Yamaha TMAX XP500F 2015 Manuals

Yamaha TMAX XP500F 2015 Manuals

Manuals and User Guides for Yamaha TMAX XP500F 2015. We have 1 Yamaha TMAX XP500F 2015 manual available for free PDF download: Service Manual

Yamaha TMAX XP500F 2015 Service Manual

Yamaha TMAX XP500F 2015 Service Manual (478 pages)

Brand: Yamaha | Category: Motorcycle | Size: 23.17 MB

Table of Contents

Table of Contents

7
- General Information
  9
- Identification
  10
- Vehicle Identification Number
  10
- Model Label
  10
- Features
  11
- Outline of the Fi System
  11
- Fi System
  12
- Multi-Function Display
  13
- Important Information
  18
- Preparation for Removal and Disassembly
  18
- Replacement Parts
  18
- Gaskets, Oil Seals and O-Rings
  18
- Lock Washers/Plates and Cotter Pins
  18
- Bearings and Oil Seals
  19
- Circlips
  19
- Rubber Parts
  19
- Quick Fasteners
  20
- Basic Service Information
  20
- Electrical System
  21
- Special Tools
  25
Specifications

33
- General Specifications
  34
- Engine Specifications
  35
- Chassis Specifications
  40
- Electrical Specifications
  43
- General Tightening Torque Specifications
  45
- Tightening Torques
  45
- Engine Tightening Torques
  46
- Chassis Tightening Torques
  49
- Engine
  53
- Lubrication Points and Lubricant Types
  53
- Chassis
  55
- Engine Oil Lubrication Chart
  56
- Lubrication System Chart and Diagrams
  56
- Lubrication Diagrams
  58
- Cooling System Diagrams
  66
- Cable Routing
  70
Periodic Checks and Adjustments

93
- General Maintenance and Lubrication Chart
  96
- Introduction
  96
- Periodic Maintenance
  96
- Periodic Maintenance Chart for the Emission Control System
  96
- Checking the Fuel Line
  99
- Checking the Spark Plugs
  99
- Adjusting the Valve Clearance
  100
- Adjusting the Engine Idling Speed
  103
- Synchronizing the Throttle Body
  104
- Checking the Cylinder Head Breather Hose
  105
- Checking the Throttle Body Joints
  105
- Checking the Canister
  106
- Checking the Exhaust System
  106
- Replacing the Air Filter Element
  106
- Cleaning the V-Belt Case Air Filter Element
  107
- Checking the Brake Fluid Level
  108
- Checking the Brake Operation
  108
- Adjusting the Front Disc Brake
  109
- Checking the Front Brake Pads
  109
- Adjusting the Rear Disc Brake
  110
- Bleeding the Hydraulic Brake System
  110
- Checking the Rear Brake Pads
  110
- Checking the Front Brake Hoses
  111
- Checking the Rear Brake Hose
  111
- Adjusting the Rear Brake Lock Cable
  112
- Checking the Rear Brake Lock
  112
- Checking the Rear Brake Lock Pads
  113
- Checking the Tires
  113
- Checking the Wheels
  113
- Checking the Wheel Bearings
  114
- Adjusting the Drive Belt Slack
  115
- Checking the Drive Belt
  115
- Checking the Swingarm
  115
- Lubricating the Drive Pulley and Drive Axle
  117
- Checking and Adjusting the Steering Head
  118
- Checking the Chassis Fasteners
  119
- Checking the Sidestand
  119
- Lubricating the Levers
  119
- Lubricating the Sidestand
  119
- Checking the Centerstand
  120
- Checking the Engine Oil Level
  120
- Checking the Front Fork
  120
- Checking the Rear Shock Absorber Assembly
  120
- Checking the Sidestand Switch
  120
- Lubricating the Centerstand
  120
- Changing the Engine Oil
  121
- Measuring the Engine Oil Pressure
  122
- Checking the Coolant Level
  123
- Changing the Coolant
  124
- Checking the Cooling System
  124
- Checking and Lubricating the Cables
  126
- Checking the Brake Light Switches
  126
- Replacing the V-Belt
  126
- Checking the Throttle Grip
  127
- Lubricating the Rear Suspension
  127
- Adjusting the Headlight Beams
  128
- Checking and Charging the Battery
  128
- Checking the Fuses
  128
Chassis

