Yamaha 2012 TMAX XP500A Manuals

Yamaha 2012 TMAX XP500A Manuals

Manuals and User Guides for Yamaha 2012 TMAX XP500A. We have 1 Yamaha 2012 TMAX XP500A manual available for free PDF download: Service Manual

Yamaha 2012 TMAX XP500A Service Manual

Yamaha 2012 TMAX XP500A Service Manual (531 pages)

Brand: Yamaha | Category: Scooter | Size: 25.67 MB

Table of Contents

Service Manual
1
How to Use this Manual
4
Symbols
5
Table of Contents
7
General Information
9
- Model Label
  10
- Vehicle Identification Number
  10
- Features
  11
- Outline of FI System
  11
- FI System
  12
- Multi-Function Display
  13
  - To Set the Clock
    13
  - Coolant Temperature Meter
    14
  - Fuel Meter
    14
  - Odometer and Tripmeter Modes
    14
  - Oil Change Indicator “Oil”
    15
  - V-Belt Replacement Indicator “V-Belt”
    15
  - Ambient Temperature Display
    16
  - Average Fuel Consumption Mode
    16
  - Instantaneous Fuel Consumption Mode
    17
  - Self-Diagnosis Device
    17
  - ABS Layout
    19
- Outline of the ABS
  19
  - Useful Terms
    20
  - Brake Force and Vehicle Stability
    21
  - Wheel Slip and Hydraulic Control
    22
  - ABS Operation and Vehicle Control
    23
  - ABS Block Diagram
    24
  - Electronic ABS Features
    24
- ABS Component Functions
  25
  - Wheel Sensors and Wheel Sensor Rotors
    25
  - ABS Warning Light
    26
  - Hydraulic Unit Assembly
    26
  - Hydraulic Control Valve
    27
  - Buffer Chamber
    28
  - Abs Ecu
    29
  - ABS Control Operation
    30
- ABS Operation
  31
- ABS Self-Diagnosis Function
  34
- Instances When the ABS Warning Light Comes on
  34
- ABS Warning Light and Operation
  37
- Gaskets, Oil Seals and O-Rings
  38
- Important Information
  38
- Lock Washers/Plates and Cotter Pins
  38
- Preparation for Removal and Disassembly
  38
- Replacement Parts
  38
- Bearings and Oil Seals
  39
- Circlips
  39
- Rubber Parts
  39
- Basic Service Information
  40
- Quick Fasteners
  40
  - Rivet Type
    40
  - Screw Type
    40
  - Electrical Parts Handling
    41
- Electrical System
  41
  - Checking the Electrical System
    42
  - Checking the Connections
    43
- Special Tools
  46
Specifications
55
- General Specifications
  56
- Engine Specifications
  57
- Chassis Specifications
  64
- Electrical Specifications
  67
- General Tightening Torque Specifications
  69
- Tightening Torques
  69
- Engine
  76
- Lubrication Points and Lubricant Types
  76
- Chassis
  78
- Engine Oil Lubrication Chart
  80
- Lubrication System Chart and Diagrams
  80
- Lubrication Diagrams
  82
- Cooling System Diagrams
  90
- Cable Routing
  94
- Handlebar (Top Side View)
  94
- Handlebar (Front Side and Left Side View)
  96
- Front Brake (Front Side and Left Side View)
  98
- Frame (Front Side View)
  100
- Frame (Left Side View)
  102
- Frame (Right Side View)
  104
- Rear Frame (Top Side and Right Side View)
  106
- Rear Brake (Top Side and Left Side View)
  108
- Throttle Body (Left Side View)
  110
- Fuel Tank (Top Side, Left Side and Right Side View)
  112
- Hydraulic Unit (Top Side and Front Side View)
  114
Periodic Checks and Adjustments
117
- Introduction
  120
- Periodic Maintenance Chart for the Emission Control System
  120
- General Maintenance and Lubrication Chart
  121
- Checking the Fuel Line
  123
- Checking the Spark Plugs
  123
- Adjusting the Valve Clearance
  124
- Adjusting the Engine Idling Speed
  127
- Synchronizing the Throttle Body
  128
- Checking the Cylinder Head Breather Hose
  129
- Checking the Throttle Body Joints
  129
- Adjusting the Exhaust Gas Volume
  130
- Checking the Exhaust System
  130
- Cleaning the V-Belt Case Air Filter Element
  131
- Replacing the Air Filter Element
