This Parts Catalogue is related to the parts for the model(s) in the below frame. When you are
orderingreplacementparts,pleaserefertothis Parts Catalogue and quote both part numbers and
part names correctly.
XP500(5GJ1)
1. Modifications or additions which have been made after issue of the Parts
Catalogue will be announced in the Yamaha Parts News.
It is advisable that you make necessary corrections to the Parts Catalogue
according to the Yamaha Parts News.
2. Abbreviations
The Following abbreviations are used in this Parts Catalogue.
“UR” Use specified parts number.
“UN” Use as many as needed.
“AP” Alternate Parts
“LM” Local Made (Parts need to be ordered locally)
“F#” Frame No. (Applicable machine No.)
3. Parts, which are to be supplied in an assembly, are listed with a dot(.) in
front of the part name as shown below.
EXAMPLE
CARBURETOR ASSY
.JET, PILOT
.NOZZLE, MAIN
4. Number of component for assembly
The numeral appearing to the right of each component part indicates the
quantity of parts for each assembly unit.
EXAMPLE
PART NO.DESCRIPTIONQ’TY REMARKS
2F58331060 FRONT FLASHER LIGHT ASSY2
1158331160.BULB (6V18W)1
1M18330960 .REFLECTOR1
5. Applicable colors of graphics are represented in the “REMARKS” as shown
below.
PART NO.DESCRIPTIONQ’TYREMARKS
2N42411000X5 FUEL TANK COMP.1MXR
3J12424010.GRAPHIC, FUEL TANK1FOR MXR
6. Applicable Serial No.
Engine Serial No.Frame Serial No.
7. Note that the illustrations for reference in finding parts numbers, not to be
used for assembling. When assembling, please use the applicable service
manual.
8. The asterisk (*) before a reference number indicates modification items
after the first edition.
A
4
MODEL LABEL
(1) A label called “Model Label” is affixed in the location as indicated in (3) below.
When using this parts catalogue, please be sure to cross–refer the “model code –
production code No.” in the catalogue to the “model code – production code No.
“indicated on the Model Label affixed onto the product concemed.
(2) “Model Label”Indication
ab
xxxx – xxx
c
x
(3) Model Label Affixing Location
a: Model Type Code
b: Production Code No.
c: Colouring Type
4TW1–010
A
(4) Model Code – Production Code Number of Model Listed in This Parts Catalog
Model
Code
5GJ1
Production
Code No.
010AUSTRIA
020BELGIUM
030
040
070ENGLAND
080GREECE
090
091
100
101
110PORTUGAL
Country
(destination)
SWITZERLAND
DENMARK
FINLAND
NORWAY
ITALY
HOLLAND
Model
Code
Production
Code No.
(destination)
Country
(5) Colouring Information
Model
Code
5GJ1
A
5
120SWEDEN
Colouring type
code
A00ALCALM YELLOWCMY
B0627
C0755SILVER 1S1
Colour
code
Colour Name
VERY DARK BLUE
COCKTAIL 4
Abbrevi-
ation
VDBC4
FIG.1 CYLINDER
REF.
NO.
10 90179–09489NUT2
11 90110–06021BOLT, HEXAGON SOCKET HEAD2
12 95027–06085BOLT, FLANGE1
13 94701–00353PLUG, SPARK (NGK CR7E)2
14 5GJ–11181–00GASKET, CYLINDER HEAD 11
15 5GJ–11190–00COVER, CYLINDER HEAD 11
PART NO.DESCRIPTIONREMARKS
1 5GJ–11101–00CYLINDER HEAD ASSY1
2 95027–08012.BOLT, FLANGE1
3 90430–08119.GASKET1
4 95617–08620BOLT, STUD4
5 90116–06475BOLT, STUD4
6 90116–09584BOLT, STUD6
7 93612–16254PIN, DOWEL2
8 90201–090P4WASHER, PLATE6
9 90179–09612NUT4
5GJ1
B
16 5GJ–11166–00PIPE, BREATHER 11
17 90467–13071CLIP1
18 90467–16181CLIP1
19 5GJ–11193–00GASKET, HEAD COVER 11
20 5GJ–11195–00GASKET2
21 99530–10116PIN, DOWEL2
22 91317–06035BOLT10
23 5GJ–11311–00CYLINDER 11
24 4BR–14251–00NIPPLE1
25 5GJ–11351–00GASKET, CYLINDER1
26 93612–16254PIN, DOWEL2
27 46X–83591–00THERMO UNIT1
2
FIG.2 CRANKSHAFT. PISTON
REF.
