val YAMAHA TMAX 2010 Owners Manual

TABLE OF CONTENTS

SAFETY INFORMATION
................. 1-1
Further safe-riding points ................ 1-5
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
Fuel gauge ...................................... 3-5
Coolant temperature gauge ............ 3-6
Multi-function display ...................... 3-6
Anti-theft alarm (optional) ............. 3-11
Handlebar switches ...................... 3-11
Front brake lever .......................... 3-13
Rear brake lever ........................... 3-13
Rear brake lock lever .................... 3-14
ABS (for ABS models) .................. 3-15
Fuel tank cap ................................ 3-16
Fuel ............................................... 3-17
Catalytic converter ........................ 3-18
Seat .............................................. 3-19
Adjusting the rider backrest .......... 3-19
Helmet holder ............................... 3-20
Storage compartments ................. 3-21
Rear view mirrors ......................... 3-22Shock absorber assembly ............ 3-23
Sidestand ..................................... 3-23
Ignition circuit cut-off system ........ 3-24
FOR YOUR SAFETY –
PRE-OPERATION CHECKS
............. 4-1
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 ............................... 5-3
Engine break-in .............................. 5-4
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT
................................... 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance chart for
the emission control system ....... 6-2
General maintenance and
lubrication chart .......................... 6-3
Removing and installing panels ..... 6-6
Checking the spark plugs ............... 6-9
Engine oil and oil filter cartridge ... 6-10
Chain drive oil .............................. 6-13
Coolant ......................................... 6-14
Replacing the air filter element ..... 6-16Adjusting the engine idling
speed ........................................ 6-16
Checking the throttle cable free
play ........................................... 6-17
Valve clearance ........................... 6-17
Tires ............................................. 6-18
Cast wheels ................................. 6-19
Front and rear brake lever free
play ........................................... 6-20
Adjusting the rear brake lock
lever cable ................................ 6-20
Checking the front and rear
brake pads ................................ 6-21
Checking the brake fluid level ...... 6-22
Changing the brake fluid .............. 6-23
Checking and lubricating the
throttle grip and cable ............... 6-23
Lubricating the front and rear
brake levers .............................. 6-24
Checking and lubricating the
centerstand and sidestand ....... 6-24
Checking the front fork ................. 6-25
Checking the steering .................. 6-26
Checking the wheel bearings ....... 6-26
Battery .......................................... 6-26
Replacing the fuses ..................... 6-28
Replacing the headlight bulb ....... 6-30
Tail/brake light .............................. 6-31
Replacing a front turn signal
light bulb ................................... 6-31
Rear turn signal light bulb ............. 6-32

INSTRUMENT AND CONTROL FUNCTIONS
3-9
1
2
3
4
5
6
7
8
9Oil 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. To reset the oil
change indicator, select it by pushing
the “SELECT” button until “OIL Trip” is
displayed, and then push the “RESET”
button at least 1 second. When pushing
the “RESET” button, “OIL Trip” starts
flashing. While “OIL Trip” is flashing,
push the “RESET” button for at least 3
seconds.
If the engine oil is changed before theoil change indicator “OIL” flashes (i.e.
before the periodic oil change interval
has been reached), the indicator “OIL”
must be reset after the oil change for
the next periodic oil change to be indi-
cated at the correct time.
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 oil change indicator
comes on for a few seconds and
then goes off.
3. If the oil change indicator does not
come on, have a Yamaha dealer
check the electrical circuit.
V-belt replacement indicator
“V-BELT”
This indicator flashes every 20000 km
(12500 mi) when the V-belt needs to be
replaced.
After changing the V-belt, reset the
V-belt replacement indicator. To reset
the V-belt replacement indicator, select
it by pushing the “SELECT” button until
“V-BELT Trip” is displayed, and then
push the “RESET” button at least 1 sec-
ond. When pushing the “RESET” but-
ton, “V-BELT Trip” starts flashing.
While “V-BELT Trip” is flashing, push
the “RESET” button for at least 3 sec-
onds.
If the V-belt is changed before the

1. Oil change indicator “OIL”
1

1. V-belt replacement indicator “V-BELT”
1

INSTRUMENT AND CONTROL FUNCTIONS
3-10
2
34
5
6
7
8
9
V-belt replacement indicator “V-BELT”
flashes (i.e. before the periodic V-belt
change interval has been reached), the
indicator “V-BELT” must be reset after
the V-belt change for the next periodic
V-belt change to be indicated at the
correct time.
The electrical circuit of the indicator can
be checked according to the following
procedure.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
2. Check that the V-belt replacement
indicator comes on for a few sec-
onds and then goes off.
3. If the V-belt replacement indicator
does not come on, have a Yamaha
dealer check the electrical circuit.
Self-diagnosis device
This model is equipped with a self-diag-
nosis device for various electrical cir-
cuits.
If a problem is detected in any of those
circuits, the engine trouble warning light
comes on and the display indicates an
error code.
The self-diagnosis device also detects
problems in the immobilizer system cir-
cuits.
If a problem is detected in any of the im-
mobilizer system circuits, the immobi-
lizer system indicator light flashes and
the display indicates an error code.
TIP

If the display indicates error code 52,this could be caused by transponder in-
terference. If this error code appears,
try the following.
1. Use the code re-registering key to
start the engine.
TIP

Make sure there are no other immobi-
lizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interfer-
ence, which may prevent the engine
from starting.
2. If the engine starts, turn it off and
try starting the engine with the
standard keys.
3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering
key and both standard keys to a
Yamaha dealer and have the stan-
dard keys re-registered.
If the display indicates any error codes,
note the code number, and then have a
Yamaha dealer check the vehicle.
1. Error code display
1

