TROUBLESHOOTING
9-3
• Thermostat
• Thermostat stays closed
• Oil cooler
• Clogged or damaged oil cooler
• Hose(s) and pipe(s)
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
Fuel system
1. Throttle body
• Faulty throttle body
• Damaged or loose throttle body joint
2. Air filter
• Clogged air filter element
Chassis
1. Brake(s)
• Dragging brake
Electrical system
1. Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
2. Ignition system
• Faulty ECU (engine control unit)
EAS28610
OVERCOOLING
Cooling system
1. Thermostat
• Thermostat stays open
EAS28620
POOR BRAKING PERFORMANCE
• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level
EAS28660
FAULTY FRONT FORK LEGS
Leaking oil
• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod bolt
• Damaged damper rod bolt copper washer
• Cracked or damaged cap bolt O-ring
Malfunction
• Bent or damaged inner tube
• Bent or damaged outer tube
• Damaged fork spring
• Worn or damaged outer tube bushing
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
EAS28670
UNSTABLE HANDLING
1. Handlebar
• Bent or improperly installed handlebar
2. Steering head components
• Improperly installed upper bracket
• Improperly installed lower bracket
(improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
3. Front fork leg(s)
• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
4. Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
5. Rear shock absorber assembly
• Faulty rear shock absorber spring
• Leaking oil or gas
6. Tire(s)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
7. Wheel(s)
• Incorrect wheel balance
• Deformed cast wheel
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
8. Frame
• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race
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 ...