  131
- Checking the Brake Operation
  132
- Adjusting the Front Disc Brake
  133
- Checking the Brake Fluid Level
  133
- Adjusting the Rear Disc Brake
  134
- Checking the Front Brake Pads
  134
- Checking the Rear Brake Pads
  134
- Bleeding the Hydraulic Brake System (ABS)
  135
- Adjusting the Rear Brake Lock Cable
  136
- Checking the Front Brake Hoses
  136
- Checking the Rear Brake Hose
  136
- Checking the Rear Brake Lock
  137
- Checking the Rear Brake Lock Pads
  138
- Checking the Tires
  138
- Checking the Wheels
  138
- Never Overload the Vehicle
  138
- Checking the Drive Belt
  139
- Checking the Swingarm
  139
- Checking the Wheel Bearings
  139
- Adjusting the Drive Belt Slack
  140
- Lubricating the Drive Pulley and Drive Axle
  141
- Checking and Adjusting the Steering Head
  142
- Checking the Chassis Fasteners
  143
- Checking the Sidestand
  143
- Lubricating the Levers
  143
- Checking the Centerstand
  144
- Checking the Engine Oil Level
  144
- Checking the Front Fork
  144
- Checking the Rear Shock Absorber Assembly
  144
- Checking the Sidestand Switch
  144
- Lubricating the Sidestand
  144
- Changing the Engine Oil
  145
- Measuring the Engine Oil Pressure
  147
- Checking the Coolant Level
  148
- Checking the Cooling System
  148
- Changing the Coolant
  149
- Replacing the V-Belt
  150
- Checking and Lubricating the Cables
  151
- Checking the Brake Light Switches
  151
- Checking the Throttle Grip
  151
- Lubricating the Rear Suspension
  151
- Checking and Charging the Battery
  152
- Checking the Fuses
  152
- Replacing the Headlight Bulbs
  152
- Adjusting the Headlight Beams
  153
Chassis
155
- General Chassis
  158
- Removing the Windshield and Front Cowling Assembly
  158
- Disassembling the Front Cowling Assembly
  159
- Removing the Storage Compartment
  160
- Removing the Bottom Cowling
  161
- Removing the Rear Cowling Assembly
  162
- Disassembling the Rear Cowling Assembly
  164
- Removing the Storage Box
  165
- Removing the Windshield
  166
- Installing the Windshield
  166
- Adjusting the Windshield Height
  167
- Removing the Front Cover
  167
- Installing the Front Cover
  168
- Removing the Windshield Inner Panel
  168
- Installing the Windshield Inner Panel
  169
- Removing the Side Panel
  169
- Installing the Side Panel
  169
- Removing the Center Cover
  170
- Installing the Center Cover
  170
- Removing the Side Cover
  170
- Installing the Side Cover
  170
- Removing the Footboard
  171
- Installing the Side Cover Moulding
  171
- Removing the Side Cover Moulding
  171
- Installing the Footboard
  172
- Removing the Rear Cover
  172
- Installing the Rear Cover
  173
- Removing the Inner Panel Center Cover
  173
- Installing the Inner Panel Center Cover
  173
- Removing the Fuel Hose
  174
- Installing the Fuel Hose
  174
- Removing the Front Wheel and Brake Discs
  175
- Disassembling the Front Wheel
  176
- Removing the Front Wheel
  177
- Checking the Front Wheel
  177
- Maintenance of the Front Wheel Sensor and Sensor Rotor
  178
- Assembling the Front Wheel
  179
- Adjusting the Front Wheel Static Balance
  180
- Installing the Front Wheel (Discs)
  181
- Removing the Rear Wheel
  184
- Removing the Rear Brake Disc and Rear Wheel Pulley
  186
- Disassembling the Rear Wheel Assembly
  187
- Removing the Rear Wheel (Disc)
  188
- Disassembling the Rear
  188
- Checking the Rear Wheel Drive Hub
  189
- Checking and Replacing the Rear Wheel Pulley
  189
- Maintenance of the Rear Wheel Sensor and Sensor Rotor
  190
- Assembling the Rear Wheel
  190
- Installing the Rear Wheel (Disc)
  191
- Adjusting the Rear Wheel Static Balance
  191
- Removing the Front Brake Pads
  194
