Yamaha XP500 Quick start guide
XP500 TMax Technical Orientation Guide
1
FEATURES AND BENEFITS
Offering high levels of performance, comfort and sophistication, the new TMax superscooter looks
sure to make as great an impression on the powered two wheeler market as the first Yamaha YZF-
R1 made in the motorcycle scene.
ENGINE FEATURES
n499cc liquid cooled 4-stroke parallel twin
engine
nDOHC 8 valve engine
nHigh capacity V-belt transmission
nHorizontally opposed reciprocating balancer
nWet multiple plate automatic centrifugal
clutch
nNew design air intake route and air filter case
nLow position radiator
nSemi dry sump with oil cooler
nNon adjustable 2-stage silent chain drive train
CHASSIS FEATURES
nMotorcycle-type high rigidity diamond shape
frame
nMotorcycle-type front fork
nHighly rigid swingarm
n14 inch front and rear wheels
nMotorcycle-type hub with fixed rear wheel axle
nSport bike type weight distribution
n50º lean angle
n33 liters luggage compartment
n1 piece dual seat with 3-stage adjustable
backrest
ELECTRICAL FEATURES
nDual multi-reflector headlight
nStylish combination taillight
nAutomobile-type meter panel with extensive
information
nHigh capacity power supply
nAnti-theft alarm pre-wiring
nGrip warmer pre-wiring
nMobile phone charger pre-wiring
XP500 TMax Technical Orientation Guide
2
ENGINE SYSTEM
Displacing 499 cc, the TMax’s highly-advanced fully automatic twin-cylinder DOHC liquid-cooled
4-stroke 8-valve engine is one of the most powerful designs available on scooters today.
A key feature of its configuration is that unlike most traditional scooter engines which pivot as one
unit with the rear suspension, this engine is fixed rigidly into the TMax’s strong tubular diamond-shape frame
in order to achieve higher levels of chassis rigidity for enhanced handling performance. The swingarm is
mounted to a pivot point at the rear of the engine, thereby keeping unsprung weight low for more responsive
rear suspension action.
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
nParallel twin with 360 degree crankshaft
n66 mm bore and 73 mm stroke
n10.1 :1 compression ratio
nLeft side drive cam chain for reduced engine width
Horizontal compact cylinder head
Horizontally opposed reciprocating balancer
Semi dry sump
High capacity V-belt transmission
Wet multiple plate automatic centrifugal clutch
Non adjustable 2-stage silent chain drive train
Pivot coaxial drive shaft eliminates chain backlash
2
1
57
3
4
6
XP500 TMax Technical Orientation Guide
3
CYLINDER HEAD
n4 valves per cylinder, DOHC
nTorsion type auto cam chain tensioner (similar to YZF-R1)
n“Shim-under-bucket” valve adjustment for long maintenance interval (same as YZF-R1/YZF-R6)
nValve clearance at cold engine condition:
Intake : 0.15 - 0.20 mm
Exhaust: 0.25 - 0.30 mm
12
34
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
55º55º
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
XP500 TMax Technical Orientation Guide
4
CYLINDER
nNew liquid-cooled cylinder body for low weight
nLeft side cam chain drive for reduced engine width
nCeramic 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
XP500 TMax Technical Orientation Guide
5
CRANKSHAFT / BALANCER
nNew design crankshaft uses replaceable full circumference plain bearings
nHorizontally opposed reciprocating balancer for excellent vibration reduction
This type achieves same vibration reduction as 3 balancer shafts to reduce primary and second-
ary inertial forces, while requiring less space.
12
3
bearing size indication
4
Bearing size indication, reading from left to right (ex. 1 2 3 4 5):
Left main bearing
Right main bearing
Conrod bearing cylinder #1
Conrod bearing balancer cylinder
Conrod bearing cylinder #2
Piston cylinder #1
Piston cylinder #2
Cam chain drive gear
Balancer piston
Balancer cylinder
XP500 TMax Technical Orientation Guide
6
PISTON
nNew combustion piston with V-groove between upper and lower compression rings for improved
sealing
nBalancer 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
XP500 TMax Technical Orientation Guide
7
CONNECTING ROD
nNewly designed connecting rods: 2 for combustion, 1 for balancer
nNew 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
XP500 TMax Technical Orientation Guide
8
CONTINUOUSLY VARIABLE TRANSMISSION
nHighly efficient V-belt transmission in order to obtain high performance
nNewly designed cooling system with fins on both rotors of the secondary sheave for improved
cooling and higher belt durability
nCooling system uses 2 air filters to provide high volume clean air cooling
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 shift rate diagram
XP500 TMax Technical Orientation Guide
9
CLUTCH
nWet type multiple plate centrifugal clutch for smooth power transmission and to meet XP’s
higher torque
nClutch uses diaphragm type 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
678
9
105
1345
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
XP500 TMax Technical Orientation Guide
10
FINAL DRIVE
nNewly designed final drive with non-adjustable 2-stage silent chain for an efficient power trans-
mission, reduced noise and low maintenance
nHigh speed first stage chain with spring-type torque absorber for a further reduction of noise
nThe 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
123
4
5
Mounted on rear wheel
clutch hub
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6
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