maintenance YAMAHA TMAX 2016 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
Smart key system ............................. 3-1
Smart key system ............................ 3-1
Operating range of the smart key system............. ....................... ...... 3-2
Handling of the smart key and
mechanical key ............................ 3-3
Smart key ........................................ 3-5
Replacing the smart key battery ...... 3-6
Vehicle power on and steering lock release .................................. 3-8
Powering off the vehicle .................. 3-9
How to lock the steering ................ 3-10
Seat opening and closing .............. 3-10
Parking mode ................................ 3-11
Instrument and control functions ... 4-1
Indicator lights and warning lights ... 4-1
Speedometer .............. ..................... 4-2
Tachometer ..................................... 4-3
Multi-function display ....................... 4-3
Handlebar switches ....................... 4-10
Front brake lever ........................... 4-11
Rear brake lever ............................ 4-12
Rear brake lock lever .................... 4-12
ABS (for ABS models) ................... 4-13
Fuel tank cap ................................. 4-14
Fuel ............................................... 4-15
Catalytic converter......................... 4-16
Adjusting the rider backrest ........... 4-17
Helmet holder ................................ 4-17
Storage compartments .................. 4-18
Windshield ..................................... 4-19
Rear view mirrors .......................... 4-21
Shock absorber assembly ............. 4-21
Sidestand ...................................... 4-22
Ignition circuit cut- off system ......... 4-22
Auxiliary DC jack ........................... 4-24 For your safety – pre-operation
checks
............................................... 5-1
Operation and important riding
points ................................................. 6-1
Starting the engine .......................... 6-2
Starting off....................................... 6-3
Acceleration and deceleration......... 6-3
Braking ............................................ 6-4
Tips for reducing fuel
consumption ................................ 6-5
Engine break-in ............................... 6-5
Parking ............................................ 6-6
Periodic maintenance and
adjustment ........................................ 7-1
Owner’s tool kit ............................... 7-2
Periodic maintenance chart for the emission control system ........ 7-3
General maintenance and lubrication chart ........................... 7-4
Removing and installing panels ...... 7-7
Checking the spark plugs................ 7-9
Engine oil and oil filter cartridge .... 7-10
Coolant.......................................... 7-13
Replacing the air filter element ..... 7-15
Adjusting the engine idling speed ......................................... 7-16
Checking the throttle grip free play ............................................ 7-16
Valve clearance ............................ 7-17
Tires .............................................. 7-17
Cast wheels .................................. 7-19
Checking the front and rear brake lever free play .................. 7-20
Adjusting the rear brake lock
cable .......................................... 7-21
Checking the rear brake lock ........ 7-21
Checking the front and rear
brake pads ................................. 7-22
Checking the brake fluid level ....... 7-22
Changing the brake fluid ............... 7-23
Drive belt slack.............................. 7-24
Checking and lubricating the cables ........................................ 7-24
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Safety information
EAU1026B
Be a Responsible Owner
As the vehicle’s owner, you are respon-
sible for the safe and proper operation
of your scooter.
Scooters are single-track vehicles.
Their safe use and operation are de-
pendent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements before
riding this scooter.
He or she should:
Obtain thorough instructions from
a competent source on all aspects
of scooter operation.
Observe the warnings and mainte-
nance requirements in this Own-
er’s Manual.
Obtain qualified training in safe
and proper riding techniques.
Obtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made neces-
sary by mechanical conditions.
Never operate a scooter without
proper training or instruction. Take
a training course. Beginners
should receive training from a cer-
tified instructor. Contact an autho-
rized scooter dealer to find out
about the training courses nearest
you.
Safe Riding
Perform the pre-operation checks each
time you use the vehicle to make sure it
is in safe operating condition. Failure to
inspect or maintain the vehicle properly
increases the possibility of an accident
or equipment damage. See page 5-1 for a list of pre-operation checks.
This scooter is designed to carry
the operator and a passenger.
The failure of motorists to detect
and recognize scooters in traffic is
the predominating cause of auto-
mobile/scooter accidents. Many
accidents have been caused by an
automobile driver who did not see
the scooter. Making yourself con-
spicuous appears to be very effec-
tive in reducing the chance of this
type of accident.
Therefore:
Wear a brightly colored jacket.
Use extra caution when you are approaching and passing
through intersections, since in-
tersections are the most likely
places for scooter accidents to
occur.
Ride where other motorists can see you. Avoid riding in another
motorist’s blind spot.
Never maintain a scooter with- out proper knowledge. Contact
an authorized scooter dealer to
inform you on basic scooter
maintenance. Certain mainte-
nance can only be carried out by
certified staff.
Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent driver’s license. Make sure that you are qualified and that you only lend your
scooter to other qualified opera-
tors.
Know your skills and limits. Staying within your limits may
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Instrument and control functions
4-16
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or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
Gasohol
There are two types of gasohol: gaso-
hol containing ethanol and that contain-
ing methanol. Gasohol containing
ethanol can be used if the ethanol con-
tent does not exceed 10% (E10). Gas-
ohol containing methanol is not
recommended by Yamaha because it
can cause damage to the fuel system
or vehicle performance problems.
EAU13434
Catalytic converter
This model is equipped with a catalytic
converter in the exhaust system.
WARNING
EWA10863
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 vehicle 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
ECA10702
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-
pairable damage to the catalytic
converter.
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For your safety – pre-operation checks
EAU63440
Inspect your vehicle each time you use it to make sure the vehicle is in safe oper-
ating condition. Always follow the inspection and maintenance procedures and
schedules described in the Owner’s Manual.
WARNING
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility
of an accident or equipment damage. Do not operate the vehicle if you find
any problem. If a problem cannot be corrected by the procedures provided
in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKSPAGE
Fuel Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check fuel tank breather hose and overflow hose for
obstructions, cracks or damage, and check hose
connections. 4-15
Engine oil Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage. 7-10
Coolant Check coolant level in reservoir.
If necessary, add recomm
ended coolant to specified
level.
Check cooling system for leakage. 7-13
Front brake Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic
system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add specified brake fluid to specified level.
Check hydraulic system for leakage. 7-20,
7-22
Rear brake Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic
system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add specified brake fluid to specified level.
Check hydraulic system for leakage. 7-20,
7-22
Throttle grip Make sure that operation is smooth.
Check throttle grip free play.
If necessary, have Yamaha dealer adjust throttle grip
free play and lubricate cable and grip housing. 7-16,
7-25
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Periodic maintenance and adjustment
EAU17246
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 charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
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
EWA15123
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 1-2 for more in-
formation about carbon monox-
ide.
WARNING
EWA15461
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
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Periodic maintenance and adjustment
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EAU17303
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replacement,
or repair of the emission control devic-
es and systems may be performed by
any repair establishment or individual
that is certified (if applicable). Yamaha
dealers are trained and equipped to
perform these particular services.
EAU17392
Owner’s tool kit
The owner’s tool kit is located under the
seat.
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
1
2
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Periodic maintenance and adjustment
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EAU46862
TIP
The annual checks must be performed every year, except if a kilometer-
based maintenance, or for the UK, a mileage-based maintenance, is per-
formed 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.
EAU63321
Periodic maintenance chart for the emission control system
NO. ITEM
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. 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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EAU64031
General maintenance and lubrication chart
NO. ITEM
1 Air filter element Replace. 
2 *V-belt case air filter
elements Clean.

