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Yamaha · Overhead-cam four-stroke twin, dry sump, separate gearbox oil, chain drive

T-Max 500

Library entry covers 2001

28 factory 31 guideline

Published source

Yamaha XP500 (TMAX) Owner's Manual 5GJ-28199-EV (English), Periodic maintenance and lubrication chart pp.6-3 to 6-5

Factory owner's handbook. Covers 2001 (XP500, EU owner's manual 5GJ-28199-EV, printed May 2001).

Open the source

59 items for a 2001 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Dry sump (separate oil tank)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Automatic or semi-automatic
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2001 Yamaha T-Max 500

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 800 km

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 1,000 km

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 1,600 km or 6 months

1 item

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline

Every 5,000 km or 12 months

5 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Adjust automatic / semi-automatic clutch

Primary and gearbox

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline

Every 5,000 km

1 item

Change engine oil

Engine

Factory

Manual: Engine oil (change). Factory: 1000km initial, 4000km later, then when indicator comes on (every 5000km)

Every 6,500 km or 12 months

1 item

Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 9,500 km or 12 months

3 items

Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 km or 12 months

6 items

Chassis fasteners (check tightness)

Engine

Factory

Factory: 10000km columns and annual check
Inspect coolant hoses and clamps

Engine

Factory

Manual: Cooling system (check coolant level and leakage). Factory: 10000km columns and annual check
Synchronize carburetors

Fuel and air

Factory

Manual: Carburetors (adjust idling speed and synchronization). Factory: Every column incl. 1000km initial and annual check
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Sidestand/centerstand (check operation, lubricate). Factory: 10000km columns and annual check
Check brake pads and discs

Brakes

Factory

Manual: Front/rear brake (check operation, fluid level, leakage). Factory: Every column incl. initial; pads replaced whenever worn to limit
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Moving parts and cables (lubricate). Factory: 10000km columns and annual check

Every 10,000 km

6 items

Check final drive for leaks and bearing play

Final drive

Factory

Manual: Chain drive oil (check for oil leakage, change). Factory: 10000km columns
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings (check play and roughness). Factory: Marked 1000km initial, then every 10000km
Inspect fork seals, stanchions and fork boots

Front end

Factory

Manual: Front fork (check operation and oil leakage). Factory: 10000km columns
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Rear shock absorber assembly (check operation and oil leakage). Factory: 10000km columns
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings (check looseness or damage). Factory: 10000km columns
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tires (check tread depth, damage, pressure). Factory: 10000km columns

Every 16,000 km or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change gearbox oil

Primary and gearbox

Guideline

Every 19,500 km or 2 years

2 items

Synchronize throttle bodies

Fuel and air

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 20,000 km

10 items

Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plugs (check condition, clean and regap). Factory: Marked at 10000km and 30000km; cols 1/10/20/30/40 x1000km
Replace oil filter

Engine

Factory

Manual: Engine oil filter cartridge (replace). Factory: Marked 1000km initial, 20000km, 40000km; chart in km only
Replace spark plugs

Engine

Factory

Manual: Spark plugs (replace). Factory: Marked at 20000km and 40000km
Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter element (clean). Factory: Clean at 10000km and 30000km
Replace air filter element

Fuel and air

Factory

Manual: Air filter element (replace). Factory: Marked at 20000km and 40000km
Replace fuel filter

Fuel and air

Factory

Manual: Fuel filter (check condition). Factory: Marked at 20000km and 40000km
V-belt case air filter elements (clean / replace)

Fuel and air

Factory

Factory: Clean at 10000km and 30000km; replace at 20000km and 40000km
Replace drive belt (wear or damage based)

Final drive

Factory

Manual: V-belt (replace). Factory: When V-belt replacement indicator light comes on (every 20000km)
Repack / replace steering head bearings

Front end

Factory

Manual: Steering bearings (lubricate, lithium-soap grease). Factory: Every 20000 km
Clean and grease rear suspension linkage

Rear suspension and frame

Factory

Manual: Rear shock absorber pivoting points (lubricate). Factory: Marked at 20000km and 40000km

Every 24,000 km or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 24,000 km

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 29,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 32,000 km or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 40,000 km

1 item

Check and adjust valve clearances

Engine

Factory

Manual: Valves (check clearance, adjust). Factory: Every 40000 km; from 50000km repeat intervals from 10000km

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

4 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Factory

Manual: Brake master cylinder and caliper internal components (replace). Factory: Every two years (NOTE under chart)
Replace brake fluid

Brakes

Factory

Manual: Brake fluid (change, with master cylinder and caliper internals). Factory: Every two years (NOTE under chart)

Every 3 years

1 item

Replace coolant

Engine

Factory

Manual: Cooling system (change coolant). Factory: Every 3 years

Every 4 years

2 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hose (replace). Factory: Every 4 years; checked every 10000km and annually

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.