brake YAMAHA TMAX 2016 Owner's Manual

Periodic maintenance and adjustment
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EAU38263
TIP
Engine air filter and V-belt air filters This model’s engine air fi lter is equipped with a disposable oil-coated paper
element, which must not be cleaned wi th compressed air to avoid damaging
it.
The engine air filter element needs to be replaced and the V-belt air filter el- ements need to be serviced more frequently when riding in unusually wet or
dusty areas.
Hydraulic brake service After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs
as required.
Every two years replace the internal components of the brake master cylin-
ders and calipers, and change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
27 Moving parts and
cables Lubricate.

28 *Throttle grip Check operation.
Check throttle grip free play,
and adjust if necessary.
Lubricate cable and grip housing. 
29 *Lights, signals and
switches Check operation.
Adjust headlight beam.

NO. ITEM
X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER READINGS
ANNUAL CHECK
110203040
0.66121824
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Periodic maintenance and adjustment
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WARNING
EWA10512
Never overload your vehicle. Opera-
tion of an overloaded vehicle could
cause 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.
TIP
The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
WARNING
EWA10472
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 optimal
characteristics.
Tire information
This model is equipped with tubeless
tires and tire air valves.
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
ageing. Old and aged tires shall be
checked by tire specialists to ascertain
their suitability for further use.
Tire air pressure (measured on cold
tires): Up to 90 kg (198 lb) load:Front: 225 kPa (2.25 kgf/cm
2, 33 psi)
Rear: 250 kPa (2.50 kgf/cm
2, 36 psi)
90 kg (198 lb) to maximum load:
Front: 225 kPa (2.25 kgf/cm
2, 33 psi)
Rear:
280 kPa (2.80 kgf/cm
2, 41 psi)
Maximum load*: 193 kg (425 lb) (XP500A)
196 kg (432 lb) (XP500)
* Total weight of rider, passenger, car- go and accessories
1. Tire sidewall
2. Tire tread depth
1 2
Minimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
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Periodic maintenance and adjustment
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EAU50861
Checking the fr ont 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
EWA14212
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. No brake lever free play
1. No brake lever free play
1
1
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Periodic maintenance and adjustment
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EAU53032
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 43–45 mm (1.69–1.77 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.
[EWA16151]
Check that the rear brake lock is re-
leased, and then make sure that the
rear wheel could rotate smoothly.
EAU52293
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 try to push the vehicle to confirm
that the rear brake lock functions
properly.
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 when the rear brake lock
lever is applied. If the indicator has
passed the wear indicator groove,
have a Yamaha dealer check the
rear brake lock.
4. Make sure that there are no tears or cracks on the rubber boot.
1. Adjusting nut
2. Rear brake lock cable length
2
1
(a)
(b)
1. Wear indicator groove
2. Wear indicator
3. Rubber boot
1 23
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Periodic maintenance and adjustment
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EAU22312
Checking the fr ont and rear
brake pads
Front brake
Rear brake
The front and rear brake pads must be
checked 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.
EAU22582
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 brake
Rear brake
WARNING
EWA15991
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.
1. Brake pad wear indicator
1. Brake pad wear indicator
1
1
1. Minimum level mark
1. Minimum level mark
Specified brake fluid: DOT 4
1
1
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Periodic maintenance and adjustment
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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 seals
may 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 vapor
lock.
NOTICE
ECA17641
Brake fluid may damage painted sur-
faces or plastic parts. Always clean
up 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.
EAU22733
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the master cylinders 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.
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Periodic maintenance and adjustment
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EAU23115
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 by a
Yamaha dealer at the intervals speci-
fied in the periodic maintenance chart.
The throttle cable is equipped with a
rubber cover. Make sure that the cover
is securely installed. Even though the
cover is installed correctly, it does not
completely protect the cable from water
entry. Therefore, use care not to pour
water directly onto the cover or cable
when washing the vehicle. If the cable
or cover becomes dirty, wipe clean with
a moist cloth.
EAU23173
Lubricating the fr ont and rear
brake levers
Front brake lever
Rear brake lever
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main-
tenance and lubrication chart.
Recommended lubricant: Silicone grease
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Periodic maintenance and adjustment
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EAU23215
Checking and l ubricating the
centerstand and sidestand
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to-
metal contact surfaces should be lubri-
cated if necessary.
WARNING
EWA10742
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it. Otherwise, the centerstand or
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
EAU23273
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10752]
2. While applying the front brake, push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
NOTICE
ECA10591
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.Recommended lubricant:Lithium-soap-based grease
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Periodic maintenance and adjustment
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EAU54502
Auxiliary lights
This model is equipped with LED-type
auxiliary lights.
If an auxiliary light does not come on,
have a Yamaha dealer check it.
EAU24182
Tail/brake light
This model is equipped with an LED-
type tail/brake light.
If the tail/brake light does not come on,
have a Yamaha dealer check it.
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Scooter care and storage
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14 structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.
Improper cleaning can damage
plastic parts (such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc.) and
the mufflers. Use only a soft,
clean cloth or sponge with wa-
ter to clean plastic. However, if
the plastic parts cannot be thor-
oughly cleaned with water, di-
luted mild detergent with water
may be used. Be sure to rinse
off any detergent residue using
plenty of water, as it is harmful
to plastic parts.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.
For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com- pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.
TIP
Salt sprayed on roads in the winter may
remain well into spring. 1. Clean the scooter with cold water and a mild detergent after the en-
gine has cooled down. NOTICE:
Do not use warm water since it
increases the corrosive action
of the salt.
[ECA10792]
2. Apply a corrosion protection spray on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
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