Yamaha XP500 TMax Technical Manual
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Also See for XP500 TMax:
- Service manual (559 pages) ,
- Owner's manual (104 pages) ,
- Owner's manual (94 pages)
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FEATURES AND BENEFITS
Offering high levels of performance, comfort and sophistication, the new TMax superscooter looks
sure to make as great an impression on the powered two wheeler market as the first Yamaha YZF-
R1 made in the motorcycle scene.
ENGINE FEATURES
n 499cc liquid cooled 4-stroke parallel twin
engine
n DOHC 8 valve engine
n High capacity V-belt transmission
n Horizontally opposed reciprocating balancer
n Wet multiple plate automatic centrifugal
n New design air intake route and air filter case
n Low position radiator
n Semi dry sump with oil cooler
n Non adjustable 2-stage silent chain drive train
XP500 TMax Technical Orientation Guide
Chassis FEATURES
n Motorcycle-type high rigidity diamond shape
n Motorcycle-type front fork
n Highly rigid swingarm
n 14 inch front and rear wheels
n Motorcycle-type hub with fixed rear wheel axle
n Sport bike type weight distribution
n 50º lean angle
n 33 liters luggage compartment
n 1 piece dual seat with 3-stage adjustable
backrest
ELECTRICAL FEATURES
n Dual multi-reflector headlight
n Stylish combination taillight
n Automobile-type meter panel with extensive
information
n High capacity power supply
n Anti-theft alarm pre-wiring
n Grip warmer pre-wiring
n Mobile phone charger pre-wiring
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Table of Contents
Related Manuals for Yamaha XP500 TMax
Summary of Contents for Yamaha XP500 TMax
- Page 1 FEATURES AND BENEFITS Offering high levels of performance, comfort and sophistication, the new TMax superscooter looks sure to make as great an impression on the powered two wheeler market as the first Yamaha YZF- R1 made in the motorcycle scene.
- Page 2 XP500 TMax Technical Orientation Guide ENGINE SYSTEM Displacing 499 cc, the TMax’s highly-advanced fully automatic twin-cylinder DOHC liquid-cooled 4-stroke 8-valve engine is one of the most powerful designs available on scooters today. A key feature of its configuration is that unlike most traditional scooter engines which pivot as one unit with the rear suspension, this engine is fixed rigidly into the TMax’s strong tubular diamond-shape frame...
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Page 3: Cylinder Head Overview
XP500 TMax Technical Orientation Guide CYLINDER HEAD n 4 valves per cylinder, DOHC n Torsion type auto cam chain tensioner (similar to YZF-R1) n “Shim-under-bucket” valve adjustment for long maintenance interval (same as YZF-R1/YZF-R6) n Valve clearance at cold engine condition: Intake : 0.15 - 0.20 mm... - Page 4 XP500 TMax Technical Orientation Guide CYLINDER n New liquid-cooled cylinder body for low weight n Left side cam chain drive for reduced engine width n Ceramic composite cylinder coating for increased cooling and longer wear life Side view Side cam chain drive ø...
- Page 5 XP500 TMax Technical Orientation Guide CRANKSHAFT / BALANCER n New design crankshaft uses replaceable full circumference plain bearings n Horizontally opposed reciprocating balancer for excellent vibration reduction This type achieves same vibration reduction as 3 balancer shafts to reduce primary and second- ary inertial forces, while requiring less space.
- Page 6 XP500 TMax Technical Orientation Guide PISTON n New combustion piston with V-groove between upper and lower compression rings for improved sealing n Balancer piston for horizontally opposed reciprocating balancing system COMBUSTION PISTON Top view V-groove Cross-section Side view ø 40 mm ø...
- Page 7 XP500 TMax Technical Orientation Guide CONNECTING ROD n Newly designed connecting rods: 2 for combustion, 1 for balancer n New type connecting rod as integral part of the horizontally opposed reciprocating balancing system FOR BALANCER FOR COMBUSTION 45 mm 45 mm...
- Page 8 XP500 TMax Technical Orientation Guide TRANSMISSION SYSTEM CONTINUOUSLY VARIABLE TRANSMISSION n Highly efficient V-belt transmission in order to obtain high performance n Newly designed cooling system with fins on both rotors of the secondary sheave for improved cooling and higher belt durability...
- Page 9 XP500 TMax Technical Orientation Guide CLUTCH n Wet type multiple plate centrifugal clutch for smooth power transmission and to meet XP’s higher torque n Clutch uses diaphragm type spring Friction plates: 5 pieces † First pinion gear ‡ Secondary shaft ‚...
- Page 10 XP500 TMax Technical Orientation Guide FINAL DRIVE n Newly designed final drive with non-adjustable 2-stage silent chain for an efficient power trans- mission, reduced noise and low maintenance n High speed first stage chain with spring-type torque absorber for a further reduction of noise n The final drive and the swingarm are integrated for improved rigidity and high speed stability ...
