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Do not spin the bearing with compressed air because this will damage the bearing surfaces. 2 глава




 

1 - 25


             
  SPECIAL TOOLS   GEN    
    INFO    
       
Tool No. Tool name/Function Illustration  
             
  Valve guide installer (4 mm)          
90890-04112            
YM-04112            
  This tool is used to install the valve          
  guides.          
             
  Valve guide reamer (4 mm)          
90890-04113            
YM-04113            
  This tool is used to rebore the new valve          
  guides.          
             
Sheave spring com- Sheave spring compressor          
pressor Sheave fixed block          
90890-04134            
YM-04134 This tool is used to hold the compression          
Sheave fixed block          
spring when removing or installing the          
90890-04135          
YM-04135 secondary sheave nut.          
             
  Plane bearing installer          
90890-04139            
  This tool is used to install the crankshaft          
  journal bearings.          
             
  Ignition checker          
90890-06754            
YM-34487            
  This tool is used to check the ignition sys-          
  tem components.          
             
  Yamaha bond No. 1215          
Bond Sealant (Quick Gasket®)          
90890-85505            
Sealant            
ACC-11001-05-01 This bond is used to seal two mating sur-          
           
  faces (e.g., crankcase mating surfaces).          
             

 

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SPEC 2


         
    SPEC    
         
CHAPTER 2        
       
SPECIFICATIONS        
GENERAL SPECIFICATIONS........................................................................ 2-1    
ENGINE SPECIFICATIONS............................................................................ 2-2    
CHASSIS SPECIFICATIONS........................................................................ 2-11    
ELECTRICAL SPECIFICATIONS................................................................. 2-15    
CONVERSION TABLE.................................................................................. 2-18    
GENERAL TIGHTENING TORQUE SPECIFICATIONS............................... 2-18    
TIGHTENING TORQUES.............................................................................. 2-19    
ENGINE TIGHTENING TORQUES......................................................... 2-19    
CHASSIS TIGHTENING TORQUES....................................................... 2-22    
LUBRICATION POINTS AND LUBRICANT TYPES.................................... 2-24    
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES................ 2-24    
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES............. 2-26    
OIL FLOW DIAGRAMS................................................................................. 2-27    
COOLANT FLOW DIAGRAMS..................................................................... 2-31    
CABLE ROUTING......................................................................................... 2-32    
XP500...................................................................................................... 2-39    
XP500A................................................................................................... 2-56    


SPEC


             
GENERAL SPECIFICATIONS   SPEC    
             
SPECIFICATIONS          
         
GENERAL SPECIFICATIONS            
             
Item Standard       Limit  
         
Model code XP500: 5VU6     ----  
  XP500A: 5VU5   ----  
             
Dimensions            
Overall length 2,235 mm (88.0 in)   ----  
Overall width 775 mm (30.5 in)   ----  
Overall height 1,410 mm (55.5 in)   ----  
Seat height 795 mm (31.3 in)   ----  
Wheelbase 1,575 mm (62.0 in)   ----  
Minimum ground clearance 130 mm (5.12 in)   ----  
Minimum turning radius 2,800 mm (110.2 in)   ----  
             
Weight            
Wet (with oil and a full fuel tank) 225 kg (496 lb) (XP500)   ----  
  230 kg (507 lb) (XP500A)   ----  
Maximum load (total of cargo, rider, 190 kg (419 lb) (XP500)   ----  
passenger, and accessories) 185 kg (408 lb) (XP500A)   ----  
             


 

 

2 - 1


ENGINE SPECIFICATIONS SPEC

 

ENGINE SPECIFICATIONS

 

        Item Standard Limit
                         
Engine    
Engine type Liquid-cooled 4-stroke, DOHC ----
Displacement 499 cm3 (30.45 cu.in) ----
Cylinder arrangement Forward inclined parallel 2-cylinder ----
Bore Ч stroke 66 Ч 73 mm (2.60 Ч 2.87 in) ----
Compression ratio 11.0: 1 ----
Engine idling speed 1,100 ~ 1,300 r/min ----
Vacuum pressure at engine idling 33 kPa (248 mmHg, 9.7 inHg) ----
speed    
Standard compression pressure 1,400 kPa (14.0 kg/cm2, 199.1 psi) at ----
(at sea level) 360 r/min  
Coolant temperature 85 ~ 100 °C (185 ~ 212 °F) ----
Oil temperature 70 °C (158 °F) ----
                         
