Yamaha TMAX XP530E-A 2017 User manual

2017
SERVICE MANUAL
XP530E-A
XP530-A
XP530D-A
BV1-28197-E0

EAS20002
XP530E-A/XP530-A/XP530D-A
SERVICE MANUAL
©2017 by Yamaha Motor Co., Ltd.
First edition, March 2017
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

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.
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
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 per-
sonal injury 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.
OIL PUMP
5-59
EAS20054
OIL PUMP
Removing the oil pump assembly
Order Job/Parts to remove Q’ty Remarks
Bottom side cowling/Side panel/Bottom center
cowling
Refer to “GENERAL CHASSIS (1)” on page
4-1.
Center cover/Fuel tank cover assembly/Side
cover (left)/Footboard (left)
Refer to “GENERAL CHASSIS (2)” on page
4-11.
V-belt case air filter element (left)/Generator
cover protector/Water pump inlet pipe/Water
pump outlet pipe/Water pump assembly
Refer to “WATER PUMP” on page 6-9.
Generator cover/Generator rotor/Starter clutch
gear
Refer to “GENERATOR AND STARTER
CLUTCH” on page 5-44.
1ylbmessapmupliO1
1niahcevirdpmupliO2
2teksaG3
1epipyreviledliO4
1epipliO5
1ylbmessaevlavfeileR6
(3)
LT
6
5
3
1
2
4
10 N・m (1.0 kgf・m, 7.4 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
OIL PUMP
5-61
EAS30337
CHECKING THE OIL PUMP
1. Check:
•Oil pump driven gear “1”
•Oil pump housing 2 “2”
•Oil pump housing 1 “3”
Cracks/damage/wear →Replace the oil
pump assembly.
2. Check:
•Oil pump operation
Rough movement →Repeat steps (1) and
(2) or replace the oil pump assembly.
EAS30338
CHECKING THE RELIEF VALVE
1. Check:
•Relief valve body
Damage/wear →Replace.
EAS30742
CHECKING THE OIL PIPES
1. Check:
•Oil pipe
•Oil delivery pipe
Damage →Replace.
Obstruction →Wash and blow out with com-
pressed air.
EAS30785
CHECKING THE OIL PUMP DRIVE CHAIN
1. Check:
•Oil pump drive chain
Cracks/stiffness →Replace the oil pump
chain and oil pump assembly as a set.
EAS30342
ASSEMBLING THE OIL PUMP
1. Lubricate:
•Inner rotor
•Outer rotor
•Oil pump shaft
(with the recommended lubricant)
2. Install:
•Inner rotors
TIP
When installing the inner rotor, align the pins “1”
in the oil pump shaft with the grooves “a” in the
inner rotor.
3. Check:
•Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-61.
EAS30343
INSTALLING THE OIL PUMP
1. Install:
•Oil pump assembly
NOTICE
ECA13890
After tightening the bolts, make sure the oil
pump turns smoothly.
Recommended lubricant
Engine oil
Oil pump bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
1
a
1
a
T
R
.
.
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.
Silicone fluid
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New
S

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
EAS10003
TABLE OF CONTENTS

1
2
3
4
5
6
7
8
9
GENERAL INFORMATION
IDENTIFICATION..............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER ......................................................1-1
MODEL LABEL...........................................................................................1-1
FEATURES .......................................................................................................1-2
YCC-T (Yamaha Chip Controlled Throttle).................................................1-2
OUTLINE OF THE CRUISE CONTROL SYSTEM (for XP530D-A) ...........1-4
OUTLINE OF THE TCS (Traction Control System)....................................1-9
MULTI-FUNCTION DISPLAY...................................................................1-12
IMPORTANT INFORMATION .........................................................................1-22
PREPARATION FOR REMOVAL AND DISASSEMBLY..........................1-22
REPLACEMENT PARTS..........................................................................1-22
GASKETS, OIL SEALS AND O-RINGS ...................................................1-22
LOCK WASHERS/PLATES AND COTTER PINS ....................................1-22
BEARINGS AND OIL SEALS ...................................................................1-22
CIRCLIPS .................................................................................................1-23
RUBBER PARTS......................................................................................1-23
BASIC SERVICE INFORMATION ..................................................................1-24
QUICK FASTENERS................................................................................1-24
ELECTRICAL SYSTEM............................................................................1-25
SPECIAL TOOLS ...........................................................................................1-29