Replace. 
3 *Front brake Check operation, fluid level and
vehicle for fluid leakage. 
Replace brake pads. Whenever worn to the limit
4 *Rear brake Check operation, fluid level and
vehicle for fluid leakage. 
Replace brake pads. Whenever worn to the limit
5 *Brake hoses Check for cracks or damage.
Check for correct routing and
clamping. 
Replace. Every 4 years
6 *Brake fluid Change. Every 2 years
7 Rear brake lock
cable Check cable length.
Adjust if necessary.
4000 km (2400 mi) after
the initial 1000 km (600 mi) and every 5000 km (3000 mi) thereafter
8 *Rear brake lock Check operation.
Check rubber boot.
Check wear indicator.
Adjust if necessary. 
9 *Wheels Check runout and for damage. 
10 *Tires Check tread depth and for
damage.
Replace if necessary.
Check air pressure.
Correct if necessary. 
11 *Wheel bearings Check bearings for looseness
or damage. 
12 *Drive belt Check belt condition.
Replace if damaged.
Check belt tension.
Adjust if necessary. Every 10000 km (6000
mi) until 40000 km (24000 mi), and every 5000 km (3000 mi) thereafterX 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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13 *Drive pulley and
drive axle Lubricate.

14 *Steering bearings Check bearing play and
steering for roughness. 
Lubricate with lithium-soap- based grease. Every 20000 km (12000 mi)
15 *Chassis fasteners Make sure that all nuts, bolts
and screws are properly
tightened. 
16 Front brake lever
pivot shaft Lubricate with silicone grease.

17 Rear brake lever
pivot shaft Lubricate with silicone grease.

18 Sidestand,
centerstand Check operation.
Lubricate with lithium-soap-
based grease. 
19 *Sidestand switch Check operation. 
20 *Front fork Check operation and for oil
leakage. 
21 *Shock absorber
assembly Check operation and shock
absorber for oil leakage. 
22 Engine oil Change. (See pages 4-6 and
7-10.) When the oil change
indicator flashes
Check oil level and vehicle for oil leakage. Every 5000 km (3000 mi)

23 Engine oil filter
cartridge Replace.

24 *Cooling system Check coolant level and vehicle
for coolant leakage. 
Change coolant. Every 3 years
25 *V- b e l t Replace. When the V-belt replacement
indicator flashes [every 20000 km (12500 mi)]
26 *Front and rear
brake switches Check operation.

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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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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