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| SPECIAL TOOLS
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| INFO
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Tool No.
| Tool name/Function
| Illustration
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| Valve guide installer (4 mm)
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90890-04112
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YM-04112
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| This tool is used to install the valve
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| guides.
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| Valve guide reamer (4 mm)
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90890-04113
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YM-04113
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| This tool is used to rebore the new valve
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| guides.
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Sheave spring com-
| Sheave spring compressor
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pressor
| Sheave fixed block
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90890-04134
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YM-04134
| This tool is used to hold the compression
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Sheave fixed block
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spring when removing or installing the
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90890-04135
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YM-04135
| secondary sheave nut.
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| Plane bearing installer
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90890-04139
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| This tool is used to install the crankshaft
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| journal bearings.
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| Ignition checker
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90890-06754
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YM-34487
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| This tool is used to check the ignition sys-
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| tem components.
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| Yamaha bond No. 1215
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Bond
| Sealant (Quick Gasket®)
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90890-85505
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Sealant
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ACC-11001-05-01
| This bond is used to seal two mating sur-
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| faces (e.g., crankcase mating surfaces).
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| SPEC
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CHAPTER 2
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SPECIFICATIONS
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GENERAL SPECIFICATIONS........................................................................
| 2-1
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ENGINE SPECIFICATIONS............................................................................
| 2-2
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CHASSIS SPECIFICATIONS........................................................................
| 2-11
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ELECTRICAL SPECIFICATIONS.................................................................
| 2-15
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CONVERSION TABLE..................................................................................
| 2-18
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GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................
| 2-18
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TIGHTENING TORQUES..............................................................................
| 2-19
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ENGINE TIGHTENING TORQUES.........................................................
| 2-19
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CHASSIS TIGHTENING TORQUES.......................................................
| 2-22
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LUBRICATION POINTS AND LUBRICANT TYPES....................................
| 2-24
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ENGINE LUBRICATION POINTS AND LUBRICANT TYPES................
| 2-24
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CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES.............
| 2-26
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OIL FLOW DIAGRAMS.................................................................................
| 2-27
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COOLANT FLOW DIAGRAMS.....................................................................
| 2-31
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CABLE ROUTING.........................................................................................
| 2-32
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XP500......................................................................................................
| 2-39
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XP500A...................................................................................................
| 2-56
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| Item
| Standard
| Limit
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Engine
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Engine type
| Liquid-cooled 4-stroke, DOHC
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Displacement
| 499 cm3 (30.45 cu.in)
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Cylinder arrangement
| Forward inclined parallel 2-cylinder
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Bore Ч stroke
| 66 Ч 73 mm (2.60 Ч 2.87 in)
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Compression ratio
| 11.0: 1
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Engine idling speed
| 1,100 ~ 1,300 r/min
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Vacuum pressure at engine idling
| 33 kPa (248 mmHg, 9.7 inHg)
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speed
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Standard compression pressure
| 1,400 kPa (14.0 kg/cm2, 199.1 psi) at
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(at sea level)
| 360 r/min
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Coolant temperature
| 85 ~ 100 °C (185 ~ 212 °F)
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Oil temperature
| 70 °C (158 °F)
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Fuel
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Recommended fuel
| Regular unleaded gasoline only
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Fuel tank capacity
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| Total (including reserve)
| 14 L (3.08 Imp gal, 3.70 US gal)
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Engine oil
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Lubrication system
| Dry sump
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Recommended oil
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| SAE10W30 or SAE10W40
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| Temp.
| API service SE, SF, SG type or higher
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-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C
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| SAE 10W/30
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| SAE 10W/40
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Quantity
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| Total amount
| 3.6 L (3.17 Imp qt, 3.81 US qt)
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| Without oil filter cartridge replace-
| 2.8 L (2.46 Imp qt, 2.96 US qt)
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| With oil filter cartridge replacement
| 2.9 L (2.55 Imp qt, 3.07 US qt)
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Oil pressure (hot)
| 150 kPa (1.50 kg/cm2, 21.8 psi) at
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| 1,200 r/min
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Relief valve opening pressure
| 450 ~ 550 kPa
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| (4.5 ~ 5.5 kg/cm2, 65.3 ~ 79.8 psi)
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Chain drive oil
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Type
| SAE 80 API GL-4 Hypoid gear oil
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Quantity
| 0.70 L (0.62 Imp qt, 0.74 US qt)
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| Standard
| Limit
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Oil filter
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Oil filter type
| Cartridge (paper)
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Bypass valve opening pressure
| 80 ~ 120 kPa
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| (0.8 ~ 1.2 kg/cm2, 11.6 ~ 17.4 psi)
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Oil pump
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Oil pump type
| Trochoid
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Inner-rotor-to-outer-rotor-tip clear-
| 0.04 ~ 0.12 mm (0.0016 ~ 0.0047 in)
| 0.20 mm
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ance
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| (0.0079 in)
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Outer-rotor-to-oil-pump-housing
| 0.045 ~ 0.085 mm (0.0018 ~ 0.0033 in)
| 0.15 mm
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clearance
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| (0.0059 in)
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Oil-pump-housing-to-inner-and-
| 0.11 ~ 0.23 mm (0.0043 ~ 0.0091 in)
| 0.30 mm
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outer-rotor clearance
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| (0.0118 in)
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Pressure check location
| MAIN GALLERY
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Cooling system
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Radiator capacity (including all
| 1.5 L (1.32 Imp qt, 1.59 US qt)
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routes)
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Coolant reservoir capacity (up to the
| 0.35 L (0.31 Imp qt, 0.37 US qt)
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maximum level mark)
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Radiator cap opening pressure
| 107.9 ~ 137.3 kPa
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| (1.08 ~ 1.37 kg/cm2, 15.6 ~ 19.9 psi)
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Radiator core
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Width
| 330 mm (12.99 in)
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Height
| 138 mm (5.43 in)
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Depth
| 24 mm (0.94 in)
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Thermostat
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Model/manufacturer
| 4JH/NIPPON THERMOSTAT
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Valve opening temperature
| 69 ~ 73 °C (156.2 ~ 163.4 °F)
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Valve full open temperature
| 85 °C (185 °F)
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Valve lift-full open
| 8.0 mm (0.31 in)
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Water pump
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Water pump type
| Single-suction centrifugal pump
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Reduction ratio
| 23/19 (1.210)
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Starting system type
| Electric starter
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Spark plugs
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Model/manufacturer Ч quantity
| CR7E/NGK Ч 2
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Spark plug gap
| 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
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Cylinder head
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Volume
| 14.97 ~ 15.57 cm3 (0.91 ~ 0.95 cu.in)
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Max warpage
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| 0.03 mm
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| (0.0012 in)
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