Yamaha TMAX XP500(N) 2001 Service Manual (P/N 5GJ1-AE1)

This factory service manual covers the 2001 Yamaha XP500(N) TMAX in its original carbureted 5GJ-series configuration. It is Yamaha’s first edition, dated September 2000 (P/N 5GJ1-AE1).

PDF Search and Wiring Diagrams

Search and navigation: The service text is searchable, and bookmarks link to all nine chapters and both regional wiring diagrams. The cover and illustrated chapter dividers have no searchable text. Small connector labels and wire-color codes are legible when zoomed in. The separate Menu bookmark points to a file outside the download.

The ZIP download contains one printable 395-page PDF, including the original cover, front matter, chapter dividers, and six blank pages.

Engine, Drivetrain, and Electrical Service

These selected service topics show the range of work covered. The manual also includes front-wheel static balancing and air injection system checks.

• Periodic maintenance: Scheduled checks for engine oil, coolant, spark plugs, and brakes, with procedures for valve clearance adjustment and hydraulic brake bleeding.

• Engine overhaul: Step-by-step procedures for engine removal and installation, camshaft timing, crankcase disassembly, and inspection of the crankshaft, cylinders, and pistons.

• Belt and chain drive: Primary and secondary sheave service, V-belt inspection, wet clutch disassembly, and secondary chain-drive removal and installation.

• Carburetion and cooling: Mikuni BS30 carburetor teardown and synchronization, fuel-level adjustment, radiator service, thermostat testing, and water-pump disassembly.

• Chassis and brakes: Front and rear brake caliper and master cylinder service, front fork overhaul, and inspection of the swingarm and pull-type monocross rear suspension.

• Electrical troubleshooting: Ignition and charging tests, starter motor inspection, starting interlock diagnosis, and separate Europe and Oceania wiring diagrams.

Yamaha wrote this manual primarily for its dealers and qualified mechanics and expects readers to understand scooter repair techniques.

Engine and Drive Inspection

Chapter 2 groups torque tables, fluid capacities, adjustment data, and wear limits. In the overhaul chapter, the oil flow diagrams and oil-pump inspection procedures help trace lubrication faults. The crankshaft section includes a bearing color-code table for selecting replacement bearings.

The belt-drive section covers sheave and roller wear as well as clutch friction-plate inspection. Yamaha cautions against getting grease on the V-belt or secondary pulley because contamination can cause the belt to slip.

Carburetor Setup and Cooling Service

The factory jetting and throttle-cable adjustment data give the mechanic a baseline for the paired Mikuni BS30 carburetors. The carburetor chapter shows how to inspect the piston-valve diaphragms and check the throttle position sensor. Coolant flow diagrams show how the thermostat, radiator, and oil cooler fit into the circuit.

Before servicing the cooling, brake, or electrical systems, review the safety warnings in the relevant chapter and follow the factory precautions for that repair area.

Wiring and Starting Faults

For a no-crank fault, the starting interlock diagram and troubleshooting chart help distinguish a brake or sidestand switch fault from a starter relay or motor fault. The self-diagnosis section explains the indicator-light codes for the throttle position sensor, speed sensor, and lean-angle cut-off switch. Battery and main-fuse specifications are also included.

The cable-routing drawings provide a final check for harness and control-cable placement after reassembly. They also identify the Great Britain headlight arrangement, where the high beam is on the right.

A Preview of Valve, Carburetor, and Charging Specs

For valve adjustment, Yamaha specifies 0.15–0.20 mm on the intake side and 0.25–0.30 mm on the exhaust side, with the engine cold at room temperature and the piston at top dead center on the compression stroke.

The Mikuni BS30 fuel-level check calls for matching readings on both carburetors, 5.5–6.5 mm below the float-chamber mating surface with the scooter upright on level ground.

The charging-system troubleshooting chart gives a stator coil resistance range of 0.338–0.413 Ω at 20 °C for evaluating the stator during a charging fault.