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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Type: Motorcycle

Vendor:

Sku: 450762

Tags: 2001 2002 2003 Motorcycle Motorcycles X Max XP 500 T-Max Yamaha

Product variants

Description

🏷️ 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:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 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:

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:

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).