engine coolant YAMAHA TMAX 2005 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2005, Model line: TMAX, Model: YAMAHA TMAX 2005Pages: 90, PDF Size: 2.51 MB
Page 6 of 90
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 ...................................3-5
Tachometer .....................................3-5
Multi-function display .......................3-5
Anti-theft alarm (optional) ................3-9
Handlebar switches .........................3-9
Front brake lever ...........................3-11
Rear brake lever ............................3-11
Rear brake lock lever .....................3-11
ABS (for ABS models) ...................3-12
Fuel tank cap .................................3-13
Fuel ................................................3-14
Catalytic converter .........................3-14
Seat ...............................................3-15
Adjusting the rider backrest ...........3-15
Helmet holder ................................3-16
Storage compartments ..................3-17
Shock absorber .............................3-18
Sidestand .......................................3-18Ignition circuit cut-off system ......... 3-19
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 ..................................... 6-10
Chain drive oil ............................... 6-13
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 .......................................... 6-21
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 ................ 6-24
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 ................... 6-26
Checking the wheel bearings ........ 6-27
Battery ........................................... 6-27
Replacing the fuses ...................... 6-29
Replacing the headlight bulb ........ 6-31
Troubleshooting ............................ 6-32
Troubleshooting charts ................. 6-33
SCOOTER CARE AND
STORAGE
........................................... 7-1
Care ................................................ 7-1
Page 21 of 90
INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
34
5
6
7
8
9
EAU11601
Speedometer
The speedometer shows the riding
speed.
When the key is turned to “ON”, the
speedometer needle will sweep once
across the speed range and then return
to zero in order to test the electrical cir-
cuit.
EAU11872
Tachometer
The electric tachometer allows the rider
to monitor the engine speed and keep it
within the ideal power range.
When the key is turned to “ON”, the ta-
chometer needle will sweep once
across the r/min range and then return
to zero r/min in order to test the electri-
cal circuit.
CAUTION:
ECA10031
Do not operate the engine in the ta-
chometer red zone.
Red zone: 8250 r/min and above
EAU33516
Multi-function display
WARNING
EWA12311
Be sure to stop the vehicle before
making any setting changes to the
multi-function display.
1. Speedometer
1
1. Tachometer
2. Tachometer red zone
12
1. Clock
2. Coolant temperature meter
3. Fuel meter
4. Odometer/tripmeters
5. “SELECT” button
6. “RESET” button
1
2
3
4
5
6
Page 23 of 90
INSTRUMENT AND CONTROL FUNCTIONS
3-7
2
34
5
6
7
8
9
flashing, push the “RESET” button for
at least one second. If you do not reset
the fuel reserve tripmeter manually, it
will reset itself automatically and the
display will return to the prior mode af-
ter refueling and traveling 5 km (3 mi).
NOTE:
The display cannot be changed back to
“TRIP F” after pushing the “RESET”
button.
Fuel meter
With the key in the “ON” position, the
fuel meter indicates the amount of fuel
in the fuel tank. The display segments
of the fuel meter disappear towards “E”
(Empty) as the fuel level decreases.
When the fuel level reaches the bottom
segment near “E”, the fuel level warn-
ing indicator and the bottom segment
will flash. Refuel as soon as possible.
Coolant temperature meter
With the key in the “ON” position, the
coolant temperature meter indicates
the temperature of the coolant. The
coolant temperature varies with chang-
es in the weather and engine load. Ifthe top segment and coolant tempera-
ture warning indicator flash, stop the
vehicle and let the engine cool. (See
page 6-33.)
CAUTION:
ECA10020
Do not operate the engine if it is
overheated.
Oil change indicator “OIL”
This indicator flashes at the initial
1000 km (600 mi), then at 5000 km
(3000 mi) and every 5000 km (3000 mi)
thereafter to indicate that the engine
oil should be changed.
After changing the engine oil, reset the
oil change indicator. (See page 6-10.)
If the engine oil is changed before theoil change indicator comes on (i.e. be-
fore the periodic oil change interval has
been reached), the indicator must be
reset after the oil change for the next
periodic oil change to be indicated at
the correct time. (See page 6-10.)
The electrical circuit of the indicator can
be checked according to the following
procedure.
1. Set the engine stop switch to “”
and turn the key to “ON”.
2. Check that the indicator comes on
for a few seconds and then goes
off.
3. If the indicator does not come on,
have a Yamaha dealer check the
electrical circuit.
NOTE:
The oil change indicator may flash
when the engine is revved with the
scooter on the centerstand, but this
does not indicate a malfunction.
