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XP500 TMax Technical Orientation Guide

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FRAME

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Newly designed tubular diamond shape frame

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

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Total 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.

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

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Ground clearance: 140 mm

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50º 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

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Summary of Contents for T max

Page 1: ...ke route and air filter case n Low position radiator n Semi dry sump with oil cooler n Non adjustable 2 stage silent chain drive train CHASSIS FEATURES n Motorcycle typehighrigiditydiamondshape frame n Motorcycle type front fork n Highly rigid swingarm n 14 inch front and rear wheels n Motorcycle typehubwithfixedrearwheelaxle n Sportbiketypeweightdistribution n 50º lean angle n 33 liters luggage c...

Page 2: ...ountedtoapivotpointattherearoftheengine therebykeepingunsprungweightlowformoreresponsive rearsuspensionaction 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 n Parallel twin with 360 degree crankshaft n 66 mm bore and 73 mm stroke n 10 1 1 compressi...

Page 3: ...ong maintenance interval same as YZF R1 YZF R6 n Valve clearance at cold engine condition Intake 0 15 0 20 mm Exhaust 0 25 0 30 mm 1 2 3 4 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 55º 55º 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 ...

Page 4: ...NDER n New liquid cooled cylinder body for low weight n Left side cam chain drive for reduced engine width n Ceramic 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 ...

Page 5: ...hieves same vibration reduction as 3 balancer shafts to reduce primary and second ary inertial forces while requiring less space 1 2 3 bearing size indication 4 Bearing size indication reading from left to right ex 1 2 3 4 5 Leftmainbearing Rightmainbearing Conrod bearing cylinder 1 Conrodbearingbalancercylinder Conrod bearing cylinder 2 Piston cylinder 1 Piston cylinder 2 Cam chain drive gear Bal...

Page 6: ...ween upper and lower compression rings for improved sealing n Balancer 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 ...

Page 7: ... connecting rods 2 for combustion 1 for balancer n New 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 ...

Page 8: ...condary sheave for improved cooling and higher belt durability n Coolingsystemuses2airfilterstoprovidehighvolumecleanaircooling 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...

Page 9: ...ype 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 6 7 8 9 10 5 1 3 4 5 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 ...

Page 10: ...in with spring type torque absorber for a further reduction of noise n The 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 1 2 3 4 5 Mounted...

Page 11: ... 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 bo...

Page 12: ...XP500 TMax Technical Orientation Guide 12 LUBRICATION SYSTEM LUBRICATION FLOW CHART ...

Page 13: ...XP500 TMax Technical Orientation Guide 13 LUBRICATION SYSTEM ...

Page 14: ...STEM CoolantReservoirTank Thermostat Radiator Water pump Coolant Fan Radiator Cap Coolingsystemcapacity 1 5liter Carburetorheatingthermostat Coolant temperature is less than 80 2 ºC OPEN Coolant temperature is more than 80 2 ºC CLOSED Mainthermostat Coolant temperature is less than 82 2 ºC OPEN Coolant temperature is more than 82 2 ºC CLOSED ...

Page 15: ... heater n Pull 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 ByTCIUnit 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...

Page 16: ...noise reduction box n Air 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 3 4 5 6 7 See Service Tips for CO adjustment and Air Induction System check procedure BLOCK HERE FOR CO ADJUSTMENT ...

Page 17: ...XP500 TMax Technical Orientation Guide 17 n 2 into 1 stainless exhaust pipes and stainless muffler EXHAUST SYSTEM Muffler ExhaustPipe EGAconnection 1 2 3 ...

Page 18: ...se 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 n Sports bike type front and rear weight distribution of 47 and 53 respectively n Ground clearance 140 mm n 50º lean angle Engine mounting positions References Overall length Wheelbase Min turn radius XP500 YP250 2 ...

Page 19: ...h easy access to fuel cap n Fuel tank capacity is 14 liters n Electricfuelpumpforstabilizedfuelsupplyusesexternalfuelfilter BODYWORK n Completely new aerodynamically efficient sports styled bodywork Integrated turn signal lights Aluminium grab bar for improved passenger comfort 1 2 Fuel lid Fuel tank cap Fuel tank 1 2 3 ...

Page 20: ... protection n Newly designed cowling mounted mirrors SEAT n One piece deeply padded dual seat n Rider seat features adjustable backrest offering 35 mm of movement in three stages n Seat is locked at left and right side for enhanced security 1 2 Fuel lid Adjustable backrest Seat height 795 mm 35 mm ...

Page 21: ...hone etc n Rear storage compartment under seat of 33 liters and it can hold a full face helmet or B4 size bag n Rear storage compartment has an interior light a special area for a U lock and pre wired for a 12V accessoryplug 1 2 Front storage compartment Rear storage compartment Interior light 4 5 6 5 440 mm 340 mm 336 mm Battery Seat locks Fuse box 3 ...

