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Adjusting the headlight beam




 

8. Install:


 

CHK

ADJ


 

headlight bulb holder cover

 

6) Connect:

 

headlight coupler 10.Install:

front cowling

 

Refer to “FRONT COWLING”.

 

 

EAS00184

ADJUSTING THE HEADLIGHT BEAM

 

• Adjust:

 

headlight beam (vertically)

 

▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼

 

• Turn the adjusting screws 1 in direction a or b.

 

Directiona Headlight beam is  
raised.  
   
     
Directionb Headlight beam is  
lowered.  
   
     

 

▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲

 

 

8. Adjust:

 

headlight beam (horizontally)

▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼

 

7. Turn the adjusting screws 2 in direction c or d.

 

Directionc Headlight beam moves  
to the right.  
   
     
Directiond Headlight beam moves  
to the left.  
   
     

 

▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲


 

 

3 - 71


 


CHAS 4


  CHAS
     
CHAPTER 4  
CHASSIS  
FRONT WHEEL AND BRAKE DISC............................................................... 4-1
REMOVING THE FRONT WHEEL (XP500)............................................. 4-6
REMOVING THE FRONT WHEEL AND FRONT WHEEL SENSOR  
(XP500A).................................................................................................. 4-6
CHECKING THE FRONT WHEEL............................................................ 4-8
CHECKING THE BRAKE DISC................................................................. 4-9
CHECKING THE FRONT WHEEL SENSOR AND SENSOR ROTOR  
(XP500A)................................................................................................ 4-11
ADJUSTING THE FRONT WHEEL STATIC BALANCE......................... 4-11
INSTALLING THE FRONT WHEEL (XP500).......................................... 4-13
INSTALLING THE FRONT WHEEL AND FRONT WHEEL SENSOR  
(XP500A)................................................................................................ 4-14
REAR WHEEL AND BRAKE DISC............................................................... 4-16
REMOVING THE REAR WHEEL (XP500).............................................. 4-20
REMOVING THE REAR WHEEL AND REAR WHEEL SENSOR  
(XP500A)................................................................................................ 4-20
CHECKING THE REAR WHEEL SENSOR AND SENSOR ROTOR  
(XP500A)................................................................................................ 4-21
CHECKING THE REAR WHEEL............................................................. 4-21
CHECKING THE REAR WHEEL DRIVE HUB........................................ 4-21
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-22
INSTALLING THE REAR WHEEL SENSOR (XP500A).......................... 4-22


  CHAS
     
FRONT AND REAR BRAKES....................................................................... 4-24
FRONT BRAKE PADS............................................................................ 4-24
REAR BRAKE PADS............................................................................... 4-25
REPLACING THE FRONT BRAKE PADS.............................................. 4-26
REPLACING THE REAR BRAKE PADS................................................. 4-28
FRONT BRAKE MASTER CYLINDER.................................................... 4-32
REAR BRAKE MASTER CYLINDER...................................................... 4-35
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER............. 4-38
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER................ 4-38
CHECKING THE FRONT AND REAR BRAKE MASTER  
CYLINDERS........................................................................................... 4-39
ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER  
CYLINDER............................................................................................. 4-40
ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER  
CYLINDER............................................................................................. 4-42
FRONT BRAKE CALIPER....................................................................... 4-45
REAR BRAKE CALIPER......................................................................... 4-48
DISASSEMBLING THE FRONT BRAKE CALIPER................................ 4-51
DISASSEMBLING THE REAR BRAKE CALIPER.................................. 4-51
CHECKING THE FRONT AND REAR BRAKE CALIPER....................... 4-52
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER....... 4-54
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER.......... 4-56
ECU (ABS) AND FAIL-SAFE RELAY (XP500A)..................................... 4-60
HYDRAULIC UNIT (XP500A).................................................................. 4-61
REMOVING THE HYDRAULIC UNIT...................................................... 4-64
CHECKING THE HYDRAULIC UNIT...................................................... 4-64
INSTALLING THE HYDRAULIC UNIT.................................................... 4-65
HANDLEBAR................................................................................................ 4-67
REMOVING THE HANDLEBAR.............................................................. 4-69
CHECKING THE HANDLEBAR.............................................................. 4-69
INSTALLING THE HANDLEBAR............................................................ 4-69
FRONT FORK................................................................................................ 4-73
REMOVING THE FRONT FORK LEGS.................................................. 4-77
DISASSEMBLING THE FRONT FORK LEGS........................................ 4-77
CHECKING THE FRONT FORK LEGS.................................................. 4-79
ASSEMBLING THE FRONT FORK LEGS.............................................. 4-80
INSTALLING THE FRONT FORK LEGS................................................ 4-83
STEERING HEAD.......................................................................................... 4-84
LOWER BRACKET................................................................................. 4-84
REMOVING THE LOWER BRACKET..................................................... 4-86
CHECKING THE STEERING HEAD....................................................... 4-86
INSTALLING THE STEERING HEAD..................................................... 4-87


CHAS

 

