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XP500 Tmax Technical Orientation Guide

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XP500 Tmax Technical Orientation Guide 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 n 499cc liquid cooled 4-stroke parallel twin n Motorcycle-type high rigidity diamond shape engine frame n DOHC 8 valve engine n Motorcycle-type front fork n High capacity V-belt transmission n Highly rigid swingarm n Horizontally opposed reciprocating balancer n 14 inch front and rear wheels n Wet multiple plate automatic centrifugal n Motorcycle-type hub with fixed rear wheel axle clutch n Sport bike type weight distribution n New design air intake route and air filter case n 50º lean angle n Low position radiator n 33 liters luggage compartment n Semi dry sump with oil cooler n 1 piece dual seat with 3-stage adjustable n Non adjustable 2-stage silent chain drive train backrest ELECTRICAL FEATURES n Dual multi-reflector headlight n Stylish combination taillight n Automobile-type meter panel with extensive information n High capacity power supply n Anti-theft alarm pre-wiring n Grip warmer pre-wiring n Mobile phone charger pre-wiring 1 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 n Parallel twin with 360 degree crankshaft n 66 mm bore and 73 mm stroke n 10.1 :1 compression ratio n 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 XP500 TMax Technical Orientation Guide CYLINDER HEAD n 4 valves per cylinder, DOHC n Torsion type auto cam chain tensioner (similar to YZF-R1) n “Shim-under-bucket” valve adjustment for long maintenance interval (same as YZF-R1/YZF-R6) n 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 105º 105º Intake valve Exhaust valve OL 50º (2) (mm) (mm) EX IN (1) 25.0 22.0 (3) (2) 4.0 4.0 (3) 83.3 82.8 55º 55º BDC (1) VALVE TIMING 3 XP500 TMax Technical Orientation Guide CYLINDER n New liquid-cooled cylinder body for low weight n Left side cam chain drive for reduced engine width n 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 XP500 TMax Technical Orientation Guide CRANKSHAFT / BALANCER n New design crankshaft uses replaceable full circumference plain bearings n 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 XP500 TMax Technical Orientation Guide PISTON n New combustion piston with V-groove between upper and lower compression rings for improved sealing n Balancer piston for horizontally opposed reciprocating balancing system COMBUSTION PISTON Top view V-groove Cross-section Side view ø 40 mm ø 66 BALANCER PISTON Top view Side view Front view 71.7 mm ø 58 Front view cross-section 6 XP500 TMax Technical Orientation Guide CONNECTING ROD n Newly designed connecting rods: 2 for combustion, 1 for balancer n New type connecting rod as integral part of the horizontally opposed reciprocating balancing system FOR COMBUSTION FOR BALANCER 16 mm 15 mm 124.5 mm 117 mm 117 45 mm 45 mm All connecting rods use the same 2-piece plain bearings 7 XP500 TMax Technical Orientation Guide TRANSMISSION SYSTEM CONTINUOUSLY VARIABLE TRANSMISSION n Highly efficient V-belt transmission in order to obtain high performance n Newly designed cooling system with fins on both rotors of the secondary sheave for improved cooling and higher belt durability n Cooling system uses 2 air filters to provide high volume clean air cooling 1 2 3 4 Engine left side Engine right side 5 Left transmission air filter 6 Air intake duct to transmission Right transmission air filter Air exhaust ports Cooling fin Secondary sheave V-belt exchange: each 20,000 km Engine cross-section rpm Speed shift rate diagram speed 8 XP500 TMax Technical Orientation Guide CLUTCH n Wet type multiple plate centrifugal clutch for smooth power transmission and to meet XP’s higher torque n Clutch uses diaphragm type spring Friction plates: 5 pieces First pinion gear Clutch plates: 6 pieces Secondary shaft Diaphragm clutch spring First wheel gear Primary drive gear Drive axle Main axle Primary driven gear 1345 678 2 5 10 9 Transmission gear reduction ratio = (primary driven gear / primary