INSTRUMENT AND CONTROL FUNCTIONS
3-17
1
2
3
4
5
6
7
8
9

EAU13221
Fuel
Make sure there is sufficient gasoline in
the tank.
WARNING

EWA10881
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
1. Before refueling, turn off the en-
gine and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the vi-
cinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.
2. Do not overfill the fuel tank. When
refueling, be sure to insert the
pump nozzle into the fuel tank filler
hole. Stop filling when the fuel
reaches the bottom of the filler
tube. Because fuel expands when
it heats up, heat from the engine or
the sun can cause fuel to spill out
of the fuel tank.3. Wipe up any spilled fuel immedi-
ately.
NOTICE:
Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plastic
parts.

[ECA10071]

4. Be sure to securely close the fuel
tank cap.
WARNING

EWA15151
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline inyour eyes, see your doctor immedi-
ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.
EAU33520
NOTICE

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
1. Fuel tank filler tube
2. Maximum fuel level
21

Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
15.0 L (3.96 US gal, 3.30 Imp.gal)

INSTRUMENT AND CONTROL FUNCTIONS
3-22
2
34
5
6
7
8
9 compartment may get wet while the
scooter is being washed, wrap any
articles stored in the compartment
in a plastic bag. Do not keep any-
thing valuable or breakable in the
storage compartment. Do not leave
the seat open for an extended period
of time, otherwise the light may
cause the battery to discharge.

[ECA16081]
NOTICE:
The shaded area is not a
storage compartment. To prevent
damaging the seat hinges, do not
place any items in this area.
[ECA16091]

TIP


Some helmets cannot be stored in
the rear storage compartment be-cause of their size or shape.

Do not leave your scooter unat-
tended with the seat open.
WARNING

EWA11241

Do not exceed the load limit of
5 kg (11 lb) for the rear storage
compartment.

Do not exceed the maximum
load of XP500 194 kg (428 lb)
XP500A 190 kg (419 lb) for the
vehicle.
EAU44970
Rear view mirrors
The rear view mirrors of this vehicle can
be folded backward for parking in nar-
row spaces. Fold the mirrors back to
their original position before riding.
WARNING

EWA14371
Be sure to fold the rear view mirrors
back to their original position before
riding.
1. Rear storage compartment
2. Shaded area
1
2

1. Parking position
2. Riding position
1
1 2
2

6-1
2
3
4
5
67
8
9

PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17241
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, depending on the
weather, terrain, geographical location,
and individual use, the maintenance in-
tervals may need to be shortened.
WARNING

EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING

EWA15121
Turn off the engine when performing
maintenance unless otherwise
specified.

A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.

Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more in-
formation about carbon monox-
ide.
EAU17391
Owner’s tool kit
The owner’s tool kit is located under the
seat. (See page 3-19.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIP

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
1. Helmet holding cable
2. Owner’s tool kit
12

PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
1
2
3
4
5
6
7
8
9

EAU46861
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.
EAU46910
Periodic maintenance chart for the emission control system
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*
Fuel injection

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

PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
1
2
3
4
5
6
7
8
9

EAU1985C
Engine oil and oil filter
cartridge
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the vehicle on the center-
stand. A slight tilt to the side can
result in a false reading.
2. Start the engine, warm it up for two
minutes, and then turn it off.
NOTICE

ECA11290
The engine must be cold before pro-
ceeding with the oil level check, oth-
erwise the check will result in a false
reading.
3. Wait two minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-left side of the crank-
case.
TIP

The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Place the vehicle on a level sur-
face.
2. Start the engine, warm it up forseveral minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.
4. Remove the engine oil filler cap,
the engine oil drain bolt and its
gasket to drain the oil from the
crankcase.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1
32

1. Engine oil filler cap
1

PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
2
3
4
5
67
8
9
11. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
12. Turn the engine off, and then
check the oil level and correct it if
necessary.
13. Reset the oil change indicator.
(See page 3-9.)
TIP

If the engine oil is changed before the
oil 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.
EAU19997
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. Place the vehicle on a level sur-
face.
2. Remove panel E. (See page 6-6.)
3. Place an oil pan under the chain
drive case to collect the used oil.
4. Remove the chain drive oil filler
cap, the chain drive oil drain bolt
and its gasket to drain the oil from
the chain drive case.5. Install the chain drive oil drain bolt
and its new gasket, and then tight-
en the bolt to the specified torque.
6. Refill with the specified amount of
the recommended oil.
7. Wipe the dipstick clean, insert it
into the oil filler hole (without
screwing it in), and then remove it
to check the oil level.
TIP

The chain drive oil should be between
the tip of the dipstick and the maximum
level mark.
1. Chain drive oil filler cap
2. Chain drive oil drain bolt
3. Gasket
1
23

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)

PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
1
2
3
4
5
6
7
8
9
8. If the chain drive oil is not between
the tip of the dipstick and the max-
imum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
9. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
NOTICE

ECA15010

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

Make sure that no oil gets on the
tire or wheel.
10. Check the chain drive case for oil
leakage. If leakage is found, checkfor the cause.
11. Install the panel.
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.
EAU46331
To check the coolant level
1. Place the vehicle on the center-
stand.
TIP


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. Check the coolant level through
the check window.
TIP

The coolant should be between the
minimum and maximum level marks.
1. Maximum level mark
2. Tip of the chain drive oil dipstick
1
2