Yamaha TMAX XP500Y 2009 Factory Service Manual (P/N LIT-11616-22-08)

Yamaha’s factory service manual covers the 2009 TMAX XP500Y, model 4B54 (USA). This is the first edition, March 2008, P/N LIT-11616-22-08, with 4B5-28197-10 also printed on the original cover.

Searchable Text, Section Bookmarks and Wiring Detail

Search and diagram detail: The manual’s text is searchable, with embedded bookmarks for chapters, service sections and the final color wiring diagram. Small component numbers, connector markings and wire-color labels in the circuit diagrams require zooming for comfortable reading.

One printable PDF contains 385 pages, including the cover and introductory material, six blank pages, the back cover and the appended color wiring diagram.

Engine, CVT and Fuel-Injection Workshop Procedures

The following selected contents show the main service areas rather than the full table of contents. Additional topics include headlight-beam adjustment and evaporative-emission canister inspection.

• Engine repair: Engine removal, cylinder-head and valve work, piston inspection, crankcase separation, and crankshaft and connecting-rod bearing checks.

• V-belt transmission and clutch: Belt replacement, primary and secondary sheave disassembly, automatic wet-clutch inspection, and internal transmission-shaft checks.

• Fuel injection: Throttle-body synchronization, throttle-position sensor adjustment, fuel-pressure testing, ECU fault-code troubleshooting, and diagnostic-mode sensor and actuator tests.

• Cooling and lubrication: Radiator-cap pressure tests, thermostat checks, water-pump seal replacement, oil-pump inspection, and engine oil-pressure measurement.

• Brake service: Front and rear caliper and master-cylinder repair, hydraulic-system bleeding, brake-disc inspection, and rear brake-lock cable adjustment.

• Steering and chassis: Telescopic front-fork rebuilding, steering-bearing service, wheel-bearing replacement, and swingarm and transmission chain-drive inspection.

• Electrical fault tracing: Ignition, starting, charging, lighting and signaling circuit diagrams, connector views, component tests, and system-specific troubleshooting charts.

Written primarily for Yamaha dealers and qualified mechanics, this manual assumes a working knowledge of vehicle mechanics and the appropriate service tools.

Engine Teardown and Internal Inspection

The engine chapter goes beyond routine maintenance with step-by-step procedures for internal disassembly, inspection and reassembly. It covers valve-guide replacement and seat lapping, piston-ring checks, camshaft timing alignment and timing-chain tensioner installation.

Bearing selection: Crankshaft and connecting-rod sections explain clearance measurement and replacement-bearing selection using stamped identification numbers and bearing color codes. Cylinder-head tightening sequences, lubrication points and component-specific torque tables support reassembly.

The connecting-rod instructions flag a critical fastener limit: nuts tightened beyond the specified angle require replacement of the bolt and nut, rather than loosening and retightening the same hardware.

Sheave Overhaul and Drive-System Service

The transmission procedures distinguish the belt-and-sheave assemblies from the wet clutch and geared transmission components. Inspection data covers sheave weights, sliders, torque-cam grooves, clutch friction plates, spring condition and shaft runout.

Special-tool references identify the equipment needed for these jobs, including sheave spring compressor 90890-04134 / YM-04134. Separate starter-clutch procedures cover roller and gear inspection and one-way engagement checks.

Fuel-System Diagnosis and Electrical Testing

Cable-routing diagrams and the self-diagnostic, diagnostic-code and actuator-operation tables help trace FI faults and identify harness connections. For an intake-pressure fault, the troubleshooting details distinguish a hose problem from an electrical fault or defective sensor.

The diagnostic section explains meter-based diagnostic mode, malfunction-history handling and ECU reinstatement checks. Electrical test sections provide resistance and voltage specifications, battery-charging guidance, and starter-interlock, stator and rectifier/regulator checks.

Cooling, Brakes and Suspension

Lubrication-system and cooling-system diagrams show oil and coolant paths alongside the component service instructions. Water-pump documentation includes exploded views, mechanical-seal installation and impeller-shaft checks; radiator and oil-cooler sections include installation and leak checks.

Brake documentation separates front and rear caliper construction, seal replacement and master-cylinder inspection. Front-fork procedures cover bushings, seals, damper rods and oil-level measurement. Bottoming the inner tube into the outer tube during separation can damage the oil-flow stopper.

The rear-shock section covers assembly removal, mounting-component checks and nitrogen-pressure precautions for handling and disposal. Review the factory precautions before working around pressurized fuel or hot coolant.

Selected Adjustment and Capacity Data

Valve adjustment: Cold intake valve clearance is specified at 0.15–0.20 mm. The adjustment section explains valve-pad selection and clearance rechecking.

Synchronization data: Intake vacuum is specified at 33.0 kPa under the listed idling conditions: 1100–1300 r/min, coolant at 85.0–100.0°C and oil at 70.0°C.

Coolant capacities: The manual distinguishes 1.48 L for the radiator and all coolant passages from 0.25 L for the reservoir filled to its maximum-level mark.