NO.
PART NO.DESCRIPTIONREMARKS
1 5GJ–W1141–00CRANK 11
2 5GJ–11416–00PLANE BEARING, CRANKSHAFT 11UR
5GJ–11416–10PLANE BEARING, CRANKSHAFT 11UR
5GJ–11416–20PLANE BEARING, CRANKSHAFT 11UR
5GJ–11416–30PLANE BEARING, CRANKSHAFT 11UR
5GJ–11416–40PLANE BEARING, CRANKSHAFT 11UR
5GJ–11416–A0PLANE BEARING, CRANKSHAFT 11UR
3 5GJ–11417–00PLANE BEARING, CRANKSHAFT 21UR
5GJ–11417–10PLANE BEARING, CRANKSHAFT 21UR
5GJ–11417–20PLANE BEARING, CRANKSHAFT 21UR
5GJ–11417–30PLANE BEARING, CRANKSHAFT 21UR
5GJ–11417–40PLANE BEARING, CRANKSHAFT 21UR
5GJ–11417–A0PLANE BEARING, CRANKSHAFT 21UR
4 5GJ–11631–00PISTON (STD)2
5 5GJ–11603–00PISTON RING SET (STD)2
5GJ1
B
6 5EB–11633–00PIN, PISTON2
7 93450–17129CIRCLIP4
8 5GJ–11650–00CONNECTING ROD ASSY2
9 5GJ–11654–00.BOLT, CONNECTING ROD2UR
5GJ–11654–10.BOLT, CONNECTING ROD2UR
10 90179–07652.NUT2
11 5GJ–11656–00PLANE BEARING, CONNECTING ROD4UR
5GJ–11656–10PLANE BEARING, CONNECTING ROD4UR
5GJ–11656–20PLANE BEARING, CONNECTING ROD4UR
5GJ–11656–30PLANE BEARING, CONNECTING ROD4UR
12 5GJ–11642–10–A0 PISTON 2 (STD)1
13 5GJ–11455–10SHAFT 11
3
FIG.2 CRANKSHAFT. PISTON
REF.
NO.
14 93450–16068CIRCLIP2
15 5GJ–11660–10CONNECTING ROD ASSY1
16 4X7–11654–01.BOLT, CONNECTING ROD2
17 90179–09379.NUT2
18 5GJ–11656–00PLANE BEARING, CONNECTING ROD2UR
19 5GJ–11312–00SLEEVE, CYLINDER1
20 90111–10002BOLT4
21 93608–60001PIN, DOWEL2
22 90179–18002NUT1
23 90387–18001COLLAR1
24 90280–05013KEY, WOODRUFF1
25 93306–90602BEARING1
PART NO.DESCRIPTIONREMARKS
5GJ–11656–10PLANE BEARING, CONNECTING ROD2UR
5GJ–11656–20PLANE BEARING, CONNECTING ROD2UR
5GJ–11656–30PLANE BEARING, CONNECTING ROD2UR
5GJ1
B
26 93101–30001OIL SEAL1
27 93102–44008OIL SEAL1
4
FIG.3 VALVE
REF.
NO.