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
1

FEATURES
1-2
EAS20008
FEATURES
EAS30852
YCC-T (Yamaha Chip Controlled Throttle)
Mechanism characteristics
Yamaha developed the YCC-T system employing the most advanced electronic control technologies.
Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast-
er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed
system has a high-speed calculating capacity that produces computations of running conditions every
1/1000th of a second.
The YCC-T system is designed to respond to the throttle action of the rider by having the ECU instan-
taneously calculate the ideal throttle valve opening and generate signals to operate the motor-driven
throttle valves and thus actively control the intake air volume.
The ECU contains two CPUs with a capacity about five times that of conventional units, making it pos-
sible for the system to respond extremely quickly to the slightest adjustments made by the rider. In par-
ticular, optimized control of the throttle valve opening provides the optimum volume of intake air for
easy-to-use torque, even in a high-revving engine.
Aims and advantages of using YCC-T
•Increased engine power
By shortening the air intake path, higher engine speed is possible Increased engine power.
•Improved driveability
Air intake volume is controlled according to the operating conditions Improved throttle response to
meet engine requirement.
Driving force is controlled at the optimal level according to the engine speed Improved throttle con-
trol.
•Engine braking control
Due to the throttle control, optimal engine braking is made possible.
•Simplified idle speed control (ISC) mechanism
The bypass mechanism and ISC actuator are eliminated A simple mechanism is used to maintain
a steady idle speed.
•Reduced weight
Compared to using a sub-throttle mechanism, weight is reduced.
3
24
1
1. Throttle valves
2. Throttle servo motor
3. Throttle position sensor
4. Accelerator position sensor

FEATURES
1-3
YCC-T system outline
5
6
7
8
3
2
1
4
1. Accelerator position sensor
2. Throttle servo motor
3. Throttle position sensor
4. ECU (Engine Control Unit)
5. Sensor input
6. Crankshaft position sensor
7. Rear wheel sensor
8. Coolant temperature sensor

FEATURES
1-4
EAS30940
OUTLINE OF THE CRUISE CONTROL SYSTEM (for XP530D-A)
This model is equipped with a cruise control system designed to maintain a set cruising speed. Be-
cause the vehicle is equipped with the YCC-T system, the cruise control system can be controlled elec-
tronically. Based on the signals that are received from the sensors and switches, the ECU calculates
the required throttle valve opening and operates the throttle servo motor to control the throttle valves.
Because the system allows the rider to maintain a set cruising speed without operating the throttle, the
system reduces the burden of maintaining a constant speed during long-distance touring. In addition,
the cruise control system is equipped with a self-diagnosis function.
13
12
11
8
9
10
7
6
5
4
3
2
1
1. Meter assembly
2. ECU (Engine Control Unit)
3. Rear brake light switch
4. Cruise control setting switch
5. Cruise control power switch
6. Front brake light switch
7. Engine stop switch
8. Grip cancel switch
9. Accelerator position sensor
10.Throttle servo motor
11.Throttle position sensor
12.Crankshaft position sensor
13.Rear wheel sensor

FEATURES
1-5
The cruise control system is designed to maintain a set cruising speed between about 50 km/h (31 mi/h)
and 140 km/h (87 mi/h).
WARNING
EWA17451
• Improper use of the cruise control system may result in loss of control, which could lead to an
accident. Do not activate the cruise control system in heavy traffic, poor weather conditions,
or among winding, slippery, hilly, rough or gravel roads.
• When traveling uphill or downhill, the cruise control system may not be able to maintain the
set cruising speed.
• To prevent accidentally activating the cruise control system, turn it off when not in use. Make
sure that the cruise control system indicator light is off.
Activating and setting the cruise control system
1. Push the cruise control power switch “ ” to turn on the system. The cruise control system indicator
light “ ” will come on.
2. Push the “SET–” side of the cruise control setting switch to activate the cruise control system. Your
current traveling speed will become the set cruising speed. The cruise control setting indicator light
“SET” will come on.
Adjusting the set cruising speed
While the cruise control system is operating, push the “RES+” side of the cruise control setting switch
to increase the set cruising speed or the “SET–” side to decrease the set speed.
TIP
Pushing the setting switch once will change the speed in increments of approximately 2.0 km/h (1.2
mi/h). Holding down the “RES+” or “SET–” side of the cruise control setting switch will increase or de-
crease the speed continuously until the switch is released.
You can also manually increase your traveling speed using the throttle. After you have accelerated, you
can set a new cruising speed by pushing the “SET–” side of the setting switch. If you do not set a new
cruising speed, when you return the throttle grip, the vehicle will decelerate to the previously set cruising
speed.
RES
SET
PASS
4
3
1
2
1. Cruise control setting switch “RES+/SET–”
2. Cruise control power switch “ ”
3. Cruise control system indicator light “ ”
4. Cruise control setting indicator light “SET”

