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Yamaha XP500 2001 Service Manual

Yamaha XP500 2001
395 pages
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Table of Contents

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Yamaha XP500 2001 Specifications

General IconGeneral
Displacement499 cc
Fuel SystemFuel injection
Ignition SystemTCI
Front SuspensionTelescopic fork
Rear SuspensionSwingarm
Front BrakeSingle disc
Rear BrakeSingle disc
Front Tire120/70-14
Rear Tire150/70-13
Wheelbase1, 590 mm
Bore x Stroke66.0 mm x 73.0 mm
TransmissionAutomatic

Summary

CHAPTER 1 GENERAL INFORMATION

IMPORTANT INFORMATION

Provides crucial guidelines for maintenance, parts, and safety procedures.

CHAPTER 2 SPECIFICATIONS

GENERAL SPECIFICATIONS

Lists overall dimensions, weight, and load capacity of the scooter.

ENGINE SPECIFICATIONS

Details engine type, displacement, bore, stroke, compression, and fluid capacities.

CHASSIS SPECIFICATIONS

Covers frame, wheel, tire, and brake system specifications.

CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

Outlines recommended service schedule based on odometer readings and time.

ENGINE CHECKS AND ADJUSTMENTS

Covers valve clearance, carburetor sync, idling speed, and oil level checks.

CHAPTER 4 CHASSIS

FRONT WHEEL AND BRAKE DISC

Details removal, disassembly, checking, assembly, and balancing of the front wheel assembly.

FRONT AND REAR BRAKES

Explains brake pad replacement, master cylinder checks, and caliper service procedures.

CHAPTER 5 OVERHAULING THE ENGINE

CAMSHAFTS

Covers removal, checking, and installation of camshafts, sprockets, and timing chain.

CYLINDER HEAD

Details removal, checking, and installation of the cylinder head assembly.

CRANKCASE AND CRANKSHAFT

Explains assembly and disassembly of crankcase, crankshaft, connecting rods, and bearings.

CHAPTER 6 COOLING SYSTEM

RADIATOR

Covers radiator and oil cooler removal, checking, and installation procedures.

THERMOSTAT

Explains thermostat checking and installation procedures.

WATER PUMP

Details water pump removal, disassembly, checking, and assembly.

CHAPTER 7 CARBURETORS

CARBURETORS

Covers carburetor removal, disassembly, checking, assembly, and installation.

AIR INDUCTION SYSTEM

Explains the air induction system, air cutoff valve, and diagrams.

CHAPTER 8 ELECTRICAL

IGNITION SYSTEM

Details ignition system circuit diagram, troubleshooting, and component checks.

ELECTRIC STARTING SYSTEM

Covers starting system circuit diagram, operation, troubleshooting, and starter motor service.

LIGHTING SYSTEM

Covers lighting system circuit diagram and troubleshooting for various lights.

SIGNAL SYSTEM

Details signal system circuit diagram and troubleshooting for horn, turn signals, and lights.

CHAPTER 9 TROUBLESHOOTING

STARTING FAILURE/HARD STARTING

Lists potential causes for engine starting issues across various systems.

FAULTY BRAKING PERFORMANCE

Details issues related to disc brakes, hydraulic systems, and brake fluid.

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