XP500 TMax Technical Orientation Guide 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 YZFR1 made in the motorcycle scene.
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.
XP500 TMax Technical Orientation Guide CYLINDER HEAD n n n n 4 valves per cylinder, DOHC Torsion type auto cam chain tensioner (similar to YZF-R1) “Shim-under-bucket” valve adjustment for long maintenance interval (same as YZF-R1/YZF-R6) Valve clearance at cold engine condition: Intake : 0.15 - 0.20 mm Exhaust: 0.25 - 0.30 mm 1 2 Intake camshaft Cam chain tensioner Exhaust camshaft Silent cam chain 4 3 Intake port Exhaust port Air Induction Ports TDC 105º (1) 25.0 22.0 (2) 4.0 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 66.0 mm ø 66.
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 secondary inertial forces, while requiring less space.
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 66 BALANCER PISTON Top view Front view Side view 71.
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 16 mm 117 mm 124.
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 n Cooling system uses 2 air filters to provide high volume clean air cooling 2 1 3 4 Engine left side Engine right side 5 Left transmission air filter Air intake duct to transmission Right transmissio
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 Clutch plates: 6 pieces Diaphragm clutch spring Primary drive gear Main axle 1 3 4 First pinion gear Secondary shaft First wheel gear Drive axle Primary driven gear 5 6 7 8 5 10 9 2 Transmission gear reduction ratio = (primary driven gear / primary drive gear) x (fi
XP500 TMax Technical Orientation Guide FINAL DRIVE n Newly designed final drive with non-adjustable 2-stage silent chain for an efficient power transmission, 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 Crankcase Drive axle First stage drive chain Second stage drive chain Taper roller bearing 1 2 3 Mounted on rear w
XP500 TMax Technical Orientation Guide LUBRICATION SYSTEM n n n n n Semi dry sump system for reduced engine size Oil tank is incorporated into the left crankcase cover Newly designed dual stage oil pump Liquid-cooled oil cooler with cartridge type oil filter (5DM-13440-00) New type oil drain bolt that allows oil from crankcase and oil tank to be drained at the same time Dual stage oil pump brings oil from oil tank to respective areas of the engine, including a spray bar over the starter gears and the stat
XP500 TMax Technical Orientation Guide LUBRICATION SYSTEM LUBRICATION FLOW CHART 12
XP500 TMax Technical Orientation Guide LUBRICATION SYSTEM 13
XP500 TMax Technical Orientation Guide COOLING SYSTEM n Low mounted radiator for design flexibility n Automatic air bleed for easy maintenance Coolant Reservoir Tank Thermostat Radiator Water pump Coolant Fan Radiator Cap Cooling system capacity: 1.
XP500 TMax Technical Orientation Guide CARBURETION SYSTEM n n n n n Twin BS30 round slide carburetors Automatic choke for easy starting Throttle Position Sensor to optimize ignition timing and reduce emissions Coolant type carburetor heater Pull-pull type throttle control Auto Choke Unit Throttle Position Sensor 2 1 Carburetor settings Marking 5GJ1 Main jet #105 Jet needle 4DK4-3 Needle jet 0 - 0M Pilot jet #22.5 Pilot screw turns out 2 1/2 Auto-choke electricity control.
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 Noise reduction box Vacuum hose to Air Cut Valve Fuel pump Reed valve Air hose (Reed Valve - Air Cut Valve) Air Cut Valve 1 See Service Tips for CO adjustment and Air Induction System check procedure 2 7 3 4 6 To exhaust port 5 BLOCK HERE FOR CO
XP500 TMax Technical Orientation Guide EXHAUST SYSTEM n 2 into 1 stainless exhaust pipes and stainless muffler Muffler Exhaust Pipe EGA connection 1 2 17 3
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.
XP500 TMax Technical Orientation Guide FUEL TANK n n n n Steel fuel tank just under rider seat Fuel lid in rider seat with easy access to fuel cap Fuel tank capacity is 14 liters Electric fuel pump for stabilized fuel supply uses external fuel filter Fuel lid Fuel tank cap Fuel tank 1 2 3 BODYWORK n Completely new aerodynamically-efficient sports styled bodywork Integrated turn signal lights Aluminium grab bar for improved passenger comfort 1 2 19
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 Fuel lid Adjustable backrest 2 1 35 mm Seat height: 795 mm 20
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.
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 Ball bearings 2 Top view 1 3 Oil level: 135 mm Oil type: SAE 7.
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. Dunlop Bridgestone : D305FA 120/70-14 M/C 55S : HOOP B03 120/70-14 M/C 55S REAR WHEEL / TIRE / BRAKE n n n n New 14 x MT 4.
