Yamaha T MAX Specification

XP500 TMax Technical Orientation Guide

1

FEATURES AND BENEFITS

Offering high levels of performance, comfort and sophistication, the new TMax superscooter looks

sure to make as great an impression on the powered two wheeler market as the first Yamaha YZF-

R1 made in the motorcycle scene.

ENGINE FEATURES

n499cc liquid cooled 4-stroke parallel twin

engine

nDOHC 8 valve engine

nHigh capacity V-belt transmission

nHorizontally opposed reciprocating balancer

nWet multiple plate automatic centrifugal

clutch

nNew design air intake route and air filter case

nLow position radiator

nSemi dry sump with oil cooler

nNon adjustable 2-stage silent chain drive train

CHASSIS FEATURES

nMotorcycle-type high rigidity diamond shape

frame

nMotorcycle-type front fork

nHighly rigid swingarm

n14 inch front and rear wheels

nMotorcycle-type hub with fixed rear wheel axle

nSport bike type weight distribution

n50º lean angle

n33 liters luggage compartment

n1 piece dual seat with 3-stage adjustable

backrest

ELECTRICAL FEATURES

nDual multi-reflector headlight

nStylish combination taillight

nAutomobile-type meter panel with extensive

information

nHigh capacity power supply

nAnti-theft alarm pre-wiring

nGrip warmer pre-wiring

nMobile phone charger pre-wiring

XP500 TMax Technical Orientation Guide

2

ENGINE SYSTEM

Displacing 499 cc, the TMax’s highly-advanced fully automatic twin-cylinder DOHC liquid-cooled

4-stroke 8-valve engine is one of the most powerful designs available on scooters today.

A key feature of its configuration is that unlike most traditional scooter engines which pivot as one

unit with the rear suspension, this engine is fixed rigidly into the TMax’s strong tubular diamond-shape frame

in order to achieve higher levels of chassis rigidity for enhanced handling performance. The swingarm is

mounted to a pivot point at the rear of the engine, thereby keeping unsprung weight low for more responsive

rear suspension action.

Another innovative feature is the horizontal configuration of the engine that keeps the centre of gravity

low for easy handling and also gives extra storage space under the dual seat.

ENGINE FEATURES

nParallel twin with 360 degree crankshaft

n66 mm bore and 73 mm stroke

n10.1 :1 compression ratio

nLeft side drive cam chain for reduced engine width

Horizontal compact cylinder head

Horizontally opposed reciprocating balancer

Semi dry sump

High capacity V-belt transmission

Wet multiple plate automatic centrifugal clutch

Non adjustable 2-stage silent chain drive train

Pivot coaxial drive shaft eliminates chain backlash

2

1

57

3

4

6

XP500 TMax Technical Orientation Guide

3

CYLINDER HEAD

n4 valves per cylinder, DOHC

nTorsion type auto cam chain tensioner (similar to YZF-R1)

n“Shim-under-bucket” valve adjustment for long maintenance interval (same as YZF-R1/YZF-R6)

nValve clearance at cold engine condition:

Intake : 0.15 - 0.20 mm

Exhaust: 0.25 - 0.30 mm

12

34

VALVE TIMING

Intake camshaft

Cam chain tensioner

Exhaust camshaft

Silent cam chain

Intake

port

Exhaust

port

(3)

(2)

(1)

Air Induction

Ports

25º 25º

OL 50º

105º

55º55º

TDC

BDC

IN

EX

Intake valve

(mm)

Exhaust valve

(mm)

(1)

(2)

(3)

25.0

4.0

83.3

22.0

4.0

82.8

XP500 TMax Technical Orientation Guide

4

CYLINDER

nNew liquid-cooled cylinder body for low weight

nLeft side cam chain drive for reduced engine width

nCeramic composite cylinder coating for increased cooling and longer wear life

Side cam chain drive

ø 66.0 mm ø 66.0 mm

Side view

Top view

XP500 TMax Technical Orientation Guide

5

CRANKSHAFT / BALANCER

nNew design crankshaft uses replaceable full circumference plain bearings

nHorizontally opposed reciprocating balancer for excellent vibration reduction

This type achieves same vibration reduction as 3 balancer shafts to reduce primary and second-

ary inertial forces, while requiring less space.

