Yamaha 2009 XP500Y TMAX Manuals

Manuals and User Guides for Yamaha 2009 XP500Y TMAX. We have 1 Yamaha 2009 XP500Y TMAX manual available for free PDF download: Service Manual

Yamaha 2009 XP500Y TMAX Service Manual

Yamaha 2009 XP500Y TMAX Service Manual (386 pages)

Brand: Yamaha | Category: Scooter | Size: 21.4 MB

Table of Contents

Table of Contents

7
- Service Manual
  1
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of Fi System
    11
    
    Fi System
    12
    
    Multi-Function Display
    13
  - Important Information
    16
    
    Preparation for Removal and Disassembly
    16
    
    Replacement Parts
    16
    
    Gaskets, Oil Seals and O-Rings
    16
    
    Lock Washers/Plates and Cotter Pins
    16
    
    Bearings and Oil Seals
    17
    
    Circlips
    17
  - Checking the Connections
    18
  - Special Tools
    19
Specifications

27
- General Specifications
  28
- Engine Specifications
  29
- Chassis Specifications
  37
- Electrical Specifications
  40
- Tightening Torques
  43
- Lubrication Points and Lubricant Types
  51
  - Engine
    51
  - Chassis
    53
- Lubrication System Diagrams
  54
  - Lubrication Diagrams
    54
- Cooling System Diagrams
  58
- Cable Routing
  62
Periodic Checks and Adjustments

79
- Periodic Maintenance
  
  82
- Engine
  
  85
- Chassis
  
  102
  - Adjusting the Front Disc Brake
    102
    
    Adjusting the Rear Disc Brake
    102
    
    Checking the Brake Fluid Level
    102
    
    Checking the Front Brake Pads
    103
    
    Checking the Rear Brake Pads
    103
    
    Checking the Front Brake Hoses
    103
    
    Checking the Rear Brake Hose
    104
    
    Adjusting the Rear Brake Lock Cable
    104
    
    Bleeding the Hydraulic Brake System
    104
    
    Checking the Chain Drive Oil Level
    105
    
    Changing the Chain Drive Oil
    106
    
    Checking and Adjusting the Steering Head
    106
    
    Checking the Front Fork
    108
    
    Checking the Tires
    108
    
    Checking the Wheels
    110
    
    Checking and Lubricating the Cables
    110
    
    Lubricating the Levers
    110
    
    Lubricating the Sidestand
    110
    
    Lubricating the Centerstand
    110
    
    Lubricating the Rear Suspension
    110
Chassis

113
- General Chassis
  
  121
  - Removing the Fuel Hose
    122
  - Installing the Fuel Hose
    122
- Front Wheel
  
  123
  - Removing the Front Wheel
    126
  - Disassembling the Front Wheel
    126
  - Checking the Front Wheel
    126
  - Assembling the Front Wheel
    127
  - Adjusting the Front Wheel Static Balance
    127
  - Installing the Front Wheel (Disc)
    128
- Rear Wheel
  
  130
  - Removing the Rear Wheel (Disc)
    132
  - Checking the Rear Wheel
    132
  - Checking the Rear Wheel Drive Hub
    132
  - Adjusting the Rear Wheel Static Balance
    132
  - Installing the Rear Wheel (Disc)
    132
- Front Brake
  
  133
- Rear Brake
  
  145
  - Introduction
    151
  - Checking the Rear Brake Disc
    151
  - Replacing the Rear Brake Pads
    151
  - Removing the Rear Brake Caliper
    153
  - Disassembling the Rear Brake Caliper
    154
  - Checking the Rear Brake Caliper
    154
  - Assembling the Rear Brake Caliper
    155
  - Installing the Rear Brake Caliper
    155
  - Removing the Rear Brake Master Cylinder
    156
  - Checking the Rear Brake Master Cylinder
    156
  - Assembling the Rear Brake Master Cylinder
    157
  - Installing the Rear Brake Master Cylinder
    157
- Handlebar
  
  159
  - Removing the Handlebar
    161
  - Checking the Handlebar
    161
  - Installing the Handlebar
    161
- Front Fork
  
  164
  - Removing the Front Fork Legs
    167
  - Disassembling the Front Fork Legs
    167
  - Checking the Front Fork Legs
    168
  - Assembling the Front Fork Legs
    168
  - Installing the Front Fork Legs
    171
- Steering Head
  
  173
  - Removing the Lower Bracket
    175
  - Checking the Steering Head
    175
  - Installing the Steering Head
    176
- Rear Shock Absorber Assembly
  
  177
- Swingarm and Transmission Chain Drive
  
  180
Engine

187
- Engine Removal
  
  190
  - Installing the Engine
    194
- Camshafts
  
  195
  - Removing the Camshafts
    198
  - Checking the Camshafts
    199
  - Checking the Camshaft Sprockets
    200
  - Checking the Timing Chain Guides
    200
  - Checking the Timing Chain Tensioner
    201
  - Installing the Camshafts
    201
- Cylinder Head
  
  204
  - Removing the Cylinder Head
    205
  - Checking the Cylinder Head
    205
  - Installing the Cylinder Head
    205
- Valves and Valve Springs
  
  208
  - Removing the Valves
    208
  - Checking the Valves and Valve Guides
    208
  - Checking the Valve Seats
    210
  - Checking the Valve Springs
    212
  - Checking the Valve Lifters
    212
  - Installing the Valves
    212
- Cylinder and Pistons
  