FEATURES
1-6
Deactivating the cruise control system
Perform one of the following operations to cancel the set cruising speed. The “SET” indicator light will
go off.
•Turn the throttle grip past the closed position in the deceleration direction.
•Apply the front or rear brake.
TIP
Traveling speed decreases as soon as the cruise control system is deactivated; unless the throttle grip
is turned.
Using the resume function
Push the “RES+” side of the cruise control setting switch to reactivate the cruise control system. The
traveling speed will return to the previously set cruising speed. The “SET” indicator light will come on.
WARNING
EWA17460
It is dangerous to use the resume function when the previously set cruising speed is too high
for current conditions.
Turning off the cruise control system
Push the cruise control power switch “ ” to turn off the cruise control system. The “ ” indicator light
and the “SET” indicator light will turn off.
TIP
Whenever the cruise control system or the vehicle power is turned off, the previously set cruising speed
is erased. You will not be able to use the resume function until a new cruising speed has been set.
Automatic deactivation of the cruise control system
The cruise control system is electronically controlled and linked with other control systems. The cruise
control system will automatically deactivate under the following conditions:
•The cruise control system is not able to maintain the set cruising speed (such as when going up a
steep hill).
•Wheel slip or wheel spin is detected. (If the traction control system is on, traction control will engage.)
•Engine trouble, etc.
If the cruise control system is automatically deactivated, the “ ” indicator light will turn off and the “SET”
indicator light will flash for 4 seconds.
If the cruise control system was automatically deactivated, please stop and confirm that your vehicle is
in good operating condition before continuing on.
When traveling on roads with steep grades, the cruise control system may not be able to maintain the
set cruising speed.
•When going uphill, the actual traveling speed may become lower than the set cruising speed. If this
occurs, accelerate to the desired traveling speed using the throttle.
•When going downhill, the actual traveling speed may become higher than the set cruising speed. If
this occurs, the setting switch cannot be used to adjust the set cruising speed. To reduce the traveling
speed, apply the brakes. When the brakes are applied, the cruise control system will deactivate.
MODE
a
b
a. Closed position b. Cruise control cancel direction

FEATURES
1-7
Meter displays during cruise control system operation
Self-diagnosis device
The cruise control system will also become deactivated when an irregularity with any of the vehicle sys-
tems is detected. The cruise control setting indicator light “SET” will go off and the cruise control system
indicator light “ ” will flash. You will not be able to use the cruise control system while the engine trou-
ble warning light is on, or while the cruise control system is malfunctioning.
NOTICE
ECA23590
If the engine trouble warning light come on, the vehicle should be checked as soon as possible
in order to avoid engine damage.
A D
d
c
b
aa
B C
A. Cruise control system is activated (cruising
speed is set)
B. Cruise control system is turned off (cruise
control setting indicator light “SET” flashes)
C. Cruise control system is turned off
D. Cruise control system is turned on (cruising
speed is not set)
a. Condition for automatically deactivating
cruise control system is detected
b. 4 seconds elapse (during this time, input from
the cruise control power switch “ ” will not
be received)
c. Cruise control power switch “ ” “ON”
d. Cruising speed is set
3 2 1
1. Engine trouble warning light “ ”
2. Cruise control system indicator light “ ”
3. Cruise control setting indicator light “SET”

FEATURES
1-8
TIP
•If the cruise control system turned off because a malfunction was detected by the FI self-diagnosis,
the cruise control power switch “ ” must be pushed once before the system can return to the normal
operating condition.
•If a switch for the cruise control system is malfunctioning (fault code No. P056C and P0564), the en-
gine trouble warning light will not come on because the normal operation of the vehicle is not affected.
Meter displays during cruise control system operation
C
E
B
A
e
d
d
a
DD
c
cb b
F G
A. Cruise control system is activated (cruising
speed is set)
B. Cruise control system is turned off (engine
trouble warning light “ ” comes on, cruise
control system is deactivated, and cruise
control system indicator light “ ” flashes)
C. Cruise control system is turned off (engine
trouble warning light “ ” goes off, cruise
control system is deactivated, and cruise
control system indicator light “ ” flashes)
D. Cruise control system is turned off
E. Cruise control system is turned on (cruising
speed is not set)
F. Malfunction detected by FI self-diagnosis
G. Malfunction not detected by FI self-diagnosis
a. Malfunction occurs
b. Cruise control power switch “ ” “OFF”
c. Cruise control power switch “ ” “ON”
d. After the cause of the malfunction has been
repaired, delete the fault code by using the
Yamaha diagnostic tool.
e. Cruising speed is set

