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Yamaha 2009 XP500Y TMAX Manuals
Manuals and User Guides for Yamaha 2009 XP500Y TMAX. We have
1
Yamaha 2009 XP500Y TMAX manual available for free PDF download: Service Manual
Yamaha 2009 XP500Y TMAX Service Manual (386 pages)
Brand:
Yamaha
| Category:
Scooter
| Size: 21.4 MB
Table of Contents
Table of Contents
7
Service Manual
1
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
11
Outline of Fi System
11
Fi System
12
Multi-Function Display
13
Important Information
16
Preparation for Removal and Disassembly
16
Replacement Parts
16
Gaskets, Oil Seals and O-Rings
16
Lock Washers/Plates and Cotter Pins
16
Bearings and Oil Seals
17
Circlips
17
Checking the Connections
18
Special Tools
19
Specifications
27
General Specifications
28
Engine Specifications
29
Chassis Specifications
37
Electrical Specifications
40
Tightening Torques
43
General Tightening Torque Specifications
43
Engine Tightening Torques
44
Chassis Tightening Torques
48
Lubrication Points and Lubricant Types
51
Engine
51
Chassis
53
Lubrication System Diagrams
54
Lubrication Diagrams
54
Cooling System Diagrams
58
Cable Routing
62
Periodic Checks and Adjustments
79
Periodic Maintenance
82
General Maintenance and Lubrication Chart
82
Introduction
82
Periodic Maintenance Chart for the Emission Control System
82
Engine
85
Adjusting the Valve Clearance
85
Synchronizing the Throttle Body
88
Adjusting the Engine Idling Speed
89
Adjusting the Throttle Cable Free Play
90
Checking the Spark Plugs
90
Measuring the Compression Pressure
91
Checking the Engine Oil Level
92
Changing the Engine Oil
93
Measuring the Engine Oil Pressure
94
Replacing the Air Filter Element
95
Replacing the V-Belt
95
Cleaning the V-Belt Case Air Filter Element
96
Checking the Throttle Body Joints
96
Checking the Fuel Line
97
Checking the Cylinder Head Breather Hose
97
Checking the Exhaust System
97
Checking the Canister
98
Checking the Coolant Level
98
Checking the Cooling System
98
Changing the Coolant
99
Chassis
102
Adjusting the Front Disc Brake
102
Adjusting the Rear Disc Brake
102
Checking the Brake Fluid Level
102
Checking the Front Brake Pads
103
Checking the Rear Brake Pads
103
Checking the Front Brake Hoses
103
Checking the Rear Brake Hose
104
Adjusting the Rear Brake Lock Cable
104
Bleeding the Hydraulic Brake System
104
Checking the Chain Drive Oil Level
105
Changing the Chain Drive Oil
106
Checking and Adjusting the Steering Head
106
Checking the Front Fork
108
Checking the Tires
108
Checking the Wheels
110
Checking and Lubricating the Cables
110
Lubricating the Levers
110
Lubricating the Sidestand
110
Lubricating the Centerstand
110
Lubricating the Rear Suspension
110
Chassis
113
General Chassis
121
Removing the Fuel Hose
122
Installing the Fuel Hose
122
Front Wheel
123
Removing the Front Wheel
126
Disassembling the Front Wheel
126
Checking the Front Wheel
126
Assembling the Front Wheel
127
Adjusting the Front Wheel Static Balance
127
Installing the Front Wheel (Disc)
128
Rear Wheel
130
Removing the Rear Wheel (Disc)
132
Checking the Rear Wheel
132
Checking the Rear Wheel Drive Hub
132
Adjusting the Rear Wheel Static Balance
132
Installing the Rear Wheel (Disc)
132
Front Brake
133
Introduction
138
Checking the Front Brake Discs
138
Replacing the Front Brake Pads
139
Removing the Front Brake Calipers
140
Disassembling the Front Brake Calipers
140
Checking the Front Brake Calipers
141
Assembling the Front Brake Calipers
141
Installing the Front Brake Calipers
141
Removing the Front Brake Master Cylinder
142
Checking the Front Brake Master Cylinder
143
Assembling the Front Brake Master Cylinder
143
Installing the Front Brake Master Cylinder
143
Rear Brake
145
Introduction
151
Checking the Rear Brake Disc
151
Replacing the Rear Brake Pads
151
Removing the Rear Brake Caliper
153
Disassembling the Rear Brake Caliper
154
Checking the Rear Brake Caliper
154
Assembling the Rear Brake Caliper
155
Installing the Rear Brake Caliper
155
Removing the Rear Brake Master Cylinder
156
Checking the Rear Brake Master Cylinder
156
Assembling the Rear Brake Master Cylinder
157
Installing the Rear Brake Master Cylinder
157
Handlebar
159
Removing the Handlebar
161
Checking the Handlebar
161
Installing the Handlebar
161
Front Fork
164
Removing the Front Fork Legs
167
Disassembling the Front Fork Legs
167
Checking the Front Fork Legs
168
Assembling the Front Fork Legs
168
Installing the Front Fork Legs
171
Steering Head
173
Removing the Lower Bracket
175
Checking the Steering Head
175
Installing the Steering Head
176
Rear Shock Absorber Assembly
177
Handling the Rear Shock Absorber
178
Disposing of a Rear Shock Absorber
178
Removing the Rear Shock Absorber Assembly
178
Checking the Rear Shock Absorber Assembly
178
Installing the Rear Shock Absorber Assembly
178
Swingarm and Transmission Chain Drive
180
Checking the Swingarm
184
Checking the Chains and Gears
184
Assembling the Transmission Chain Drive Assembly
184
Installing the Transmission Chain Drive Assembly