PART NO.DESCRIPTIONREMARKS
1 5GJ–12111–00VALVE, INTAKE4
2 5GJ–12121–00VALVE, EXHAUST4
3 5EB–12126–00SEAT, VALVE SPRING 28
4 4GY–12113–00SPRING, VALVE INNER8
5 5EB–12127–00RETAINER, VALVE SPRING8
6 1HX–12118–00COTTER, VALVE16
7 4TV–12119–00SEAL, VALVE STEM8
8 1HX–12168–00PAD, ADJUSTING 2 (1.20)8UR
1HX–12168–20PAD, ADJUSTING 2 (1.25)8UR
1HX–12168–40PAD, ADJUSTING 2 (1.30)8UR
1HX–12168–60PAD, ADJUSTING 2 (1.35)8UR
1HX–12168–80PAD, ADJUSTING 2 (1.40)8UR
1HX–12168–A0PAD, ADJUSTING 2 (1.45)8UR
1HX–12168–F0PAD, ADJUSTING 2 (1.50)8UR
1HX–12168–H1PAD, ADJUSTING 2 (1.55)8UR
5GJ1
B
1HX–12168–K1PAD, ADUSTING 2 (1.60)8UR
1HX–12168–M1PAD, ADJUSTING 2 (1.65)8UR
1HX–12168–R1PAD, ADJUSTING 2 (1.70)8UR
1HX–12168–U1PAD, ADJUSTING 2 (1.75)8UR
1HX–12168–W1PAD, ADJUSTING 2 (1.80)8UR
1HX–12168–Y1PAD, ADJUSTING 2 (1.85)8UR
1HX–12169–11PAD, ADJUSTING 2 (1.90)8UR
1HX–12169–31PAD, ADJUSTING 2 (1.95)8UR
1HX–12169–50PAD, ADJUSTING 2 (2.00)8UR
1HX–12169–70PAD, ADJUSTING 2 (2.05)8UR
1HX–12169–90PAD, ADJUSTING 2 (2.10)8UR
1HX–12169–E0PAD, ADJUSTING 2 (2.15)8UR
5
FIG.3 VALVE
REF.
NO.
PART NO.DESCRIPTIONREMARKS
8 1HX–12169–G0PAD, ADJUSTING 2 (2.20)8UR
1HX–12169–J0PAD, ADJUSTING 2 (2.25)8UR
1HX–12169–L0PAD, ADJUSTING 2 (2.30)8UR
1HX–12169–N0PAD, ADJUSTING 2 (2.35)8UR
1HX–12169–T0PAD, ADJUSTING 2 (2.40)8UR
9 5EB–12153–20LIFTER, VALVE8BLUE
5EB–12153–09LIFTER, VALVE8GREEN
5GJ1
B
6
FIG.4 CAMSHAFT. CHAIN
REF.
NO.
10 90119–06020BOLT, WITH WASHER2
PART NO.DESCRIPTIONREMARKS
1 5GJ–12170–00CAMSHAFT ASSY 11
2 5GJ–12180–00CAMSHAFT ASSY 21
3 94581–89132CHAIN1
4 5BE–12241–00GUIDE, STOPPER 21
5 5GJ–12210–00TENSIONER ASSY, CAM CHAIN1
6 4FM–12213–00GASKET, TENSIONER CASE1
7 91317–06025BOLT2
8 5GJ–12251–00DAMPER, CHAIN 11
9 5GJ–12252–00DAMPER, CHAIN 21
5GJ1
B
7
FIG.5 WATER PUMP
REF.
NO.
10 99009–12400.CIRCLIP1
11 93210–33133O–RING1
12 97027–06030BOLT2
13 92907–06600WASHER, PLATE2
14 5GJ–12481–00PIPE 11
15 5GJ–12482–00PIPE 21
PART NO.DESCRIPTIONREMARKS
1 5GJ–12420–00WATER PUMP ASSY1
2 5GJ–12421–00.HOUSING, WATER PUMP1
3 93306–00106.BEARING1
4 93102–12442.OIL SEAL1
5 11H–12438–00.SEAL, MECHANICAL1
6 5GJ–12450–00.IMPELLER SHAFT ASSY1
7 5GJ–12422–00.COVER, HOUSING1
8 1WG–12439–00.O–RING1
9 91317–06020.BOLT2
5GJ1
B
16 93210–21190O–RING3
17 97027–06016BOLT2
18 92907–06600WASHER, PLATE2
8
FIG.6 RADIATOR. HOSE
REF.
