wheel YAMAHA TMAX 2006 Owners Manual

TABLE OF CONTENTS
SAFETY INFORMATION
...................1-1
Further safe-riding points .................1-4
DESCRIPTION
...................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS
........................................3-1
Immobilizer system ..........................3-1
Main switch/steering lock .................3-2
Indicator and warning lights .............3-3
Speedometer ...................................3-4
Tachometer .....................................3-4
Multi-function display .......................3-5
Anti-theft alarm (optional) ................3-8
Handlebar switches .........................3-8
Front brake lever ...........................3-10
Rear brake lever ............................3-10
Rear brake lock lever .....................3-10
ABS (for ABS models) ...................3-11
Fuel tank cap .................................3-12
Fuel ................................................3-13
Catalytic converter .........................3-13
Seat ...............................................3-14
Adjusting the rider backrest ...........3-14
Helmet holder ................................3-15
Storage compartments ..................3-16
Shock absorber .............................3-17
Sidestand .......................................3-17Ignition circuit cut-off system ......... 3-18
PRE-OPERATION CHECKS
.............. 4-1
Pre-operation check list ................... 4-2
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
Starting the engine .......................... 5-1
Starting off ....................................... 5-2
Acceleration and deceleration ......... 5-2
Braking ............................................ 5-3
Tips for reducing fuel
consumption ................................ 5-4
Engine break-in ............................... 5-4
Parking ............................................ 5-5
PERIODIC MAINTENANCE AND
MINOR REPAIR
.................................. 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance and lubrication
chart ............................................. 6-3
Removing and installing cowlings
and panels ................................... 6-6
Checking the spark plugs ................ 6-9
Engine oil and oil filter cartridge .... 6-11
Chain drive oil ............................... 6-14
Coolant .......................................... 6-15
Cleaning the air filter element ....... 6-16
Adjusting the engine idling
speed ......................................... 6-17Checking the throttle cable free
play ............................................ 6-18
Valve clearance ............................ 6-18
Tires .............................................. 6-19
Cast wheels .................................. 6-21
Front and rear brake lever free
play ............................................ 6-21
Adjusting the rear brake lock lever
cable .......................................... 6-22
Checking the front and rear brake
pads ........................................... 6-22
Checking the brake fluid level ....... 6-23
Changing the brake fluid ............... 6-24
Checking and lubricating the throttle
grip and cable ............................ 6-25
Lubricating the front and rear brake
levers ......................................... 6-25
Checking and lubricating the
centerstand and sidestand ........ 6-25
Checking the front fork .................. 6-26
Checking the steering ................... 6-27
Checking the wheel bearings ........ 6-27
Battery ........................................... 6-28
Replacing the fuses ...................... 6-29
Replacing the headlight bulb ........ 6-31
Troubleshooting ............................ 6-32
Troubleshooting charts ................. 6-33
SCOOTER CARE AND
STORAGE
........................................... 7-1
Matte black caution ......................... 7-1

SAFETY INFORMATION
1-2
1

Always signal before turning or
changing lanes. Make sure that
other motorists can see you.

The posture of the operator and
passenger is important for proper
control.

The operator should keep both
hands on the handlebar and
both feet on the footboard during
operation to maintain control of
the scooter.

The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.

Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.

Never ride under the influence of
alcohol or other drugs.

This scooter is designed for
on-road use only. It is not suitable
for off-road use.
Protective apparel
The majority of fatalities from scooter
accidents are the result of head inju-ries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.

Always wear an approved helmet.

Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision which could delay seeing
a hazard.

The use of a jacket, substantial
shoes, trousers, gloves, etc., is ef-
fective in preventing or reducing
abrasions or lacerations.

Never wear loose-fitting clothes,
otherwise they could catch on the
control levers or wheels and cause
injury or an accident.

Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protec-
tive clothing that covers your legs,
ankles, and feet.

Passengers should also observe
the above precautions.
Modifications
Modifications made to this scooter notapproved by Yamaha, or the removal of
original equipment, may render the
scooter unsafe for use and may cause
severe personal injury. Modifications
may also make your scooter illegal to
use.
Loading and accessories
Adding accessories or cargo to your
scooter can adversely affect stability
and handling if the weight distribution of
the scooter is changed. To avoid the
possibility of an accident, use extreme
caution when adding cargo or accesso-
ries to your scooter. Use extra care
when riding a scooter that has added
cargo or accessories. Here are some
general guidelines to follow if loading
cargo or adding accessories to your
scooter:
Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.

