replace the bulb.
1. Headlight bulb holder2. Unhook.
1
2
1. Do not touch the glass part of the bulb.
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
2
3
4
5
6
7
8
9
EAU43050
Replacing a front turn signal light bulb
1. Place the scooter on the center-stand.
2. Remove the socket (together withthe bulb) by turning it counter-clockwise.
3. Remove the defective bulb by pull-ing it out.
4. Insert a new bulb into the socket.5. Install the socket (together with the
bulb) by turning it clockwise.
EAU24270
Replacing a rear turn signal light bulb
1. Place the scooter on the center-stand.
2. Remove cowling C. (Seepage 6-6.)
3. Remove the socket (together withthe turn signal light bulb) by turningit counterclockwise.
4. Remove the defective bulb bypushing it in and turning it counter-clockwise.
5. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.
6. Install the socket (together with the
bulb) by turning it clockwise.7. Install the cowling.
1. Turn signal light bulb socket
1
1. Turn signal light bulb socket
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
1
2
3
4
5
6
7
8
9
EAU24330
License plate light
If the license plate light does not comeon, have a Yamaha dealer check theelectrical circuit or replace the bulb.
EAU43230
Replacing an auxiliary light bulb
This model is equipped with two auxil-iary lights. If an auxiliary light bulb burnsout, replace it as follows.
1. Remove the socket (together withthe bulb) by pulling it out.
2. Remove the defective bulb by pull-ing it out.
3. Insert a new bulb into the socket.4. Install the socket (together with the
bulb) by pushing it in.
EAU25880
Troubleshooting
Although Yamaha scooters receive athorough inspection before shipmentfrom the factory, trouble may occur dur-ing operation. Any problem in the fuel,compression, or ignition systems, forexample, can cause poor starting andloss of power.The following troubleshooting chartsrepresent quick and easy proceduresfor checking these vital systems your-self. However, should your scooter re-quire any repair, take it to a Yamahadealer, whose skilled technicians havethe necessary tools, experience, andknow-how to service the scooter prop-erly.Use only genuine Yamaha replace-ment parts. Imitation parts may look likeYamaha parts, but they are often inferi-or, have a shorter service life and canlead to expensive repair bills.
1. Auxiliary light bulb socket
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
2
3
4
5
6
7
8
9
EAU42500
Troubleshooting charts
Starting problems or poor engine performance
WARNING
EWA10840
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level inthe fuel tank.
1. FuelThere is enough fuel.
There is no fuel.
Check the compression.
Supply fuel. The engine does not start. Check the compression.
Operate the electric starter.
2. CompressionThere is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealercheck the vehicle.
Remove the spark plugsand check the electrodes.
3. Ignition Wipe off with a dry cloth and correct thespark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.Have a Yamaha dealercheck the vehicle.
The engine does not start.Check the battery.
Operate the electric starter.
4. BatteryThe engine turns over quickly.
The engine turns over slowly.
The battery is good.
Check the battery lead connections,and charge the battery if necessary.
Dry
Wet Operate the electric starter.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
1
2
3
4
5
6
7
8
9
Engine overheating
WARNING
EWAT1040
�
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may beblown 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-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.
NOTE:
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.
Wait until the engine has cooled.
Check the coolant level in the reservoir and radiator.
The coolant level is OK.
The coolant level is low.Check the cooling systemfor leakage.
Have a Yamaha dealer checkand repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a Yamaha dealer check and repair the cooling system.
There isleakage.
There is no leakage.
7-1
2
3
4
5
6
7
8
9
SCOOTER CARE AND STORAGE
EAU37833
Matte color caution
CAUTION:
ECA15192
Some models are equipped withmatte colored finished parts. Besure to consult a Yamaha dealer foradvice on what products to use be-fore cleaning the vehicle. Using abrush, harsh chemical products orcleaning compounds when cleaningthese parts will scratch or damagetheir surface. Wax also should notbe applied to any matte colored fin-
ished parts.
EAU26100
Care
While the open design of a scooter re-veals the attractiveness of the technol-ogy, it also makes it more vulnerable.Rust and corrosion can develop even ifhigh-quality components are used. Arusty exhaust pipe may go unnoticedon a car, however, it detracts from theoverall appearance of a scooter. Fre-quent and proper care does not onlycomply with the terms of the warranty,but it will also keep your scooter lookinggood, extend its life and optimize itsperformance.
