Yamaha TMAX XP500F 2015 User manual

2015
SERVICE MANUAL
XP500F
LIT-11616-28-54 2PW-28197-10

EAS20002
XP500F
SERVICE MANUAL
©2014 by Yamaha Motor Corporation, U.S.A.
First edition, November 2014
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-28-54

EAS20003
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS30001
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to
the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP

EAS20004
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1
7
3
5
6
2
4

EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOCTITE®).
Engine oil Replace the part with a new one.
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New

EAS10003 TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9

1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES......................................................................................................1-2
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
MULTI-FUNCTION DISPLAY....................................................................1-4
IMPORTANT INFORMATION .........................................................................1-9
PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-9
REPLACEMENT PARTS...........................................................................1-9
GASKETS, OIL SEALS AND O-RINGS ....................................................1-9
LOCK WASHERS/PLATES AND COTTER PINS .....................................1-9
BEARINGS AND OIL SEALS ..................................................................1-10
CIRCLIPS ................................................................................................1-10
RUBBER PARTS.....................................................................................1-10
BASIC SERVICE INFORMATION.................................................................1-11
QUICK FASTENERS...............................................................................1-11
ELECTRICAL SYSTEM...........................................................................1-12
SPECIAL TOOLS ..........................................................................................1-16

IDENTIFICATION
1-1
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the right side of the frame.
EAS30003
MODEL LABEL
The model label “1” is affixed to the storage box.
This information will be needed to order spare
parts.
1

FEATURES
1-2
EAS20008
FEATURES
EAS30005
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions. In a conventional carburetor system,
the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of
the intake air and the fuel that is metered by the jet used in the respective chamber. Despite the same
volume of intake air, the fuel volume requirement varies with the engine operating conditions, such as
acceleration, deceleration, or operation under a heavy load. Carburetors that meter the fuel through the
use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be
achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for engines to deliver more performance and cleaner exhaust gases increase, it
becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system in place
of a conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the
engine at all times by using a microprocessor that regulates the fuel injection volume according to the
engine operating conditions detected by various sensors.
Adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better
fuel economy, and reduced exhaust emissions.
17
1. Fuel injector
2. Lean angle sensor
3. ECU (engine control unit)
4. Intake air temperature sensor
5. Engine trouble warning light
6. Battery
7. Intake air pressure sensor
8. Fuel hose
9. O2sensor
10.Fuel pump
11.Crankshaft position sensor
12.Fuel tank
13.Coolant temperature sensor
14.Throttle position sensor
15. Spark plug
16.Ignition coil
17.Speed sensor

FEATURES
1-3
EAS30617
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump)
maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the
energizing signal from the ECU (engine control unit) energizes the fuel injector, the fuel passage opens,
causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the
volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU (engine control unit). Signals
that are input from the throttle position sensor, crankshaft position sensor, intake air pressure sensor,
intake air temperature sensor, coolant temperature sensor, and O2sensor enable the ECU (engine
control unit) to determine the injection duration. The injection timing is determined through the signals
from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can
be supplied at all times in accordance with the driving conditions.
Illustration is for reference only.
1. Fuel pump
2. Fuel injector
3. Ignition coil
4. ECU (engine control unit)
5. Catalyst
6. O2sensor
7. Coolant temperature sensor
8. Crankshaft position sensor
9. Intake air pressure sensor
10.Throttle body
11.Intake air temperature sensor
12.Air filter case
13. Throttle position sensor
A. Fuel system
B. Air system
C. Control system

