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XP500 TMax Technical Orientation Guide

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FUEL TANK

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Steel fuel tank just under rider seat

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Fuel lid in rider seat with easy access to fuel cap

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Fuel tank capacity is 14 liters

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Electric fuel pump for stabilized fuel supply uses external fuel filter

BODYWORK

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Completely new aerodynamically-efficient sports styled bodywork

Integrated turn signal lights

Aluminium grab bar for improved passenger comfort

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2

Fuel lid

Fuel tank cap

Fuel tank

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2

3

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Summary of Contents for XP500

Page 1: ...e 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...

Page 2: ...untedtoapivotpointattherearoftheengine therebykeepingunsprungweightlowformoreresponsive rearsuspensionaction Another innovative feature is the horizontal configuration of the engine that keeps the cen...

Page 3: ...long 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 ca...

Page 4: ...INDER 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 cha...

Page 5: ...ieves 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 lef...

Page 6: ...etween upper and lower compression rings for improved sealing n Balancer piston for horizontally opposed reciprocating balancing system Top view Cross section Side view 66 40 mm V groove COMBUSTION PI...

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 us...

Page 8: ...ondary sheave for improved cooling and higher belt durability n Coolingsystemuses2airfilterstoprovidehighvolumecleanaircooling TRANSMISSION SYSTEM Engine left side Engine right side Left transmission...

Page 9: ...pe 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...

Page 10: ...n 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 dr...

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 fi...

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: ...YSTEM CoolantReservoirTank Thermostat Radiator Water pump Coolant Fan Radiator Cap Coolingsystemcapacity 1 5liter Carburetorheatingthermostat Coolant temperature is less than 80 2 C OPEN Coolant tempe...

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 tha...

Page 16: ...oise 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 Valv...

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: ...e 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 ty...

Page 19: ...easy access to fuel cap n Fuel tank capacity is 14 liters n Electricfuelpumpforstabilizedfuelsupplyusesexternalfuelfilter BODYWORK n Completely new aerodynamically efficient sports styled bodywork In...

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 le...

Page 21: ...one 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...

Page 22: ...35 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...

Page 23: ...4 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 brak...

Page 24: ...m n Theoptionalelectricalaccessoriesare mobilephonecharger gripwarmersandanti theftalarmsystem ELECTRICAL SYSTEM HEADLIGHT ASSEMBLY n Newly designed multi reflector dual headlight Low beam 12V 55W H7...

Page 25: ...ed 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 sy...

Page 26: ...tor 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 f...

Page 27: ...he 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 f...

Page 28: ...ilemaintainingthefollowingconditions n Oil temperature 65 75 C n Coolant temperature 75 85 C n Intake vacuum 33 39 kPa n Idle revolution 1150 1250 rpm CO measurement should be 3 0 AIR INDUCTION SYSTEM...

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...

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 an...

Page 31: ...en 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...

Page 32: ...ft 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 secondar...

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: ...tive 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 w...

Page 35: ...splacement 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 Sys...

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...

Page 37: ...mshaft 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 Intak...

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 K...

Page 39: ...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...

Page 40: ...ion 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 ho...

Page 41: ...ter 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 Spr...

Page 42: ...nded 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 degr...

Page 43: ...n 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 T...

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

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

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