Before cleaning
1. Cover the muffler outlet with aplastic bag after the engine hascooled down.
2. Make sure that all caps and coversas well as all electrical couplersand connectors, including thespark plug cap, are tightly in-stalled.
3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply such prod-
ucts onto seals, gaskets and wheelaxles. Always rinse the dirt and de-greaser off with water.
Cleaning
CAUTION:
ECA10780
�
Avoid using strong acidic wheelcleaners, especially on spokedwheels. If such products areused on hard-to-remove dirt, donot leave the cleaner on the af-fected area any longer than in-structed. Also, thoroughly rinsethe area off with water, immedi-ately dry it, and then apply a cor-rosion protection spray.
�
Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Use onlya soft, clean cloth or spongewith mild detergent and water toclean plastic.
�
Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abrasivecleaning products, solvent or
SCOOTER CARE AND STORAGE
7-2
1
2
3
4
5
6
7
8
9
thinner, fuel (gasoline), rust re-movers or inhibitors, brake flu-id, antifreeze or electrolyte.
�
Do not use high-pressure wash-ers or steam-jet cleaners sincethey cause water seepage anddeterioration in the following ar-eas: seals (of wheel and swing-arm bearings, fork and brakes),electric components (couplers,connectors, instruments,switches and lights), breatherhoses and vents.
�
For scooters equipped with awindshield: Do not use strongcleaners or hard sponges asthey will cause dulling orscratching. Some cleaning com-pounds for plastic may leavescratches on the windshield.Test the product on a small hid-den part of the windshield tomake sure that it does not leaveany marks. If the windshield isscratched, use a quality plasticpolishing compound after
washing.
After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottlebrushfor hard-to-reach areas. Stubborn dirtand insects will come off more easily ifthe area is covered with a wet cloth fora few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roadsduring winter are extremely corrosive incombination with water, carry out thefollowing steps after each ride in therain, near the sea or on salt-sprayedroads.
NOTE:
Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the scooter with cold waterand a mild detergent after the en-gine has cooled down.
CAUTION:
ECA10790
Do not use warm water since it in-creases the corrosive action of the
salt.
2. Apply a corrosion protection sprayon all metal, including chrome- andnickel-plated, surfaces to preventcorrosion.
After cleaning
1. Dry the scooter with a chamois oran absorbing cloth.
2. Use a chrome polish to shinechrome, aluminum and stain-less-steel parts, including the ex-haust system. (Even the thermallyinduced discoloring of stain-less-steel exhaust systems can beremoved through polishing.)
3. To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all metal,including chrome- and nickel-plat-ed, surfaces.
4. Use spray oil as a universal clean-er to remove any remaining dirt.
5. Touch up minor paint damagecaused by stones, etc.
6. Wax all painted surfaces.7. Let the scooter dry completely be-
fore storing or covering it.
SCOOTER CARE AND STORAGE
7-3
2
3
4
5
6
7
8
9
WARNING
EWA10940
�
Make sure that there is no oil orwax on the brakes or tires. Ifnecessary, clean the brakediscs and brake linings with aregular brake disc cleaner or ac-etone, and wash the tires withwarm water and a mild deter-gent.
�
Before operating the scootertest its braking performance
and cornering behavior.
CAUTION:
ECA10800
�
Apply spray oil and wax spar-ingly and make sure to wipe offany excess.
�
Never apply oil or wax to anyrubber and plastic parts, buttreat them with a suitable careproduct.
�
Avoid using abrasive polishingcompounds as they will wear
away the paint.
NOTE:
Consult a Yamaha dealer for advice on
what products to use.
EAU36550
Storage
Short-term
Always store your scooter in a cool, dryplace and, if necessary, protect itagainst dust with a porous cover.
CAUTION:
ECA10820
�
Storing the scooter in a poorlyventilated room or covering itwith a tarp, while it is still wet,will allow water and humidity toseep in and cause rust.
�
To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi-
cals are stored.