FEATURES
1-4
EAS30618
MULTI-FUNCTION DISPLAY
WARNING
EWA17650
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit. Changing settings while riding
can distract the operator and increase the
risk of an accident.
The multi-function display is equipped with the
following:
• a fuel meter
• a coolant temperature meter
• an odometer
• two tripmeters (which show the distance trav-
eled since they were last set to zero)
• a fuel reserve tripmeter (which shows the dis-
tance traveled when the remaining fuel in the
fuel tank reaches approximately 3.0 L (0.79 US
gal, 0.66 Imp.gal))
• a self-diagnosis device
•aclock
• an ambient temperature display
• a fuel consumption display (average and in-
stantaneous consumption functions)
• an oil change tripmeter (which shows the dis-
tance traveled since the last engine oil change)
• a V-belt replacement tripmeter (which shows
the distance traveled since the last V-belt re-
placement)
TIP
• Be sure to turn the vehicle power on before us-
ing the “SELECT” and “RESET” buttons.
• When the vehicle power is turned on, all of the
display segments of the multi-function display
will appear one after the other and then disap-
pear, in order to test the electrical circuits.
Clock
[To set the clock]
1. Push the “SELECT” and “RESET” buttons to-
gether for at least two seconds.
2. When the hour digits start flashing, push the
“RESET” button to set the hours.
3. Push the “SELECT” button, and the minute
digits will start flashing.
4. Push the “RESET” button to set the minutes.
5. Push the “SELECT” button and then release
it to start the clock.
1. “SELECT” button
2. Fuel meter
3. Fuel level warning indicator “ ”
4. Odometer
5. Coolant temperature warning indicator “ ”
6. Coolant temperature meter
7. “RESET” button
1. Tripmeter/fuel reserve tripmeter
2. Ambient temperature/average fuel
consumption/instantaneous fuel consumption
1. Clock
2
34
5
6
11 7
2
1
1
1. Clock
1

FEATURES
1-5
Odometer and tripmeter modes
Pushing the “SELECT” button switches the dis-
play between the odometer mode and the trip-
meter modes in the following order:
Odo →Trip 1 →Trip 2 →V-Belt Trip →Oil Trip
→Odo
When approximately 3.0 L (0.79 US gal, 0.66
Imp.gal) of fuel remains in the fuel tank, the dis-
play will automatically change to the fuel reserve
tripmeter mode “Trip F” and start counting the
distance traveled from that point. In that case,
pushing the “SELECT” button switches the dis-
play between the various tripmeter and odome-
ter modes in the following order:
Odo →Trip 1 →Trip 2 →Trip F →V-Belt Trip
→Oil Trip →Odo
To reset a tripmeter, select it by pushing the “SE-
LECT” button until “Trip F”, “Trip 1” or “Trip 2” is
displayed. While “Trip F”, “Trip 1” or “Trip 2” is
displayed, push the “SELECT” button for at least
one second. If you do not reset the fuel reserve
tripmeter manually, it will reset itself automatical-
ly and the display will return to the prior mode af-
ter refueling and traveling 5 km (3 mi).
TIP
The display cannot be changed back to “Trip F”
after resetting the fuel reserve tripmeter.
Fuel meter
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear towards “E” (Empty) as the fuel level
decreases. When the fuel level reaches the bot-
tom segment near “E”, the fuel level warning in-
dicator, “F”, “E”, and the bottom segment will
flash. Refuel as soon as possible.
Coolant temperature meter
The coolant temperature meter indicates the
temperature of the coolant. The coolant temper-
ature varies with changes in the weather and en-
gine load. If the top segment, “H”, “C”, and
coolant temperature warning indicator flash,
stop the vehicle and let the engine cool.
1. Odometer/tripmeters/fuel reserve tripmeter
1. Oil change tripmeter
1. V-belt replacement tripmeter
1
1
1
1. Fuel reserve tripmeter
1

FEATURES
1-6
NOTICE
ECA20730
Do not continue to operate the engine if it is
overheating.
Oil change indicator “Oil”
This indicator flashes at the initial 1000 km (600
mi), then at 5000 km (3000 mi) and every 5000
km (3000 mi) thereafter to indicate that the en-
gine oil should be changed.
After changing the engine oil, reset the oil
change indicator. To reset the oil change indica-
tor, select it by pushing the “SELECT” button un-
til “Oil Trip” is displayed, and then push the
“SELECT” button at least one second. When
pushing the “SELECT” button, “Oil Trip” starts
flashing. While “Oil Trip” is flashing, push the
“SELECT” button for at least three seconds.
If the engine oil is changed before the oil change
indicator “Oil” flashes (i.e. before the periodic oil
change interval has been reached), the indicator
“Oil” must be reset after the oil change for the
next periodic oil change to be indicated at the
correct time.
The electrical circuit of the indicator can be
checked according to the following procedure.
1. Set the engine stop switch to “ ” and turn
the power of the vehicle on.
2. Check that the oil change indicator comes on
for a few seconds and then goes off.
3. If the oil change indicator does not come on,
check the electrical circuit.
(Refer to “SIGNALING SYSTEM” on page
8-19)
V-belt replacement indicator “V-Belt”
This indicator flashes every 20000 km (12500
mi) when the V-belt needs to be replaced.
After changing the V-belt, reset the V-belt re-
placement indicator. To reset the V-belt replace-
ment indicator, select it by pushing the
“SELECT” button until “V-Belt Trip” is displayed,
and then push the “SELECT” button at least one
second. When pushing the “SELECT” button,
“V-Belt Trip” starts flashing. While “V-Belt Trip” is
flashing, push the “SELECT” button for at least
three seconds.
If the V-belt is changed before the V-belt re-
placement indicator “V-Belt” flashes (i.e. before
the periodic V-belt change interval has been
reached), the indicator “V-Belt” must be reset af-
ter the V-belt change for the next periodic V-belt
change to be indicated at the correct time.
The electrical circuit of the indicator can be
checked according to the following procedure.
1. Turn the vehicle on and make sure that the
engine stop switch is set to “ ”.
2. Check that the V-belt replacement indicator
comes on for a few seconds and then goes
off.
3. If the V-belt replacement indicator does not
come on, check the electrical circuit.
(Refer to “SIGNALING SYSTEM” on page
8-19)
1. Oil change indicator “Oil”
1
1. V-belt replacement indicator “V-Belt”
1

