TROUBLESHOOTING
9-2
• Improper throttle cable free play
• Flooded throttle body
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
3. Ignition coil
• Faulty spark plug lead
4. Ignition system
• Faulty ECU (engine control unit)
• Faulty crankshaft position sensor
EAS28510
POOR MEDIUM-AND-HIGH-SPEED
PERFORMANCE
Refer to “STARTING FAILURE/HARD START-
ING” on page 9-1.
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Fuel pump
• Faulty fuel pump
EAS28580
FAULTY CLUTCH
Engine operates but scooter will not move
1. V-belt
• Bent, damaged or worn V-belt
• Slipping V-belt
2. Primary pulley cam and primary pulley slider
• Damaged or worn primary pulley cam
• Damaged or worn primary pulley slider
3. Clutch spring(s)
• Damaged clutch spring
4. Transmission gear(s)
• Damaged transmission gear
Clutch slips
1. Clutch
• Improperly assembled clutch
• Fatigued clutch spring
• Worn friction plate
• Worn clutch plate
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
3. Primary sliding sheave
• Seized primary sliding sheave
Poor starting performance
1. V-belt
• V-belt slips
• Oil or grease on the V-belt
2. Primary sliding sheave
• Faulty operation
• Worn pin groove
• Worn pin
3. Clutch shoe(s)
• Bent, damaged or worn clutch shoe
Poor speed performance
1. V-belt
• Oil or grease on the V-belt
2. Primary pulley weight(s)
• Faulty operation
• Worn primary pulley weight
3. Primary fixed sheave
• Worn primary fixed sheave
4. Primary sliding sheave
• Worn primary sliding sheave
5. Secondary fixed sheave
• Worn secondary fixed sheave
6. Secondary sliding sheave
• Worn secondary sliding sheave
EAS28600
OVERHEATING
Engine
1. Clogged coolant passages
• Cylinder head(s) and piston(s)
• Heavy carbon buildup
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
Cooling system
1. Coolant
• Low coolant level
2. Radiator
• Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
3. Water pump
• Damaged or faulty water pump
Summary of Contents for 2009 XP500Y TMAX
Page 1: ...2009 SERVICE MANUAL XP500Y LIT 11616 22 08 4B5 28197 10 ...
Page 6: ......
Page 8: ......
Page 26: ...SPECIAL TOOLS 1 17 ...
Page 47: ...TIGHTENING TORQUES 2 20 Cylinder head tightening sequence ...
Page 56: ...LUBRICATION SYSTEM DIAGRAMS 2 29 1 2 3 4 4 ...
Page 57: ...LUBRICATION SYSTEM DIAGRAMS 2 30 1 Secondary shaft 2 Drive axle 3 Clutch 4 Crankshaft ...
Page 60: ...COOLING SYSTEM DIAGRAMS 2 33 1 2 3 4 5 6 7 8 9 10 11 12 ...
Page 64: ...CABLE ROUTING 2 37 A B A C D E F G H I J K L 1 2 1 2 3 3 4 5 6 6 7 A A A A A A A A ...
Page 78: ...CABLE ROUTING 2 51 ...
Page 81: ......
Page 115: ......
Page 172: ...FRONT FORK 4 57 2 3 ...
Page 186: ...SWINGARM AND TRANSMISSION CHAIN DRIVE 4 71 ...
Page 270: ...TRANSMISSION 5 81 ...
Page 294: ...THROTTLE BODY 7 9 ...
Page 297: ......
Page 309: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 14 Battery 15 Main fuse ...
Page 311: ...CHARGING SYSTEM 8 14 ...
Page 321: ...SIGNALING SYSTEM 8 24 ...
Page 325: ...COOLING SYSTEM 8 28 ...
Page 353: ...FUEL PUMP SYSTEM 8 56 ...
Page 356: ...ELECTRICAL COMPONENTS 8 59 2 1 3 4 5 6 10 8 9 11 7 ...
Page 376: ...ELECTRICAL COMPONENTS 8 79 ...
Page 383: ......
Page 384: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...