12

3

bearing size indication

4

Bearing size indication, reading from left to right (ex. 1 2 3 4 5):

Left main bearing

Right main bearing

Conrod bearing cylinder #1

Conrod bearing balancer cylinder

Conrod bearing cylinder #2

Piston cylinder #1

Piston cylinder #2

Cam chain drive gear

Balancer piston

Balancer cylinder

XP500 TMax Technical Orientation Guide

6

PISTON

nNew combustion piston with V-groove between upper and lower compression rings for improved

sealing

nBalancer piston for horizontally opposed reciprocating balancing system

Top view

Cross-section Side view

ø 66

ø 40 mm

V-groove

COMBUSTION PISTON

BALANCER PISTON

Top view Side view Front view

Front view cross-section

ø 58

71.7

mm

XP500 TMax Technical Orientation Guide

7

CONNECTING ROD

nNewly designed connecting rods: 2 for combustion, 1 for balancer

nNew type connecting rod as integral part of the horizontally opposed reciprocating balancing

system

FOR COMBUSTION FOR BALANCER

All connecting rods use the same 2-piece plain bearings

45 mm 45 mm

15

mm

16

mm

124.5 mm

117 mm

XP500 TMax Technical Orientation Guide

8

CONTINUOUSLY VARIABLE TRANSMISSION

nHighly efficient V-belt transmission in order to obtain high performance

nNewly designed cooling system with fins on both rotors of the secondary sheave for improved

cooling and higher belt durability

nCooling system uses 2 air filters to provide high volume clean air cooling

TRANSMISSION SYSTEM

Engine left side Engine right side

Left transmission air filter

Air intake duct to transmission

Right transmission air filter

Air exhaust ports

Cooling fin

Secondary sheave

2

Engine cross-section

4

rpm

speed

1

5

6

3

V-belt exchange: each 20,000 km

Speed shift rate diagram

XP500 TMax Technical Orientation Guide

9

CLUTCH

nWet type multiple plate centrifugal clutch for smooth power transmission and to meet XP’s

higher torque

nClutch uses diaphragm type spring

First pinion gear

 Secondary shaft

First wheel gear

Drive axle

Primary driven gear

Friction plates: 5 pieces

Clutch plates: 6 pieces

Diaphragm clutch spring

Primary drive gear

 Main axle

678

9

105

1345

2

Transmission gear reduction ratio

= (primary driven gear / primary drive gear) x (first wheel gear / first pinion gear)

= (52 / 32) x (36 / 22)

= 2.659

Clutch-in revolution: 1800 ± 300 rpm

XP500 TMax Technical Orientation Guide

10

FINAL DRIVE

nNewly designed final drive with non-adjustable 2-stage silent chain for an efficient power trans-

mission, reduced noise and low maintenance

nHigh speed first stage chain with spring-type torque absorber for a further reduction of noise

nThe final drive and the swingarm are integrated for improved rigidity and high speed stability

Crankcase

Drive axle

First stage drive chain

Second stage drive chain

Taper roller bearing

Rear drive case

Oil dip stick 1

2

Oil level

Gear ratio: (41 / 25) x (40 / 29) = 2.262

Final drive oil capacity: 700 cc

Type: SAE 80, hypoid

123

4

5

Mounted on rear wheel

clutch hub

XP500 TMax Technical Orientation Guide

11

nSemi dry sump system for reduced engine size

nOil tank is incorporated into the left crankcase cover

nNewly designed dual stage oil pump

nLiquid-cooled oil cooler with cartridge type oil filter (5DM-13440-00)

nNew type oil drain bolt that allows oil from crankcase and oil tank to be drained at the same time

LUBRICATION SYSTEM

Dual stage oil pump brings oil from oil tank to respective areas of the engine, including a spray bar

over the starter gears and the stator assembly.

The oil pump also has a scavenging pump that returns the oil to the oil tank.

The scavenged oil fills the tank until it is full and then overflows back into the sump area to main-

tain a constant level in the sump.