Maximum load:
XP500 190 kg (419 lb)
XP500A 185 kg (408 lb)

INSTRUMENT AND CONTROL FUNCTIONS
3-3
2
34
5
6
7
8
9

EAU11003
Indicator and warning lights
EAU11030
Turn signal indicator lights “” and
“”
The corresponding indicator light flash-
es when the turn signal switch is
pushed to the left or right.
EAU11080
High beam indicator light “”
This indicator light comes on when thehigh beam of the headlight is switched
on.
EAU11480
Engine trouble warning light “”
This warning light comes on when an
electrical circuit monitoring the engine
is defective. When this occurs, have a
Yamaha dealer check the self-diagno-
sis system.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.
EAU11551
ABS warning light “” (for ABS
models)
CAUTION:

ECA10830
If the ABS warning light comes on or
flashes while riding, the ABS may be
defective. If this occurs, have a
Yamaha dealer check the electrical
circuit.
See page 3-11 for an explanation of the
ABS.The electrical circuit of the warning light
can be checked by setting the engine
stop switch to “ ” and turning the key
to “ON”. The warning light should come
on for a few seconds, and then go off. If
the warning light does not come on or
remains on, have a Yamaha dealer
check the electrical circuit.
WARNING

EWA11350
When the ABS warning light comes
on or flashes while riding, the brake
system reverts to conventional brak-
ing. Therefore, be careful not to
cause the wheel to lock during emer-
gency braking.
NOTE:

The ABS warning light may come on
while pushing the start switch and while
accelerating the engine with the scoot-
er on its centerstand, but this does not
indicate a malfunction.
EAU26873
Immobilizer system indicator light
“”
The electrical circuit of the indicator
1. Turn signal indicator lights “ ” and “ ”
2. High beam indicator light “ ”
3. Immobilizer system indicator light “ ”
4. Engine trouble warning light “ ”
5. Anti-lock Brake System (ABS) warning
light “ ” (for ABS models)
1
2
3
4
5
ABS
ABS

INSTRUMENT AND CONTROL FUNCTIONS
3-10
1
2
3
4
5
6
7
8
9

EAU12900
Front brake lever
The front brake lever is located on the
right handlebar grip. To apply the front
brake, pull this lever toward the handle-
bar grip.
EAU12950
Rear brake lever
The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the handle-
bar grip.
EAU12962
Rear brake lock lever
This vehicle is equipped with a rear
brake lock lever to prevent the rear
wheel from moving while stopped at
traffic signals, railroad crossings, etc.
To lock the rear wheel
Push the rear brake lock lever to the left
until it snaps into place.
To unlock the rear wheel
Push the rear brake lock lever back to
the original position.
NOTE:


Be sure to check that the rear
wheel does not move when the
1. Front brake lever
1

1. Rear brake lever
1

1. Rear brake lock lever
1

INSTRUMENT AND CONTROL FUNCTIONS
3-11
2
34
5
6
7
8
9
rear brake lock lever is applied.


To provide secure locking of the
rear wheel, apply the rear brake le-
ver first before moving the rear
brake lock lever to the left.
WARNING

EWA12361
Never move the rear brake lock lever
to the left while the vehicle is mov-
ing, otherwise loss of control or an
accident may result. Make sure that
the vehicle is stopped before mov-
ing the rear brake lock lever to the
left.
EAU12991
ABS (for ABS models)
The Yamaha ABS (Anti-lock Brake
System) features a dual electronic con-
trol system, which acts on the front and
rear brakes independently. The ABS
securely controls wheel lockup during
emergency braking on changing road
surfaces and under various weather
conditions, thereby maximizing tire ad-
hesion and performance while provid-
ing a smooth braking action. The ABS
is monitored by an ECU (Electronic
Control Unit), which will have recourse
to manual braking if a malfunction oc-
curs.
WARNING

EWA10090

The ABS performs best on long
braking distances.

On certain (rough or gravel)
roads, the braking distance may
be longer with than without the
ABS. Therefore, always keep a
sufficient distance to the vehi-
cle ahead to match the riding
speed.
NOTE:


When the ABS is activated, the
brakes are operated in the usual
way. A pulsating action may be felt
at the brake levers, but this does
not indicate a malfunction.

This ABS has a test mode which
allows the owner to experience the
pulsating at the brake levers when
the ABS is operating. However,
special tools are required, so
please consult your Yamaha deal-
er when performing this test.

PRE-OPERATION CHECKS
4-3
1
2
3
4
5
6
7
8
9

Wheels and tires

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.6-19, 6-21
Brake levers

Make sure that operation is smooth.

Lubricate lever pivoting points if necessary.6-25
Centerstand, sidestand

Make sure that operation is smooth.

Lubricate pivots if necessary.6-25
Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened.

Tighten if necessary.—
Instruments, lights, signals
and switches

Check operation.

