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2001-2007 Yamaha XP500 TMAX service manual Preview image 1
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2001-2007 Yamaha XP500 TMAX service manual

Models covered in this manual:

XP500(N), TMAX / Yamaha

Serial numbers: From JYASJ031000000101 to JYASJ031000230867

Production year(s): 2001, 2002, 2003, 2004, 2005 2006, 2007

File specifications

File size: 14.05 MB
File type: PDF
Language: English

Printable: Yes
Estimated download time: 0.29 Minutes
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Product Information

Table of Contents

GENERAL INFORMATION

  1. Specifications
    • Model Identification
    • Dimensions
    • Weight
    • Engine Specifications
    • Chassis Specifications
    • Electrical Specifications
  2. Torque Values

MAINTENANCE

  1. Periodic Inspection and Maintenance
    • Maintenance Intervals
    • Maintenance Procedures
    • Engine Oil Change
    • Transmission Oil Change
    • Coolant Change
    • Brake Fluid Change
    • Lubrication Points
    • Inspection Procedures

ENGINE

  1. Engine Overhaul
    • Engine Removal
    • Engine Disassembly
    • Engine Inspection
    • Engine Reassembly
    • Engine Installation
  2. Cylinder Head/Valve
    • Removal
    • Inspection
    • Installation
  3. Cylinder/Piston
    • Removal
    • Inspection
    • Installation
  4. Crankshaft/Transmission
    • Removal
    • Inspection
    • Installation

FUEL SYSTEM

  1. Fuel Tank
    • Removal
    • Installation
    • Inspection
  2. Fuel Lines
    • Inspection
    • Replacement
  3. Carburetor
    • Removal
    • Disassembly
    • Cleaning
    • Assembly
    • Installation
    • Adjustment

COOLING SYSTEM

  1. Radiator
    • Removal
    • Inspection
    • Installation
  2. Cooling Fan
    • Removal
    • Inspection
    • Installation
  3. Coolant Hoses
    • Inspection
    • Replacement

ELECTRICAL SYSTEM

  1. Charging System
    • Battery Removal and Installation
    • Battery Charging
    • Battery Inspection
    • Battery Connections
    • Battery Testing
  2. Ignition System
    • Ignition Coil Removal, Inspection, Installation
    • Spark Plug Inspection, Replacement
  3. Starting System
    • Starter Motor Removal, Inspection, Installation
    • Starter Relay Inspection, Replacement
  4. Lighting and Signaling Systems
    • Headlight Removal, Inspection, Installation
    • Taillight Removal, Inspection, Installation
    • Turn Signal Removal, Inspection, Installation
  5. Electrical Components
    • Fuse Inspection and Replacement
    • Relay Inspection and Replacement
  6. Wiring Diagram

CHASSIS

  1. Front Suspension
    • Removal
    • Inspection
    • Installation
  2. Rear Suspension
    • Removal
    • Inspection
    • Installation
  3. Wheels and Tires
    • Wheel Removal and Installation
    • Tire Inspection and Replacement
  4. Steering
    • Inspection
    • Adjustment

BRAKES

  1. Brake System
    • Brake Lines Inspection, Replacement
    • Brake Pads Inspection, Replacement
    • Brake Fluid Change

BODY AND FRAME

  1. Body Panels
    • Removal
    • Installation
  2. Seat
    • Removal
    • Installation
  3. Frame
    • Inspection
    • Maintenance

TROUBLESHOOTING

  1. Engine Issues
    • Starting Problems
    • Performance Issues
  2. Electrical Issues
    • Battery Problems
    • Lighting Problems
  3. Mechanical Issues
    • Suspension Problems
    • Brake Problems

APPENDIX

  1. Technical Data
  2. Special Tools
  3. Service Data
  4. Conversion Tables

INDEX


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