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Yamaha 2012 TMAX XP500A User Manual

Yamaha 2012 TMAX XP500A
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SERVICE MANUAL
XP500A
2012
59C-28197-E1

Table of Contents

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Yamaha 2012 TMAX XP500A Specifications

General IconGeneral
Engine TypeLiquid-cooled, 4-stroke, DOHC, 4-valve
Displacement499cc
Bore x Stroke66.0 mm x 73.0 mm
Compression Ratio11.0 : 1
Fuel SystemFuel Injection
TransmissionV-Belt Automatic
Final DriveBelt
Front SuspensionTelescopic forks
Rear SuspensionSwingarm
Front BrakeDual hydraulic disc
Front Tire120/70-15
Rear Tire160/60-15
Width775 mm
Seat Height800 mm
Wheelbase1, 580 mm
Ground Clearance125 mm
Wet Weight217 kg
IgnitionTCI
Curb Weight217 kg
Rear BrakeSingle hydraulic disc
Fuel Capacity15 liters
Length2, 200 mm
Height1420mm
Maximum Torque52.3 Nm (5.3 kg-m) @ 6, 250 rpm

Summary

SPECIFICATIONS

TIGHTENING TORQUES

Torque values for standard fasteners and engine/chassis components.

PERIODIC MAINTENANCE

GENERAL MAINTENANCE AND LUBRICATION CHART

Comprehensive schedule for checks, maintenance, and lubrication at different intervals.

Engine Checks and Adjustments

Procedures for checking fuel lines, spark plugs, valve clearance, and idling speed.

Brake System Checks and Adjustments

Checking brake fluid, pads, hoses, and bleeding the hydraulic system.

Engine Oil and Coolant Service

Procedures for checking engine oil level, changing oil, and checking coolant.

CHASSIS

FRONT WHEEL

Steps for removing, disassembling, checking, and installing the front wheel.

REAR WHEEL

Steps for removing, disassembling, checking, and installing the rear wheel.

FRONT BRAKE

Procedures for removing/disassembling brake pads, calipers, master cylinder.

REAR BRAKE

Procedures for removing/disassembling brake pads, caliper, master cylinder, and lock.

ABS (ANTI-LOCK BRAKE SYSTEM)

Procedures for removing the hydraulic unit assembly and related components.

FRONT FORK

Steps for removing, disassembling, checking, assembling, and installing front fork legs.

STEERING HEAD

Procedures for removing, checking, and installing steering head components.

ENGINE

ENGINE INSPECTION

Initial checks including compression pressure measurement.

ENGINE REMOVAL

Steps for removing and installing the engine assembly and related components.

V-BELT AUTOMATIC TRANSMISSION

Procedures for removing, disassembling, checking, and installing V-belt and sheaves.

CRANKSHAFT

Procedures for removing crankshaft, connecting rods, bearings, and checking runout.

FUEL SYSTEM

ELECTRICAL SYSTEM

IGNITION SYSTEM

Circuit diagram and troubleshooting steps for the ignition system.

ELECTRIC STARTING SYSTEM

Circuit diagram and troubleshooting for the electric starting system.

CHARGING SYSTEM

Circuit diagram and troubleshooting steps for the charging system.

LIGHTING SYSTEM

Circuit diagram and troubleshooting for headlights, taillights, and indicators.

ABS (ANTI-LOCK BRAKE SYSTEM)

Circuit diagram and detailed troubleshooting for the ABS system.

TROUBLESHOOTING

TROUBLESHOOTING AT THE ABS WARNING LIGHT

Guide for diagnosing ABS warning light behavior and related malfunctions.

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Information on diagnostic codes, sensor operation checks, and actuator tests.