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Yamaha TMAX TECH MAX 2020 User Manual

Yamaha TMAX TECH MAX 2020
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2020
SERVICE MANUAL
TMAX
TMAX TECH MAX
XP560EL
XP560D
B3T-28197-20

Table of Contents

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Yamaha TMAX TECH MAX 2020 Specifications

General IconGeneral
Displacement562 cc
Compression Ratio10.9:1
Lubrication SystemWet sump
Fuel SystemFuel Injection
Ignition SystemTCI
Starter SystemElectric
Transmission SystemV-Belt Automatic
Final DriveBelt
Front Suspension SystemTelescopic fork
Front Travel120 mm
Rear Suspension SystemSwingarm
Rear Travel117 mm
Front Tyre120/70-15
Seat Height800 mm
Wheel Base1, 575 mm
Minimum Ground Clearance135 mm
Wet Weight220 kg
Engine TypeLiquid-cooled, 4-stroke, DOHC, 4-valve
Maximum Torque55.7 Nm (5.7 kg-m) @ 5, 250 rpm
Front BrakeDual 267 mm discs
Rear BrakeSingle hydraulic disc
Rear Tyre160/60-15
Fuel Tank Capacity15 litres
FeaturesHeated Grips, Adjustable windscreen, Traction control

Summary

SPECIFICATIONS

GENERAL SPECIFICATIONS

Provides dimensions, weight, loading capacity, and model details for XP560E, XP560D_RUS, XP560D_ZAF.

ENGINE SPECIFICATIONS

Details combustion cycle, cooling system, valve train, displacement, bore, stroke, compression, fuel, and engine oil.

CHASSIS SPECIFICATIONS

Covers frame, wheels, tires, front and rear brakes, and front/rear suspension specifications.

ELECTRICAL SPECIFICATIONS

Lists system voltage, ignition system, engine control unit, ignition coil, spark plug cap, and charging system details.

TIGHTENING TORQUES

Specifies torque values for engine and chassis items, including nuts, bolts, and unions.

PERIODIC MAINTENANCE

CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL

Procedure for using the YDT to check the vehicle, including removing covers, connecting to the coupler, and checking DTCs.

ADJUSTING THE VALVE CLEARANCE

Procedure for adjusting valve clearance on a cold engine, including removing parts and calculating valve pad thickness.

ENGINE

ENGINE INSPECTION

Details on measuring compression pressure, including procedure and specifications.

ENGINE REMOVAL

Step-by-step instructions for removing the exhaust assembly and the engine.

CAMSHAFTS

Procedures for removing, checking, and installing camshafts, including lobe dimensions and runout.

CYLINDER HEAD

Instructions for removing, checking, and installing the cylinder head, including warpage measurement.

VALVES AND VALVE SPRINGS

Procedures for removing, checking, and installing valves, valve springs, and related components.

CYLINDER AND PISTONS

Instructions for removing, checking, and installing cylinders and pistons, including ring and pin measurements.

V-BELT AUTOMATIC TRANSMISSION

CLUTCH

REMOVING THE CLUTCH

Procedure for removing the clutch assembly, including draining engine oil and coolant.

DISASSEMBLING THE CLUTCH

Detailed steps for disassembling the clutch, including removing clips, stopper plates, springs, and plates.

CRANKCASE

SEPARATING THE CRANKCASE

Instructions for removing engine, cylinder head, pistons, starter motor, generator, and clutch assemblies.

CRANKSHAFT

REMOVING THE CRANKSHAFT ASSEMBLY

Procedure to remove the crankshaft assembly, balancer cylinder, and oil seal.

REMOVING THE CONNECTING RODS

Steps for removing connecting rod caps, connecting rods, and big end bearings.

CHECKING THE CRANKSHAFT AND CONNECTING RODS

Procedure to measure crankshaft runout and check journal, pin, and bearing surfaces.

TRANSMISSION

REMOVING THE TRANSMISSION

Procedure to remove secondary shaft, collars, O-rings, gears, drive axle, and wheel gears.

ELECTRICAL SYSTEM

SELF-DIAGNOSTIC FUNCTION

YDT

Information about the Yamaha Diagnostic Tool (YDT) and its usage for identifying malfunctions.

SYSTEM DIAGRAM

ECU CIRCUIT DIAGRAM

Detailed circuit diagram for the Engine Control Unit (ECU).

FUEL INJECTION SYSTEM

BASIC PROCESS FOR TROUBLESHOOTING

General troubleshooting steps for fuel injection system issues, focusing on MIL and DTC checks.

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)

Table detailing DTCs related to the fuel injection system, including probable causes and symptoms.

SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System))

Table listing DTCs related to the ABS system, their symptoms, and check points.

ABS (Anti-lock Brake System)

CIRCUIT DIAGRAM

Wiring diagram for the ABS system.

[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON

Troubleshooting steps for when only the ABS warning light fails to illuminate.

[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON

Troubleshooting steps when all indicator lights fail to illuminate.

[A-3] THE ABS WARNING LIGHT COMES ON

Troubleshooting steps when the ABS warning light remains on.

[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE

Troubleshooting steps when only the ABS ECU fails to communicate.

[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE

Troubleshooting steps when both ABS ECU and FI ECU fail to communicate.

DTC TABLE

Table listing DTCs, their symptoms, probable causes, vehicle symptoms, and fail-safe operations.

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