129
- General Chassis (1)
  133
- Installing the Windshield
  135
- Removing the Windshield
  135
- Adjusting the Windshield Height
  136
- Installing the Front under Cover
  136
- Removing the Front under Cover
  136
- Installing the Front Cover
  137
- Removing the Front Cover
  137
- General Chassis (2)
  138
- Installing the Windshield Inner Panel
  138
- Removing the Windshield Inner Panel
  138
- Installing the Center Cover
  140
- Installing the Side Panel
  140
- Removing the Center Cover
  140
- Removing the Side Panel
  140
- Installing the Side Cover
  141
- Removing the Side Cover
  141
- Removing the Side Cover Moulding
  141
- Installing the Side Cover Moulding
  142
- Removing the Footboard
  142
- General Chassis (3)
  143
- Installing the Footboard
  143
- General Chassis (4)
  146
- Installing the Inner Panel Center Cover
  146
- Removing the Inner Panel Center Cover
  146
- General Chassis (5)
  150
- Installing the Rear Cover
  150
- Removing the Rear Cover
  150
- Installing the Fuel Hose
  152
- Removing the Fuel Hose
  152
- Front Wheel
  153
- Checking the Front Wheel
  156
- Disassembling the Front Wheel
  156
- Removing the Front Wheel
  156
- Assembling the Front Wheel
  157
- Adjusting the Front Wheel Static Balance
  158
- Installing the Front Wheel (Front Brake Disc)
  159
- Rear Wheel
  162
- Checking the Rear Wheel
  166
- Checking the Rear Wheel Drive Hub
  166
- Disassembling the Rear Wheel
  166
- Removing the Rear Wheel (Disc Brake)
  166
- Assembling the Rear Wheel
  167
- Checking and Replacing the Rear Wheel Pulley
  167
- Adjusting the Rear Wheel Static Balance
  168
- Installing the Rear Wheel (Disc Brake)
  168
- Front Brake
  170
- Checking the Front Brake Discs
  176
- Introduction
  176
- Replacing the Front Brake Pads
  177
- Disassembling the Front Brake Calipers
  178
- Removing the Front Brake Calipers
  178
- Assembling the Front Brake Calipers
  179
- Checking the Front Brake Calipers
  179
- Installing the Front Brake Calipers
  180
- Assembling the Front Brake Master Cylinder
  181
- Checking the Front Brake Master Cylinder
  181
- Installing the Front Brake Master Cylinder
  181
- Removing the Front Brake Master Cylinder
  181
- Rear Brake
  184
- Checking the Rear Brake Disc
  193
- Introduction
  193
- Replacing the Rear Brake Pads
  193
- Removing the Rear Brake Caliper
  194
- Assembling the Rear Brake Caliper
  195
- Checking the Rear Brake Caliper
  195
- Disassembling the Rear Brake Caliper
  195
- Installing the Rear Brake Caliper
  196
- Assembling the Rear Brake Master Cylinder
  197
- Checking the Rear Brake Master Cylinder
  197
- Installing the Rear Brake Master Cylinder
  197
- Removing the Rear Brake Master Cylinder
  197
- Replacing the Rear Brake Lock Pads
  198
- Checking the Rear Brake Lock Caliper
  200
- Removing the Rear Brake Lock Caliper
  200
- Replacing the Rear Brake Lock Cable
  200
- Assembling the Rear Brake Lock Caliper
  201
- Installing the Rear Brake Lock Caliper
  202
- Handlebar
  203
- Checking the Handlebar
  206
- Installing the Handlebar
  206
- Removing the Handlebar
  206
- Front Fork
  209
- Disassembling the Front Fork Legs
  213
- Removing the Front Fork Legs
  213
- Checking the Front Fork Legs
  214
- Assembling the Front Fork Legs
  215
- Installing the Front Fork Legs
  219
- Steering Head
  220
- Checking the Steering Head
  222
- Removing the Lower Bracket
  222
- Installing the Steering Head
  223
- Belt Drive
  224
- Checking the Drive Belt
  226
- Installing the Drive Belt
  226
- Checking the Rear Shock Absorber Assembly
  228
- Disposing of a Rear Shock Absorber
  228
- Handling the Rear Shock Absorber
  228
- Installing the Rear Shock Absorber Assembly
  228
- Rear Shock Absorber Assembly
  228
- Removing the Rear Shock Absorber Assembly
  228
- Swingarm
  230
- Checking the Swingarm
  232
- Installing the Swingarm
  232
- Removing the Swingarm
  232
Engine

