1XP500 TMAX Technical Orientation Guide.pdf

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XP500 TMax Technical Orientation Guide
FEATURES AND BENEFITS
Offering high levels of performance, comfort and sophistication, the new TMax superscooter looks
sure to make as great an impression on the powered two wheeler market as the first Yamaha YZF-
R1 made in the motorcycle scene.
ENGINE FEATURES
CHASSIS FEATURES
499cc liquid cooled 4-stroke parallel twin
engine
Motorcycle-type high rigidity diamond shape
frame
DOHC 8 valve engine
Motorcycle-type front fork
High capacity V-belt transmission
Highly rigid swingarm
Horizontally opposed reciprocating balancer
14 inch front and rear wheels
Wet multiple plate automatic centrifugal
clutch
Motorcycle-type hub with fixed rear wheel axle
Sport bike type weight distribution
New design air intake route and air filter case
50º lean angle
Low position radiator
33 liters luggage compartment
Semi dry sump with oil cooler
1 piece dual seat with 3-stage adjustable
backrest
Non adjustable 2-stage silent chain drive train
ELECTRICAL FEATURES
Dual multi-reflector headlight
Stylish combination taillight
Automobile-type meter panel with extensive
information
High capacity power supply
Anti-theft alarm pre-wiring
Grip warmer pre-wiring
Mobile phone charger pre-wiring
1
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XP500 TMax Technical Orientation Guide
ENGINE SYSTEM
Displacing 499 cc, the TMax’s highly-advanced fully automatic twin-cylinder DOHC liquid-cooled
4-stroke 8-valve engine is one of the most powerful designs available on scooters today.
A key feature of its configuration is that unlike most traditional scooter engines which pivot as one
unit with the rear suspension, this engine is fixed rigidly into the TMax’s strong tubular diamond-shape frame
in order to achieve higher levels of chassis rigidity for enhanced handling performance. The swingarm is
mounted to a pivot point at the rear of the engine, thereby keeping unsprung weight low for more responsive
rear suspension action.
Another innovative feature is the horizontal configuration of the engine that keeps the centre of gravity
low for easy handling and also gives extra storage space under the dual seat.
ENGINE FEATURES
Parallel twin with 360 degree crankshaft
66 mm bore and 73 mm stroke
10.1 :1 compression ratio
Left side drive cam chain for reduced engine width
Horizontal compact cylinder head
Horizontally opposed reciprocating balancer
Semi dry sump
High capacity V-belt transmission
Wet multiple plate automatic centrifugal clutch
Non adjustable 2-stage silent chain drive train
Pivot coaxial drive shaft eliminates chain backlash
4
2
3
1
5
7
6
2
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XP500 TMax Technical Orientation Guide
CYLINDER HEAD
4 valves per cylinder, DOHC
Torsion type auto cam chain tensioner (similar to YZF-R1)
“Shim-under-bucket” valve adjustment for long maintenance interval (same as YZF-R1/YZF-R6)
Valve clearance at cold engine condition:
Intake : 0.15 - 0.20 mm
Exhaust: 0.25 - 0.30 mm
1
2
Intake camshaft
Cam chain tensioner
Exhaust camshaft
Silent cam chain
3
4
Intake
port
Exhaust
port
Air Induction
Ports
TDC
25º 25º
OL 50º
105º
105º
Intake valve
(mm)
Exhaust valve
(mm)
(2)
IN
EX
(1)
(2)
(3)
25.0
4.0
83.3
22.0
4.0
82.8
(3)
55º
55º
BDC
(1)
VALVE TIMING
3
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XP500 TMax Technical Orientation Guide
CYLINDER
New liquid-cooled cylinder body for low weight
Left side cam chain drive for reduced engine width
Ceramic composite cylinder coating for increased cooling and longer wear life
Side view
Side cam chain drive
ø 66.0 mm
ø 66.0 mm
Top view
4
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XP500 TMax Technical Orientation Guide
CRANKSHAFT / BALANCER
New design crankshaft uses replaceable full circumference plain bearings
Horizontally opposed reciprocating balancer for excellent vibration reduction
This type achieves same vibration reduction as 3 balancer shafts to reduce primary and second-
ary inertial forces, while requiring less space.
Piston cylinder #1
1
2
Piston cylinder #2
Cam chain drive gear
Balancer piston
bearing size indication
3
4
Bearing size indication, reading from left to right (ex. 1 2 3 4 5):
Left main bearing
Right main bearing
Conrod bearing cylinder #1
Conrod bearing balancer cylinder
Conrod bearing cylinder #2
Balancer cylinder
5
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