NO.
10 5GJ–12467–00COVER, RADIATOR1
11 5GJ–12485–00PIPE 51
12 5GJ–12476–00PIPE 61
13 5GJ–12477–00PIPE 71
14 4JH–12462–00CAP, RADIATOR1
15 5GJ–12591–00SUPT, FILLER NECK1
PART NO.DESCRIPTIONREMARKS
1 5GJ–12483–00PIPE 31
2 90450–32015HOSE CLAMP ASSY8
3 46X–12410–00THERMOSTAT ASSY1
4 5GJ–12413–00COVER, THERMOSTAT1
5 95027–06025BOLT, FLANGE2
6 5GJ–12484–00PIPE 41
7 95807–06010BOLT, FLANGE2
8 5GJ–12461–00RADIATOR ASSY1
9 5GJ–12405–00BLOWER ASSY1
5GJ1
B
16 95807–06012BOLT, FLANGE1
17 5GJ–1243A–00HOSE 11
18 5GJ–1243E–00HOSE 21
19 90467–15141CLIP4
20 5GJ–1243F–00HOSE,31
21 90467–10035CLIP6
22 90467–09120CLIP1
23 90467–12053CLIP3
24 5GJ–1244G–00HOSE, 41
25 5AH–1240G–00THERMOSTAT COVER ASSY1
26 5GJ–12491–00CLAMP 11
27 5GJ–12588–00HOSE 51
9
FIG.6 RADIATOR. HOSE
REF.
NO.
28 5GJ–12589–00HOSE 61
29 5GJ–12551–00HOSE 71
30 90464–13001CLAMP1
31 90480–16301GROMMET3
32 90387–0714BCOLLAR2
33 95807–06030BOLT, FLANGE2
34 5GH–82560–00THERMO SWITCH ASSY1
35 5GJ–82560–00THERMO SWITCH ASSY1
PART NO.DESCRIPTIONREMARKS
5GJ1
B
10
FIG.7 OIL PUMP
REF.
NO.
10 5GJ–13410–00STRAINER HOUSING ASSY1
11 93210–14579O–RING1
12 90110–06004BOLT, HEXAGON SOCKET HEAD2
13 22F–13411–01STRAINER, OIL1
14 3LD–13113–00SEAT, CHECK BALL1
15 93505–08030BALL1
PART NO.DESCRIPTIONREMARKS
1 5GJ–13300–00OIL PUMP ASSY1
2 92017–06050BOLT, BUTTON HEAD3
3 5GJ–13161–00PIPE, DELIVERY 11
4 93210–06422O–RING1
5 90110–06004BOLT, HEXAGON SOCKET HEAD1
6 5GJ–13475–00GASKET2
7 94580–25058CHAIN (DID25 58L)1
8 5GJ–13405–00OIL PIPE COMP. 11
9 93210–09525O–RING2
5GJ1
B
16 90501–104F9SPRING, COMPRESSION1
17 5GJ–13470–00OIL COOLER ASSY1
18 4JH–13473–00.O–RING1
19 90401–20170BOLT, UNION1
20 5DM–13440–00ELEMENT ASSY, OIL CLEANER1
21 4G0–13490–01RELIEF VALVE ASSY1
22 93210–10096O–RING1
11
FIG.8 INTAKE
REF.
NO.
