wheel YAMAHA TMAX 2006 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU21960
Cast wheels
To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.

The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU33453
Front and rear brake lever free
play
Front
Rear
There should be no free play at the
brake lever ends. If there is free play,
have a Yamaha dealer inspect thebrake system.
WARNING

EWA14211
A soft or spongy feeling in the brake
lever can indicate the presence of air
in the hydraulic system. If there is air
in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the vehicle. Air in the
hydraulic system will diminish the
braking performance, which may re-
sult in loss of control and an acci-
dent.

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
EAU23290
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.

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SCOOTER CARE AND STORAGE
EAU37831
Matte black caution
CAUTION:

ECA15191
Some models are equipped with
matte black finished parts. Be sure
to consult a Yamaha dealer for ad-
vice on what products to use before
cleaning the vehicle. Using a brush,
harsh chemical products or clean-
ing compounds when cleaning
these parts will scratch or damage
their surface. Wax also should not
be applied to any matte black fin-
ished parts.
EAU26100
Care
While the open design of a scooter re-
veals the attractiveness of the technol-
ogy, it also makes it more vulnerable.
Rust and corrosion can develop even if
high-quality components are used. A
rusty exhaust pipe may go unnoticed
on a car, however, it detracts from the
overall appearance of a scooter. Fre-
quent and proper care does not only
comply with the terms of the warranty,
but it will also keep your scooter looking
good, extend its life and optimize its
performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:

ECA10780

Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.

Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.

Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or

SCOOTER CARE AND STORAGE
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9 thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.

For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:

Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the scooter with cold water
and a mild detergent after the en-
gine has cooled down.
CAUTION:

ECA10790
Do not use warm water since it in-
creases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the scooter with a chamois or
an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stain-
less-steel parts, including the ex-
haust system. (Even the thermally
induced discoloring of stain-
less-steel exhaust systems can be
removed through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean-
er to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the scooter dry completely be-
fore storing or covering it.

SCOOTER CARE AND STORAGE
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fuel from deteriorating.
3. Perform the following steps to pro-
tect the cylinders, piston rings, etc.
from corrosion.
a. Remove the spark plug caps
and the spark plugs.
b. Pour a teaspoonful of engine oil
into the spark plug bores.
c. Install the spark plug caps onto
the spark plugs, and then place
the spark plugs on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder walls with oil.)
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
WARNING

EWA10950
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
4. Lubricate all control cables and thepivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place
[less than 0 °C (30 °F) or more
than 30 °C (90 °F)]. For more in-
formation on storing the battery,
see page 6-28.
NOTE:

Make any necessary repairs before
storing the scooter.

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SPECIFICATIONS
EAU2633E
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 starterLubrication 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)
Fuel injection:
Manufacturer:
AISAN
Model/quantity:
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)

SPECIFICATIONS
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89 Front tire:

Type:
Tubeless
Size:
120/70R14 M/C 55H
Manufacturer/model:
DUNLOP/D252F
Manufacturer/model:
BRIDGESTONE/TH01F
Rear tire:
Type:
Tubeless
Size:
160/60R15 M/C 67H
Manufacturer/model:
DUNLOP/D252
Manufacturer/model:
BRIDGESTONE/TH01R
Loading:
Maximum load:
XP500 190 kg (419 lb)
XP500A 185 kg (408 lb)
* (Total weight of rider, passenger, cargo
and accessories)

Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm
2

)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2

)Loading condition:
XP500 90–190 kg (198–419 lb)
XP500A 90–185 kg (198–408 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm
2

)
Rear:
280 kPa (41 psi) (2.80 kgf/cm
2

)
Front wheel:
Wheel type:
Cast wheel
Rim size:
14M/C x MT3.50
Rear wheel:
Wheel type:
Cast wheel
Rim size:
15M/C x MT5.00
Front brake:
Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Left hand operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
120.0 mm (4.72 in)
Rear suspension:
Type:
Swingarm
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
117.0 mm (4.61 in)
Electrical system:
Ignition system:
Transistorized coil ignition (digital)
Charging system:
AC magneto
Battery:
Model:
GT9B-4
Voltage, capacity:
12 V, 8.0 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage
×
quantity:
Headlight:
12 V, 60 W/55.0 W
×
1
Headlight:
12 V, 55.0 W
×
1

INDEX
A
ABS (for ABS models) .............................3-11
ABS warning light (for ABS models) ..........3-3
Acceleration and deceleration ...................5-2
Air filter element, cleaning .......................6-16
Anti-theft alarm (optional) ..........................3-8
B
Battery .....................................................6-28
Brake fluid, changing ...............................6-24
Brake fluid level, checking .......................6-23
Brake lever, front .....................................3-10
Brake lever, rear ......................................3-10
Brake levers, lubricating ..........................6-25
Braking ......................................................5-3
C
Care ...........................................................7-1
Catalytic converter ...................................3-13
Caution, matte black ..................................7-1
Centerstand and sidestand, checking and
lubricating ..............................................6-25
Chain drive oil ..........................................6-14
Coolant ....................................................6-15
Cowlings and panels, removing and
installing ..................................................6-6
D
Dimmer switch ...........................................3-9
E
Engine break-in .........................................5-4
Engine idling speed .................................6-17
Engine oil and oil filter cartridge ..............6-11
Engine stop switch.....................................3-9
Engine trouble warning light ......................3-3
F
Front and rear brake lever free play ........6-21Front and rear brake pads, checking....... 6-22
Front fork, checking ................................. 6-26
Fuel ......................................................... 3-13
Fuel consumption, tips for reducing .......... 5-4
Fuel tank cap ........................................... 3-12
Fuses, replacing ...................................... 6-29
H
Handlebar switches ................................... 3-8
Hazard switch ............................................ 3-9
Headlight bulb, replacing ......................... 6-31
Helmet holder .......................................... 3-15
High beam indicator light ........................... 3-3
Horn switch................................................ 3-9
I
Identification numbers ............................... 9-1
Ignition circuit cut-off system ................... 3-18
Immobilizer system.................................... 3-1
Immobilizer system indicator light ............. 3-3
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 ............................................... 3-9
Periodic maintenance and lubrication
chart ........................................................ 6-3
Pre-operation check list ............................. 4-2
R
Rear brake lock lever .............................. 3-10Rear brake lock lever cable, adjusting .... 6-22
Rider backrest, adjusting......................... 3-14
S
Safe-riding points ...................................... 1-4
Safety information ..................................... 1-1
Seat ......................................................... 3-14
Shock absorber ....................................... 3-17
Sidestand ................................................ 3-17
Spark plugs, checking ............................... 6-9
Specifications ............................................ 8-1
Speedometer............................................. 3-4
Starting off ................................................. 5-2
Starting the engine .................................... 5-1
Start switch................................................ 3-9
Steering, checking................................... 6-27
Storage...................................................... 7-3
Storage compartments ............................ 3-16
T
Tachometer ............................................... 3-4
Throttle cable free play, checking ........... 6-18
Throttle grip and cable, checking and
lubricating ............................................. 6-25
Tires ........................................................ 6-19
Tool kit....................................................... 6-1
Troubleshooting ...................................... 6-32
Troubleshooting charts............................ 6-33
Turn signal indicator lights ........................ 3-3
Turn signal switch ..................................... 3-9
V
Valve clearance....................................... 6-18
Vehicle identification number .................... 9-1
W
Wheel bearings, checking ....................... 6-27
Wheels .................................................... 6-21