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
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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