Your shopping cart
😊 Product added to cart successfully   Product removed to cart successfully
Your shopping cart is empty!
Continue shopping
1 of 2

Yamaha XP500 TMAX 2001 2002 2003 Workshop Service Repair Manual

Regular price
$16.99
Sale price
$16.99
Regular price
🏷️ Basic Information Identification Make: Yamaha Model: XP500 TMAX Model Generation: First Generation Model Years Covered: 2001, 2002, 2003 Codes Chassis Code: SJ02 👋 Introduction Market Position Segment: Maxi-scooter, Sport...
17 people are viewing this right now
Type: Motorcycle
Vendor:
Sku: 420792
Yamaha XP500 TMAX 2001 2002 2003 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XP500 TMAX
Model Generation:
First Generation
Model Years Covered:
2001, 2002, 2003
Codes
Chassis Code:
SJ02
👋 Introduction
Market Position
Segment:
Maxi-scooter, Sport Scooter
Target Audience:
Commuters, touring riders seeking motorcycle-like performance in a scooter package
Competitive Analysis
Competitors Early 2000S:
Suzuki Burgman 650 (later models), Honda Silver Wing (later models), various European maxi-scooters
Key Features
Performance Focus:
Designed to offer motorcycle-like handling and performance
Engine Configuration:
Parallel-twin engine, a significant departure from typical scooter single-cylinder setups
Chassis Design:
Motorcycle-style frame and front suspension for enhanced rigidity and handling
Storage:
Generous under-seat storage compartment
Brand Perception
Yamaha Quality:
Yamaha's reputation for reliability and engineering excellence
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Adjustments, Overhaul
Page Count
Total Pages:
393
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete Engine Assembly, Cylinder Head, Crankshaft, Piston, Valves, Camshaft, Lubrication System, Cooling System, Fuel System (Injection and Carburetion - if applicable, though TMAX is FI)
Transmission:
Automatic Transmission (CVT), Drive Belt, Clutch, Gearbox Components
Chassis:
Frame, Suspension (Front Fork, Rear Shock Absorber), Swingarm, Steering System
Brakes:
Front and Rear Brake Systems (Hydraulic Lines, Calipers, Discs, Master Cylinders), Parking Brake
Electrical:
Ignition System, Starting System, Charging System (Alternator, Regulator/Rectifier), Lighting System, Wiring Diagrams, Battery, ECU (Electronic Control Unit) Diagnostics
Fuel System:
Fuel Tank, Fuel Pump, Fuel Injectors, Throttle Body, EFI (Electronic Fuel Injection) System
Bodywork:
Fairings, Seat, Storage Compartments, Windscreen, Body Panel Removal and Installation
Procedures Included
Maintenance:
Regular Inspections, Oil Changes, Filter Replacements, Spark Plug Service, Brake Fluid Flush, Coolant Replacement, Drive Belt Inspection/Replacement
Troubleshooting:
Diagnosis of common problems, guided troubleshooting steps for various systems
Repair:
Step-by-step repair instructions for all major components and systems
Removal Installation:
Detailed procedures for removing and installing components
Disassembly Assembly:
Comprehensive instructions for taking apart and putting back together various units
Adjustments:
Throttle cable adjustment, brake lever adjustment, suspension settings
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine rebuild)
Diagnostics:
Includes diagnostic procedures and troubleshooting charts
Special Tools
Usage Details:
References specific Yamaha special service tools required for certain procedures, with illustrations of their use
Specifications
Torque Values:
Detailed torque specifications for all critical fasteners
Wear Limits:
Includes specified wear limits for key components to ensure proper function and longevity
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Yes, all pages are printable
Resolution:
High-quality, clear text and diagrams suitable for printing
Binding Type
Binding:
Not applicable (digital PDF download)
Paper Type
Paper Type:
Not applicable (digital PDF download)
Software Requirement
Reader:
Adobe Reader required
Compatibility
Operating Systems:
Compatible with Windows, Mac, and Linux OS
Delivery
Download Type:
Instant Download
Shipping:
No shipping costs or delays
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, Liquid-cooled, DOHC, 4-valve, Parallel-twin
Displacement:
499 cc
Bore X Stroke:
66.0 mm x 73.0 mm
Compression Ratio:
11.0:1
Carburetion Injection:
Fuel Injection (Mikuni DFI)
Ignition:
TCI (Transistor Controlled Ignition)
Lubrication:
Wet Sump
Performance
Horsepower Approx:
43 hp @ 7500 rpm
Torque Approx:
46 Nm (34 lb-ft) @ 6000 rpm
Fuel System
Fuel Capacity:
14 Liters (3.7 US gal)
🔧 Transmission
Standard
Type:
Automatic Continuously Variable Transmission (CVT)
Drive:
Belt Drive
Optional
Optional Transmissions:
N/A (CVT is standard)
Features
Clutch:
Automatic Centrifugal Clutch
📐 Dimensions
Exterior
Overall Length:
2255 mm (88.8 in)
Overall Width:
775 mm (30.5 in)
Overall Height:
1390 mm (54.7 in)
Seat Height:
800 mm (31.5 in)
Wheelbase:
1545 mm (60.8 in)
Weights
Dry Weight:
203 kg (447.5 lbs)
Wet Weight Approx:
222 kg (489.4 lbs)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle/Scooter safety ratings differ from cars and are not typically provided in this format)
Active Features
Brakes:
Dual front disc brakes, single rear disc brake
Lighting:
Halogen headlights, LED taillight
Passive Features
Frame Design:
Rigid aluminum die-cast frame contributes to stability
Wind Protection:
Full fairing and windscreen for rider protection
💡 Technology Features
Infotainment
Infotainment Features:
Basic analogue/digital instrument cluster (speedometer, tachometer, odometer, fuel gauge, clock)
Driver Assistance
Assistance Systems:
N/A (No electronic driver assistance systems in the modern automotive sense)
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first
Air Filter Check:
Every 10,000 km (6,000 miles)
Spark Plug Replacement:
Every 20,000 km (12,000 miles)
Drive Belt Inspection:
Every 10,000 km (6,000 miles), replacement interval varies based on wear
Fluid Specifications
Engine Oil:
Yamaha Genuine Oil SAE 10W-40 or Yamalube 4-stroke 10W-40 (API SG or higher, JASO MA)
Engine Oil Capacity:
2.0 L (2.1 US qt) without filter change, 2.2 L (2.3 US qt) with filter change
Coolant:
High-quality ethylene glycol-based antifreeze coolant (50% solution with distilled water)
Brake Fluid:
DOT 4
Final Drive Oil:
Yamalube Gear Oil (SAE 80 API GL-4)
Final Drive Oil Capacity:
0.20 L (0.21 US qt)
Known Issues
Common Wear Items:
Drive belt wear, suspension bushings, brake pads
Potential Electrical:
Regulator/rectifier failures can occur on some models, though not exclusively to this generation
Fuel Injection System:
While generally robust, occasional cleaning of fuel injectors or throttle body may be beneficial
📚 Vehicle History
Brand Heritage
Yamaha Motorsports:
Yamaha's extensive experience in motorcycle design and racing
Model Evolution
Tmax Introduction:
The TMAX was a groundbreaking model upon its introduction, aiming to blend the convenience of a scooter with the performance of a motorcycle.
First Generation:
The 2001-2003 models represent the initial iteration of this successful platform.
Production
Manufacturing Origin:
Japan (for initial models)
🏆 Awards & Recognition
Recognitions
Market Impact:
Widely recognized for setting a new standard in the maxi-scooter segment, earning praise for its performance and handling.
Sale

Unavailable

Sold Out