REAR SHOCK ABSORBER......................................................................... 4-89
HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER.... 4-90
DISPOSING OF A REAR SHOCK ABSORBER  
AND GAS CYLINDER............................................................................ 4-90
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................... 4-91
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY  
AND GAS CYLINDER............................................................................ 4-91
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY................. 4-92
ANTI-LOCK BRAKE SYSTEM (XP500A)..................................................... 4-93
ABS COMPONENTS............................................................................... 4-93
CIRCUIT DIAGRAM................................................................................ 4-95
CAUTIONS FOR OPERATION............................................................... 4-97
TROUBLESHOOTING............................................................................ 4-98

CHAS


FRONT WHEEL AND BRAKE DISC CHAS

 

CHASSIS

 

FRONT WHEEL AND BRAKE DISC

 

 

T. 40 Nm (4.0 m kg, 29 ft Ib)         40 Nm (4.0 m   kg, 29 ft   Ib)
R.            
                            T.
  59 Nm (5.9 m kg, 43 ft Ib)     R.    
T.                
R.                      
                                       
                                       
    23 Nm (2.3 m kg, 17 ft Ib)              
  T.              
  R.                  
    (6)                                  
LT                                    
                                       
                                     
                              LTLT        
                              (6)      
                                     
                                     
                        18 Nm (1.8 m•kg, 13 ft• Ib)
                          T.R.

 

 

Order Job/Part Q’ty           Remarks  
                 
  Removing the front wheel and brake     Remove the parts in the order listed.  
  disc (XP500)     NOTE:          
        Place the scooter on a suitable stand so  
        that the front wheel is elevated.  
  Front brake caliper (left and right)                
          Refer to “REMOVING  
           
  Front wheel axle pinch bolt     Loosen.       THE FRONT WHEEL  
  Front wheel axle             (XP500)” and “INSTALL-  
           
  Front wheel             ING THE FRONT WHEEL  
  Speed sensor             (XP500)”.  
           
  Collar                
  Dust cover                
  Brake disc                
        For installation, reverse the removal pro-  
        cedure.          
                   

 

4 - 1


FRONT WHEEL AND BRAKE DISC CHAS

 

Order Job/Part Q’ty Remarks
       
  Disassembling the front wheel   Remove the parts in the order listed.
  (XP500)    
  Oil seal    
  Bearing    
  Collar    
      For assembly, reverse the disassembly
      procedure.
       

 

 

4 - 2


FRONT WHEEL AND BRAKE DISC CHAS

 

EAS00889                                                
                                                   
                                                   
    59 Nm (5.9 m   kg, 43 ft   Ib)       T. 40 Nm (4.0 m kg, 29 ft Ib)
          R.    
  T.                              
  R.                                  
T. 23 Nm (2.3 m kg, 17 ft Ib)                              
R.                                
                                                 
    (6)                                          
                                               
                                                 
  LT                           40 Nm (4.0 m   kg, 29 ft   Ib)
                           
                          T.
                          R.    
                                                 
                          LT 18 Nm (1.8 m kg, 13 ft Ib)    
                        T.    
                      R.        
                      (6)                        
                                                 
                                                 
                          T. 30 Nm (3.0 m kg, 22 ft Ib)
                    R.    
                                             
                                                 
.             Job/Part   Q’ty   Remarks                
Order                            

  Removing the front wheel and brake   Remove the parts in the order listed.
  disc (XP500A)   NOTE:        
      Place the scooter on a suitable stand so
      that the front wheel is elevated.
             
  Front cowling upper cover   Refer to “COVER AND PANEL” in chap-
      ter 3.    
  Front wheel sensor coupler   Disconnect.     Refer to “REMOVING
   
  Front brake caliper (left and right)           THE FRONT WHEEL
  Front wheel sensor           AND FRONT WHEEL
  Front wheel axle pinch bolt   Loosen.   SENSOR (XP500A)” and
 
  Front wheel axle           “INSTALLING THE
        FRONT WHEEL AND
  Front wheel          
        FRONT WHEEL SENSOR
  Sensor housing          
        (XP500A)”.
       
             

 


 

 

4 - 3


FRONT WHEEL AND BRAKE DISC CHAS

 

                                                 
                                                 
  59 Nm (5.9 m   kg, 43 ft   Ib)       T. 40 Nm (4.0 m kg, 29 ft Ib)
        R.    
T.                              
R.                                  
T.   kg, 17 ft Ib)                              
R.23 Nm (2.3 m                                  
                                               
  (6)                                          
                                             
                                               
LT                           40 Nm (4.0 m   kg, 29 ft   Ib)
                         
                        T.
                        R.    
                                               
                        LT 18 Nm (1.8 m kg, 13 ft Ib)    
                      T.    
                    R.        
                    (6)                        
                                               
                                               
                        T. 30 Nm (3.0 m kg, 22 ft Ib)
                  R.    
                                           
                                               
.           Job/Part   Q’ty   Remarks                
Order                            
  Collar (left)                                      
  Collar (right)                                      
  Dust cover                                      
  Brake disc                                      

 

For installation, reverse the removal procedure.

 


 

4 - 4


FRONT WHEEL AND BRAKE DISC CHAS

 

 

LS

 

 

 

 

LS

 

 

 

Order Job/Part Q’ty Remarks
       
  Disassembling the front wheel   Remove the parts in the order listed.
  (XP500A)    
  Oil seal    
  Bearing    
  Collar    
      For assembly, reverse the disassembly
      procedure.
       

 

 

4 - 5


FRONT WHEEL AND BRAKE DISC CHAS

 

EAS00520

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