  216
  - Removing the Pistons
    216
  - Checking the Cylinders and Pistons
    216
  - Checking the Piston Rings
    217
  - Checking the Piston Pins
    218
  - Installing the Pistons and Cylinder
    218
- Electric Starter
  
  220
  - Checking the Starter Motor
    222
  - Assembling the Starter Motor
    222
  - Installing the Starter Motor
    223
- V-Belt Automatic Transmission
  
  225
- Generator and Starter Clutch
  
  237
  - Removing the Generator
    239
  - Removing the Starter Clutch
    239
  - Checking the Starter Clutch
    240
  - Checking the Oil Strainer
    240
  - Installing the Starter Clutch
    240
  - Installing the Generator
    241
- Clutch
  
  243
  - Removing the Clutch
    246
  - Disassembling the Clutch
    246
  - Checking the Friction Plates
    247
  - Checking the Clutch Plates
    247
  - Checking the Clutch Damper Springs
    247
  - Checking the Clutch Spring Plate
    247
  - Checking the Clutch Springs
    248
  - Checking the Clutch Housing
    248
  - Checking the Clutch Boss
    248
  - Checking the Pressure Plate
    248
  - Assembling the Clutch
    248
  - Installing the Clutch
    249
- Oil Pump
  
  251
  - Checking the Oil Pump
    253
  - Checking the Relief Valve
    253
  - Checking the Oil Pipes
    253
  - Checking the Oil Pump Drive Chain
    253
  - Assembling the Oil Pump
    254
  - Installing the Oil Pump
    254
- Crankcase
  
  255
  - Disassembling the Crankcase
    258
  - Checking the Crankcase
    258
  - Checking the Timing Chain
    258
  - Assembling the Crankcase
    258
- Crankshaft
  
  260
- Transmission
  
  268
  - Checking the Transmission
    269
Cooling System

271
- Radiator
  
  274
  - Checking the Radiator
    274
  - Installing the Radiator
    274
- Oil Cooler
  
  275
  - Checking the Oil Cooler
    277
  - Installing the Oil Cooler
    277
- Thermostat
  
  278
  - Checking the Thermostat
    279
  - Installing the Thermostat Assembly
    279
- Water Pump
  
  280
  - Disassembling the Water Pump
    282
  - Checking the Water Pump
    282
  - Assembling the Water Pump
    282
  - Installing the Water Pump
    283
  - Fuel System
    285
    
    Fuel Tank
    288
    
    Throttle Body
    290
Electrical System

295
- Ignition System
  
  298
  - Circuit Diagram
    298
  - Troubleshooting
    300
- Electric Starting System
  
  302
  - Circuit Diagram
    302
  - Starting Circuit Cut-Off System Operation
    304
  - Troubleshooting
    306
- Charging System
  
  308
  - Circuit Diagram
    308
  - Troubleshooting
    310
- Lighting System
  
  312
  - Circuit Diagram
    312
  - Troubleshooting
    314
- Signaling System
  
  316
  - Circuit Diagram
    316
  - Troubleshooting
    318
- Cooling System
  
  322
  - Circuit Diagram
    322
  - Troubleshooting
    324
- Fuel Injection System
  
  326
  - Circuit Diagram
    326
  - Ecu Self-Diagnostic Function
    328
  - Self-Diagnostic Function Table
    329
  - Troubleshooting Method
    331
  - Diagnostic Mode
    332
  - Troubleshooting Details
    337
- Fuel Pump System
  
  350
  - Circuit Diagram
    350
  - Troubleshooting
    352
- Electrical Components
  
  354
  - Checking the Switches
    358
  - Checking the Bulbs and Bulb Sockets
    361
  - Checking the Fuses
    362
  - Checking and Charging the Battery
    363
  - Checking the Relays
    366
  - Checking the Turn Signal Relay
    367
  - Checking the Diode
    368
  - Checking the Spark Plug Caps
    368
  - Checking the Ignition Coil
    368
  - Checking the Ignition Spark Gap
    369
  - Checking the Crankshaft Position Sensor
    369
  - Checking the Lean Angle Sensor
    370
  - Checking the Starter Motor Operation
    370
  - Checking the Stator Coil
    371
  - Checking the Rectifier/Regulator
    371
  - Checking the Horn
    372
  - Checking the Fuel Sender
    372
  - Checking the Speed Sensor
    373
  - Checking the Radiator Fan Motor
    373
  - Checking the Coolant Temperature Sensor
    373
  - Checking the Throttle Position Sensor
    374
  - Checking the Intake Air Pressure Sensor
    374
  - Checking the Intake Air Temperature Sensor
    375
  - General Information
    377
    
    Troubleshooting
    378
    
    General Information
    378
    
    Starting Failure/Hard Starting
    378
    
    Incorrect Engine Idling Speed
    378
    
    Poor Medium-And-High-Speed Performance
    379
    
    Faulty Clutch
    379
    
    Overheating
    379
    
    Overcooling
    380
    
    Poor Braking Performance
    380
    
    Faulty Front Fork Legs
    380
    
    Unstable Handling
    380
    
    Faulty Lighting or Signaling System
    381
    
    Wiring Diagram
    382
  - Troubleshooting
    377

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