Long-term
Before storing your scooter for severalmonths:
1. Follow all the instructions in the“Care” section of this chapter.
2. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and the
SCOOTER CARE AND STORAGE
7-4
1
2
3
4
5
6
7
8
9
fuel from deteriorating.3. Perform the following steps to pro-
tect the cylinders, piston rings, etc.from corrosion.a. Remove the spark plug caps
and the spark plugs.b. Pour a teaspoonful of engine oil
into the spark plug bores.c. Install the spark plug caps onto
the spark plugs, and then placethe spark plugs on the cylinderhead so that the electrodes aregrounded. (This will limit spark-ing during the next step.)
d. Turn the engine over severaltimes with the starter. (This willcoat the cylinder walls with oil.)
e. Remove the spark plug capsfrom the spark plugs, and theninstall the spark plugs and thespark plug caps.
WARNING
EWA10950
To prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turning
the engine over.
4. Lubricate all control cables and the
pivoting points of all levers andpedals as well as of the sidestand/centerstand.
5. Check and, if necessary, correctthe tire air pressure, and then liftthe scooter so that both of itswheels are off the ground. Alterna-tively, turn the wheels a little everymonth in order to prevent the tiresfrom becoming degraded in onespot.
6. Cover the muffler outlet with aplastic bag to prevent moisturefrom entering it.
7. Remove the battery and fullycharge it. Store it in a cool, dryplace and charge it once a month.Do not store the battery in an ex-cessively cold or warm place [lessthan 0 °C (30 °F) or more than 30°C (90 °F)]. For more informationon storing the battery, see page6-29.
NOTE:
Make any necessary repairs before
storing the scooter.
8-1
2
3
4
5
6
7
8
9
SPECIFICATIONS
EAU2633J
Dimensions:
Overall length: 2235 mm (88.0 in)
Overall width: 775 mm (30.5 in)
Overall height: 1410 mm (55.5 in)
Seat height: 795 mm (31.3 in)
Wheelbase: 1575 mm (62.0 in)
Ground clearance: 130 mm (5.12 in)
Minimum turning radius: 2800 mm (110.2 in)
Weight:
With oil and fuel: XP500 227.0 kg (500 lb)XP500A 232.0 kg (511 lb)
Engine:
Engine type: Liquid cooled 4-stroke, DOHC
Cylinder arrangement: Forward-inclined parallel 2-cylinder
Displacement: 499.0 cm
3
Bore
×
stroke: 66.0
×
73.0 mm (2.60
×
2.87 in)Compression ratio:
11.00 :1
Starting system: Electric starter
Lubrication system: Dry sump
Engine oil:
Type: SAE10W30 or SAE10W40
Recommended engine oil grade: API service SG type or higher, JASO stan-dard MA
Engine oil quantity:
Without oil filter cartridge replacement: 2.80 L (2.96 US qt) (2.46 Imp.qt)
With oil filter cartridge replacement: 2.90 L (3.07 US qt) (2.55 Imp.qt)
Chain drive oil:
Type: SAE80 API GL-4 Hypoid gear oil
Quantity: 0.70 L (0.74 US qt) (0.62 Imp.qt)
Cooling system:
Coolant reservoir capacity (up to the maxi-mum level mark):
0.35 L (0.37 US qt) (0.31 Imp.qt)Radiator capacity (including all routes):
1.50 L (1.59 US qt) (1.32 Imp.qt)
Air filter:
Air filter element: Dry element
Fuel:
Recommended fuel: Regular unleaded gasoline only
Fuel tank capacity: 14.0 L (3.70 US gal) (3.08 Imp.gal)
Fuel injector:
Manufacturer: AISAN
Model/quantity: 1100-87B60/1100-87B70
Spark plug (s):
Manufacturer/model: NGK/CR7E
Spark plug gap: 0.7–0.8 mm (0.028–0.031 in)
Clutch:
Clutch type: Wet, multiple-disc automatic
Transmission:
Primary reduction system: Spur gear/helical gear
Primary reduction ratio: 52/32
×
36/22 (2.659)Secondary reduction system:
Chain driveSecondary reduction ratio:
41/25
×
40/29 (2.262)Transmission type:
V-belt automaticOperation:
Centrifugal automatic type
Chassis:
Frame type: Diamond
Caster angle: 28.00 °
SPECIFICATIONS
8-2
1
2
3
4
5
6
7
8
9
Trail: 95.0 mm (3.74 in)
Front tire:
Type: Tubeless
Size: 120/70R14 M/C 55H
Manufacturer/model: DUNLOP/D252F
Manufacturer/model: BRIDGESTONE/TH01F
Rear tire:
Type: Tubeless
Size: 160/60R15 M/C 67H
Manufacturer/model: DUNLOP/D252
Manufacturer/model: BRIDGESTONE/TH01R
Loading:
Maximum load: XP500 188 kg (414 lb)XP500A 183 kg (403 lb)
* (Total weight of rider, passenger, cargo and accessories)
Tire air pressure (measured on coldtires):
Loading condition: 0–90 kg (0–198 lb)
Front: 225 kPa (33 psi) (2.25 kgf/cm
2
)
Rear: 250 kPa (36 psi) (2.50 kgf/cm
2
)Loading condition:
XP500 90–188 kg (198–414 lb)XP500A 90–183 kg (198–403 lb)
Front: 225 kPa (33 psi) (2.25 kgf/cm
2
)Rear:
280 kPa (41 psi) (2.80 kgf/cm
2
)
Front wheel:
Wheel type: Cast wheel
Rim size: 14M/C x MT3.50
Rear wheel:
Wheel type: Cast wheel
Rim size: 15M/C x MT5.00
Front brake:
Type: Dual disc brake
Operation: Right hand operation
Recommended fluid: DOT 4
Rear brake:
Type: Single disc brake
Operation: Left hand operation
Recommended fluid: DOT 4
Front suspension:
Type: Telescopic fork
Spring/shock absorber type: Coil spring/oil damper
Wheel travel: 120.0 mm (4.72 in)
Rear suspension:
Type: Swingarm
Spring/shock absorber type: Coil spring/gas-oil damper
Wheel travel: 117.0 mm (4.61 in)
Electrical system:
Ignition system: Transistorized coil ignition (digital)
Charging system: AC magneto
Battery:
Model: GT9B-4
Voltage, capacity: 12 V, 8.0 Ah
Headlight:
Bulb type: Halogen bulb
Bulb voltage, wattage
×
quantity:
Headlight: 12 V, 60 W/55.0 W
×
1Headlight:
12 V, 55.0 W
×
1
SPECIFICATIONS
8-3
2
3
4
5
6
7
8
9
Tail/brake light: 12 V, 5.0 W/21.0 W
×
2Front turn signal/position light:
12 V, 21 W/5.0 W
×
2Rear turn signal light:
12 V, 21.0 W
×
2Auxiliary light:
12 V, 5.0 W
×
2License plate light:
12 V, 5.0 W
×
1Meter lighting:
14 V, 2.0 W
×
3High beam indicator light:
14 V, 1.4 W
×
1Turn signal indicator light:
14 V, 1.4 W
×
2Engine trouble warning light:
14 V, 1.4 W
×
1ABS warning light:
XP500A 14 V, 1.4 W
×
1Immobilizer system indicator light:
LED
Fuses:
Main fuse: 30.0 A
Headlight fuse: 15.0 A
Signaling system fuse: XP500 20.0 AXP500A 15.0 A
Ignition fuse: 10.0 A
Parking lighting fuse: 10.0 A
Radiator fan fuse: 15.0 A
Fuel injection system fuse: 10.0 A
ABS control unit fuse: XP500A 5.0 A
ABS motor fuse: XP500A 30.0 A
Backup fuse: 10.0 A
9-1
1
2
3
4
5
6
7
8
9
CONSUMER INFORMATION
EAU26351
Identification numbers
Record the key identification number,vehicle identification number and mod-el label information in the spaces pro-vided below for assistance whenordering spare parts from a Yamahadealer or for reference in case the vehi-cle is stolen.KEY IDENTIFICATION NUMBER:
VEHICLE IDENTIFICATION NUMBER:
MODEL LABEL INFORMATION:
EAU26381
Key identification number
The key identification number isstamped into the key tag. Record thisnumber in the space provided and useit for reference when ordering a newkey.
EAU26410
Vehicle identification number
The vehicle identification number isstamped into the frame.