- Page 11 XP500 TMax Technical Orientation Guide LUBRICATION SYSTEM n Semi dry sump system for reduced engine size n Oil tank is incorporated into the left crankcase cover n Newly designed dual stage oil pump n Liquid-cooled oil cooler with cartridge type oil filter (5DM-13440-00)
- Page 12 XP500 TMax Technical Orientation Guide LUBRICATION SYSTEM LUBRICATION FLOW CHART...
- Page 13 XP500 TMax Technical Orientation Guide LUBRICATION SYSTEM...
- Page 14 XP500 TMax Technical Orientation Guide COOLING SYSTEM n Low mounted radiator for design flexibility n Automatic air bleed for easy maintenance Coolant Reservoir Tank … Coolant Fan ‚ Thermostat † Radiator Cap ƒ Radiator „ Water pump Cooling system capacity: 1.5 liter Carburetor heating thermostat: Coolant temperature is less than 80±2 ºC: OPEN...
- Page 15 XP500 TMax Technical Orientation Guide CARBURETION SYSTEM n Twin BS30 round slide carburetors n Automatic choke for easy starting n Throttle Position Sensor to optimize ignition timing and reduce emissions n Coolant type carburetor heater n Pull-pull type throttle control ...
- Page 16 XP500 TMax Technical Orientation Guide AIR INTAKE SYSTEM n Air filter case position in upper front body cowling for effective use of space n Air intake system uses noise reduction box n Air Induction System for reduced emissions Air filter case …...
- Page 17 XP500 TMax Technical Orientation Guide EXHAUST SYSTEM n 2 into 1 stainless exhaust pipes and stainless muffler Muffler ‚ Exhaust Pipe ƒ EGA connection...
- Page 18 XP500 TMax Technical Orientation Guide CHASSIS Like the all-new engine, the TMax’s advanced high-rigidity chassis has been developed using some of the latest motorcycle technology in its frame and suspension designs. n Sports bike type front and rear weight distribution of 47% and 53% respectively n Ground clearance: 140 mm n 50º...
- Page 19 XP500 TMax Technical Orientation Guide FUEL TANK n Steel fuel tank just under rider seat n Fuel lid in rider seat with easy access to fuel cap n Fuel tank capacity is 14 liters n Electric fuel pump for stabilized fuel supply uses external fuel filter ...
- Page 20 XP500 TMax Technical Orientation Guide WINDSCREEN n Large size windscreen for enhanced weather protection n Newly designed cowling mounted mirrors SEAT n One piece deeply padded dual seat n Rider seat features adjustable backrest offering 35 mm of movement in three stages n Seat is locked at left and right side for enhanced security ...
- Page 21 XP500 TMax Technical Orientation Guide STORAGE COMPARTMENTS n Small compartment in the right side front cowling of 1.2 liter for sunglasses, mobile phone, etc. n Rear storage compartment under seat of 33 liters and it can hold a full face helmet or B4 size bag...
- Page 22 XP500 TMax Technical Orientation Guide FRONT SUSPENSION n Motorcycle type front suspension uses upper clamp and 38 mm fork tubes for increased high speed stability n Front wheel travel: 120 mm Lower clamp ‚ Upper clamp ƒ Ball bearings...
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Page 23: Front Wheel / Tire / Brake Overview
XP500 TMax Technical Orientation Guide FRONT WHEEL / TIRE / BRAKE n New 14 x MT 3.50 cast wheel n Front disc brake diameter: 282 mm n Front brake: two piston pin slide-type caliper Front brake caliper Front wheel Tires. - Page 24 XP500 TMax Technical Orientation Guide ELECTRICAL SYSTEM GENERATOR n The generator supplies ample power for electrical accessories n Generator capacity: 22A, 14V @ 5000 rpm n The optional electrical accessories are: mobile phone charger, grip warmers and anti-theft alarm system...
- Page 25 XP500 TMax Technical Orientation Guide TAILLIGHT ASSEMBLY n Newly designed dual taillight Tail / brake light : 12V, 21/5W ‚ Turn signal light : 12V, 21W ƒ License plate light : 12V, 5W Taillight License plate light LEAN ANGLE CUT-OFF SWITCH...
- Page 26 XP500 TMax Technical Orientation Guide INSTRUMENTATION n Automobile-style instrument panel for extensive information and easy reading n Speedometer uses electronic front wheel speed sensor (same type as FZS600) n Main switch has luminescent ring (similar to YP250) Digital clock †...
- Page 27 XP500 TMax Technical Orientation Guide SERVICE TIPS The Service Tips portion of the Technical Orientation Guide is designed to further familiarize you with some key servicing points of the TMax. It is not designed to replace the TMax Service Manual.
- Page 28 XP500 TMax Technical Orientation Guide CARBURETOR ACCESS Carburetor adjustment is easily accessible through the center of the floorboard. The vacuum plugs for carburetor synchronization are on the intake manifolds and the fuel mixture screws for CO adjustment are on the top of carburetors.
