Yamaha XP500 TMAX 2001-2003 Workshop Service Repair Manual

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This manual covers the Yamaha XP500 TMAX for the model years 2001, 2002, and 2003. The XP500 TMAX is a sport scooter designed to blend the convenience of a scooter...

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Typ: Motorcycle

Anbieter:

Art.-Nr: 69659

Stichworte: 2001 2002 2003 Motorcycle Motorcycles TMAX XP500 XP500 TMAX Yamaha

Produktvarianten

Beschreibung

This manual covers the Yamaha XP500 TMAX for the model years 2001, 2002, and 2003. The XP500 TMAX is a sport scooter designed to blend the convenience of a scooter with the performance and handling characteristics of a motorcycle. Known for its liquid-cooled, 4-stroke, DOHC parallel-twin engine and automatic CVT transmission, it offers a unique riding experience. Engineering quality is evident in its robust construction and performance-oriented design, making it a benchmark in the maxi-scooter segment. This full factory service repair manual provides comprehensive information for maintaining and repairing your Yamaha XP500 TMAX. It includes detailed, step-by-step procedures for disassembly, component replacement, and assembly across all major systems, including the engine, fuel system, cooling system, brakes, suspension, and electrical system. With hundreds of pages, photos, and illustrations, this manual is an invaluable resource for DIY enthusiasts and professional mechanics alike, offering a cost-effective solution for all service needs.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XP500 TMAX

Model Years Covered:

2001, 2002, 2003

Product Type:

Workshop Service Repair Manual

👋 Introduction

Market Position

Target Audience:

DIY enthusiasts and professional mechanics

Value Proposition:

Cost-effective way to maintain and repair the vehicle

Competitive Analysis

Comparison To Alternatives:

More economical than printed manuals or dealership service

Key Features

Content Highlight:

Comprehensive, factory-quality information for all aspects of the vehicle

Accessibility:

Instant download, no shipping costs or waiting

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete factory service and repair information

Styles Covered:

All styles

Page Count

Estimated Page Count:

Hundreds of pages

Manual Type

Type:

Official Full Factory Service Repair Manual

Language

Language:

English

Format

File Format:

Delivery Method:

Download

📖 Manual Coverage

Systems Covered

List:

• General Information

• Fuel System

• Cooling System

• Engine Top End

• Clutch

• Engine Lubrication System

• Engine Removal/Installation

• Crankshaft/Transmission

• Wheels/Tires

• Final Drive

• Brakes

• Suspension

• Steering

• Frame

• Electrical System

• Appendix

Procedures Included

List:

• Step-by-step repair procedures

• Complete disassembly instructions

• Maintenance procedures

• Troubleshooting

• Electrical system diagnostics and repair

• Component replacement

• Assembly procedures

Technical Depth

Level Of Detail:

Detailed, suitable for do-it-yourselfers and experienced mechanics

Visual Aids:

Hundreds of photos and illustrations, enlarged inset views

Diagnostic Features:

Troubleshooting guides combined with detailed wiring diagrams

📊 Manual Specifications

File Format

Compatibility:

All PC-based Windows operating systems and Mac

Print Quality

Printability:

Printable in its entirety or selected pages without restriction

Binding Type

Digital Binding:

N/A (Downloadable PDF)

Paper Type

Digital Paper Type:

N/A (Digital file)

Requirements

Software Requirement:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, parallel-twin

Displacement:

499cc (approximately, based on model history)

Bore X Stroke:

Refer to manual for exact specifications (typical for this era: ~66mm x 73mm)

Compression Ratio:

Refer to manual for exact specifications (typical for this era: ~11.0:1)

Performance

Horsepower:

Refer to manual for exact specifications (estimated 38-40 HP at crank)

Torque:

Refer to manual for exact specifications (estimated 30-32 lb-ft at crank)

Fuel System

Fuel Delivery:

Fuel Injection (FI) - Specifics detailed in manual

Fuel Type:

Unleaded gasoline - Specific octane rating detailed in manual

Air Filtration:

Details on air filter type and replacement intervals

Lubrication System

Oil Type:

Yamalube or equivalent SAE 10W-40 API SG or higher (verify in manual)

Oil Capacity:

Refer to manual for exact specifications (typically around 2.2-2.5 liters with filter change)

Cooling System

Type:

Liquid-cooled

Coolant Type:

Yamaha-specific coolant or equivalent ethylene glycol-based antifreeze mixture (50/50) - Verify in manual

Coolant Capacity:

Refer to manual for exact specifications

Ignition System

Type:

TCI (Transistor Controlled Ignition) - Specifics in manual

Spark Plug Type:

NGK CR9E or equivalent - Verify in manual

Engine Top End

Valve Clearance Intake:

Refer to manual for exact specifications (e.g., 0.12-0.20 mm)

Valve Clearance Exhaust:

Refer to manual for exact specifications (e.g., 0.16-0.24 mm)

🔧 Transmission

Standard

Type:

Automatic (CVT - Continuously Variable Transmission)

Drive System:

Belt drive to rear wheel (via final drive)

Features

Clutch Type:

Wet, centrifugal, automatic

Transmission Fluid:

Specific CVT fluid recommended - verify in manual

📐 Dimensions

Exterior

Overall Length:

Refer to manual for exact specifications (e.g., approx. 2270 mm)

Overall Width:

Refer to manual for exact specifications (e.g., approx. 775 mm)

Overall Height:

Refer to manual for exact specifications (e.g., approx. 1425 mm)

Seat Height:

Refer to manual for exact specifications (e.g., approx. 800 mm)

Weights

Dry Weight:

Refer to manual for exact specifications (e.g., approx. 203 kg)

Wet Weight:

Refer to manual for exact specifications (e.g., approx. 220 kg)

Fuel Tank Capacity:

Refer to manual for exact specifications (e.g., approx. 15 liters)

🛡️ Safety Features

Ratings

Crash Test Results:

Not applicable for this vehicle type

Active Features

Braking System Front:

Dual hydraulic disc brakes - Specific caliper and disc size detailed in manual

Braking System Rear:

Hydraulic disc brake - Specific caliper and disc size detailed in manual

Refer to manual for availability (ABS was an option on some models/markets)

Passive Features

Lighting System:

Halogen headlights, LED taillight, turn signals - Lamp specifications in manual

Instrumentation:

Analogue tachometer, digital speedometer, fuel gauge, clock, etc. - See manual for details

💡 Technology Features

Infotainment

Dashboard:

Comprehensive analogue and digital display providing essential vehicle data.

Driver Assistance

ABS Availability:

Optional on some models, detailed in manual if equipped.

Connectivity

Connectivity Features:

Not applicable for this era of vehicle; focus is on mechanical and electrical systems.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual (typically every 3,000-5,000 km or annually)

Air Filter Cleaning/Replacement:

Refer to manual (typically every 6,000-10,000 km)

Spark Plug Replacement:

Refer to manual (typically every 10,000-15,000 km)

Cv Belt Inspection/Replacement:

Refer to manual (critical component, inspection typically around 20,000 km, replacement interval varies)

Valve Clearance Check:

Refer to manual (e.g., every 20,000 km)

Fluid Specifications

Brake Fluid:

DOT 4 (Verify in manual)

Known Issues

Common Wear Items:

CVT belt, brake pads, tires, suspension bushings (refer to manual for specific checks)

Potential Problems:

Issues with fuel injection sensors or components, starter motor wear are potential areas to inspect as per manual's troubleshooting guides.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Company, Japan

Model Evolution

Introduction Era:

The TMAX marked a significant entry into the high-performance scooter market for Yamaha.

Positioning:

Designed as a 'maxi-scooter' or 'sport scooter' bridging the gap between traditional scooters and motorcycles.

Production

Production Period Covered:

2001-2003 (first generation)

Manufacturing Location:

Primarily manufactured in Japan

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

The TMAX was widely praised for its performance and handling, setting a benchmark in the sport scooter segment.