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Yamaha XP 500 T-Max 2001-2003 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: XP 500 T-Max Model Variant: First Generation Production Years Covered: 2001, 2002, 2003 👋 Introduction Market Position Segment: Maxi-scooter / Sport Scooter Unique...
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Taper: Motorcycle
Distributeur:
Yamaha
UGS: 450762
Mots clés: 2001 2002 2003 Motorcycle Motorcycles X Max XP 500 T-Max Yamaha
Yamaha XP 500 T-Max 2001-2003 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XP 500 T-Max
Model Variant:
First Generation
Production Years Covered:
2001, 2002, 2003
👋 Introduction
Market Position
Segment:
Maxi-scooter / Sport Scooter
Unique Selling Proposition:
Blends scooter practicality with motorcycle-like performance and handling.
Competitive Analysis
Key Competitors Era:
Suzuki Burgman 400/650, Honda Silver Wing, Aprilia Scarabeo.
Key Features
Design Philosophy:
Sporty ergonomics, powerful engine, motorcycle-style chassis and suspension.
Target Audience:
Commuters seeking performance, touring riders, riders wanting a sporty yet practical two-wheeler.
📋 Manual Details
Coverage Areas
Primary Focus:
Workshop Service and Repair
Geographic Coverage:
Global (Standard Yamaha Specifications)
Page Count
Total Pages:
393
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, inspection, tuning, internal components, external components, cooling system, lubrication system, fuel injection system.
Drivetrain:
Continuously Variable Transmission (CVT) system, clutch, drive belt, final drive (chain/belt specifics for model).
Chassis:
Frame, suspension (front telescopic fork, rear swingarm), steering system, wheel and tire maintenance.
Brakes:
Front and rear brake systems, hydraulic lines, brake fluid specifications, caliper service, disc maintenance, parking brake.
Electrical:
Wiring diagrams, ignition system, starting system, lighting system, battery maintenance, charging system (stator, regulator/rectifier), fuses, relays, dashboard instrumentation.
Bodywork And Trim:
Fairings, seat removal, storage compartment access, panel installation and removal.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, coolant flushes, brake bleeding, drive belt inspection/replacement, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnostic procedures for common faults, symptom-based troubleshooting charts, electrical system diagnostics.
Repair And Overhaul:
Engine rebuild procedures, transmission disassembly and reassembly, suspension fork service, brake caliper overhaul, starter motor repair.
Adjustments:
Throttle cable adjustment, idle speed adjustment, brake lever adjustment, suspension preload adjustment.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Assumes technician familiarity with motorcycle mechanics.
Diagnostic Information:
Detailed diagnostic flowcharts and specifications for electrical and mechanical systems.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable if properly OCR'd, enabling quick navigation.
Print Quality
Quality Expectation:
High-resolution digital reproduction of original factory documentation, ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (Digital PDF Format)
Paper Type
Paper:
N/A (Digital PDF Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, Liquid-cooled, DOHC, Parallel-twin
Displacement:
499 cc (493.5 cc)
Bore X Stroke:
66.0 mm x 73.0 mm
Compression Ratio:
11.0:1
Performance
Horsepower Estimated:
44.2 hp @ 7,500 rpm (approx.)
Torque Estimated:
48.4 Nm @ 6,000 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline, Octane Rating 86 or higher.
Ignition
Ignition System:
TCI (Transistor Controlled Ignition)
Cooling System
Cooling Method:
Liquid Cooling
Lubrication
Lubrication System:
Wet Sump
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 API SE, SF, SG or SH
Engine Oil Capacity:
2.1 Liters (with oil filter change)
🔧 Transmission
Standard
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Drive Type:
Automatic Belt Drive
Final Drive:
V-belt, Automatic Centrifugal Clutch
Features
Clutch Type:
Automatic, Dry, Multiple Disc
Transmission Fluid Type:
Yamaha Gear Oil 10W-30 API GL-4 (or equivalent)
Transmission Oil Capacity:
0.25 Liters
📐 Dimensions
Exterior
Length:
2,205 mm (86.8 in)
Width:
775 mm (30.5 in)
Height:
1,425 mm (56.1 in) (with windshield)
Seat Height:
800 mm (31.5 in)
Wheelbase:
1,540 mm (60.6 in)
Weights
Dry Weight:
200 kg (441 lbs)
Wet Weight:
215 kg (474 lbs) (approx.)
Capacities
Fuel Tank Capacity:
14 Liters (3.7 US gal)
Coolant Capacity:
1.7 Liters
Storage Capacity:
Under-seat storage for one full-face helmet.
🛡️ Safety Features
Ratings
Crash Test Data:
N/A (Motorcycle/Scooter Safety Standards Vary by Region)
Active Features
Braking System:
Front: Dual Hydraulic Disc, Rear: Hydraulic Disc.
Parking Brake:
Hand-operated, located on right handlebar.
Passive Features
Lighting:
Halogen Headlight, LED Taillight, Turn Signals.
Instrumentation:
Speedometer, Tachometer, Fuel Gauge, Odometer, Trip Meter, Warning Lights.
💡 Technology Features
Infotainment
Dashboard Features:
Analog tachometer, digital speedometer, fuel gauge, clock, odometer, trip meter, various indicator lights.
Connectivity
Connectivity Features:
None (Basic instrumentation)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 10,000 km (6,000 miles).
Drive Belt Inspection:
Every 10,000 km (6,000 miles) for wear and cracks; replacement recommended around 20,000-30,000 km or as needed.
Spark Plug Replacement:
Every 20,000 km (12,000 miles).
Brake Fluid Replacement:
Every 2 years or 20,000 km.
Fluid Specifications
Coolant Type:
High-quality ethylene glycol-based coolant with demineralized water (50:50 mixture).
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
Drive belt (can stretch/crack with age/mileage), front fork seals (leaks), brake pads, tires.
Potential Electrical Issues:
Regulator/rectifier failure (can lead to battery charging issues), stator coil degradation over time.
Engine Notes:
Generally robust parallel-twin, but requires consistent maintenance, especially regarding cooling system integrity.
📚 Vehicle History
Brand Heritage
Manufacturer Focus:
Yamaha's long history in motorcycle and motorsport development.
Model Evolution
Introduction Year:
2001
Design Intent:
To create a maxi-scooter that offers the performance and handling characteristics of a sport motorcycle.
Production
Manufacturing Location:
Japan (Primary)
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The T-Max was critically acclaimed upon its release for setting a new benchmark in maxi-scooter performance and handling.
Ratings
Rider Satisfaction:
Consistently high rider satisfaction due to its blend of performance and practicality.
Certifications
Emissions Standards:
Compliant with relevant emissions standards for the model years (e.g., Euro 2).
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