drive gear) x (first wheel gear / first pinion gear) = (52 / 32) x (36 / 22) = 2.659 Clutch-in revolution: 1800 ± 300 rpm 9 XP500 TMax Technical Orientation Guide FINAL DRIVE n Newly designed final drive with non-adjustable 2-stage silent chain for an efficient power trans- mission, reduced noise and low maintenance n High speed first stage chain with spring-type torque absorber for a further reduction of noise n The final drive and the swingarm are integrated for improved rigidity and high speed stability Crankcase Drive axle 123 First stage drive chain Mounted on rear wheel Second stage drive chain clutch hub Taper roller bearing 5 Gear ratio: (41 / 25) x (40 / 29) = 2.262 4 Rear drive case 1 Oil dip stick Final drive oil capacity: 700 cc Type: SAE 80, hypoid 2 Oil level 10 XP500 TMax Technical Orientation Guide LUBRICATION SYSTEM n Semi dry sump system for reduced engine size n Oil tank is incorporated into the left crankcase cover n Newly designed dual stage oil pump n Liquid-cooled oil cooler with cartridge type oil filter (5DM-13440-00) n New type oil drain bolt that allows oil from crankcase and oil tank to be drained at the same time Dual stage oil pump brings oil from oil tank to respective areas of the engine, including a spray bar over the starter gears and the stator assembly. The oil pump also has a scavenging pump that returns the oil to the oil tank. The scavenged oil fills the tank until it is full and then overflows back into the sump area to main- tain a constant level in the sump. Oil filter Oil tank space Oil cooler Oil pump Oil spray bar Drain bolt Crankcase cover 34 5 12 7 6 Engine oil capacity Total amount : 3.6 liters = 2.2 liters in crankcase + 1.4 liter in oil tank Without oil filter replacement : 2.8 liters With oil filter replacement : 2.9 liters Engine oil change: every 5,000 km 11 XP500 TMax Technical Orientation Guide LUBRICATION SYSTEM LUBRICATION FLOW CHART 12 XP500 TMax Technical Orientation Guide LUBRICATION SYSTEM 13 XP500 TMax Technical Orientation Guide COOLING SYSTEM n Low mounted radiator for design flexibility n Automatic air bleed for easy maintenance Coolant Reservoir Tank Coolant Fan Thermostat Radiator Cap Radiator Water pump Cooling system capacity: 1.5 liter Carburetor heating thermostat: Coolant temperature is less than 80±2 ºC: OPEN Coolant temperature is more than 80±2 ºC: CLOSED Main thermostat: Coolant temperature is less than 82±2 ºC: OPEN Coolant temperature is more than 82±2 ºC: CLOSED 14 XP500 TMax Technical Orientation Guide CARBURETION SYSTEM n Twin BS30 round slide carburetors n Automatic choke for easy starting n Throttle Position Sensor to optimize ignition timing and reduce emissions n Coolant type carburetor heater n Pull-pull type throttle control Auto Choke Unit Throttle Position Sensor 2 1 Carburetor settings Marking 5GJ1 Auto-choke electricity control. Main jet #105 By thermo switch. Jet needle 4DK4-3 coolant temperature is more than 60 ± 3ºC: ON coolant temperature is less than 55 ± 3ºC: OFF Needle jet 0 - 0M By TCI Unit Pilot jet #22.5 more than 800 rpm: ON Pilot screw turns out 2 1/2 less than 375 rpm: OFF 15 XP500 TMax Technical Orientation Guide AIR INTAKE SYSTEM n Air filter case position in upper front body cowling for effective use of space n Air intake system uses noise reduction box n Air Induction System for reduced emissions Air filter case Reed valve Noise reduction box Air hose (Reed Valve - Air Cut Valve) Vacuum hose to Air Cut Valve Air Cut Valve Fuel pump 1 See Service Tips for CO adjustment and Air Induction System check procedure 2 7 34 6 To exhaust port 5 BLOCK HERE FOR CO ADJUSTMENT 16 XP500 TMax Technical Orientation Guide EXHAUST SYSTEM n 2 into 1 stainless exhaust pipes and stainless muffler Muffler Exhaust Pipe EGA connection 123 17 XP500 TMax Technical Orientation Guide CHASSIS Like the all-new engine, the TMax’s advanced high-rigidity chassis has been developed using some of the latest motorcycle technology in its frame and suspension designs.
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