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 HEADLIGHT ASSEMBLY n Newly designed multi-reflector dual headlight Low beam High beam Auxiliary lights : 12V, 55W (H7 - 12V, 55W) : 12V, 60W (H4 - 12V, 60/55W) : 12V, 5Wx2 For UK specifications, the positions of the left a
XP500 TMax Technical Orientation Guide TAILLIGHT ASSEMBLY n Newly designed dual taillight Tail / brake light : 12V, 21/5W Turn signal light : 12V, 21W License plate light : 12V, 5W License plate light Taillight 2 2 3 1 LEAN ANGLE CUT-OFF SWITCH Shuts off fuel pump if TMax falls on its side with running engine Switch can not be activated if TMax is leaned over while cornering If activated, the main switch must be turned “off” and then back “on” again to start the engine ANTI-THEFT ALARM PRE-WIRI
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 Speedometer with integrated trip/odometer Coolant temperature gauge Fuel gauge Oil indicator reset button 1 10 9 8 Trip meter reset button High beam indicator V-belt change indicator Engine oil change indicator
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. For complete servicing details please refer to the Service Manual. ENGINE OIL LEVEL CHECK Start checking from cold engine condition. n Put the TMax on the main stand on level ground and check that the oil is at minimum level in the sight glass.
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. AIR CUT VALVE The Air Cut Valve for the Air Induction System is located under the windshield on the left side of the air box.
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. n The stator, pick up coil and alarm connectors are located under the left side.
XP500 TMax Technical Orientation Guide CHECKING TDC AND CAM TIMING POSITION n n n n Remove the left and right floorboards as shown earlier. Remove the valve cover according to the service manual. Remove the inspection plug on the left crankcase cover just above the water pump. Remove the small cover on the front of the right side crankcase cover to access the primary sheave nut. n Rotate the primary sheave nut clockwise until the TDC mark on the rotor is aligned with the mark in the inspection window.
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 TPS l l l Defect(s) System Response Disconnected l The igniter-unit stays set to wide-open Short circuit. throttle ignition timing. Mechanical l Oil indicator displays condition code. Malfunction. Condition Code Speed l Disconnected l Oil indicator displays condition code.
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. To disassemble the primary sheave: n Remove the screws. n Remove the sheave cap. n Remove the cam. n Remove and inspect the weights and sliders for damage.
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.
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 vehicles already in service as well as to new vehicles that are being prepared for sale.
XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS XP500 – General Specifications Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Weight: Dry (without oil and fuel) Wet (with oil and a full fuel tank) Maximum load-except motorcycle Performance: Minimum turning radius Engine: Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Standard compression pressure (at sea level) Starting system type Lubrication System: Type O
XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Clutch type Transmission type Chassis: Frame type Caster angle Trail Tire: Tire type Size(front) Size(rear) Manufacturer (front) Manufacturer (rear) Brake: Front brake type Rear brake type Suspension: Front suspension Rear suspension Shock Absorber: Front fork type Rear shock absorber assembly type Wheel Travel: Front wheel travel R
XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Oil level indicator light High beam indicator light V-belt replacement indicator light Tire pressure (cold): Loading condition A Front Rear Loading Condition B Front Rear High speed riding Front Rear Maintenance Specification Cylinder Head Volume Max. warpage Cylinder Bore Taper limit Max.
XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Valve head diameter A exhaust Valve face width B intake Valve face width B exhaust Valve seat width C intake Valve seat width C exhaust Valve margin thickness D intake Valve margin thickness D exhaust Valve stem diameter-intake Valve stem diameter-exhaust Valve guide inside diameter-intake Valve guide inside diameter-exhaust Valve stem to valve guideclearance-intake Valve stem to valve guideclearance-exhaust Valve stem runout Valve seat width-int
XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Plating/coating 2nd ring: Ring type Dimensions (B x T) End gap (installed) Ring side clearance Plating/coating Oil ring: Dimensions (B x T) End gap (installed) Ring side clearance Plating/coating Connecting rod: Oil clearance (using plasti-gauge) Bearing color code Connecting rod length Crankshaft: Width A Width B Max.
XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Fuel level (using special tool) Main jet Main air jet Jet needle Needle jet Pilot air jet 1 Pilot air jet 2 Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw turns out Valve seat size Throttle valve size Idling condition: Engine idle speed CO% with AIS blocked Intake vacuum Water temparature ((degreeC)) Oil temparature ((degree C)) Fuel pump: Pump type Model/manufacturer Consumption amperage (max.
XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Steering: Steering bearing type Lock to lock angle (left)((degree)) Lock to lock angle (Right)((degree)) Front suspension: Front fork travel Fork spring free length Installed length Collar length Spring rate (K 1) Spring rate (K 2) Spring rate (K 3) Spring stroke (K 1) Spring stroke (K 2) Spring stroke (K 3) Optional spring available Oil Quantity Oil Level Recommended oil Inner tube outer diameter Rear suspension: Rear shock absorber assembly tra
XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Disc outside diameter x thickness Max. deflection Brake pad lining thickness-inner Brake pad lining thickness-outer Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Rear disc brake: Disc brake type Disc outside diameter x thickness Max.
XP500 TMax Technical Orientation Guide GENERAL SPECIFICATIONS Withstand voltage Battery: Specific gravity Electric starting system: System type Starter motor: Model/manufacturer Power output Armature coil resistance ((ohm)) Brush overall length Brush spring force Commutator diameter Mica undercut (depth) Starter relay: Model/manufacturer Amperage Coil resistance ((ohm)) Horn: Quantity Model/manufacturer Max.
XP500 TMax Technical Orientation Guide WIRING DIAGRAM 44
XP500 TMax Technical Orientation Guide WIRING DIAGRAM 45
