lock YAMAHA TMAX 2009 User Guide

INSTRUMENT AND CONTROL FUNCTIONS
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EAU13432
Catalytic converter
This model is equipped with a catalytic
converter in the exhaust system.
WARNING

EWA10861
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:

Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.

Park the motorcycle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.

Make sure that the exhaust sys-
tem has cooled down before do-
ing any maintenance work.

Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
NOTICE

ECA10701
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-pairable damage to the catalytic
converter.
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”.
TIP

Do not push inward when turning the
key.
3. Fold the seat up.
1. Open.
1

INSTRUMENT AND CONTROL FUNCTIONS
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9To 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.
TIP

Make sure that the seat is properly se-
cured before riding.
EAU14270
Adjusting the rider backrest
The rider backrest can be adjusted to
the three different positions shown.
Adjust the backrest as follows.
1. Open the seat. (See page 3-18.)
2. Remove the backrest bolts.3. Slide the backrest forward or back-
ward to the desired position.
4. Install and securely tighten the
backrest bolts.
5. Close the seat.
1. Rider backrest
1

1. Rider backrest
2. Bolt
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU1770A
Periodic maintenance and lubrication chart
TIP


The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.

From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).

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
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
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 (24000 mi)
4
Air filter element

Replace.
√√
5*
V-belt case air filter
elements

Clean.
√√

Replace.
√√
6*
Front brake

Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√

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

Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√

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

Check operation.

Adjust.
√√√√√√

PERIODIC MAINTENANCE AND ADJUSTMENT
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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 the
brake 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. Front brake lever free play
1. Rear brake lever free play
1
1

1. Adjusting nut
2. Rear brake lock lever cable length
2
1
(b)
(a)

PERIODIC MAINTENANCE AND ADJUSTMENT
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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.
EAU22410
Front brake pads
Each front brake pad is provided with a
wear indicator, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicator while applying the
brake. If a brake pad has worn to thepoint that the wear indicator almost
touches the brake disc, 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. Wear indicator
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1. Brake caliper bolt
2. Lining thickness
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PERIODIC MAINTENANCE AND ADJUSTMENT
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stalling the bolts, then tightening
them to the specified torque.
NOTICE

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.
EAU40260
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 ADJUSTMENT
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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.
EAU22731
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the master cylinders and
calipers as well as the brake hoses re-
placed at the intervals listed below or
whenever they are damaged or leak-
ing.

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 ADJUSTMENT
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9 For XP500A For XP500 For XP500A

1. Fuse box
2. ABS solenoid fuse
3. ABS motor fuse
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1. Headlight fuse
2. Ignition fuse
3. Backup fuse (for odometer and clock)
4. Radiator fan fuse
5. Fuel injection system fuse
6. Signaling system fuse
7. Spare fuse
8. Parking lighting fuse
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7 7 8
123456

1. Headlight fuse
2. Ignition fuse
3. Backup fuse (for odometer and clock)
4. Radiator fan fuse
5. Fuel injection system fuse
6. Signaling system fuse
7. Spare fuse
8. ABS control unit fuse
9. Parking lighting fuse
10. Spare fuse
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7 7 9
1
810
23456

PERIODIC MAINTENANCE AND ADJUSTMENT
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3. Place a new headlight bulb into po-
sition, and then secure it with the
bulb holder.
4. Install the headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.

EAU43040
Tail/brake light
If the tail/brake light does not come on,
have a Yamaha dealer check its electri-
cal circuit or replace the bulb.
EAU43051
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 burnt-out 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.
1. Headlight bulb holder
2. Unhook.
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1. Turn signal light bulb socket
1

PERIODIC MAINTENANCE AND ADJUSTMENT
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9 Engine 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.
TIP

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 TIP.)
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.