- Removing the Front Brake Master Cylinder
  195
- Disassembling the Front Brake Master Cylinder
  196
- Removing the Front Brake Calipers
  197
- Disassembling the Front Brake Calipers
  198
- Checking the Front Brake Discs
  199
- Replacing the Front Brake Pads
  200
- Checking the Front Brake Calipers
  202
- Assembling the Front Brake Calipers
  202
- Installing the Front Brake Calipers
  203
- Checking the Front Brake Master Cylinder
  204
- Assembling the Front Brake Master Cylinder
  204
- Installing the Front Brake Master Cylinder
  205
- Removing the Rear Brake Pads
  207
- Removing the Rear Brake Master Cylinder
  208
- Disassembling the Rear Brake Master Cylinder
  209
- Removing the Rear Brake Caliper
  210
- Disassembling the Rear Brake Caliper
  211
- Removing the Rear Brake Lock Pads
  212
- Removing the Rear Brake Lock Caliper
  213
- Disassembling the Rear Brake Lock Caliper
  214
- Replacing the Rear Brake Pads
  215
- Checking the Rear Brake Disc
  215
- Checking the Rear Brake Caliper
  217
- Installing the Rear Brake Caliper
  218
- Checking the Rear Brake Master Cylinder
  219
- Assembling the Rear Brake Master Cylinder
  219
- Installing the Rear Brake Master Cylinder
  219
- Replacing the Rear Brake Lock Pads
  221
- Replacing the Rear Brake Lock Cable
  222
- Checking the Rear Brake Lock Caliper
  223
- Assembling the Rear Brake Lock Caliper
  223
- Installing the Rear Brake Lock Caliper
  224
- ABS (Anti-Lock Brake System)
  225
- Removing the Hydraulic Unit Assembly
  225
- Checking the Hydraulic Unit Assembly
  227
- Checking the Brake Pipes
  228
- Installing the Hydraulic Unit Assembly
  228
- Hydraulic Unit Operation Test 1
  230
- Hydraulic Unit Operation Test 2
  231
- Removing the Handlebar
  233
- Installing the Handlebar
  235
- Checking the Handlebar
  235
- Removing the Front Fork Legs
  238
- Disassembling the Front Fork Legs
  239
- Checking the Front Fork Legs
  241
- Assembling the Front Fork Legs
  242
- Installing the Front Fork Legs
  244
- Steering Head
  246
- Removing the Lower Bracket
  246
- Checking the Steering Head
  247
- Installing the Steering Head
  248
- Removing the Drive Belt
  249
- Checking the Drive Belt
  250
- Installing the Drive Belt
  250
- Removing the Rear Shock Absorber Assembly
  251
- Handling the Rear Shock Absorber
  252
- Disposing of a Rear Shock Absorber
  252
- Checking the Rear Shock Absorber Assembly
  252
- Installing the Rear Shock Absorber Assembly
  252
- Removing the Swingarm
  254
- Installing the Swingarm
  256
- Checking the Swingarm
  256
Engine
259
- Engine Inspection
  262
- Measuring the Compression Pressure
  262
- Engine Removal
  264
  - Removing the Exhaust Assembly
    264
  - Disconnecting the Leads
    265
  - Removing the Engine
    267
- Installing the Engine
  268
- Camshafts
  269
  - Removing the Cylinder Head Cover
    269
  - Removing the Camshafts
    270
- Removing the Camshafts
  272
- Checking the Camshafts
  273
- Checking the Camshaft Sprockets
  274
- Checking the Timing Chain Guides
  275
- Checking the Timing Chain Tensioner
  275
- Installing the Camshafts
  275
- Removing the Cylinder Head
  279
- Checking the Cylinder Head
  280
- Installing the Cylinder Head
  280
- Removing the Valves and Valve Springs
  282
- Removing the Valves
  283
- Valves and Valve Springs
  283
- Checking the Valves and Valve Guides
  284
- Checking the Valve Seats
  285
- Checking the Valve Springs
  287
- Checking the Valve Lifters
  288
- Installing the Valves
  288
- Removing the Cylinder and Pistons
  290
- Checking the Cylinders and Pistons
  291
- Removing the Pistons
  291
- Checking the Piston Rings
  292
- Checking the Piston Pins
  293
- Installing the Pistons and Cylinder