FEATURES
1-9
TIP
This section explains the operation of the cruise control system according to the meter displays when
a malfunction is detected in the fuel injection system.
EAS30855
OUTLINE OF THE TCS (Traction Control System)
The traction control system controls excessive spinning (slipping) of the rear wheel when accelerating
on slippery surfaces, such as unpaved or wet roads.
The ECU monitors the front and rear wheel speeds using the signals from the front and rear wheel sen-
sors, and detects rear wheel slipping according to the difference between the wheel speeds. If the slip-
ping exceeds the preset value, the ECU controls the slipping using integrated control of the ignition
timing, fuel cut-off, and throttle valve opening of the YCC-T system.
The traction control system can be set to one of three operation modes or turned off.
TCS (Traction control system) layout
12
4
765
39
8
1. Traction control system indicator light
2. Throttle servo motor
3. Fuel injector
4. Rear wheel sensor
5. Spark plugs
6. Ignition coil
7. Front wheel sensor
8. ECU
9. ABS ECU

FEATURES
1-10
TCS (Traction control system) block diagram
The signals from the front and rear wheel sensors are sent to the ECU through the ABS ECU, and the
ECU calculates the amount of slip according to the difference between the detected front and rear
wheel speeds.
If the amount of slip exceeds the preset value, the ECU controls the ignition timing, fuel cut-off, and
throttle valve opening of the YCC-T system so that the amount of slip is less than the preset value. The
traction control system indicator light in the meter assembly flashes when the traction control system
has activated.
1A
B
D
G
E
H
F
4
C
A
3
2
1. Front wheel sensor
2. Rear wheel sensor
3. ABS ECU
4. ECU
A. Signal conversion
B. Slip amount calculation
C. Exceeds preset value
D. Actuator control
E. Fuel cut-off
F. Ignition timing (retarded)
G. Traction control system indicator light
(flashes)
H. YCC-T motor throttle valve opening
(decreased)

FEATURES
1-11
Traction control system
The traction control system (TCS) helps maintain traction when accelerating on slippery surfaces, such
as unpaved or wet roads. If sensors detect that the rear wheel is starting to slip (uncontrolled spinning),
the traction control system assists by regulating engine power as needed until traction is restored.
When traction control has engaged, the “ ” indicator light will flash. You may notice changes in engine
response or exhaust sounds.
WARNING
EWA18860
The traction control system is not a substitute for riding appropriately for the conditions. Trac-
tion control cannot prevent loss of traction due to excessive speed when entering turns, when
accelerating hard at a sharp lean angle, or while braking, and cannot prevent front wheel slip-
ping. As with any vehicle, approach surfaces that may be slippery with caution and avoid espe-
cially slippery surfaces.
Setting the traction control system
When the vehicle is turned on, traction control is automatically turned on.
To turn the traction control system off, refer to “Setting mode” on page 1-16.
TIP
Turn the traction control system off to help free the rear wheel if the vehicle gets stuck in mud, sand, or
other soft surfaces.
NOTICE
ECA19650
Use only the specified tires. Using different sized tires will prevent the traction control system
from controlling tire rotation accurately.
Resetting the traction control system
The traction control system will automatically disable under certain conditions; such as when a sensor
fault is detected, or when only one wheel is allowed to rotate for more than a few seconds. Should this
happen, the “ ” indicator light will come on, and possibly the “ ” warning light, too.
TIP
When the vehicle is on the centerstand, do not rev the engine for an extended period of time. Otherwise,
the traction control system will automatically disable and need to be reset.
If the traction control system automatically disables, try resetting it as follows.
1. Stop the vehicle and turn it off completely.
2. Wait a few seconds and then turn the vehicle power on.
3. The “ ” indicator light should turn off and the system be enabled.
TIP
If the “ ” indicator light remains on after resetting, check the fuel injection system (Refer to “FUEL IN-
JECTION SYSTEM” on page 8-55).
4. Check the vehicle and turn off the “ ” warning light.
1
1. Traction control system indicator light “ ”