NOTE:
The vehicle identification number isused to identify your vehicle and maybe used to register it with the licensing
authority in your area.
1. Key identification number2. Code re-registering key (red bow)3. Standard keys (black bow)
1. Vehicle identification number
1
CONSUMER INFORMATION
9-2
2
3
4
5
6
7
8
9
EAU26500
Model label
The model label is affixed to the insideof the rear storage compartment. (Seepage 3-16.) Record the information onthis label in the space provided. This in-formation will be needed when orderingspare parts from a Yamaha dealer.
1. Model label
1
INDEX
A
ABS (for ABS models) ............................ 3-11ABS warning light (for ABS models) ......... 3-3Acceleration and deceleration................... 5-2Air filter element, cleaning....................... 6-17Anti-theft alarm (optional).......................... 3-8Auxiliary light bulb, replacing .................. 6-35
B
Battery..................................................... 6-29Brake fluid, changing .............................. 6-25Brake fluid level, checking ...................... 6-24Brake lever, front..................................... 3-10Brake lever, rear ..................................... 3-10Brake levers, lubricating.......................... 6-26Braking...................................................... 5-3
C
Care .......................................................... 7-1Catalytic converter .................................. 3-14Centerstand and sidestand, checking and
lubricating ............................................. 6-26Chain drive oil ......................................... 6-14Coolant.................................................... 6-15Cowlings and panels, removing and
installing.................................................. 6-6
D
Dimmer switch .......................................... 3-9
E
Engine break-in......................................... 5-4Engine idling speed................................. 6-18Engine oil and oil filter cartridge.............. 6-11Engine stop switch .................................... 3-9Engine trouble warning light...................... 3-3
F
Front and rear brake lever free play........ 6-22
Front and rear brake pads, checking.......6-23Front fork, checking .................................6-27Fuel..........................................................3-13Fuel consumption, tips for reducing...........5-4Fuel tank cap ...........................................3-12Fuses, replacing ......................................6-30
H
Handlebar switches ...................................3-9Hazard switch ..........................................3-10Headlight bulb, replacing .........................6-32Helmet holder ..........................................3-15High beam indicator light ...........................3-3Horn switch................................................3-9
I
Identification numbers................................9-1Ignition circuit cut-off system ...................3-18Immobilizer system....................................3-1Immobilizer system indicator light..............3-4Indicator and warning lights .......................3-3
K
Key identification number ..........................9-1
L
License plate light ....................................6-35
M
Main switch/steering lock...........................3-2Matte color, caution ...................................7-1Model label ................................................9-2Multi-function display .................................3-5
P
Parking.......................................................5-5Part locations.............................................2-1Pass switch................................................3-9Periodic maintenance and lubrication
chart ........................................................6-3
Pre-operation check list .............................4-2
R
Rear brake lock lever ..............................3-11Rear brake lock lever cable, adjusting ....6-22Rider backrest, adjusting.........................3-15
S
Safe-riding points ......................................1-4Safety information .....................................1-1Seat .........................................................3-14Shock absorber .......................................3-17Sidestand ................................................3-18Spark plugs, checking ...............................6-9Specifications ............................................8-1Speedometer.............................................3-4Starting off .................................................5-2Starting the engine ....................................5-1Start switch................................................3-9Steering, checking...................................6-28Storage......................................................7-3Storage compartments ............................3-16
T
Tachometer ...............................................3-5Tail/brake light .........................................6-33Throttle cable free play, checking............6-19Throttle grip and cable, checking and
lubricating..............................................6-25Tires ........................................................6-19Tool kit .......................................................6-1Troubleshooting.......................................6-35Troubleshooting charts............................6-36Turn signal indicator lights.........................3-3Turn signal light bulb (front), replacing ....6-34Turn signal light bulb (rear), replacing.....6-34Turn signal switch......................................3-9
INDEX
V
Valve clearance .......................................6-19Vehicle identification number.....................9-1
W
Wheel bearings, checking .......................6-28Wheels.....................................................6-21
PRINTED ON RECYCLED PAPERYAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN2006.10–0.2×1 !
(E)
PRINTED ON RECYCLED PAPERYAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN2006.10–0.2×1 !
(E)
Top Related