lock YAMAHA TMAX 2007 User Guide

INSTRUMENT AND CONTROL FUNCTIONS
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move it.
3. Close the lid.
WARNING

EWA11260
Make sure that the fuel tank cap is
properly installed and locked in
place before riding the scooter.
EAU13211
Fuel
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
WARNING

EWA10880

Do not overfill the fuel tank, oth-
erwise it may overflow when the
fuel warms up and expands.

Avoid spilling fuel on the hot en-
gine.
CAUTION:

ECA10070
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, sincefuel may deteriorate painted surfac-
es or plastic parts.
EAU33520
CAUTION:

ECA11400
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
1. Fuel tank filler tube
2. Fuel level
2
1

Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
14.0 L (3.70 US gal) (3.08 Imp.gal)

INSTRUMENT AND CONTROL FUNCTIONS
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EAU13431
Catalytic converter
This model is equipped with a catalytic
converter in the exhaust system.
WARNING

EWA10860
The exhaust system is hot after op-
eration. Make sure that the exhaust
system has cooled down before do-
ing any maintenance work.
CAUTION:

ECA10700
The following precautions must be
observed to prevent a fire hazard or
other damages.

Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.

Never park the vehicle near pos-
sible fire hazards such as grass
or other materials that easily
burn.

Do not allow the engine to idle
too long.
EAU13932
Seat
To open the seat
1. Place the scooter on the center-
stand.
2. Insert the key into the main switch,
and then turn it counterclockwise
to “OPEN”.
NOTE:

Do not push inward when turning the
key.
3. Fold the seat up.
To close the seat
1. Fold the seat down, and then push
it down to lock it in place.
2. Remove the key from the main
switch if the scooter will be left un-
attended.
NOTE:

Make sure that the seat is properly se-
cured before riding.
1. Open.
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU17706
Periodic maintenance and lubrication chart
NOTE:


The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.

From 50000 km, repeat the maintenance intervals starting from 10000 km.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040
1*
Fuel line


Check fuel hoses for cracks or damage.
√√√√ √
2
Spark plugs

Check condition.

Clean and regap.
√√

Replace.
√√
3*
Valves

Check valve clearance.

Adjust.Every 40000 km
4
Air filter element

Clean.
√√

Replace.
√√
5*
V-belt case air filter ele-
ments

Clean.
√√

Replace.
√√
6*
Front brake

Check operation, fluid level and vehicle for fluid leak-
age.
√√√√√ √

Replace brake pads. Whenever worn to the limit
7*
Rear brake

Check operation, fluid level and vehicle for fluid leak-
age.
√√√√√ √

Replace brake pads. Whenever worn to the limit
8
Rear brake lock

Check operation.

Adjust.
√√√√√ √

PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
EAU33473
Adjusting the rear brake lock
lever cable
Rear brake lock lever cable adjustment
may be required if the rear brake lock
lever does not hold properly. When the
rear brake lock lever is not in use, the
rear brake lock lever cable length
should measure 45 mm to 47 mm (1.77
in to 1.85 in) at the rear brake caliper.
Periodically check the rear brake lock
lever cable length and, if necessary,
adjust it as follows.
To increase the rear brake lock lever
cable length, turn the adjusting nut at
the rear brake caliper in direction (a).
1. Adjusting nut
2. Rear brake lock lever cable length
2
1
(b)
(a)

PERIODIC MAINTENANCE AND MINOR REPAIR
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To decrease the rear brake lock lever
cable length, turn the adjusting nut in
direction (b).
WARNING

EWA10650
If proper adjustment cannot be ob-
tained as described, have a Yamaha
dealer make this adjustment.
EAU22390
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22430
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wearindicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22493
Rear brake pads
1. Remove the rear brake caliper by
removing the bolts.
2. Check each rear brake pad for
damage and measure the lining
thickness. If a brake pad is dam-
aged or if the lining thickness is
less than 0.8 mm (0.03 in), have a
Yamaha dealer replace the brake
pads as a set.
3. Install the rear brake caliper by in-
1. Brake pad wear indicator groove
1 1

1. Bolt
2. Lining thickness
1
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PERIODIC MAINTENANCE AND MINOR REPAIR
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stalling the bolts, then tightening
them to the specified torque.
CAUTION:

ECA12822
Do not apply the rear brake or rear
brake lock after the brake caliper
has been removed, otherwise the
brake caliper piston will be forced
out.
EAU22710
Checking the brake fluid level
Front brake
Rear brake
Insufficient brake fluid may allow air toenter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:

When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.

Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.

Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.

Be careful that water or dust does
not enter the brake fluid reservoir
Tightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf, 28.9 ft·lbf)
1. Minimum level mark
1. Minimum level mark
1
1

Recommended brake fluid:
DOT 4

PERIODIC MAINTENANCE AND MINOR REPAIR
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when refilling. Water will signifi-
cantly lower the boiling point of the
fluid and may result in vapor lock,
and dirt may clog the ABS hydrau-
lic unit valves.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.

As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22730
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.

Brake hoses: Replace every four
years.
EAU23111
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.

PERIODIC MAINTENANCE AND MINOR REPAIR
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amperage.
NOTE:

To access the main fuse, remove the
main fuse box cover as shown.
For non-ABS models For ABS models
1. Main fuse
2. Spare main fuse
3. Main fuse box cover
21
3

1. Signaling system fuse
2. Headlight fuse
3. Ignition fuse
4. Radiator fan fuse
5. Fuel injection system fuse
6. Backup fuse (for odometer and clock)
7. Spare fuse
7
123456

1. Signaling system fuse
2. Headlight fuse
3. Ignition fuse
4. Radiator fan fuse
5. Fuel injection system fuse
6. Backup fuse (for odometer and clock)
7. Spare fuse
7
123456

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU43050
Replacing a front turn signal
light bulb
1. Place the scooter on the center-
stand.
2. Remove the socket (together with
the bulb) by turning it counter-
clockwise.
3. Remove the defective bulb by pull-
ing it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with the
bulb) by turning it clockwise.
EAU24270
Replacing a rear turn signal
light bulb
1. Place the scooter on the center-
stand.
2. Remove cowling C. (See
page 6-6.)
3. Remove the socket (together with
the turn signal light bulb) by turning
it counterclockwise.
4. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
5. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
6. Install the socket (together with thebulb) by turning it clockwise.
7. Install the cowling.
1. Turn signal light bulb socket
1

1. Turn signal light bulb socket1

PERIODIC MAINTENANCE AND MINOR REPAIR
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9Engine overheating
WARNING

EWAT1040

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.

Place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the de-
tent 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.