YAMAHA TMAX 2013 Repair Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
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installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
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 falsereading.
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.
TIPThe engine oil should be between theminimum 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 for several minutes, and then turn it1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1
23
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9off.
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.
5. Check the O-ring for damage andreplace it if necessary.
TIPSkip steps 6–8 if the oil filter cartridge isnot being replaced.
6. Remove the oil filter cartridge with an oil filter wrench.TIPAn oil filter wrench is available at aYamaha dealer.
7. Apply a thin coat of clean engine oil to the O-ring of the new oil filter
cartridge.
1. Engine oil filler cap
1
1. Engine oil drain bolt
2. O-ring
3. Gasket
1. Engine oil drain bolt
2. O-ring1 2
3
1 2
1. Oil filter wrench
2. Oil filter cartridge
2
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
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TIPMake sure that the O-ring is properlyseated.8. Install the new oil filter cartridge, and then tighten it to the specified
torque with a torque wrench. 9. Install the engine oil drain bolt and
its new gasket, and then tighten
the bolt to the specified torque.
10. Refill with the specified amount of the recommended engine oil, and
then install and tighten the oil filler
cap.
TIPBe sure to wipe off spilled oil on any
parts after the engine and exhaust sys-tem have cooled down.
NOTICE
ECA11620

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Make sure that no foreign mate-rial enters the crankcase.
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 3-8.)
TIPIf the engine oil is changed before the
oil change indicator comes on (i.e. be-
fore the periodic oil change interval has
1. O-ring
1. Torque wrench
1
1
Tightening torque:Oil filter cartridge:17 Nm (1.7 m·kgf, 12 ft·lbf)
Tightening torque: Engine oil drain bolt:43 Nm (4.3 m·kgf, 31 ft·lbf)
Recommended engine oil: See page 8-1.
Oil quantity: Without oil filter cartridge replace-
ment:2.70 L (2.85 US qt, 2.38 Imp.qt)
With oil filter cartridge replacement: 2.90 L (3.07 US qt, 2.55 Imp.qt)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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9been 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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er 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 element
1. 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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94. 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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PERIODIC MAINTENANCE AND ADJUSTMENT
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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.
EAU51971
Tires Tires are the only contact between the
vehicle and the road. Safety in all con-
ditions of riding depends on a relatively
small area of road contact. Therefore, it
is essential to maintain the tires in good
condition at all times and replace them
at the appropriate time with the speci-
fied 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
1. Throttle grip free play
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
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9weight of rider, passenger, car-
go, and accessories approved
for this model.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.
Tires age, even if they have not been
used or have only been used occasion-
ally. Cracking of the tread and sidewall
rubber, sometimes accompanied by
carcass deformation, is an evidence of
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)
XP500 90–198 kg (198–437 lb)
XP500A 90–194 kg (198–428 lb):
Front: 225 kPa (2.25 kgf/cm2, 33 psi)
Rear: 280 kPa (2.80 kgf/cm2, 41 psi)
Maximum load*:
XP500 198 kg (437 lb)
XP500A 194 kg (428 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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PERIODIC MAINTENANCE AND ADJUSTMENT
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ageing. Old and aged tires shall be
checked by tire spec
ialists to ascertain
their suitability for further use.
WARNING
EWA16100

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics 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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PERIODIC MAINTENANCE AND ADJUSTMENT
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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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