Page 22: ...135 mm Oil type SAE 7 5 WT REAR SUSPENSION SWINGARM n Single pull type rear shock absorber horizontally positioned underneath the engine for low centre of gravity and increased storage space n Swingarm and final drive are combined for improved rigidity n Swingarm pivots independently of engine for more responsive suspension reaction n Rear wheel travel and shock absorber stroke 120 mm Swingarm Sho...

Page 23: ...14 M C 55S Bridgestone HOOP B03 120 70 14 M C 55S REAR WHEEL TIRE BRAKE n New 14 x MT 4 50 cast wheel n Rear wheel uses motorcycle type clutch hub and fixed axle for enhanced stability n Rear disc brake diameter 267 mm n Rear brake 1 piston pin slide type caliper Tires Dunlop D305 150 70 14 M C 66S Bridgestone HOOP B02 150 70 14 M C 66S Rear brake caliper Clutch hub Front brake caliper 1 2 1 Front...

Page 24: ...pm n Theoptionalelectricalaccessoriesare mobilephonecharger gripwarmersandanti theftalarmsystem ELECTRICAL SYSTEM HEADLIGHT ASSEMBLY n Newly designed multi reflector dual headlight Low beam 12V 55W H7 12V 55W High beam 12V 60W H4 12V 60 55W Auxiliarylights 12V 5Wx2 For UK specifications the positions of the left and right headlights are opposite 3 1 2 ...

Page 25: ...ted the main switch must be turned off and then back on again to start the engine ANTI THEFT ALARM PRE WIRING n Main wiring harness is pre wired from factory with connectors for an aftermarket alarm system n Location behind left side body cover GRIP WARMER PRE WIRING n Main wiring harness is pre wired from factory with connectors for an aftermarket grip warmer n Location under handlebar cover MOBI...

Page 26: ...ator Engine oil change indicator Time set buttons left minutes right hours INSTRUMENTATION n Automobile style instrument panel for extensive information and easy reading n Speedometer uses electronic front wheel speed sensor same type as FZS600 n Main switch has luminescent ring similar to YP250 l Oil change indicator lights up at 1 000 km 5 000 km and then every 5 000 km l V belt indicator lights...

Page 27: ...the front tire COOLANT RESERVOIR There is a small cutout on the right side cowl under the floorboard area to check the reservoir coolant level If coolant is below the minimum level pull up the rubber floorboard mat and remove the screw that holds the filler cap access lid and the cap to add coolant AIR FILTER REPLACEMENT n Remove the mirrors and the windshield with the base do not remove the winds...

Page 28: ...ilemaintainingthefollowingconditions n Oil temperature 65 75 ºC n Coolant temperature 75 85 ºC n Intake vacuum 33 39 kPa n Idle revolution 1150 1250 rpm CO measurement should be 3 0 AIR INDUCTION SYSTEM CHECK PROCEDURE 1 Adjust CO following the above procedure 2 Restore the secondary air supply to the air induction system unit 3 ChecktheCOreadingwhilemaintainingtheaboveconditions oiltemperature co...

Page 29: ... the swingarm n Removetheaxlenut n Remove the rear brake caliper from the swingarm n Loosen the axle pinch bolt on the right side n Remove the axle and spacer n Pull the wheel to the right to slide the hub out of the splines and pull the wheel out of the swingarm n Be sure to grease the hub splines before re installation V BELT REPLACEMENT The V belt on the TMax can be replaced by taking off l Rig...

Page 30: ... To prevent this from happening apply a small amount of grease to the adjusting shim and the valve lifter before reassembly This will hold the shim and lifter in place while the cams are reinstalled and timed RESET ENGINE OIL CHANGE INDICATOR To reset the engine oil indicator push the oil indicator reset button on the instrument panel for 2 5 seconds The required reset time is to prevent accidenta...

Page 31: ...pen throttle ignition timing l Oil indicator displays condition code l Oil indicator displays condition code l The system stops fuel pump operation l Oil indicator displays condition code Speed Sensor Lean Angle Switch Circuit Defect s System Response Condition Code Remarks l Disconnected l Short circuit l Mechanical Malfunction l Disconnected l Disconnected l Short circuit l Mechanical Malfunctio...

Page 32: ...aft splines with the special grease and that the sheave plate splines are properly aligned with the crankshaft splines SECONDARYSHEAVE REMOVALAND DISASSEMBLY Follow the same procedures for the secondary sheaveremovalastheprimarysheaveusingthe oppositesideofthesheaveholdingtool n Installthesecondaryspringcompressortoolin a vise n Install the secondary sheave onto the tool n Removethenutandspringfro...

Page 33: ...Following special tools are NOT new but they are used only for ATV It is possible that motorcycle dealers have do not have the proper tools ...