Fuel    
Recommended fuel Regular unleaded gasoline only ----
Fuel tank capacity    
  Total (including reserve) 14 L (3.08 Imp gal, 3.70 US gal) ----
                         
Engine oil    
Lubrication system Dry sump ----
Recommended oil    
                      SAE10W30 or SAE10W40 ----
        Temp. API service SE, SF, SG type or higher  
-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C    
                         
               
      SAE 10W/30    
             
      SAE 10W/40    
Quantity    
  Total amount 3.6 L (3.17 Imp qt, 3.81 US qt) ----
  Without oil filter cartridge replace- 2.8 L (2.46 Imp qt, 2.96 US qt) ----
  ment    
  With oil filter cartridge replacement 2.9 L (2.55 Imp qt, 3.07 US qt) ----
Oil pressure (hot) 150 kPa (1.50 kg/cm2, 21.8 psi) at ----
                      1,200 r/min  
Relief valve opening pressure 450 ~ 550 kPa ----
                      (4.5 ~ 5.5 kg/cm2, 65.3 ~ 79.8 psi)  
Chain drive oil    
Type SAE 80 API GL-4 Hypoid gear oil ----
Quantity 0.70 L (0.62 Imp qt, 0.74 US qt) ----
                         


 

 

2 - 2


ENGINE SPECIFICATIONS SPEC

 

      Item Standard Limit
                 
Oil filter    
Oil filter type Cartridge (paper) ----
Bypass valve opening pressure 80 ~ 120 kPa ----
              (0.8 ~ 1.2 kg/cm2, 11.6 ~ 17.4 psi)  
Oil pump    
Oil pump type Trochoid ----
Inner-rotor-to-outer-rotor-tip clear- 0.04 ~ 0.12 mm (0.0016 ~ 0.0047 in) 0.20 mm
ance   (0.0079 in)
Outer-rotor-to-oil-pump-housing 0.045 ~ 0.085 mm (0.0018 ~ 0.0033 in) 0.15 mm
clearance   (0.0059 in)
Oil-pump-housing-to-inner-and- 0.11 ~ 0.23 mm (0.0043 ~ 0.0091 in) 0.30 mm
outer-rotor clearance   (0.0118 in)
Pressure check location MAIN GALLERY ----
                 
Cooling system    
Radiator capacity (including all 1.5 L (1.32 Imp qt, 1.59 US qt) ----
routes)    
Coolant reservoir capacity (up to the 0.35 L (0.31 Imp qt, 0.37 US qt) ----
maximum level mark)    
Radiator cap opening pressure 107.9 ~ 137.3 kPa ----
              (1.08 ~ 1.37 kg/cm2, 15.6 ~ 19.9 psi)  
Radiator core    
Width 330 mm (12.99 in) ----
Height 138 mm (5.43 in) ----
Depth 24 mm (0.94 in) ----
Thermostat    
Model/manufacturer 4JH/NIPPON THERMOSTAT ----
Valve opening temperature 69 ~ 73 °C (156.2 ~ 163.4 °F) ----
Valve full open temperature 85 °C (185 °F) ----
Valve lift-full open 8.0 mm (0.31 in) ----
Water pump    
Water pump type Single-suction centrifugal pump ----
Reduction ratio 23/19 (1.210) ----
                 
Starting system type Electric starter ----
                 
Spark plugs    
Model/manufacturer Ч quantity CR7E/NGK Ч 2 ----
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) ----
                 
Cylinder head    
Volume 14.97 ~ 15.57 cm3 (0.91 ~ 0.95 cu.in) ----
Max warpage ---- 0.03 mm
                (0.0012 in)
               
                 
                 
                 
                 


 

2 - 3


ENGINE SPECIFICATIONS SPEC

 

Item Standard Limit
         
Camshafts    
Drive system Chain drive (left) ----
Camshaft cap inside diameter 23.000 ~ 23.021 mm (0.9055 ~ 0.9063 in) ----
Camshaft journal diameter 22.967 ~ 22.980 mm (0.9042 ~ 0.9047 in) ----
Camshaft-journal-to-camshaft cap 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) 0.08 mm
clearance   (0.0031 in)
Intake camshaft lobe dimensions    
         
         

A

 

                 
                 
    B          
             
Measurement A 33.252 ~ 33.352 mm (1.3091 ~ 1.3131 in) 33.152 mm
                (1.3052 in)
Measurement B 24.956 ~ 25.056 mm (0.9825 ~ 0.9865 in) 24.856 mm
                (0.9786 in)
Exhaust camshaft lobe dimensions    
                 
                 

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