🏷️ Basic Information

Make:

Yamaha

Model:

XP500N T-MAX

Year:

2001, 2002, 2003

Product Type:

Workshop Repair Service Manual

👋 Introduction

Segment:

Premium Sport Scooter / Maxi-Scooter.

Target Audience:

Urban commuters seeking performance and comfort, touring riders, experienced scooter enthusiasts.

Competitors:

Suzuki Burgman 650, Honda Silver Wing 600, Gilera Nexus 500, Aprilia Atlantic 500.

Design Philosophy:

Motorcycle-like handling and performance in a scooter package.

Powertrain Layout:

Forward-mounted engine, underseat storage, motorcycle-style chassis.

📋 Manual Details

Primary Coverage:

Repair, overhaul, maintenance, and troubleshooting of Yamaha XP500N T-MAX.

Total Pages:

393

Type:

Workshop Service Manual

Language:

Assumed English (based on typical availability for this model and description, requires explicit confirmation if non-English)

Format:

PDF (Digital Download)

📖 Manual Coverage

Engine Management:

Fuel injection system, ignition system, emission control systems, engine diagnosis.

Drivetrain:

Automatic transmission (CVT), clutch, final drive (belt and roller system).

Chassis:

Frame, suspension (front forks, rear shock absorber), steering system, wheel and tire information.

Brakes:

Front and rear brake systems, hydraulic lines, caliper overhaul, brake fluid specifications.

Electrical:

Wiring diagrams, battery, charging system (alternator, regulator/rectifier), lighting, instrumentation, starter motor, fuses, relays.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, throttle body.

Cooling System:

Radiator, fan, water pump, coolant specifications, thermostat.

Bodywork And Trim:

Fairings, seat, storage compartments, panel removal and installation procedures.

Scheduled Maintenance:

Oil changes, filter replacements, spark plug checks, drive belt inspection/replacement, brake fluid flush, coolant checks.

Engine Overhaul:

Top-end rebuild (cylinder head, valves), bottom-end rebuild (crankshaft, connecting rods, pistons), gasket replacement.

Transmission Service:

Drive belt tensioning and replacement, clutch roller inspection, transmission fluid type and change interval.

Suspension Repair:

Front fork seal replacement, rear shock absorber inspection and replacement.

Brake System Repair:

Brake pad replacement, caliper piston service, bleeding procedures, master cylinder inspection.

Electrical Diagnostics:

Troubleshooting electrical faults, component testing (e.g., ignition coil, stator, battery).

Troubleshooting Guides:

Diagnostic flowcharts and symptom-based troubleshooting for common issues.

Depth:

Comprehensive, covering from routine maintenance to complete engine and component rebuilds, suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

Format:

PDF

Quality:

High-resolution scans, generally clear text and legible diagrams (quality can vary slightly with original source).

Binding:

N/A (Digital PDF format)

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, DOHC, parallel-twin cylinder.

Displacement:

499 cc

Bore X Stroke:

66.0 mm x 73.0 mm

Compression Ratio:

10.0:1 (Typical for early models, confirm with manual)

Horsepower:

Approx. 40-43 hp @ 7,500 rpm (Varies by market and tune, refer to manual for specific output)

Torque:

Approx. 45-48 Nm @ 6,000 rpm (Varies by market and tune, refer to manual for specific output)

Fuel Delivery:

Electronic Fuel Injection (EFI) with twin throttle bodies.

Fuel Type:

Unleaded gasoline, 91 octane or higher recommended.

Ignition Type:

Digital CDI with electronic advance.

Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher.

Coolant Type:

Yamaha Coolant (or equivalent) 50/50 mix of ethylene glycol and deionized water.

🔧 Transmission

Type:

Automatic Continuously Variable Transmission (CVT) with V-belt drive.

Options:

N/A (CVT is standard)

Drive System:

Belt drive to rear wheel.

Clutch Type:

Automatic centrifugal clutch.