184
Engine
187
Engine Removal
190
Installing the Engine
194
Camshafts
195
Removing the Camshafts
198
Checking the Camshafts
199
Checking the Camshaft Sprockets
200
Checking the Timing Chain Guides
200
Checking the Timing Chain Tensioner
201
Installing the Camshafts
201
Cylinder Head
204
Removing the Cylinder Head
205
Checking the Cylinder Head
205
Installing the Cylinder Head
205
Valves and Valve Springs
208
Removing the Valves
208
Checking the Valves and Valve Guides
208
Checking the Valve Seats
210
Checking the Valve Springs
212
Checking the Valve Lifters
212
Installing the Valves
212
Cylinder and Pistons
216
Removing the Pistons
216
Checking the Cylinders and Pistons
216
Checking the Piston Rings
217
Checking the Piston Pins
218
Installing the Pistons and Cylinder
218
Electric Starter
220
Checking the Starter Motor
222
Assembling the Starter Motor
222
Installing the Starter Motor
223
V-Belt Automatic Transmission
225
Removing the Primary Sheave and Secondary Sheave
230
Disassembling the Secondary Sheave
230
Checking the V-Belt
231
Checking the Primary Sheave
231
Checking the V-Belt Case Air Duct
231
Checking the Primary Sheave Weights
231
Checking the Sliders
231
Checking the Secondary Sheave
231
Assembling the Primary Sheave
232
Assembling the Secondary Sheave
232
Installing the Primary Sheave Assembly, Secondary Sheave Assembly and V-Belt
233
Installing the V-Belt Case
235
Generator and Starter Clutch
237
Removing the Generator
239
Removing the Starter Clutch
239
Checking the Starter Clutch
240
Checking the Oil Strainer
240
Installing the Starter Clutch
240
Installing the Generator
241
Clutch
243
Removing the Clutch
246
Disassembling the Clutch
246
Checking the Friction Plates
247
Checking the Clutch Plates
247
Checking the Clutch Damper Springs
247
Checking the Clutch Spring Plate
247
Checking the Clutch Springs
248
Checking the Clutch Housing
248
Checking the Clutch Boss
248
Checking the Pressure Plate
248
Assembling the Clutch
248
Installing the Clutch
249
Oil Pump
251
Checking the Oil Pump
253
Checking the Relief Valve
253
Checking the Oil Pipes
253
Checking the Oil Pump Drive Chain
253
Assembling the Oil Pump
254
Installing the Oil Pump
254
Crankcase
255
Disassembling the Crankcase
258
Checking the Crankcase
258
Checking the Timing Chain
258
Assembling the Crankcase
258
Crankshaft
260
Removing the Connecting Rods
262
Removing the Crankshaft Journal Bearings
262
Checking the Crankshaft and Connecting Rods
262
Installing the Crankshaft Journal Bearings
265
Installing the Connecting Rods
266
Installing the Crankshaft Assembly
267
Transmission
268
Checking the Transmission
269
Cooling System
271
Radiator
274
Checking the Radiator
274
Installing the Radiator
274
Oil Cooler
275
Checking the Oil Cooler
277
Installing the Oil Cooler
277
Thermostat
278
Checking the Thermostat
279
Installing the Thermostat Assembly
279
Water Pump
280
Disassembling the Water Pump
282
Checking the Water Pump
282
Assembling the Water Pump
282
Installing the Water Pump
283
Fuel System
285
Fuel Tank
288
Throttle Body
290
Electrical System
295
Ignition System
298
Circuit Diagram
298
Troubleshooting
300
Electric Starting System
302
Circuit Diagram
302
Starting Circuit Cut-Off System Operation
304
Troubleshooting
306
Charging System
308
Circuit Diagram
308
Troubleshooting
310
Lighting System
312
Circuit Diagram
312
Troubleshooting
314
Signaling System
316
Circuit Diagram
316
Troubleshooting
318
Cooling System
322
Circuit Diagram
322
Troubleshooting
324
Fuel Injection System
326
Circuit Diagram
326
Ecu Self-Diagnostic Function
328
Self-Diagnostic Function Table
329
Troubleshooting Method
331
Diagnostic Mode
332
Troubleshooting Details
337
Fuel Pump System
350
Circuit Diagram
350
Troubleshooting
352
Electrical Components
354
Checking the Switches
358
Checking the Bulbs and Bulb Sockets
361
Checking the Fuses
362
Checking and Charging the Battery
363
Checking the Relays
366
Checking the Turn Signal Relay
367
Checking the Diode
368
Checking the Spark Plug Caps
368
Checking the Ignition Coil
368
Checking the Ignition Spark Gap
369
Checking the Crankshaft Position Sensor
369
Checking the Lean Angle Sensor
370
Checking the Starter Motor Operation
370
Checking the Stator Coil
371
Checking the Rectifier/Regulator
371
Checking the Horn
372
Checking the Fuel Sender
372
Checking the Speed Sensor
373
Checking the Radiator Fan Motor
373
Checking the Coolant Temperature Sensor
373
Checking the Throttle Position Sensor
374
Checking the Intake Air Pressure Sensor
374
Checking the Intake Air Temperature Sensor
375
General Information
377
Troubleshooting
378
General Information
378
Starting Failure/Hard Starting
378
Incorrect Engine Idling Speed
378
Poor Medium-And-High-Speed Performance
379
Faulty Clutch
379
Overheating
379
Overcooling
380
Poor Braking Performance
380
Faulty Front Fork Legs
380
Unstable Handling
380
Faulty Lighting or Signaling System
381
Wiring Diagram
382
Troubleshooting
377
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