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Yamaha XP500 TMax User Manual

Yamaha XP500 TMax
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XP500 TMax Technical Orientation Guide
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.
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
clutch
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
CHASSIS FEATURES
n Motorcycle-type high rigidity diamond shape
frame
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

Table of Contents

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Yamaha XP500 TMax Specifications

General IconGeneral
Engine TypeLiquid-cooled, 4-stroke, DOHC, 4-valve
Compression Ratio10.9:1
Fuel SystemFuel Injection
Ignition SystemTCI
TransmissionV-Belt Automatic
Rear SuspensionSwingarm
Front BrakeDual hydraulic disc
Front Tire120/70-15
Rear Tire160/60-15
Seat Height800 mm
Wet Weight220 kg
Overall Length2, 200 mm
Overall Width775 mm
Overall Height1, 420 mm
Wheelbase1, 575 mm
Ground Clearance125 mm
Front SuspensionTelescopic fork
Rear BrakeHydraulic disc
Fuel Tank Capacity15.0 L

Summary

Features and Benefits

Engine Features

Lists key engine components and technologies for the TMax superscooter.

Chassis Features

Highlights frame, suspension, wheels, and ergonomic features of the chassis.

Electrical Features

Details lighting, instrumentation, and electrical accessory provisions.

Engine System

Engine Features

Provides detailed specifications and technical features of the TMax engine.

Cylinder Head

Cylinder Head Specifications

Details valve train components, camshaft specifications, and valve timing.

Cylinder

Cylinder Features

Describes the cylinder body, liquid cooling, and left-side cam chain drive.

Crankshaft/Balancer

Crankshaft and Balancer Design

Explains the crankshaft, horizontally opposed balancer, and bearing system.

Piston

Piston Design and Dimensions

Details combustion and balancer piston features, including V-groove and dimensions.

Connecting Rod

Connecting Rod Specifications

Describes the connecting rods used for combustion and the balancing system.

Transmission System

Continuously Variable Transmission

Explains the CVT system, V-belt, cooling, and transmission filters.

Clutch

Clutch Operation and Specifications

Details the wet multi-plate centrifugal clutch, spring type, and gear reduction ratio.

Final Drive

Final Drive Assembly and Gear Ratio

Covers the final drive chain, swingarm integration, and gear ratio calculation.

Lubrication System

Lubrication System Components

Describes the semi dry sump system, oil pump, cooler, and oil capacity.

Lubrication Flow Chart

Illustrates the oil flow path for scavenging and feeding pumps.

Cooling System

Cooling System Components and Thermostats

Details the radiator, pump, fan, and thermostat operation for engine cooling.

Carburetion System

Carburetor Specifications and Auto-Choke Control

Lists carburetor settings and auto-choke electrical control logic.

Air Intake System

Air Intake System Components

Describes the air filter case, noise reduction box, and induction system.

Exhaust System

Exhaust System Components

Details the 2-into-1 stainless exhaust pipes and muffler assembly.

Chassis

Frame Design and Specifications

Covers the high-rigidity chassis, frame design, and dimensional references.

Fuel Tank

Fuel Tank and Bodywork

Describes the fuel tank location, capacity, and aerodynamically styled bodywork.

Windscreen

Windscreen and Seat Features

Details windscreen protection and seat design with adjustable backrest.

Storage Compartments

Storage Compartment Details

Outlines front and rear storage compartment sizes and features.

Front Suspension

Front and Rear Suspension Systems

Explains front fork, rear shock absorber, and swingarm design.

Front Wheel / Tire / Brake

Front and Rear Wheel, Tire, and Brake Specifications

Details wheel, tire, and brake caliper specifications for front and rear.

Electrical System

Generator and Headlight Assembly

Covers generator capacity and the design of the dual multi-reflector headlight.

Taillight Assembly, Switches, and Accessory Wiring

Details taillight assembly, lean angle switch, and accessory pre-wiring.

Instrumentation

Instrument Panel Layout and Indicators

Describes the instrument panel layout, speedometer, and indicator lights.

Service Tips

Fluid Level Checks and Maintenance

Provides guidance on checking engine oil, final drive, and coolant levels.

Carburetor Access

Carburetor Adjustment, Air System, and Access

Details CO adjustment, air induction system, and access for related components.

Components Under Rear Cowl

Component Locations and Maintenance

Identifies components under the rear cowl and outlines V-belt replacement.

TDC and Cam Timing

Timing, Valve Adjustment, and Oil Indicator Reset

Explains timing checks, valve adjustment precautions, and oil indicator reset.

Special Tools

Special Tools for TMAX Maintenance

Lists specialized tools required for clutch and bearing maintenance procedures.

Sheave and Bearing Maintenance

Sheave and Bearing Maintenance Procedures

Details primary/secondary sheave removal and main bearing replacement.

Periodic Checks and Adjustments

Periodic Maintenance and Lubrication Chart

Provides a schedule for regular checks, adjustments, and lubrication intervals.

Wiring Diagram

Wiring Diagram and Component Identification

Details the electrical wiring schematic and its component color codes.

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