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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.
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
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
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5 7 6
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
OL 50º
Intake valve Exhaust valve
(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
Side view
ø 66.0 mm ø 66.0 mm
Top view
Piston cylinder #1 1 2
Piston cylinder #2
Cam chain drive gear
Balancer piston
Balancer cylinder
COMBUSTION PISTON
Top view
V-groove
ø 66
BALANCER PISTON
71.7
mm
ø 58
16
mm 15
mm
124.5 mm
117 mm
45 mm 45 mm
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
rpm
speed
1 3 4 5 6 7 8
5 10 9
Crankcase
Drive axle 1 2 3
First stage drive chain
Mounted on rear wheel
Second stage drive chain clutch hub
Taper roller bearing
5
4
Gear ratio: (41 / 25) x (40 / 29) = 2.262
2
Oil level
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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.
1 2
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
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12
13
Main thermostat:
Coolant temperature is less than 82±2 ºC: OPEN
Coolant temperature is more than 82±2 ºC: CLOSED
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2 1
Carburetor settings
15
2
7
3 4
To exhaust port 5
16
Muffler
Exhaust Pipe
EGA connection
1 2 3
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FRAME
n Newly designed tubular diamond shape frame
n Frame uses engine as a stressed member for added rigidity and enhanced handling performance
n Total configuration keeps centre of gravity low and wheelbase short
References
XP500 YP250
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Fuel lid
Fuel tank cap
Fuel tank
1 2 3
BODYWORK
n Completely new aerodynamically-efficient sports styled bodywork
Integrated turn signal lights
Aluminium grab bar for improved passenger comfort
1 2
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SEAT
n One piece deeply padded dual seat
n Rider seat features adjustable backrest offering 35 mm of movement in three stages
n Seat is locked at left and right side for enhanced security
Fuel lid
Adjustable backrest 2
35 mm
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1
3
336 mm
6 5 4
340 mm
5
440 mm
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Lower clamp
Upper clamp
Ball bearings
2 Top view
Swingarm
Shock absorber
Top view of swingarm
Final drive 1
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Tires.
Dunlop : D305FA 120/70-14 M/C 55S
Bridgestone : HOOP B03 120/70-14 M/C 55S
Tires.
Dunlop : D305 150/70-14 M/C 66S
Bridgestone : HOOP B02 150/70-14 M/C 66S
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HEADLIGHT ASSEMBLY
n Newly designed multi-reflector dual headlight
For UK specifications, the positions of the left and right headlights are opposite
1 2
3
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2 2
3
1
25
1 2 3 4
10 9 8 7 6 5
l Oil change indicator lights up at 1,000 km, 5,000 km and then every 5,000 km.
l V-belt indicator lights up every 20,000 km.
See Service Tips for details.
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RADIATOR FILL
The radiator fill cap is located just inside the lower right side of the front fairing near the front tire.
COOLANT RESERVOIR
There is a small cutout on the right side cowl under the floorboard area to check the reservoir
coolant level. If coolant is below the minimum level, pull up the rubber floorboard mat and remove
the screw that holds the filler cap access lid and the cap to add coolant.
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CO ADJUSTMENT
1 Cut the secondary air supply by blocking the hose between the Air Cut Valve and the Reed Valve
(See pg.16 for Illustration).
2 Connect the exhaust gas analyzer to the head pipe fittings.
3 Disconnect the crankcase breather hose. This will prevent any oil contamination or combustion
blow-by from affecting the EGA readings.
4 Warm up the engine for several minutes at idle rpm.
5 Adjust the CO while maintaining the following conditions::
n Oil temperature : 65 ~ 75 ºC
n Coolant temperature : 75 ~ 85 ºC
n Intake vacuum : 33 ~ 39 kPa
n Idle revolution : 1150 ~ 1250 rpm.
CO measurement should be: 3.0%
V-BELT REPLACEMENT
The V-belt on the TMax can be replaced by taking off:
l Right middle side panel
l Right floorboard
l Small shroud
To reset the V-belt indicator light, disconnect the 2-pin jumper connector for 2 to 5 seconds with the
main switch turned on, then reconnect it.
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To prevent this from happening, apply a small amount of grease to the adjusting shim and the valve
lifter before reassembly. This will hold the shim and lifter in place while the cams are reinstalled
and timed.
SELF-DIAGNOSTICS
The oil indicator light of the TMax has 3 functions:
n Oil indicator bulb check
n Indicate replacement timing of engine oil
n Indicate an electrical problem (self-diagnostics).
Function 1
The oil indicator lights up momentarily when the main switch is turned on, in order to indicate that the oil
indicator light bulb is working properly.
Function 2
The oil indicator lights up continuously in order to indicate that the engine oil has to be replaced.
It lights up initially at 1,000 km and 5,000 km, after that it lights up every 5,000 km (10,000 -
15,000 - etc.).
NOTE:
The mileage is counted by the igniter after every reset, it therefore is possible that the timing of the
light is different from the odometer reading.
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Function 3
If the igniter detects an electrical problem, the engine oil indicator will flash according to patterns mentioned
as Condition Codes in the table below.
Circuit Defect(s) System Response Condition Code Remarks
TPS l Disconnected l The igniter-unit stays set to wide-open Light on : 0.5 s
l Short circuit. throttle ignition timing.
l Mechanical l Oil indicator displays condition code. Light off : 0.5 s
Malfunction.
Pattern interval: 3.0 s
Speed l Disconnected l Oil indicator displays condition code.
Sensor
SPECIAL TOOLS
There are three new special tools introduced for the TMax:
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Clean and check the sheave surfaces for cracks or other damage. Clean the entire sheave assembly of the
old grease and repack it with 80 to 90 grams of the same special sheave grease as used on the YP250 and
re-assemble.
When re-installing the primary sheave on the crankshaft, be sure to grease the crankshaft splines with the
special grease and that the sheave plate splines are properly aligned with the crankshaft splines.
Clean and inspect all parts for wear or damage. Lube all sliding parts with assembly lube and reassemble
the sheave.
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