  294
- Electric Starter
  296
  - Removing the Starter Motor
    296
  - Disassembling the Starter Motor
    297
- Checking the Starter Motor
  298
- Assembling the Starter Motor
  299
- Installing the Starter Motor
  299
- Removing the V-Belt Case Cover
  300
- V-Belt Automatic Transmission
  300
- Disassembling the Secondary Sheave
  305
- Removing the Primary Sheave and Secondary Sheave
  305
- Checking the Primary Sheave Weights
  306
- Checking the Sliders
  306
- Checking the V-Belt Case Air Duct
  306
- Assembling the Primary Sheave
  307
- Assembling the Secondary Sheave
  307
- Checking the Secondary Sheave
  307
- Installing the Primary Sheave Assembly, Secondary Sheave Assembly and V-Belt
  309
- Installing the V-Belt Case
  310
  - Removing the Generator Rotor and Starter Clutch
    311
  - Removing the Stator Coil and Oil Tank
    313
- Checking the Starter Clutch
  314
- Removing the Generator
  314
- Removing the Starter Clutch
  314
- Assembling the Oil Tank
  315
- Checking the Oil Strainer
  315
- Installing the Starter Clutch
  315
- Installing the Generator
  316
  - Removing the Clutch
    318
  - Disassembling the Clutch
    319
- Disassembling the Clutch
  321
- Removing the Clutch
  321
- Checking the Clutch Damper Springs
  322
- Checking the Clutch Spring Plate
  322
- Checking the Friction Plates
  322
- Checking the Clutch Boss
  323
- Checking the Clutch Housing
  323
- Checking the Clutch Springs
  323
- Checking the Pressure Plate and Thrust Plate
  323
- Assembling the Clutch
  324
- Installing the Clutch
  325
  - Removing the Oil Pump Assembly
    326
  - Disassembling the Oil Pump Assembly
    327
- Assembling the Oil Pump
  328
- Checking the Oil Pump Drive Chain
  328
- Checking the Relief Valve
  328
- Installing the Oil Pump
  328
  - Separating the Crankcase
    330
  - Removing the Oil Seals and Bearings
    332
- Assembling the Crankcase
  333
- Checking the Crankcase
  333
- Checking the Timing Chain
  333
- Disassembling the Crankcase
  333
  - Removing the Crankshaft Assembly
    335
  - Removing the Connecting Rods
    336
- Checking the Crankshaft and Connecting Rods
  337
- Removing the Crankshaft Journal Bearings
  337
- Installing the Connecting Rods
  341
- Installing the Crankshaft Journal Bearings
  341
- Installing the Crankshaft Assembly
  343
- Removing the Transmission
  344
- Checking the Transmission
  345
Cooling System
347
- Removing the Radiator
  348
- Checking the Radiator
  350
- Installing the Radiator
  350
- Removing the Oil Cooler
  352
- Checking the Oil Cooler
  353
- Installing the Oil Cooler
  353
- Removing the Thermostat
  354
- Checking the Thermostat
  355
- Installing the Thermostat Assembly
  355
  - Removing the Water Pump
    356
  - Disassembling the Water Pump
    357
- Assembling the Water Pump
  358
- Checking the Water Pump
  358
- Installing the Water Pump
  359
Fuel System
361
- Removing the Fuel Tank
  362
- Removing the Fuel Pump
  363
- Checking the Fuel Pump Body
  363
- Checking the Fuel Pump Operation
  363
- Checking the Rollover Valve
  363
- Fuel Tank
  363
- Checking the Fuel Pressure
  364
- Installing the Fuel Pump
  364
- Installing the Fuel Tank
  364
- Removing the Throttle Body
  366
- Disassembling the Throttle Body Assembly
  368
- Removing the Fuel Hose (Injector Side)
  369
- Checking the Injectors
  369
- Checking the Throttle Body
  369
- Installing the Injectors
  369
- Adjusting the Throttle Position Sensor
  370
- Installing the Fuel Hose (Injector Side)
  370
General Information
373
Electrical System
373
- Ignition System
  376
- Circuit Diagram
  376
- Electric Starting System
  380
- Starting Circuit Cut-Off System Operation
