
ENGINE SPECIFICATIONS
2-4
Valve, valve seat, valve guide
Valve clearance (cold)
Intake
0.15–0.22 mm (0.0059–0.0087 in)
Exhaust
0.25–0.32 mm (0.0098–0.0126 in)
Valve dimensions
Valve head diameter (intake)
25.9–26.1 mm (1.0197–1.0276 in)
Valve head diameter (exhaust)
21.9–22.1 mm (0.8622–0.8701 in)
Valve face width (intake)
1.202–2.475 mm (0.0473–0.0974 in)
Valve face width (exhaust)
1.202–2.475 mm (0.0473–0.0974 in)
Valve seat width (intake)
0.90–1.10 mm (0.0354–0.0433 in)
Limit
1.6 mm (0.06 in)
Valve seat width (exhaust)
0.90–1.10 mm (0.0354–0.0433 in)
Limit
1.6 mm (0.06 in)
Valve margin thickness (intake)
0.50–0.90 mm (0.0197–0.0354 in)
Valve margin thickness (exhaust)
0.50–0.90 mm (0.0197–0.0354 in)
Valve stem diameter (intake)
3.975–3.990 mm (0.1565–0.1571 in)
Limit
3.945 mm (0.1553 in)
Valve stem diameter (exhaust)
3.960–3.975 mm (0.1559–0.1565 in)
Limit
3.930 mm (0.1547 in)
Valve guide inside diameter (intake)
4.000–4.012 mm (0.1575–0.1580 in)
Limit
4.050 mm (0.1594 in)
Valve guide inside diameter (exhaust)
4.000–4.012 mm (0.1575–0.1580 in)
Limit
4.050 mm (0.1594 in)
Valve-stem-to-valve-guide clearance (intake)
0.010–0.037 mm (0.0004–0.0015 in)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust)
0.025–0.052 mm (0.0010–0.0020 in)
Limit
0.100 mm (0.0039 in)
Valve stem runout
0.040 mm (0.0016 in)
Valve spring
Free length (intake)
36.73 mm (1.45 in)
Limit
34.89 mm (1.37 in)
Summary of Contents for 2012 TMAX XP500A
Page 1: ...SERVICE MANUAL XP500A 2012 59C 28197 E1 ...
Page 6: ......
Page 8: ......
Page 54: ...SPECIAL TOOLS 1 45 ...
Page 79: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ...
Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20410 LUBRICATION DIAGRAMS ...
Page 84: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ...
Page 86: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ...
Page 88: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 ...
Page 90: ...COOLING SYSTEM DIAGRAMS 2 35 EAS20420 COOLING SYSTEM DIAGRAMS ...
Page 92: ...COOLING SYSTEM DIAGRAMS 2 37 ...
Page 94: ...CABLE ROUTING 2 39 EAS20430 CABLE ROUTING Handlebar top side view ...
Page 96: ...CABLE ROUTING 2 41 Handlebar front side and left side view ...
Page 98: ...CABLE ROUTING 2 43 Front brake front side and left side view ...
Page 100: ...CABLE ROUTING 2 45 Frame front side view ...
Page 102: ...CABLE ROUTING 2 47 Frame left side view ...
Page 104: ...CABLE ROUTING 2 49 Frame right side view ...
Page 106: ...CABLE ROUTING 2 51 Rear frame top side and right side view ...
Page 108: ...CABLE ROUTING 2 53 Rear brake top side and left side view ...
Page 110: ...CABLE ROUTING 2 55 Throttle body left side view ...
Page 112: ...CABLE ROUTING 2 57 Fuel tank top side left side and right side view ...
Page 114: ...CABLE ROUTING 2 59 Hydraulic unit top side and front side view ...
Page 116: ...CABLE ROUTING 2 61 ...
Page 119: ......
Page 154: ...PERIODIC MAINTENANCE 3 35 ...
Page 258: ...SWINGARM 4 101 ...
Page 329: ...OIL PUMP 5 68 ECA13890 After tightening the bolts make sure the oil pump turns smoothly ...
Page 346: ...TRANSMISSION 5 85 ...
Page 371: ...THROTTLE BODY 7 10 Throttle position sensor screw 3 5 Nm 0 35 m kgf 2 5 ft lbf ...
Page 372: ...THROTTLE BODY 7 11 ...
Page 375: ......
Page 376: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...
Page 380: ...ELECTRIC STARTING SYSTEM 8 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...
Page 386: ...CHARGING SYSTEM 8 11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...
Page 389: ...CHARGING SYSTEM 8 14 ...
Page 390: ...LIGHTING SYSTEM 8 15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...
Page 394: ...SIGNALING SYSTEM 8 19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...
Page 399: ...SIGNALING SYSTEM 8 24 ...
Page 400: ...COOLING SYSTEM 8 25 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...
Page 404: ...FUEL INJECTION SYSTEM 8 29 EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...
Page 445: ...FUEL INJECTION SYSTEM 8 70 ...
Page 446: ...FUEL PUMP SYSTEM 8 71 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...
Page 449: ...FUEL PUMP SYSTEM 8 74 ...
Page 450: ...IMMOBILIZER SYSTEM 8 75 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...
Page 459: ...IMMOBILIZER SYSTEM 8 84 ...
Page 460: ...ABS ANTI LOCK BRAKE SYSTEM 8 85 EAS28790 ABS ANTI LOCK BRAKE SYSTEM EAS27730 CIRCUIT DIAGRAM ...
Page 462: ...ABS ANTI LOCK BRAKE SYSTEM 8 87 EAS27740 ABS COMPONENTS CHART ...
Page 464: ...ABS ANTI LOCK BRAKE SYSTEM 8 89 EAS27750 ABS COUPLER LOCATION CHART ...
Page 468: ...ABS ANTI LOCK BRAKE SYSTEM 8 93 EAS27810 BASIC PROCESS FOR TROUBLESHOOTING ...
Page 493: ...ABS ANTI LOCK BRAKE SYSTEM 8 118 ...
Page 494: ...ELECTRICAL COMPONENTS 8 119 EAS27973 ELECTRICAL COMPONENTS ...
Page 496: ...ELECTRICAL COMPONENTS 8 121 ...
Page 498: ...ELECTRICAL COMPONENTS 8 123 EAS27981 CHECKING THE SWITCHES ...
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