V-belt replacement indicator
“V-BELT”
This indicator flashes every 20000 km
(12500 mi) when the V-belt needs to be
Page 38 of 90
PRE-OPERATION CHECKS
4-2
1
2
3
4
5
6
7
8
9
EAU15603
Pre-operation check list
ITEM CHECKS PAGE
Fuel
Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-14
Engine oil
Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-10
Chain drive oil
Check vehicle for oil leakage. 6-13
Coolant
Check coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-15
Front brake
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-22, 6-23
Rear brake
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-22, 6-23
Throttle grip
Make sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-18, 6-24
Page 48 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
1
2
3
4
5
6
7
8
9
10
*
Brake hoses
Check for cracks or damage.
√√√√ √
Replace. Every 4 years
11
*
Wheels
Check runout and for damage.
√√√√
12
*
Tires
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√√√√ √
13
*
Wheel bearings
Check bearing for looseness or damage.
√√√√
14
*
Steering bearings
Check bearing play and steering for roughness.
√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
15
*
Chassis fasteners
Make sure that all nuts, bolts and screws are properly
tightened.
√√√√ √
16
Sidestand, centerstand
Check operation.
Lubricate.
√√√√ √
17
*
Sidestand switch
Check operation.
√√√√√ √
18
*
Front fork
Check operation and for oil leakage.
√√√√
19
*
Shock absorber assem-
bly
Check operation and shock absorber for oil leakage.
√√√√
20
*
Electronic fuel injection
Adjust engine idling speed and synchronization.
√√√√√ √
21
Engine oil
Change. (See pages 3-5 and 6-10.)
√
When the oil change indicator flashes
(every 5000 km)
Check oil level and vehicle for oil leakage. Every 5000 km
√
22
Engine oil filter cartridge
Replace.
√√√
23
*
Cooling system
Check coolant level and vehicle for coolant leakage.
√√√√ √
Change. Every 3 years
24
Chain drive oil
Check vehicle for oil leakage.
Change.
√√√√
25
*
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
Page 59 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
2
3
4
5
67
8
9
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU20122
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:
The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Remove the coolant reservoir cov-
er by removing the screw.3. Check the coolant level in the cool-
ant reservoir.
NOTE:
The coolant should be between the
minimum and maximum level marks.4. If the coolant is at or below the
minimum level mark, open the res-
ervoir cap, add coolant to the max-
imum level mark, and then close
the reservoir cap.
1. Coolant reservoir cover
2. Screw
1
2
1. Maximum level mark
2. Minimum level mark
12
Page 60 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
1
2
3
4
5
6
7
8
9
CAUTION:
ECA10470
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protectedagainst frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
WARNING
EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
5. Install the coolant reservoir cover
by installing the screw.
NOTE:
The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.
If the engine overheats, see page
6-33 for further instructions.
EAU21120
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove cowling A. (See
page 6-6.)
2. Remove the windshield by remov-
ing the screws.
3. Remove the air filter case cover by
removing the screws, and then pull
the air filter element out.
1. Coolant reservoir cap
Coolant reservoir capacity (up to the
maximum level mark):
0.35 L (0.37 US qt) (0.31 Imp.qt)
1
1. Screw
1
1(×5)
Page 78 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
1
2
3
4
5
6
7
8
9Engine overheating
WARNING
EWA10400
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing
sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.
