Yamaha XP500N 2001-2003 Workshop Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 69660

Tags: 2001 2002 2003 Misc Motorcycle Motorcycles XP500N Yamaha

Product variants

Description

This manual covers the XP500N TMAX, a groundbreaking maxi-scooter first introduced in 2001. Designed to offer the practicality of a scooter with the performance and handling characteristics of a motorcycle, the XP500N features a powerful 499cc parallel-twin engine, a robust aluminum frame, and a comfortable riding position. Its innovative design, including a motorcycle-style suspension and dual front disc brakes, quickly established it as a benchmark in its class, appealing to commuters and touring riders alike. This generation of the TMAX represents a commitment to engineering excellence and rider-focused design. This comprehensive workshop service repair manual provides detailed guidance for the maintenance, repair, and troubleshooting of the XP500N TMAX for the model years 2001 through 2003. It includes full coverage of the engine, transmission, electrical system, chassis, bodywork, and braking system, along with specific procedures for routine maintenance, component removal and installation, and diagnostic troubleshooting. With detailed technical specifications, torque values, and wiring diagrams, this manual serves as an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their TMAX.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XP500N TMAX

Model Designation:

Model Code:

XP500N

Product Type:

Workshop Service Repair Manual

Product Format:

PDF Download

Codes

Applicable Years:

2001, 2002, 2003

👋 Introduction

Market Position

Segment:

Maxi-scooter

Target Audience:

Commuters, touring riders seeking motorcycle-like performance with scooter convenience

Competitive Analysis

Key Competitors Early 2000S:

Suzuki Burgman 650 (later), Aprilia Leonardo 250, Gilera Nexus 500 (later)

Key Features

Engine Layout:

Parallel-twin, liquid-cooled

Chassis Design:

Motorcycle-style aluminum frame

Transmission:

Automatic (CVT) with V-belt drive

Suspension:

Telescopic front forks and swingarm with rear shock absorber

Braking:

Dual front disc brakes, single rear disc brake

📋 Manual Details

Coverage Areas

Engine:

Full coverage

Transmission:

Full coverage

Electrical System:

Full coverage

Chassis:

Full coverage

Bodywork:

Full coverage

Suspension:

Full coverage

Braking System:

Full coverage

Fuel System:

Full coverage

Cooling System:

Full coverage

Exhaust System:

Full coverage

Troubleshooting:

Comprehensive

Maintenance:

Comprehensive

Specifications:

Detailed

Page Count

Estimated Pages:

Hundreds (Exact count not specified, indicative of a complete manual)

Manual Type

Type:

Factory Service Repair Manual

Purpose:

Repair, maintenance, and troubleshooting

Language

Language:

English (Assumed standard for official factory manuals)

Format

Format:

Downloadable:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, cylinder head, valve train, piston, crankshaft, lubrication system, cooling system, fuel injection system, ignition system, starting system, charging system

Powertrain:

Automatic transmission (CVT), clutch operation, final drive (belt drive system), gearbox components

Electrical:

Wiring diagrams, battery, charging system, lighting, ignition, starting motor, instruments, sensors, ECU diagnostics, fuse/relay locations

Chassis Suspension:

Front fork, rear shock absorber, swingarm, linkages, steering system, wheel bearings

Brakes:

Front and rear disc brake systems, brake pad replacement, caliper service, hydraulic lines, master cylinders, parking brake system

Body And Frame:

Body panels, fairings, seat, fuel tank, storage compartments, frame inspection and repair, mounting points

Wheels And Tires:

Tire inspection and replacement, wheel removal and installation, wheel balancing

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain/belt adjustment (if applicable), brake fluid flush, coolant checks/changes, battery maintenance

Component Removal Installation:

Step-by-step instructions for removing and reinstalling all major components

Troubleshooting Guides:

Diagnostic charts, symptom-cause-remedy tables for electrical and mechanical issues

Torque Specifications:

Precise torque values for critical fasteners

Special Tool Requirements:

Identification of specific tools needed for certain procedures

Wiring Diagrams:

Detailed electrical schematics for all circuits

Technical Depth

Depth:

Comprehensive rebuild and diagnostic procedures, suitable for professional technicians and advanced DIY enthusiasts

📊 Manual Specifications

File Format

Quality:

High-resolution, clear and legible text and diagrams

Searchable:

Typically searchable PDF for quick information retrieval

Print Quality

Printable:

Yes, designed for full or partial printing

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Type:

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

Displacement:

499 cc

Bore X Stroke:

66.0 mm x 73.0 mm

Compression Ratio:

10.0:1

Maximum Power:

Approx. 32 kW (43 hp) at 7,500 rpm (manufacturer specific, may vary slightly)

Maximum Torque:

Approx. 45 Nm (33.2 lb-ft) at 6,000 rpm (manufacturer specific, may vary slightly)

Fuel System

Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, minimum octane rating 91 (RON+MON)/2

Fuel Tank Capacity:

14 Liters (3.7 US gallons)

🔧 Transmission

Standard

Type:

Automatic Continuously Variable Transmission (CVT) with V-belt

Optional

Optional Types:

N/A (CVT is standard)

Features

Drive System:

Belt drive to rear wheel

Gear Ratios:

Variable ratios managed by the CVT system

Transmission Fluid Type:

Yamalube Gear Oil or equivalent SAE 80 API GL-4 (Refer to manual for exact specification and capacity)

📐 Dimensions

Exterior

Overall Length:

Approx. 2,170 mm (85.4 in)

Overall Width:

Approx. 765 mm (30.1 in)

Overall Height:

Approx. 1,380 mm (54.3 in)

Seat Height:

Approx. 800 mm (31.5 in)

Weights

Dry Weight:

Approx. 217 kg (478 lbs)

Wet Weight:

Approx. 232 kg (511 lbs) (with all fluids)

Max Load Capacity:

Refer to manual for specific rider and luggage limits

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle/scooter safety is typically assessed differently than cars)

Active Features

Braking System:

Dual front discs and rear disc for effective stopping power

Lighting:

Halogen headlights, LED taillight

Passive Features

Frame Construction:

Rigid aluminum die-cast frame for stability

Storage Compartment:

Under-seat storage for helmet or cargo

💡 Technology Features

Infotainment

Instrument Panel:

Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, clock, warning lights.

Driver Assistance

ABS was an optional feature on some models, not standard on all XP500N variants.

Connectivity

Connectivity Features:

N/A (No advanced connectivity features like Bluetooth or smartphone integration on this model).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 km or 6 months, whichever comes first (Refer to manual for specific mileage recommendation)

Oil Filter Replacement:

At every engine oil change

Spark Plug Replacement:

Refer to manual for specific interval, typically around 10,000-20,000 km

Air Filter Cleaning Replacement:

Every 5,000 km or annual inspection

Brake Fluid Change:

Every 2 years or as needed

Coolant Change:

Every 2 years or as needed

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher (Refer to manual for precise specification)

Engine Oil Capacity:

Approx. 1.9 Liters (with filter change)

Cooling Fluid Type:

Yamaha Coolant (or equivalent) mixture of 50% ethylene glycol and 50% deionized water

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Drive belt, brake pads, tires, suspension bushings, and seals are typical wear items.

Potential Failures:

While generally reliable, early models may exhibit issues related to the automatic choke or stator if not properly maintained. The manual will help diagnose and repair these.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Company, established in 1955, known for motorcycles, marine products, and musical instruments.

Model Evolution

Tmax Introduction:

The TMAX was introduced in 2001 as Yamaha's flagship maxi-scooter, designed to bridge the gap between scooters and motorcycles with sports-bike handling and performance.

First Generation Xp500:

The XP500N represents the first generation of the TMAX. Subsequent generations saw updates to styling, engine performance, and technology.

Production

Manufacturing Location:

France (Originally assembled by MBK, a Yamaha subsidiary)

🏆 Awards & Recognition

Recognitions

Market Reception:

The TMAX was critically acclaimed upon its release for its sporty performance and handling, establishing a new benchmark for maxi-scooters.

Ratings

User Reviews:

Consistently receives positive reviews for its power, comfort, and versatility for both commuting and touring.