10 5GJ–14463–00JOINT, AIR CLEANER 21
11 97707–50520SCREW, TAPPING5
12 90465–08371CLAMP1
13 90480–12497GROMMET2
14 90387–067V1COLLAR2
15 90460–56071CLAMP, HOSE2
PART NO.DESCRIPTIONREMARKS
1 5GJ–13586–00JOINT, CARBURETOR 11
2 5GJ–13596–00JOINT, CARBURETOR 21
3 93210–32738O–RING2
4 91317–06020BOLT4
5 5GJ–13575–00BAND2
6 5GJ–14431–00SILENCER, INTAKE 11
7 5GJ–14453–00JOINT, AIR CLEANER 11
8 1JK–14462–00SEAL1
9 5GJ–14432–00SILENCER, INNER1
5GJ1
B
16 95807–06020BOLT, FLANGE2
17 5GJ–14411–00CASE, AIR CLEANER 11
18 5GJ–1440F–00JOINT, AIR FILTER 11
19 5GJ–1440G–00JOINT, AIR FILTER 21
20 5GJ–1441A–00COVER, CLEANER CASE 11
21 4KN–14452–00SEAL1
22 97707–50520SCREW, TAPPING10
23 4BH–14451–00ELEMENT, AIR CLEANER1
24 5GJ–14412–00CAP, CLEANER CASE 11
25 5GJ–14437–00DUCT1
26 3KJ–14452–30SEAL1
27 90480–12497GROMMET3
12
FIG.8 INTAKE
REF.
NO.
28 90387–067V1COLLAR3
29 59V–14457–00SEAL1
30 90467–22080CLIP1
31 90460–56071CLAMP, HOSE2
32 95807–06020BOLT, FLANGE3
PART NO.DESCRIPTIONREMARKS
5GJ1
B
13
FIG.9 CARBURETOR
REF.
NO.
10 1NT–14142–22..JET, PILOT (#22.5)1
11 5GJ–1414M–30..NOZZLE, MAIN1
12 620–1423A–71..JET,MAIN (#102.5)1
13 137–14153–00..WASHER, MAIN JET1
14 5GJ–24411–00..DIAPHRAGM1
15 4VR–14933–00..SPRING, DIAPHRAGM1
PART NO.DESCRIPTIONREMARKS
1 5GJ–14900–00CARBURETOR ASSY1
2 5GJ–14901–00.CARBURETOR ASSY 11
3 5GJ–14902–00.CARBURETOR ASSY 21
4 5GJ–14105–00..PILOT SCREW SET1
5 5GJ–1490J–00..NEEDLE SET1
6 5GJ–14993–00..PLUNGER, STARTER1
7 4HM–14107–20..NEEDLE VALVE SET1
8 22F–14991–00..CAP1
9 3G2–14231–17..JET, POWER (#85)1
5GJ1
B
16 5GJ–14147–00..O–RING1
17 537–14186–00..PIN, FLOAT1
18 4G0–14985–00..FLOAT1
19 98507–04006..SCREW, PAN HEAD1
20 3UH–14945–00..PLATE1
21 5AP–14280–00..COVER, CARBURETOR1
22 98507–04014..SCREW, PAN HEAD2
23 92907–04100..WASHER, SPRING2
24 98507–05008..SCREW, PAN HEAD5
25 5GJ–14945–00..PLATE1
26 5EL–1490H–00..DIAPHRAGM SET 51
27 98507–04012..SCREW, PAN HEAD4
14
FIG.9 CARBURETOR
REF.
NO.
28 92907–04100..WASHER, SPRING4
29 12R–14191–00..PLUG, DRAIN1
30 5GJ–14103–00.THROTTLE SCREW SET1
31 822–14147–00.O–RING4
32 1WG–14251–00.NIPPLE1
33 36Y–14147–00.O–RING4
34 5GJ–14919–00.CLIP1
35 4WM–14565–00.SCREW2
36 4XY–85885–00.THROTTLE SENSOR ASSY1
37 5GJ–14389–00.NIPPLE ASSY1
38 5GJ–14197–00.PIPE1
39 5GJ–14197–10.PIPE1
40 3H3–24376–00.PIPE, JOINT 11
41 5GJ–14149–00.PIPE1
42 5GJ–14348–00.PIPE 11
PART NO.DESCRIPTIONREMARKS
5GJ1
B
43 5GJ–14349–00.PIPE1
44 14X–14937–00.CLIP2
45 1WG–14922–00.SCREW, THROTTLE1
46 1HX–14133–00.SPRING, THROTTLE STOP1
47 620–14212–00.SPRING, PILOT ADJUSTING1
15
FIG. 10 EXHAUST
REF.