FEATURES
1-7
Ambient temperature display, average fuel
consumption, and instantaneous fuel con-
sumption modes
Push the “RESET” button to switch the display
between the ambient temperature display “Air”,
the average fuel consumption mode “AVE_ _._
MPG”, and the instantaneous fuel consumption
mode “MPG” in the following order:
Air →AVE_ _._ MPG →MPG →Air
Ambient temperature display
This display shows the ambient temperature
from 15 °F to 104 °F in 1 °F increments.
The temperature displayed may vary from the
ambient temperature. Pushing the “RESET” but-
ton switches the ambient temperature display to
the average fuel consumption and instanta-
neous fuel consumption modes.
Average fuel consumption mode
The average fuel consumption is displayed
“AVE_ _._ MPG”.
This display shows the average fuel consump-
tion since it was last reset.
When the display is set to “AVE_ _._ MPG”, the
average distance that can be traveled on 1.0
Imp.gal of fuel is shown.
To reset the average fuel consumption display,
select it by pushing the “RESET” button, and
then push the “RESET” button for at least one
second.
TIP
After resetting an average fuel consumption dis-
play, “_ _._” is shown for that display until the ve-
hicle has traveled 1 km (0.6 mi).
Instantaneous fuel consumption mode
The instantaneous fuel consumption is dis-
played “MPG”.
The distance that can be traveled on 1.0 Imp.gal
of fuel under the current riding conditions is
shown.
TIP
If traveling at speeds under 10 km/h (6.0 mi/h),
“_ _._” is displayed.
1. Ambient temperature/average fuel
consumption/instantaneous fuel consumption
1. Ambient temperature display
1
1
1. Average fuel consumption display
1. Instantaneous fuel consumption display
1
1

FEATURES
1-8
Self-diagnosis device
This model is equipped with a self-diagnosis de-
vice for various electrical circuits.
If a problem is detected in any of those circuits,
the engine trouble warning light comes on and
the display indicates a fault code.
If the display indicates any fault codes, note the
code number, and check the fuel injection sys-
tem (Refer to “FUEL INJECTION SYSTEM” on
page 8-31).
NOTICE
ECA20220
If the display indicates a fault code, the vehi-
cle should be checked as soon as possible
in order to avoid engine damage.
1. Fault code display
1

IMPORTANT INFORMATION
1-9
EAS20009
IMPORTANT INFORMATION
EAS30006
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning equip-
ment.
Refer to “SPECIAL TOOLS” on page 1-16.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
4. During disassembly, clean all of the parts and
place them in trays in the order of disassem-
bly. This will speed up assembly and allow for
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS30007
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS30008
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
EAS30009
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
1. Oil
2. Lip
3. Spring
4. Grease

IMPORTANT INFORMATION
1-10
EAS30010
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” so that the
manufacturer marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
NOTICE
ECA13300
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EAS30011
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
EAS30012
RUBBER PARTS
Check rubber parts for deterioration during in-
spection. Some of the rubber parts are sensitive
to gasoline, flammable oil, grease, etc. Do not al-
low any items other than the specified one to
contact the parts.

BASIC SERVICE INFORMATION
1-11
EAS20010
BASIC SERVICE INFORMATION
EAS30013
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push
the pin in with a screwdriver. Make sure that the
pin is flush with the fastener’s head.
Screw type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.