Yamaha TMAX XP530E-A 2017 Manuale utente

2017

SERVICE MANUAL

XP530E-A

XP530-A

XP530D-A

BV1-28197-E0

EAS20002

XP530E-A/XP530-A/XP530D-A

SERVICE MANUAL

First edition, March 2017

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

EAS20003

IMPORTANT

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-

ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles

should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-

cle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and

will appear in future editions of this manual where applicable.

TIP

Designs and specifications are subject to change without notice.

EAS30001

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential per-

sonal injury hazards. Obey all safety messages that follow this symbol

to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could

result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid

damage to the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

WARNING

NOTICE

TIP

EAS20004

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid

out with the individual steps in sequential order.

•The manual is divided into chapters and each chapter is divided into sections. The current section title

“1” is shown at the top of each page.

•Sub-section titles “2” appear in smaller print than the section title.

•To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each

removal and disassembly section.

•Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-

sembly step.

•Symbols “5” indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

•A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation

and assembly procedure, reverse the steps.

•Jobs “7” requiring more information (such as special tools and technical data) are described sequen-

tially.

OIL PUMP

5-59

EAS20054

OIL PUMP

Removing the oil pump assembly

Order Job/Parts to remove Q’ty Remarks

Bottom side cowling/Side panel/Bottom center

cowling

Refer to “GENERAL CHASSIS (1)” on page

4-1.

Center cover/Fuel tank cover assembly/Side

cover (left)/Footboard (left)

Refer to “GENERAL CHASSIS (2)” on page

4-11.

V-belt case air filter element (left)/Generator

cover protector/Water pump inlet pipe/Water

pump outlet pipe/Water pump assembly

Refer to “WATER PUMP” on page 6-9.

Generator cover/Generator rotor/Starter clutch

gear

Refer to “GENERATOR AND STARTER

CLUTCH” on page 5-44.

1ylbmessapmupliO1

1niahcevirdpmupliO2

2teksaG3

1epipyreviledliO4

1epipliO5

1ylbmessaevlavfeileR6

(3)

10 N・m (1.0 kgf・m, 7.4 lb・ft)

OIL PUMP

5-61

EAS30337

CHECKING THE OIL PUMP

1. Check:

•Oil pump driven gear “1”

•Oil pump housing 2 “2”

•Oil pump housing 1 “3”

Cracks/damage/wear →Replace the oil

pump assembly.

2. Check:

•Oil pump operation

Rough movement →Repeat steps (1) and

(2) or replace the oil pump assembly.

EAS30338

CHECKING THE RELIEF VALVE

1. Check:

•Relief valve body

Damage/wear →Replace.

EAS30742

CHECKING THE OIL PIPES

1. Check:

•Oil pipe

•Oil delivery pipe

Damage →Replace.

Obstruction →Wash and blow out with com-

pressed air.

EAS30785

CHECKING THE OIL PUMP DRIVE CHAIN

1. Check:

•Oil pump drive chain

Cracks/stiffness →Replace the oil pump

chain and oil pump assembly as a set.

EAS30342

ASSEMBLING THE OIL PUMP

1. Lubricate:

•Inner rotor

•Outer rotor

•Oil pump shaft

(with the recommended lubricant)

2. Install:

•Inner rotors

TIP

When installing the inner rotor, align the pins “1”

in the oil pump shaft with the grooves “a” in the

inner rotor.

3. Check:

•Oil pump operation

Refer to “CHECKING THE OIL PUMP” on

page 5-61.

EAS30343

INSTALLING THE OIL PUMP

1. Install:

•Oil pump assembly

NOTICE

ECA13890

After tightening the bolts, make sure the oil

pump turns smoothly.

Recommended lubricant

Engine oil

Oil pump bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)

EAS20005

SYMBOLS

The following symbols are used in this manual for easier understanding.

TIP

The following symbols are not relevant to every vehicle.

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool Wheel bearing grease

Tightening torque Lithium-soap-based grease

Wear limit, clearance Molybdenum disulfide grease

Engine speed Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil Replace the part with a new one.

Silicone fluid

New

GENERAL INFORMATION 1

SPECIFICATIONS 2

PERIODIC CHECKS AND ADJUSTMENTS 3

CHASSIS 4

ENGINE 5

COOLING SYSTEM 6

FUEL SYSTEM 7

ELECTRICAL SYSTEM 8

TROUBLESHOOTING 9

EAS10003

TABLE OF CONTENTS

GENERAL INFORMATION

IDENTIFICATION..............................................................................................1-1

VEHICLE IDENTIFICATION NUMBER ......................................................1-1

MODEL LABEL...........................................................................................1-1

FEATURES .......................................................................................................1-2

YCC-T (Yamaha Chip Controlled Throttle).................................................1-2

OUTLINE OF THE CRUISE CONTROL SYSTEM (for XP530D-A) ...........1-4

OUTLINE OF THE TCS (Traction Control System)....................................1-9

MULTI-FUNCTION DISPLAY...................................................................1-12

IMPORTANT INFORMATION .........................................................................1-22

PREPARATION FOR REMOVAL AND DISASSEMBLY..........................1-22

REPLACEMENT PARTS..........................................................................1-22

GASKETS, OIL SEALS AND O-RINGS ...................................................1-22

LOCK WASHERS/PLATES AND COTTER PINS ....................................1-22

BEARINGS AND OIL SEALS ...................................................................1-22

CIRCLIPS .................................................................................................1-23

RUBBER PARTS......................................................................................1-23

BASIC SERVICE INFORMATION ..................................................................1-24

QUICK FASTENERS................................................................................1-24

ELECTRICAL SYSTEM............................................................................1-25

SPECIAL TOOLS ...........................................................................................1-29

IDENTIFICATION

1-1

EAS20007

IDENTIFICATION

EAS30002

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped

into the right side of the frame.

EAS30003

MODEL LABEL

The model label “1” is affixed to the storage box.

This information will be needed to order spare

parts.

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