- Page 29 XP500 TMax Technical Orientation Guide OTHER COMPONENTS LOCATED UNDER REAR COWL n The Main fuse, starter relay, flasher relay, starter cut-off relay, fuel pump relay, seat lock cable junction and regulator/rectifier are all located under the right side rear cowl.
- Page 30 XP500 TMax Technical Orientation Guide CHECKING TDC AND CAM TIMING POSITION n Remove the left and right floorboards as shown earlier. n Remove the valve cover according to the service manual. n Remove the inspection plug on the left crankcase cover just above the water pump.
- Page 31 XP500 TMax Technical Orientation Guide Function 3 If the igniter detects an electrical problem, the engine oil indicator will flash according to patterns mentioned as Condition Codes in the table below. Circuit Defect(s) System Response Condition Code Remarks Light on : 0.5 s...
- Page 32 XP500 TMax Technical Orientation Guide PRIMARY SHEAVE REMOVAL AND DISASSEMBLY After the V-belt has been removed: n Install the sheave holder on the primary sheave. n Take off the nut. n Take off the front sheave. n Take off the rear sheave from the crankshaft.
- Page 33 Following special tools are NOT new, but they are used only for ATV. It is possible that motorcycle dealers have do not have the proper tools.
- Page 34 XP500 TMax Technical Orientation Guide PERIODIC CHECKS AND ADJUSTMENTS This chapter includes information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to ve- hicles already in service as well as to new vehicles that are being prepared for sale.
- Page 35 XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS XP500 – General Specifications Dimensions: Overall length 2235mm Overall width 775mm Overall height 1410mm Seat height 795mm Wheelbase 1575mm Minimum ground clearance 130mm Weight: Dry (without oil and fuel) 197kg Wet (with oil and a full fuel tank)
- Page 36 XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Transmission: Primary reduction system Helical gear/spur gear Primary reduction ratio 52/32x36/22(2.659) Secondary reduction system Chain drive Secondary reduction ratio 41/25x40/29(2.262) Clutch type Wet multiple-disc automation Transmission type V-Belt automatic Chassis: Frame type Diamond Caster angle 28º...
- Page 37 XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Oil level indicator light 12V1.7Wx1 High beam indicator light 12V1.7Wx1 V-belt replacement indicator light 12V1.7Wx1 Tire pressure (cold): Loading condition A 0~90kg Front 200kPA(2kgf/cm2) Rear 225kPa(2.25kgf/cm2) Loading Condition B 90~183kg Front 225kPa(2.25kgf/cm2) Rear 250kPa(2.5gf/cm2)
- Page 38 XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Valve head diameter A exhaust 21.9~22.1mm Valve face width B intake 1.14~1.98mm Valve face width B exhaust 1.14~1.98mm Valve seat width C intake 0.9~1.1mm Valve seat width C exhaust 0.9~1.1mm Valve margin thickness D intake 0.6~0.8mm...
- Page 39 XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Plating/coating Chrome plated/ferox coating 2nd ring: Ring type Plain Dimensions (B x T) 0.8x2.5mm End gap (installed) 0.4~0.5mm Ring side clearance 0.020~0.055mm Plating/coating Parkerrizing Oil ring: Dimensions (B x T) 1.5x2.0mm End gap (installed) 0.10~0.35mm...
- Page 40 XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Fuel level (using special tool) 29.5~30.5mm Main jet #102.5 Main air jet #100 Jet needle 4DK4-3/5 Needle jet O-0M (#893) Pilot air jet 1 Pilot air jet 2 #170 Pilot outlet Pilot jet #22.5...
- Page 41 XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Steering: Steering bearing type Angular bearing Lock to lock angle (left)((degree)) 38.5º Lock to lock angle (Right)((degree)) 38.5º Front suspension: Front fork travel 120mm Fork spring free length 428.5mm Installed length 419.5mm Collar length 129.6mm...
- Page 42 XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Disc outside diameter x thickness 282x5mm Max. deflection 0.15mm Brake pad lining thickness-inner <Limit> 0.8mm Brake pad lining thickness-outer <Limit> 0.8mm Master cylinder inside diameter 14mm Caliper cylinder inside diameter 30.16mm Caliper cylinder inside diameter 33.34mm...
- Page 43 XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Withstand voltage 200V Battery: Specific gravity 1.32 Electric starting system: System type Constant mesh Starter motor: Model/manufacturer SM-13/YAMAHA Power output 07kW Armature coil resistance ((ohm)) 0.0015~0.0025Ω Brush overall length 12mm <Limit> Brush spring force 7.65~10.01N(780~1021gf)
- Page 44 XP500 TMax Technical Orientation Guide WIRING DIAGRAM...
- Page 45 XP500 TMax Technical Orientation Guide WIRING DIAGRAM...
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