Oil filter

Oil cooler

Oil spray bar

Crankcase cover

Oil tank space

Oil pump

Drain bolt

12

34

5

6

7

Engine oil capacity

Total amount : 3.6 liters = 2.2 liters in crankcase + 1.4 liter in oil tank

Without oil filter replacement : 2.8 liters

With oil filter replacement : 2.9 liters

Engine oil change: every 5,000 km

XP500 TMax Technical Orientation Guide

12

LUBRICATION SYSTEM

LUBRICATION FLOW CHART

XP500 TMax Technical Orientation Guide

13

LUBRICATION SYSTEM

XP500 TMax Technical Orientation Guide

14

nLow mounted radiator for design flexibility

nAutomatic air bleed for easy maintenance

COOLING SYSTEM

Coolant Reservoir Tank

Thermostat

Radiator

Water pump

Coolant Fan

Radiator Cap

Cooling system capacity: 1.5 liter

Carburetor heating thermostat:

Coolant temperature is less than 80±2 ºC: OPEN

Coolant temperature is more than 80±2 ºC: CLOSED

Main thermostat:

Coolant temperature is less than 82±2 ºC: OPEN

Coolant temperature is more than 82±2 ºC: CLOSED

XP500 TMax Technical Orientation Guide

15

nTwin BS30 round slide carburetors

nAutomatic choke for easy starting

nThrottle Position Sensor to optimize ignition timing and reduce emissions

nCoolant type carburetor heater

nPull-pull type throttle control

CARBURETION SYSTEM

Auto Choke Unit

Throttle Position Sensor

Carburetor settings

Auto-choke electricity control.

By thermo switch.

coolant temperature is more than 60 ± 3ºC: ON

coolant temperature is less than 55 ± 3ºC: OFF

By TCI Unit

more than 800 rpm: ON

less than 375 rpm: OFF

1

2

Marking

Main jet

Jet needle

Needle jet

Pilot screw turns out

Pilot jet

5GJ1

#105

4DK4-3

0 - 0M

2 1/2

#22.5

XP500 TMax Technical Orientation Guide

16

nAir filter case position in upper front body cowling for effective use of space

nAir intake system uses noise reduction box

nAir Induction System for reduced emissions

AIR INTAKE SYSTEM

Air filter case

Noise reduction box

Vacuum hose to Air Cut Valve

Fuel pump

Reed valve

Air hose (Reed Valve - Air Cut Valve)

Air Cut Valve

To exhaust port

1

2

34

5

6

7

See Service Tips for CO adjustment and

Air Induction System check procedure

BLOCK HERE FOR CO ADJUSTMENT

XP500 TMax Technical Orientation Guide

17

n2 into 1 stainless exhaust pipes and stainless muffler

EXHAUST SYSTEM

Muffler

Exhaust Pipe

EGA connection

12

3

XP500 TMax Technical Orientation Guide

18

FRAME

nNewly designed tubular diamond shape frame

nFrame uses engine as a stressed member for added rigidity and enhanced handling performance

nTotal configuration keeps centre of gravity low and wheelbase short

CHASSIS

Like the all-new engine, the TMax’s advanced high-rigidity chassis has been developed using some

of the latest motorcycle technology in its frame and suspension designs.

nSports bike type front and rear weight distribution of 47% and 53% respectively

nGround clearance: 140 mm

n50º lean angle

Engine mounting positions

References

Overall length

Wheelbase

Min. turn radius

XP500 YP250

2,235 mm 2,120 mm

1,575 mm 1,540 mm

2.8 m 2.6 m

XP500 TMax Technical Orientation Guide

19

FUEL TANK

nSteel fuel tank just under rider seat

nFuel lid in rider seat with easy access to fuel cap

nFuel tank capacity is 14 liters

nElectric fuel pump for stabilized fuel supply uses external fuel filter

BODYWORK

nCompletely new aerodynamically-efficient sports styled bodywork

Integrated turn signal lights

Aluminium grab bar for improved passenger comfort

12

Fuel lid

Fuel tank cap

Fuel tank

123

XP500 TMax Technical Orientation Guide

20

WINDSCREEN

nLarge size windscreen for enhanced weather protection

nNewly designed cowling mounted mirrors

SEAT

nOne piece deeply padded dual seat

nRider seat features adjustable backrest offering 35 mm of movement in three stages

nSeat is locked at left and right side for enhanced security

1

2

Fuel lid

Adjustable backrest

Seat height: 795 mm

35 mm

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Yamaha T MAX Specification

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Yamaha T MAX Specification

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