Correct if necessary.—
Sidestand switch

Check operation of ignition circuit cut-off system.

If system is defective, have Yamaha dealer check vehicle.3-17
ITEM CHECKS PAGE

5-1
2
3
4
56
7
8
9

OPERATION AND IMPORTANT RIDING POINTS
EAU15970
WARNING

EWA11250

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.

Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.

For safety, always start the en-
gine with the centerstand down.

When the centerstand is down
and the engine is idling, keep
your hands and feet away from
the rear wheel.
EAU36510
Starting the engine
CAUTION:

ECA10250
See page 5-4 for engine break-in in-
structions prior to operating the ve-
hicle for the first time.
In order for the ignition circuit cut-off
system to enable starting, the side-
stand must be up.
WARNING

EWA10290

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-18.

Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
CAUTION:

ECA15020
The following warning lights, indica-
tor light and indicators should come
on for a few seconds, then go off.

Engine trouble warning light

ABS warning light (for ABS
models)

Immobilizer system indicator
light

V-belt replacement indicator

Oil change indicator
If a warning light, indicator light or
indicator does not go off, see page
3-3 or 3-5 for the corresponding
warning light, indicator light or indi-
cator circuit check.
2. Close the throttle completely.
3. Start the engine by pushing the
start switch while applying the front
or rear brake.
NOTE:

If the engine does not start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt.
CAUTION:

ECA11040
For maximum engine life, never ac-
celerate hard when the engine is

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
2
3
4
5
67
8
9

9*
Brake hoses

Check for cracks or damage.
√√√√ √

Replace. Every 4 years
10

*
Wheels

Check runout and for damage.
√√√√
11

*
Tires

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
√√√√ √
12

*
Wheel bearings

Check bearing for looseness or damage.
√√√√
13

*
Steering bearings

Check bearing play and steering for roughness.
√√√√√

Lubricate with lithium-soap-based grease. Every 20000 km
14

*
Chassis fasteners

Make sure that all nuts, bolts and screws are properly
tightened.
√√√√ √
15

Sidestand, centerstand

Check operation.

Lubricate.
√√√√ √
16

*
Sidestand switch

Check operation.
√√√√√ √
17

*
Front fork

Check operation and for oil leakage.
√√√√
18

*
Shock absorber assem-
bly

Check operation and shock absorber for oil leakage.
√√√√
19

*
Fuel injection

Adjust engine idling speed and synchronization.
√√√√√ √
20

Engine oil

Change. (See pages 3-5 and 6-11.)
√
When the oil change indicator flashes (every
5000 km)

Check oil level and vehicle for oil leakage. Every 5000 km
√
21

Engine oil filter cartridge

Replace.
√√√
22

*
Cooling system

Check coolant level and vehicle for coolant leakage.
√√√√ √

Change. Every 3 years
23

Chain drive oil

Check vehicle for oil leakage.

Change.
√√√√
24

*
V-belt

Replace.When the V-belt replacement indicator flashes (every
20000 km)
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
2
3
4
5
67
8
9

EAU19993
Chain drive oil
The chain drive oil should be changed
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Remove panel F. (See page 6-6.)
2. Place an oil pan under the chain
drive case to collect the used oil.
3. Remove the oil filler cap and drain
bolt to drain the oil from the chain
drive case.
4. Install the chain drive oil drain bolt,
and then tighten it to the specified
torque.5. Add the specified amount of the
recommended oil.
6. Wipe the dipstick clean, insert it
into the oil filler hole (without
screwing it in), and then remove it
to check the oil level.
NOTE:

The chain drive oil should be between
the minimum and maximum level
marks.7. If the chain drive oil is below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
8. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
CAUTION:

ECA15010

Make sure that no foreign mate-
rial enters the chain drive case.

Make sure that no oil gets on the
tire or wheel.
9. Check the chain drive case for oil
leakage. If leakage is found, check
for the cause.
1. Chain drive oil filler cap
2. Chain drive oil drain bolt
1
2

Tightening torque:
Chain drive oil drain bolt:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
Recommended chain drive oil:
See page 8-1.
Oil quantity:
0.70 L (0.74 US qt) (0.62 Imp.qt)

1. Maximum level mark
2. Minimum level mark
1
2

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
2
3
4
5
67
8
9 Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:

The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
Tire information
This model is equipped with tubeless
tires.
WARNING

EWA10470

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.

The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
1. Tire sidewall
2. Tire tread depth
Minimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
12

Front tire:
Size:
120/70R14 M/C 55H
Manufacturer/model:
DUNLOP/D252F
BRIDGESTONE/TH01F
Rear tire:
Size:
160/60R15 M/C 67H
Manufacturer/model:
DUNLOP/D252
BRIDGESTONE/TH01R