  382
- Charging System
  386
- Lighting System
  390
- Signaling System
  394
- Fuel Injection System
  404
- ECU Self-Diagnostic Function
  406
- Engine Trouble Warning Light Indication and Fuel Injection System Operation
  406
- Checking the Engine Trouble Warning Light
  406
- ECU Detects an Abnormal Signal from a Sensor
  407
- Troubleshooting Method
  408
- Diagnostic Mode
  409
- Features of the Yamaha Diagnostic Tool
  410
- Functions of the Yamaha Diagnostic Tool
  410
- Connecting the Yamaha Diagnostic Tool
  411
- Troubleshooting Details
  412
- Fuel Pump System
  446
- Immobilizer System
  450
- Part Replacement and Key Code Registration Requirements
  453
- Code Re-Registering Key Registration
  453
- Standby Mode
  454
- Standard Key Registration
  454
- Voiding the Standard Key Code
  455
- Self-Diagnosis Fault Code Indication
  457
- Immobilizer System Indicator Light Fault Code Indication
  458
- ABS Components Chart
  462
- ABS Coupler Location Chart
  464
- Checking the ABS ECU
  466
- ABS Troubleshooting Outline
  466
- ABS Operation When the ABS Warning Light Comes on
  466
- Maintenance of the ABS ECU
  466
- Self-Diagnosis and Servicing
  467
- Special Precautions for Handling and Servicing a Vehicle Equipped with ABS
  467
- Basic Instructions for Troubleshooting
  467
- Basic Process for Troubleshooting
  468
- The ABS Warning Light and All Other Indicator Lights Fail to Come on
  469
- Checking the ABS Warning Light
  469
- Only the ABS Warning Light Fails to Come on
  469
- The ABS Warning Light Flashes
  470
- The ABS Warning Light Comes on
  470
- The Multi-Function Display Does Not Display the Fault Code
  471
- The ABS Warning Light Remains on
  471
- Diagnosis Using the Fault Codes
  472
- Fault Code Table
  472
- Deleting the Fault Codes
  490
- Delete Function Test
  490
- Final Check
  492
- Checking Procedures
  492
- Electrical Components
  494
- Checking the Switches
  498
- Checking the Bulbs and Bulb Sockets
  501
- Types of Bulbs
  501
- Checking the Condition of the Bulb Sockets
  501
- Checking the Fuses
  502
- Charging Method Using a Variable-Current (Voltage) Charger
  504
- Charging Method Using a Constant Voltage Charger
  505
- Checking the Relays
  506
- Checking the Turn Signal/Hazard Relay
  507
- Checking the Diode
  508
- Checking the Spark Plug Caps
  509
- Checking the Ignition Coil
  509
- Checking the Ignition Spark Gap
  510
- Checking the Crankshaft Position Sensor
  510
- Checking the Lean Angle Sensor
  510
- Checking the Stator Coil
  511
- Checking the Starter Motor Operation
  511
- Checking the Rectifier/Regulator
  512
- Checking the Horn
  512
- Checking the Fuel Sender
  513
- Checking the Fuel Meter/Fuel Level Warning Light
  513
- Checking the Radiator Fan Motor
  513
- Checking the Coolant Temperature Sensor
  514
- Checking the Throttle Position Sensor
  514
- Checking the Intake Air Pressure Sensor
  515
- Checking the Intake Air Temperature Sensor
  515
- Checking the Fuel Injectors
  516
Troubleshooting
517
- Poor Engine Idling Speed Performance
  518
- Starting Failure/Hard Starting
  518
- Poor Medium-And-High-Speed Performance
  519
- Faulty Clutch
  519
- Overheating
  519
- Faulty Front Fork Legs
  520
- Unstable Handling
  520
- Poor Braking Performance
  520
- Overcooling
  520
- Faulty Lighting or Signaling System
  521
- Self-Diagnostic Function and Diagnostic Code Table
  522
- Communication Error with the Meter
  523
- Diagnostic Code: Sensor Operation Table
  523
- Diagnostic Code: Actuator Operation Table
  525
- Wiring Diagram XP500A 2012
  526
- Color Code
  526
- Wiring Diagram XP500A
  529

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