Yamaha XP500 Kurzanleitung

XP500 TMax Technical Orientation Guide

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

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

XP500 TMax Technical Orientation Guide

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

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

55º55º

TDC

BDC

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

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

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.

bearing size indication

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

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

XP500 TMax Technical Orientation Guide

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

124.5 mm

117 mm

XP500 TMax Technical Orientation Guide

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

Engine cross-section

rpm

speed

V-belt exchange: each 20,000 km

Speed shift rate diagram

XP500 TMax Technical Orientation Guide

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

105

1345

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

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

Oil level

Gear ratio: (41 / 25) x (40 / 29) = 2.262

Final drive oil capacity: 700 cc

Type: SAE 80, hypoid

123

Mounted on rear wheel

clutch hub

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