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Yamaha XP500 Technical Manual

Summary of XP500

  • Page 1

    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 featu...

  • Page 2

    Xp500 tmax technical orientation guide 2 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 tradit...

  • Page 3

    Xp500 tmax technical orientation guide 3 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....

  • Page 4

    Xp500 tmax technical orientation guide 4 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 cam chain drive ø 66.0 mm ø 66.0 mm side view top view.

  • Page 5

    Xp500 tmax technical orientation guide 5 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...

  • Page 6

    Xp500 tmax technical orientation guide 6 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 top view cross-section side view ø 66 ø 40 mm v-groove combustion piston bala...

  • Page 7

    Xp500 tmax technical orientation guide 7 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 combustion for balancer all connecting rods use the same 2-piece plain ...

  • Page 8

    Xp500 tmax technical orientation guide 8 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 use...

  • Page 9

    Xp500 tmax technical orientation guide 9 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 † first pinion gear ‡ secondary shaft ˆ first wheel gear ‰ drive axle Š primary driven gear  friction plates:...

  • Page 10

    Xp500 tmax technical orientation guide 10 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 ...

  • Page 11

    Xp500 tmax technical orientation guide 11 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) n new type oil drain bolt that allows oil fr...

  • Page 12

    Xp500 tmax technical orientation guide 12 lubrication system lubrication flow chart.

  • Page 13

    Xp500 tmax technical orientation guide 13 lubrication system.

  • Page 14

    Xp500 tmax technical orientation guide 14 n low mounted radiator for design flexibility n automatic air bleed for easy maintenance cooling system  coolant reservoir tank ‚ thermostat ƒ radiator „ water pump … coolant fan † radiator cap cooling system capacity: 1.5 liter carburetor heating thermosta...

  • Page 15

    Xp500 tmax technical orientation guide 15 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 carburetion system  auto choke unit ‚ thro...

  • Page 16

    Xp500 tmax technical orientation guide 16 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 intake system  air filter case ‚ noise reduction box ƒ vacuum hose to air cut val...

  • Page 17

    Xp500 tmax technical orientation guide 17 n 2 into 1 stainless exhaust pipes and stainless muffler exhaust system  muffler ‚ exhaust pipe ƒ ega connection 1 2 3.

  • Page 18

    Xp500 tmax technical orientation guide 18 frame n newly designed tubular diamond shape frame n frame uses engine as a stressed member for added rigidity and enhanced handling performance n total configuration keeps centre of gravity low and wheelbase short chassis like the all-new engine, the tmax’s...

  • Page 19

    Xp500 tmax technical orientation guide 19 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 bodywork n completely new aerodynamically-effi...

  • Page 20

    Xp500 tmax technical orientation guide 20 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...

  • Page 21

    Xp500 tmax technical orientation guide 21 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 n rear storage compartment has an in...

  • Page 22

    Xp500 tmax technical orientation guide 22 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 top view oil level: 135 mm oil type: sae 7.5 wt rear suspens...

  • Page 23

    Xp500 tmax technical orientation guide 23 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 tires. Dunlop : d305fa 120/70-14 m/c 55s bridgestone : hoop b03 120/70-14 m/c 55s rear wheel / tire / brake n new 14...

  • Page 24

    Xp500 tmax technical orientation guide 24 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 electrical system headlight assembly...

  • Page 25

    Xp500 tmax technical orientation guide 25 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 shuts off fuel pump if tmax falls on its side with run...

  • Page 26

    Xp500 tmax technical orientation guide 26 1 2 3 4 5 6 7 8 9 10  digital clock ‚ speedometer with integrated trip/odometer ƒ coolant temperature gauge „ fuel gauge … oil indicator reset button † trip meter reset button ‡ high beam indicator ˆ v-belt change indicator ‰ engine oil change indicator Š t...

  • Page 27

    Xp500 tmax technical orientation guide 27 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. If not, add enough oil to bring it up to the minimum level and start the engine ...

  • Page 28

    Xp500 tmax technical orientation guide 28 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 cu...

  • Page 29

    Xp500 tmax technical orientation guide 29 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 al...

  • Page 30

    Xp500 tmax technical orientation guide 30 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. N remove the small co...

  • Page 31

    Xp500 tmax technical orientation guide 31 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. Special tools there are three new special tools introduced for the tmax: light on : 0.5 s ligh...

  • Page 32

    Xp500 tmax technical orientation guide 32 sheave holder used on secondary sheave 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 crankshaf...

  • 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 33 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. T...

  • Page 35

    Xp500 tmax technical orientation guide 34 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 f...

  • Page 36

    Xp500 tmax technical orientation guide 35 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 aut...

  • Page 37

    Xp500 tmax technical orientation guide 36 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....

  • Page 38

    Xp500 tmax technical orientation guide 37 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 valve margin thickness d...

  • Page 39

    Xp500 tmax technical orientation guide 38 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....

  • Page 40

    Xp500 tmax technical orientation guide 39 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 #85 pilot air jet 2 #170 pilot outlet 0.8 pilot jet #22.5 bypass 1 0.8 bypass 2 0.8 bypass 3 0.8 pilot screw turns out 2 ...

  • Page 41

    Xp500 tmax technical orientation guide 40 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 spri...

  • Page 42

    Xp500 tmax technical orientation guide 41 disc outside diameter x thickness 282x5mm max. Deflection 0.15mm brake pad lining thickness-inner 6mm 0.8mm brake pad lining thickness-outer 6mm 0.8mm master cylinder inside diameter 14mm caliper cylinder inside diameter 30.16mm caliper cylinder inside diame...

  • Page 43

    Xp500 tmax technical orientation guide 42 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)) 0.0015~0.0025 Ω brush overall length 12mm 4mm brush sp...

  • Page 44

    Xp500 tmax technical orientation guide 44 wiring diagram.

  • Page 45

    Xp500 tmax technical orientation guide 45 wiring diagram.