Page 34: ...ntive maintenance procedures will ensure more reliable vehicle operation a longer service life and reduce the need for costly overhaul work This information applies to ve hicles already in service as well as to new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter PERIODIC CHECKS AND ADJUSTMENTS ...

Page 35: ...isplacement 499cc Bore x stroke 66 x 73mm Compression ratio 10 1 1 Standard compression pressure at sea level 1450kPa 360r min 14 5kgf cm2 360r min Starting system type Electric starter Lubrication System Type Dry sump Oil Type or Grade Engine oil SAE 10W30SE or SAE10W40SE Chain drive oil SAE80API GL 4 hypoid gear oil Oil Capacity Periodic oil change 2 8L With oil filter replacement 2 9L Total amo...

Page 36: ... disc brake Suspension Front suspension Telescopic fork Rear suspension Swingarm Shock Absorber Front fork type Coil spring oil damper Rear shock absorber assembly type Coil spring gas oil damper Wheel Travel Front wheel travel 120mm Rear wheel travel 120mm Electrical Ignition system type Transistorized coil ignition digital Charging system type A C magneto Battery voltage capacity 12V8Ah Battery ...

Page 37: ...haft cap inside diameter 23 000 23 021mm Camshaft journal to camshaft cap clearance 0 020 0 054mm Camshaft lobe dimensions Intake measurement A 33 252 33 352 Intake measurement B 24 956 25 056 Intake measurement C 8 196 8 396mm Exhuast measurement A 33 252 33 352 Exhaust measurement B 24 956 25 056 Exhaust measurement C 8 196 8 396 Valve Timing Intake open BTDC degree 25º Intake closed ABDC degree...

Page 38: ...t material exhaust V557W Valve spring Free length intake 35 59mm Free length exhaust 35 59mm Spring rate intake K1 18 845N mm 1 92kgf mm Spring rate intake K2 24 52N mm 2 5kgf mm Spring rate exhaust K1 18 845N mm 1 92kgf mm Spring rate exhaust K2 24 52N mm 2 5kgf mm Installed length intake valve closed 30 39mm Installed length exhaust valve closed 30 39mm Spring tilt intake degree 2 5º 1 6mm Sprin...

Page 39: ...5 118 60mm Max runout C 0 03mm Big end side clearance D 0 160 0 262mm Big end radial clearance E 0 026 0 050mm Journal oil clearance using plasti gauge 0 040 0 082mm Bearing color code 1 Blue 2 Black 3 Brown 4 Green Ballancer drive method Piston Clutch Friction plate thickness 2 75 3 05mm Plate quantity 5pcs Wear limit 2 65mm Friction plate thickness 1 8 2 0mm Plate quantity 2pcs Wear limit 1 7mm ...

Page 40: ...tion amperage max 0 8A Output pressure 8 3 12 3kPa 0 08 0 12kgf cm2 Oil filter type Wire mesh Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance 0 04 0 12mm Outer rotor to pump housing clearance 0 045 0 085mm Housing and rotor clearance 0 11 0 23mm Bypass valve opening pressure 80 120kPa 0 8 1 2kgf cm2 Relief valve operating pressure 450 550kPa 4 5 5 5kgf cm2 Oil pressure hot...

Page 41: ...outer diameter 38mm Rear suspension Rear shock absorber assembly travel 44 5mm Spring free length 190mm Installed length 180mm Spring rate K 1 226N mm 23 05kgf mm Spring rate K 2 294N mm 29 98kgf mm Spring stroke K 1 0 30mm Spring stroke K 2 30 0 44 5mm Optional spring available No Enclosed gas air pressure STD 4900kPa 49kgf cm2 Swingarm Free play limit at the end of the swingarm radial 1mm Free p...

Page 42: ...ed fluid Dot 4 Brake lever and brake pedal Brake lever free play pivot 1 8 2 6mm Brake lever free play lever end 6 7 14 1mm Throttle grip free play 3 5mm Ignition system Ignition timing B T D C degree 10º 1200r min Advancer type Digital Transistorized coil ignition Pickup coil resistance ohm 210Ω 10 Gy B T C I unit model manufacturer J4T120 MITSUBISHI Ignition coil Model manufacturer JO313 DENSO P...

Page 43: ...rn Horn type Plane Quantity 2pcs Model manufacturer YF 12 NIKKO Max amperage 3A Turn signal hazard relay Relay type Full transistor Model manufacturer FE246BH DENSO Self cancelling device built in No Turn signal blinking frequency 75 95cyl min Wattage 21Wx2 3 4W Fuel gauge Model manufacturer 5GJ NIPPON SEIKI Sender unit resistance full ohm 4 10Ω Sender unit resistance empty ohm 90 100Ω Circuit bre...

Page 44: ...XP500 TMax Technical Orientation Guide 44 WIRING DIAGRAM ...

Page 45: ...XP500 TMax Technical Orientation Guide 45 WIRING DIAGRAM ...

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