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Yamaha XP500 TMAX Service Repair Manual 01-07

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🏷️ Basic Information Identification Make: Yamaha Model: TMAX Product Name: Yamaha XP500 TMAX Service Repair Manual 01-07 Codes Model Code: XP500 👋 Introduction Market Position Segment: Maxi-scooter, sport scooter, premium...
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Taper: Motorcycle
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Yamaha XP500 TMAX Service Repair Manual 01-07
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TMAX
Product Name:
Yamaha XP500 TMAX Service Repair Manual 01-07
Codes
Model Code:
XP500
👋 Introduction
Market Position
Segment:
Maxi-scooter, sport scooter, premium commuter.
Key Selling Points:
Performance, comfort, practicality, motorcycle-like handling.
Competitive Analysis
Competitors:
Honda Silver Wing, Suzuki Burgman, Aprilia Scarabeo.
Key Features
Distinguishing Features Of Tmax:
Aluminium frame, motorcycle-style suspension, powerful twin-cylinder engine, automatic transmission.
Manual Value Proposition
Benefits For Owner:
Enables DIY maintenance, reduces repair costs, extends vehicle lifespan, improves understanding of vehicle mechanics.
📋 Manual Details
Coverage Areas
Years Covered:
2001, 2002, 2003, 2004, 2005, 2006, 2007
Geographic Coverage:
Global (specifications may vary by region)
Page Count
Estimated Page Count:
Hundreds of pages
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, disassembly, assembly, lubrication, internal components, piston, rings, cylinder, crankshaft, connecting rods, cylinder head, valves, timing system.
Fuel System:
Fuel injection system, throttle body, injectors, fuel pump, fuel pressure regulator, fuel filter, fuel tank maintenance.
Cooling System:
Radiator, coolant, water pump, thermostat, hoses, fan, cooling system troubleshooting and repair.
Electrical System:
Ignition system, starter motor, alternator, battery, lighting, charging system, wiring diagrams, fuses, relays.
Drivetrain:
CVT (Continuously Variable Transmission) system, drive belt, clutch, torque converter, final drive, gears, lubrication.
Brakes:
Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, brake discs, bleeding procedures, parking brake.
Suspension:
Front telescopic forks, rear swingarm, shock absorbers, springs, bushings, lubrication, adjustment, and repair.
Steering:
Handlebar assembly, steering stem bearings, lubrication, adjustment.
Chassis Frame:
Frame components, subframe, body panels, fasteners, alignment checks.
Bodywork:
Fairings, seat, storage compartments, panels, removal and installation procedures.
Procedures Included
Preventive Maintenance:
Oil changes, filter replacements, spark plug service, drive belt inspection and replacement, brake fluid flush, coolant checks.
Troubleshooting:
Diagnostic charts, common problem identification and solutions, error code interpretation.
Rebuilding Overhaul:
Detailed step-by-step instructions for complete engine, transmission, and suspension rebuilds.
Adjustments:
Carburetor (if applicable, though TMAX is FI), throttle cable, brake levers, suspension settings.
Disassembly Reassembly:
Comprehensive guides for all major components and systems.
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine rebuilds and electrical diagnostics).
Diagnostic Capabilities:
Detailed troubleshooting guides and diagnostic flowcharts.
Specifications Data:
Torque specifications, clearances, tolerances, electrical resistance values.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable PDF for efficient information retrieval.
Print Quality
Print Readability:
Designed for clear digital viewing and printing.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve inline-twin
Displacement:
499 cc
Performance
Bore X Stroke:
66.0 mm x 72.0 mm
Compression Ratio:
11.0:1
Fuel Induction:
Electronic Fuel Injection (EFI)
Ignition:
TCI (Transistor Controlled Ignition)
Starting System:
Electric
Estimated Horsepower:
Approx. 43.5 HP @ 7500 RPM
Estimated Torque:
Approx. 45.1 Nm @ 6000 RPM
Fuel System
Fuel Type:
Unleaded gasoline
🔧 Transmission
Standard
Type:
Automatic (CVT - Continuously Variable Transmission)
Features
Drive System:
Belt drive to rear wheel
Clutch Type:
Automatic centrifugal clutch
📐 Dimensions
Exterior
Length:
Approx. 2,205 mm (2001-2003), 2,250 mm (2004-2007)
Width:
Approx. 775 mm (2001-2003), 780 mm (2004-2007)
Height:
Approx. 1,430 mm (2001-2003), 1,445 mm (2004-2007)
Wheelbase:
Approx. 1,540 mm (2001-2003), 1,550 mm (2004-2007)
Weights
Dry Weight:
Approx. 202 kg (2001-2003), 203 kg (2004-2007)
Wet Weight:
Approx. 220 kg (2001-2003), 221 kg (2004-2007)
Cargo
Underseat Storage:
Spacious underseat storage compartment, typically fits one full-face helmet and other items.
🛡️ Safety Features
Ratings
Crash Test Information:
Motorcycle safety standards apply; specific crash test ratings not typically available for scooters.
Active Features
Braking System:
Dual front disc brakes, single rear disc brake, optional ABS on some later models.
Lighting:
Halogen headlight, LED taillight, turn signals.
Passive Features
Frame Construction:
Lightweight aluminum die-cast frame for rigidity and stability.
Wind Protection:
Full fairing and windscreen for rider protection.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer and speedometer, LCD display for odometer, trip meters, fuel gauge, clock, and warning lights.
Driver Assistance
ABS Availability:
Optional ABS (Anti-lock Braking System) available on some variants from 2004 onwards.
Connectivity
Connectivity Features:
N/A (Basic vehicle technology for this era).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 km or 6 months, whichever comes first.
Oil Filter Replacement:
Concurrent with engine oil changes.
Drive Belt Inspection:
Every 10,000 km; replacement typically recommended around 20,000-30,000 km or as needed.
Spark Plug Replacement:
Refer to manual for specific interval, often around 10,000-15,000 km.
Coolant Change:
Every 2 years or 20,000 km, whichever comes first.
Fluid Specifications
Engine Oil Type:
Yamaha recommends Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher.
Engine Oil Capacity:
Approx. 2.0 L (without filter change), 2.1 L (with filter change).
Brake Fluid Type:
DOT 4
Coolant Type:
High-quality ethylene glycol-based coolant (50% mixture with distilled water)
Known Issues
Common Wear Items:
Drive belt, tires, brake pads, fork seals, battery.
Potential Problems Early Models:
Some early models may have experienced minor issues with fuel pump or starter motor, generally addressed through recalls or service bulletins.
📚 Vehicle History
Brand Heritage
Yamaha Legacy:
Yamaha Motor Company is renowned for its innovation in motorcycles, musical instruments, and marine products, with a strong legacy of performance and reliability.
Model Evolution
Tmax Introduction:
The TMAX was introduced in 2001, revolutionizing the maxi-scooter market with its blend of scooter convenience and motorcycle performance.
Generation Changes 01-07:
Minor updates and refinements occurred between 2001 and 2007, including aesthetic changes, minor engine tweaks, and chassis improvements in the 2004 facelift.
Production
Manufacturing Location:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Market Reception:
The TMAX was widely praised upon its release for its innovative design and superior performance, setting a new benchmark for maxi-scooters.
Ratings
Owner Satisfaction:
Generally high owner satisfaction due to its blend of performance, comfort, and practicality.
Certifications
Emissions Standards:
Meets emissions standards relevant to the model years and respective markets.
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