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2012 TMAX XP500A
Yamaha 2012 TMAX XP500A Manuals
Manuals and User Guides for Yamaha 2012 TMAX XP500A. We have
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Yamaha 2012 TMAX XP500A manual available for free PDF download: 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
Normal Braking (ABS Not Activated)
31
Depressurizing Phase
32
Emergency Braking (ABS Activated)
32
Pressurizing Phase
33
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 Tightening Torque
70
Cylinder Head Tightening Sequence
72
Chassis Tightening Torque
73
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
Removing the V-Belt and Primary/Secondary Sheave
302
Disassembling the Primary Sheave
303
Disassembling the Secondary Sheave
304
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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