NO.
10 4BD–14766–00WASHER, PROTECTOR8
11 98980–06010SCREW, BIND3
12 5GJ–1465R–00PLATE, PROTECTOR1
13 5GJ–1465T–00PLATE, PROTECTOR1
14 5GJ–14799–00CAP1
15 90111–06020BOLT1
PART NO.DESCRIPTIONREMARKS
1 5GJ–14710–00MUFFLER ASSY 11
2 4BR–14613–00GASKET, EXHAUST PIPE2
3 95607–08200NUT, SELF–LOCKING4
4 36Y–27424–00DAMPER, FOOTREST 21
5 90387–10636COLLAR1
6 90201–10669WASHER, PLATE1
7 95807–10040BOLT, FLANGE1
8 90176–10075NUT, CROWN1
9 5GJ–14629–00STAY, PROTECTOR1
5GJ1
C
16 90111–06015BOLT2
17 91380–06016BOLT5
18 92990–06200WASHER, PLAIN5
19 90480–10332GROMMET2
20 5GJ–14871–00PIPE 11
21 5GJ–14815–00GASKET2
22 95707–06500NUT, FLANGE4
23 5GJ–14873–01PIPE 32
24 90467–19065CLIP4
25 5GJ–14808–00REED VALVE ASSY1
26 91317–06010BOLT3
27 5GJ–14875–00PIPE 51
2
FIG. 10 EXHAUST
REF.
NO.
28 90467–19160CLIP2
29 1TA–14840–00AIR CUT VALVE ASS’Y1
30 90462–20188CLAMP1
31 98507–06014SCREW, PAN HEAD1
32 92907–06600WASHER, PLATE1
33 5GJ–13542–00HOSE, VACUUM SENSING 11
34 90467–07138CLIP1
35 90467–08092CLIP1
36 5GJ–14876–00PIPE 61
37 90467–24096CLIP2
PART NO.DESCRIPTIONREMARKS
5GJ1
C
3
FIG. 11 CRANKCASE
REF.
NO.
10 93210–22382O–RING1
11 90110–08004BOLT, HEXAGON SOCKET HEAD1
12 90430–08119GASKET1
PART NO.DESCRIPTIONREMARKS
1 5GJ–15100–00CRANKCASE ASSY1
2 99530–10114.PIN, DOWEL2
3 95027–06035BOLT, FLANGE5
4 95027–06050BOLT, FLANGE8
5 95027–08110BOLT, FLANGE8
6 5GJ–15481–00BOLT 11
7 214–11198–01GASKET1
8 93210–48364O–RING1
9 4H7–15189–00PLUG1
5GJ1
C
4
FIG. 12 CRANKCASE COVER 1
REF.
NO.
10 93210–16325O–RING1
11 5GJ–15451–00GASKET, CRANKCASE COVER 11
12 99530–10114PIN, DOWEL2
13 95027–06035BOLT, FLANGE19
14 5GJ–15363–00PLUG, OIL1
15 93210–19123O–RING1
PART NO.DESCRIPTIONREMARKS
1 5GJ–15411–00COVER, CRANKCASE 11
2 2H7–15361–00GAUGE, LEVEL1
3 5GJ–15414–00COVER, AIR CLEANER1
4 5GJ–15417–00COVER, CAP1
5 90149–06020SCREW3
6 5GJ–15453–00GASKET, CARBURETOR COVER1
7 99530–10114PIN, DOWEL2
8 95027–06035BOLT, FLANGE7
9 36Y–15189–00PLUG1
5GJ1
C
16 5GJ–15415–00COVER, GENERATOR1
17 5GJ–15486–00GROMMET1
18 3KJ–15481–00BOLT 11
19 5GJ–15316–00DAMPER, ENGINE MOUNT 11
20 5GJ–15337–00DAMPER 41
5
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