Page 83 of 90
8-1
2
3
4
5
6
7
89
SPECIFICATIONS
EAU26338
Dimensions:
Overall length:
2235 mm (88.0 in)
Overall width:
775 mm (30.5 in)
Overall height:
1410 mm (55.5 in)
Seat height:
795 mm (31.3 in)
Wheelbase:
1575 mm (62.0 in)
Ground clearance:
130 mm (5.12 in)
Minimum turning radius:
2800 mm (110.2 in)
Weight:
With oil and fuel:
XP500 225.0 kg (496 lb)
XP500A 230.0 kg (507 lb)
Engine:
Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward-inclined parallel 2-cylinder
Displacement:
499.0 cm
3
(30.45 cu.in)
Bore
×
stroke:
66.0
×
73.0 mm (2.60
×
2.87 in)
Compression ratio:
11.00 :1
Starting system:
Electric starter Lubrication system:
Dry sump
Engine oil:
Type:
SAE10W30 or SAE10W40
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Without oil filter cartridge replacement:
2.80 L (2.96 US qt) (2.46 Imp.qt)
With oil filter cartridge replacement:
2.90 L (3.07 US qt) (2.55 Imp.qt)
Chain drive oil:
Type:
SAE80 API GL-4 Hypoid gear oil
Quantity:
0.70 L (0.74 US qt) (0.62 Imp.qt)
Cooling system:
Coolant reservoir capacity (up to the maxi-
mum level mark):
0.35 L (0.37 US qt) (0.31 Imp.qt)
Radiator capacity (including all routes):
1.50 L (1.59 US qt) (1.32 Imp.qt)
Air filter:
Air filter element:
Dry element
Fuel:
Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
14.0 L (3.70 US gal) (3.08 Imp.gal)
Electronic fuel injection:
Manufacturer:
AISAN
Model:
1100-87B60/1100-87B70
Spark plug(s):
Manufacturer/model:
NGK/CR7E
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Clutch:
Clutch type:
Wet, multiple-disc automatic
Transmission:
Primary reduction system:
Spur gear/helical gear
Primary reduction ratio:
52/32
×
36/22 (2.659)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
41/25
×
40/29 (2.262)
Transmission type:
V-belt automatic
Operation:
Centrifugal automatic type
Chassis:
Frame type:
Diamond
Caster angle:
28.00 °
Trail:
95.0 mm (3.74 in)
Page 88 of 90
INDEX
A
ABS (for ABS models) ............................ 3-12
ABS warning light (for ABS models) ......... 3-4
Acceleration and deceleration................... 5-2
Air filter element, cleaning....................... 6-16
Anti-theft alarm (optional).......................... 3-9
B
Battery..................................................... 6-27
Brake fluid, changing .............................. 6-24
Brake fluid level, checking ...................... 6-23
Brake lever, front..................................... 3-11
Brake lever, rear ..................................... 3-11
Brake levers, lubricating.......................... 6-25
Braking ...................................................... 5-3
C
Care .......................................................... 7-1
Catalytic converter .................................. 3-14
Centerstand and sidestand, checking
and lubricating ...................................... 6-25
Chain drive oil ......................................... 6-13
Coolant.................................................... 6-15
Cowlings and panels, removing and
installing.................................................. 6-6
D
Dimmer switch ........................................ 3-10
E
Engine break-in ......................................... 5-4
Engine idling speed................................. 6-17
Engine oil and oil filter cartridge .............. 6-10
Engine stop switch .................................. 3-10
Engine trouble warning light...................... 3-4
F
Front and rear brake lever free play........ 6-21
Front and rear brake pads, checking ...... 6-22Front fork, checking .................................6-26
Fuel ..........................................................3-14
Fuel consumption, tips for reducing ...........5-4
Fuel tank cap ...........................................3-13
Fuses, replacing ......................................6-29
H
Handlebar switches ...................................3-9
Hazard switch ..........................................3-10
Headlight bulb, replacing .........................6-31
Helmet holder ..........................................3-16
High beam indicator light ...........................3-3
Horn switch ..............................................3-10
I
Identification numbers................................9-1
Ignition circuit cut-off system ...................3-19
Immobilizer system ....................................3-1
Immobilizer system indicator light ..............3-4
Indicator and warning lights .......................3-3
K
Key identification number ..........................9-1
M
Main switch/steering lock ...........................3-2
Model label ................................................9-2
Multi-function display .................................3-5
P
Parking.......................................................5-5
Part locations .............................................2-1
Pass switch ..............................................3-10
Periodic maintenance and lubrication
chart ........................................................6-3
Pre-operation check list .............................4-2
R
Rear brake lock lever ...............................3-11
Rear brake lock lever cable, adjusting .....6-21Rider backrest, adjusting ......................... 3-15
S
Safe-riding points ...................................... 1-4
Safety information ..................................... 1-1
Seat ......................................................... 3-15
Shock absorber ....................................... 3-18
Sidestand ................................................ 3-18
Spark plugs, checking ............................... 6-9
Specifications ............................................ 8-1
Speedometer ............................................. 3-5
Starting off ................................................. 5-2
Starting the engine .................................... 5-1
Start switch .............................................. 3-10
Steering, checking ................................... 6-26
Storage ...................................................... 7-3
Storage compartments ............................ 3-17
T
Tachometer ............................................... 3-5
Throttle cable free play, checking............ 6-18
Throttle grip and cable, checking and
lubricating .............................................. 6-24
Tires ........................................................ 6-19
Tool kit ....................................................... 6-1
Troubleshooting....................................... 6-32
Troubleshooting charts ............................ 6-33
Turn signal indicator lights......................... 3-3
Turn signal switch.................................... 3-10
V
Valve clearance ....................................... 6-18
Vehicle identification number .................... 9-1
W
Wheel bearings, checking ....................... 6-27
Wheels .................................................... 6-21