235
- Engine Inspection
  238
- Measure the Compression Pressure
  238
- Engine Removal
  239
- Installing the Engine
  246
- Camshafts
  247
- Removing the Camshafts
  250
- Checking the Camshafts
  251
- Checking the Camshaft Sprockets
  252
- Checking the Timing Chain Guides
  252
- Checking the Timing Chain Tensioner
  253
- Installing the Camshafts
  253
- Cylinder Head
  257
- Checking the Cylinder Head
  258
- Installing the Cylinder Head
  258
- Removing the Cylinder Head
  258
- Checking the Valves and Valve Guides
  261
- Removing the Valves
  261
- Valves and Valve Springs
  261
- Checking the Valve Seats
  263
- Checking the Valve Lifters
  265
- Checking the Valve Springs
  265
- Installing the Valves
  266
- Checking the Cylinders and Pistons
  269
- Cylinder and Pistons
  269
- Removing the Piston
  269
- Checking the Piston Rings
  270
- Checking the Piston Pins
  271
- Installing the Piston and Cylinder
  271
- Electric Starter
  273
- Checking the Starter Motor
  275
- Assembling the Starter Motor
  276
- Installing the Starter Motor
  276
- V-Belt Automatic Transmission
  280
- Disassembly the Secondary Sheave
  283
- Removing the Primary Sheave and Secondary Sheave
  283
- Checking the Primary Sheave
  284
- Checking the Primary Sheave Weights
  284
- Checking the Secondary Sheave
  284
- Checking the Sliders
  284
- Checking the V-Belt
  284
- Checking the V-Belt Case Air Duct
  284
- Assembling the Primary Sheave
  285
- Assembling the Secondary Sheave
  285
- Installing the Primary Sheave Assembly, Secondary Sheave Assembly and V-Belt
  286
- Installing the V-Belt Case
  288
- Generator and Starter Clutch
  289
- Checking the Starter Clutch
  293
- Removing the Generator
  293
- Removing the Starter Clutch
  293
- Assembling the Oil Tank
  294
- Checking the Oil Strainer
  294
- Installing the Starter Clutch
  294
- Installing the Generator
  295
- Clutch
  297
- Disassembling the Clutch
  300
- Removing the Clutch
  300
- Checking the Clutch Damper Springs
  301
- Checking the Clutch Plates
  301
- Checking the Clutch Spring Plate
  301
- Checking the Friction Plates
  301
- Checking the Clutch Boss
  302
- Checking the Clutch Housing
  302
- Checking the Clutch Springs
  302
- Checking the Pressure Plate and Thrust Plate
  302
- Assembling the Clutch
  303
- Installing the Clutch
  304
- Oil Pump
  305
- Assembling the Oil Pump
  307
- Checking the Oil Pipes
  307
- Checking the Oil Pump
  307
- Checking the Oil Pump Drive Chain
  307
- Checking the Relief Valve
  307
- Installing the Oil Pump
  307
- Crankcase
  308
- Assembling the Crankcase
  311
- Checking the Crankcase
  311
- Checking the Timing Chain
  311
- Disassembling the Crankcase
  311
- Crankshaft
  313
- Checking the Crankshaft and Connecting Rods
  315
- Removing the Connecting Rods
  315
- Removing the Crankshaft Journal Bearings
  315
- Installing the Connecting Rods
  319
- Installing the Crankshaft Journal Bearings
  319
- Installing the Crankshaft Assembly
  321
- Transmission
  322
- Checking the Transmission
  323
- Cooling System
  325
- Fuel System
  343
- Electrical System
  355
- Troubleshooting
  465

Advertisement

Advertisement

Related Products

Yamaha Categories

Motorcycle Musical Instrument Electronic Keyboard Receiver Amplifier

More Yamaha Manuals