Drive Belt Replacement Interval:

Refer to manual, typically around 20,000 km or 2 years, inspect earlier.

📐 Dimensions

Length:

Approx. 2,250 mm (Confirm with manual, varies slightly by year/market)

Width:

Approx. 775 mm (Confirm with manual)

Height:

Approx. 1,415 mm (Confirm with manual)

Wheelbase:

Approx. 1,540 mm (Confirm with manual)

Dry Weight:

Approx. 221 kg (Confirm with manual)

Wet Weight:

Approx. 234 kg (Confirm with manual)

Fuel Tank Capacity:

15 Liters (Approx.)

Front Tire Size:

120/70-15

Rear Tire Size:

160/60-15

Wheel Type:

Cast Aluminum Alloy.

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycle/Scooter safety is typically assessed by specific vehicle tests, not general crash ratings like cars. Focus is on handling and braking performance.)

Braking System:

Dual front disc brakes, single rear disc brake. Linked braking system (LBS) available on some variants, which activates front and rear brakes with a single lever actuation. ABS not standard on early models, optional on some later versions.

Lighting:

Halogen headlights, LED taillight, turn signals.

Chassis Stability:

Rigid frame and motorcycle-like suspension contribute to stable handling.

💡 Technology Features

Dashboard Instrumentation:

Analog tachometer, digital speedometer, fuel gauge, odometer, trip meter, clock, coolant temperature warning light, oil warning light, engine diagnostic indicator.

ABS:

Optional Anti-lock Braking System (ABS) available on some variants (XP500N typically refers to non-ABS, XP500N-A for ABS, confirm specific VIN/market)

Charging Ports:

N/A (Standard on this generation, no built-in USB or 12V outlets.)

Headlight Type:

Dual Halogen headlights for enhanced nighttime visibility.

🔧 Maintenance

Engine Oil Change:

Every 5,000 km or 6 months, whichever comes first.

Oil Filter Replacement:

Every 10,000 km or 12 months (often replaced with every second oil change).

Spark Plug Replacement:

Every 10,000 km or 12 months (check condition more frequently).

Air Filter Cleaning/Replacement:

Inspect every 5,000 km, clean as needed, replace every 20,000 km or as indicated by condition.

Transmission Drive Belt Inspection:

Inspect every 10,000 km, replace as needed based on wear and tension.

Brake Fluid Replacement:

Every 2 years, or as per manual recommendation.

Coolant Replacement:

Every 2 years, or as per manual recommendation.

Engine Oil Specification:

SAE 10W-40 API SG or higher (Yamalube 4 recommended).

Brake Fluid Specification:

DOT 4 (refer to manual for specific system requirements).

Coolant Specification:

50/50 mixture of Yamaha Coolant and distilled water.

Common Wear Items:

Drive belt wear, rear tire wear due to performance orientation, front brake pads, steering head bearings.

Potential Issues:

Water pump seal leaks (less common on this generation but possible with age/mileage), starter clutch wear, charging system component failure (rectifier/regulator).

Maintenance Tips:

Regular inspection of the drive belt and cooling system is crucial. Ensure proper torque on wheel nuts and critical engine fasteners.

📚 Vehicle History

Yamaha Legacy:

Yamaha Motor Company, known for its broad range of motorcycles, musical instruments, and marine products. Established reputation for engineering innovation and quality in the powersports industry.

Tmax Introduction:

The Yamaha T-MAX (XP500) was first introduced in 2001, creating the 'sport scooter' segment with its blend of motorcycle chassis dynamics and scooter convenience.

Xp500N Design:

The 'N' designation typically refers to standard models without ABS for this generation. The 2001-2003 models established the fundamental platform that would see continuous evolution.

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Segment Creation:

Pioneered the sport-scooter market segment, earning acclaim for its handling and performance capabilities.

Critical Reception:

Generally praised by automotive journalists for its blend of scooter practicality and motorcycle performance, often cited for its comfortable ride and capable handling.