YAMAHA TMAX 2012 Repair Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
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been reached), the indicator must be
reset after the oil change for the next
periodic oil change to be indicated at
the correct time.
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.
EAU52020
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 theside can result in a false reading.
2. Check the coolant level through the check window.
TIPThe coolant should be between theminimum and maximum level marks. 3. If the coolant is at or below the
minimum level mark, remove the
left floorboard mat by pulling it up.
4. Remove the coolant reservoir cov-
1. Coolant level check window
2. Maximum level mark
3. Minimum level mark
1. Floorboard mat
2
3
1
1
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9er by removing the screw.
5. Open the coolant reservoir cap, add coolant to the maximum level
mark, and then close the reservoir
cap. WARNING! Remove only
the coolant reservoir cap. Never
attempt to remove the radiator
cap when the engine is
hot.
[EWA15161]
NOTICE: 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 cooling system will not
be protected against frost and
corrosion. If water has been
added to the coolant, have a
Yamaha dealer check the anti-
freeze content of the coolant as
soon as possible, otherwise the
effectiveness of the coolant will
be reduced.
[ECA10472]

6. Install the coolant reservoir cover by installing the screw.
7. Place the left floorboard mat in the original position and push it down-
ward to secure it.
EAU52030
Replacing the air filter element The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.
To replace the air filter element1. Remove panel C. (See page 6-8.)
2. Remove the air filter case cover by removing the screws.
3. Pull the air filter element out.
1. Coolant reservoir cover
2. Screw
1 2
1. Coolant reservoir capCoolant reservoir capacity (up to the
maximum level mark):
0.27 L (0.29 US qt, 0.24 Imp.qt)
1
1. Screw
2. Air filter case cover
1
1 2
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4. Insert a new air filter element into
the air filter case. NOTICE: Make
sure that the air filter element is
properly seated in the air filter
case. The engine should never
be operated without the air filter
element installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
[ECA10481]

5. Install the air filter case cover by in- stalling the screws.
6. Install the panel.
EAU33482
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.
1. Remove panel D. (See page 6-8.)
2. Check the engine idling speed and, if necessary, adjust it to spec-
ification by turning the idle adjust-
ing screw. To increase the engine
idling speed, turn the screw in di-
rection (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
TIPIf the specified idling speed cannot be
obtained as described above, have aYamaha dealer make the adjustment.
3. Install the panel.
1. Air filter element
1
1. Idle adjusting screwEngine idling speed: 1100–1300 r/min
1(a)(b)
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EAU21384
Checking the throttle grip free
play The throttle grip free play should mea-
sure 3.0–5.0 mm (0.12–0.20 in) at the
inner edge of the throttle grip. Periodi-
cally check the throttle grip free play
and, if necessary, have a Yamaha
dealer adjust it.
EAU21401
Valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU51970
Tires To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
EWA10503
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).

The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approvedfor this model.
1. Throttle grip free play
1
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WARNING
EWA10511
Never overload your vehicle. Opera-
tion of an overloaded vehicle couldcause an accident.Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
TIPThe tire tread depth limits may differ
from country to country. Always complywith the local regulations.
WARNING
EWA10471

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.

The replacement of all wheel
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience to do so.

Ride at moderate speeds after
changing a tire since the tire
surface must first be “broken
in” for it to develop its optimalcharacteristics.
Tire information
This model is equipped with tubeless
tires, tire air valves and cast wheels.WARNING
EWA16100

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
Tire air pressure (measured on cold
tires): 0–90 kg (0–198 lb): Front:
225 kPa (2.25 kgf/cm
2, 33 psi)
Rear: 250 kPa (2.50 kgf/cm2, 36 psi)
90–198 kg (198–437 lb): Front:225 kPa (2.25 kgf/cm2, 33 psi)
Rear: 280 kPa (2.80 kgf/cm2, 41 psi)
Maximum load*:
198 kg (437 lb)
* Total weight of rider, passenger, car- go and accessories
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
1 2
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9characteristics of the vehicle
may be different, which could
lead to an accident.

Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.

Use only the tire valves and
valve cores listed below toavoid tire deflation during a ride.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
EAU51920
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, warpage or oth-
er damage before each ride. If any
damage is found, have a Yamaha
dealer replace 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.

After repairing or replacing the
front tire, tighten the valve stem nut
and locknut to the specified
torques.
Front tire: Size:120/70R15 M/C 56H
Manufacturer/model:
DUNLOP/GPR-100F
BRIDGESTONE/BT011F
Tire air valve:
PVR59A
Valve core: #9100 (original)
Rear tire: Size:160/60R15 M/C 67H
Manufacturer/model: DUNLOP/GPR-100L
BRIDGESTONE/BT012R
Tire air valve: TR412
Valve core:
#9100 (original)
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EAU50860
Checking the front and rear
brake lever free play Front
Rear
There should be no free play at thebrake 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.
1. Valve stem nut
2. Valve stem locknutTightening torques:
Valve stem nut:
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Valve stem locknut: 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
1
2
1. No brake lever free play
1. No brake lever free play
1
1
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EAU53030
Adjusting the rear brake lock
cable Rear brake lock 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 cable length should mea-
sure 43 mm–45 mm (1.69 in–1.77 in) at
the rear brake caliper.
Periodically check the rear brake lock
cable length and, if necessary, adjust it
as follows.
To increase the rear brake lock cable
length, turn the adjusting nut at the rear
brake caliper in direction (a). To de-crease the rear brake lock cable length,
turn the adjusting nut in direction (b).
WARNING! If proper adjustment
cannot be obtained as described,
have a Yamaha dealer make this ad-
justment.
[EWA16150]

Check that the rear brake lock is re-
leased, and then make sure that the
rear wheel could rotate smoothly.
EAU52291
Checking the rear brake lock The rear brake lock must be checked at
the intervals specified in the periodic
maintenance and lubrication chart.
1. Adjust the rear brake lock cable.
2. Apply the rear brake lock, and then pushing the vehicle for properly
locks the rear brake lock.
3. The rear brake lock caliper is pro- vided with a wear indicator, which
allows you to check the rear brake
lock pads. To check the rear brake
lock pads, check the position of the
indicator while applying the rear
brake lock lever. If the indicator
has passed the wear indicator
groove, have a Yamaha dealer
check the rear brake lock.
4. Make sure that there is no tears and cracks on the rubber boot.
1. Adjusting nut
2. Rear brake lock cable length
1
2
(a)
(b)
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EAU22311
Checking the front and rear
brake pads Front brake
Rear brake
The front and rear brake pads must bechecked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. Each brake pad is
provided with a wear indicator, which
allows you to check the brake pad wear
without having 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 the point that the wear indi-
cator almost touches the brake disc,
have a Yamaha dealer replace the
brake pads as a set.
1. Wear indicator groove
2. Wear indicator
3. Rubber boot
1
2
3
1. Brake pad wear indicator
1. Brake pad wear indicator
1
1
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EAU22581
Checking the brake fluid level Before riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brakeRear brake
WARNING
EWA15990
Improper maintenance can result in
loss of braking ability. Observe
these precautions:
Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.

Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.

Use only the specified brake flu-
id; otherwise, the rubber sealsmay deteriorate, causing leak-
age.

Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.

Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vaporlock.
NOTICE
ECA17640
Brake fluid may damage painted sur-
faces or plastic parts. Always cleanup spilled fluid immediately.
As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake sys-
tem leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brake
fluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
1. Minimum level mark
1
1. Minimum level markSpecified brake fluid:
DOT 4
1
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