Page 42 of 94
FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
1
2
3
4
5
6
7
8
9
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.6-20, 6-21, 6-22
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.6-17, 6-23
Wheels and tires
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-18, 6-19
Brake levers
Make sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-24
Centerstand, sidestand
Make sure that operation is smooth.
Lubricate pivots if necessary.6-24
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 not working correctly, have Yamaha dealer check vehicle.3-23
ITEM CHECKS PAGE
Page 49 of 94
PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
2
3
4
5
67
8
9
EAU1770C
General maintenance and lubrication chart
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1
Air filter element
Replace.
√√
2*
V-belt case air filter
elements
Clean.
√√
Replace.
√√
3*
Front brake
Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√
Replace brake pads. Whenever worn to the limit
4*
Rear brake
Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√
Replace brake pads. Whenever worn to the limit
5*
Brake hoses
Check for cracks or damage.
√√√√√
Replace. Every 4 years
6
Rear brake lock
Check operation.
Adjust.
√√√√√√
7*
Wheels
Check runout and for damage.
√√√√
8*
Tires
Check tread depth and for
damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√√√√√
9*
Wheel bearings
Check bearing for looseness or
damage.
√√√√
10 *
Steering bearings
Check bearing play and steering
for roughness.
√√√√√
Lubricate with
lithium-soap-based grease.Every 20000 km (12000 mi)
Page 64 of 94
PERIODIC MAINTENANCE AND ADJUSTMENT
6-18
1
2
3
4
5
6
7
8
9
EAU33601
Tires
To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
EWA10501
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
WARNING
EWA10511
Never overload your vehicle. Opera-
tion of an overloaded vehicle could
cause an accident.Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
TIP
The tire tread depth limits may differ
from 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 (2.25 kgf/cm 2
, 33 psi)
Rear:
250 kPa (2.50 kgf/cm 2
, 36 psi)
XP500 90–194 kg (198–428 lb)
XP500A 90–190 kg (198–419 lb):
Front:
225 kPa (2.25 kgf/cm 2
, 33 psi)
Rear:
280 kPa (2.80 kgf/cm
2
, 41 psi)
Maximum load*:
XP500 194 kg (428 lb)
XP500A 190 kg (419 lb)
* Total weight of rider, passenger, car-
go and accessories
1. Tire sidewall
2. Tire tread depth
Minimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
12
Page 85 of 94
SCOOTER CARE AND STORAGE
7-4
2
3
4
5
6
78
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 place
the spark plugs on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder walls with oil.)
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
WARNING!
To prevent damage or injury
from sparking, make sure to
ground the spark plug elec-
trodes while turning the en-
gine over.
[EWA10951]
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, correct
the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully
charge it. Store it in a cool, dry place
and charge it once a month. Do not
store the battery in an excessively
cold or warm place [less than 0 °C
(30 °F) or more than 30 °C (90 °F)].
For more information on storing the
battery, see page 6-26.
TIP
Make any necessary repairs before
storing the scooter.
Page 87 of 94
SPECIFICATIONS
8-2
2
3
4
5
6
7
89
Front tire:
Type:
Tubeless
Size:
120/70R15 M/C 56H
Manufacturer/model:
DUNLOP/GPR-100F
Manufacturer/model:
BRIDGESTONE/BT011F
Rear tire:
Type:
Tubeless
Size:
160/60R15 M/C 67H
Manufacturer/model:
DUNLOP/GPR-100L
Manufacturer/model:
BRIDGESTONE/BT012R
Loading:
Maximum load:
XP500 194 kg (428 lb)
XP500A 190 kg (419 lb)
* (Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
225 kPa (2.25 kgf/cm
2
, 33 psi)
Rear:
250 kPa (2.50 kgf/cm
2
, 36 psi)Loading condition:
XP500 90–194 kg (198–428 lb)
XP500A 90–190 kg (198–419 lb)
Front:
225 kPa (2.25 kgf/cm
2
, 33 psi)
Rear:
280 kPa (2.80 kgf/cm
2
, 41 psi)
Front wheel:
Wheel type:
Cast wheel
Rim size:
15M/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 forkSpring/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:
116.0 mm (4.57 in)
Electrical system:
Ignition system:
TCI (digital)
Charging system:
AC magneto
Battery:
Model:
YTZ10S
Voltage, capacity:
12 V, 8.6 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage
×× × ×
quantity:
Headlight:
12 V, 60 W/55 W
×
1
Headlight:
12 V, 55 W
×
1
Tail/brake light:
12 V, 5.0 W/21.0 W
×
1
Front turn signal light:
12 V, 21.0 W
×
2