check engine YAMAHA TMAX 2019 User Guide

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For your safety – pre-operation checks
EAU63441
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. 5-20,
5-22
Engine oil Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage. 8-10
Coolant Check coolant level in reservoir.
If necessary, add recomm
ended coolant to specified
level.
Check cooling system for leakage. 8-13
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. 8-20,
8-22
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. 8-20,
8-22
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. 8-17,
8-25
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Operation and important riding points
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EAU77082
Starting the engine
NOTICE
ECA10251
See page 7-5 for engine break-in in-
structions prior to operating the ve-
hicle for the first time.
In order for the ignition circuit cut-off
system to enable starting, the sides-
tand must be up. (See page 5-29.) 1. With the smart key turned on, ap- proach the vehicle.
2. Push the “ON/ ” switch.
Upon authentication of the smart
key, the beeper will sound twice
and the centerstand and steering
locks (if applied) will be released.
All indicator and warning lights
should come on briefly and then go
off.
The ABS warning light should
come on when the power of the ve-
hicle is turned on, and go off once
the vehicle reaches a traveling
speed of 10 km/h (6 mi/h) or high-
er.
NOTICE
ECA22510
If a warning or indicator light does
not work as described above, see
page 5-2 for the corresponding warning and indicator light circuit
check.
3. Close the throttle completely.
4. Start the engine by pushing the “ON/ ” switch while applying the
front or rear brake.
If the engine does not start within 5
seconds of pressing the “ON/ ”
switch, wait 10 seconds before
pressing the switch again to allow
the battery voltage to restore.
NOTICE
ECA11043
For maximum engine life, never ac-
celerate hard when the engine is
cold!
1. “ON/ ” switch
1
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Operation and important riding points
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EAU16821
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
Avoid high engine speeds during
acceleration.
Avoid high engine speeds with no
load on the engine.
Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16842
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU36532
0–1000 km (0–600 mi)
Avoid prolonged operation above 5100
r/min. NOTICE: After 1000 km (600
mi) of operation, the engine oil must
be changed, and the oil filter car-
tridge or element replaced.
[ECA11283]
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 6100
r/min.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
NOTICE
ECA10311
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.
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Periodic maintenance and adjustment
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EAU71033
Periodic maintenance charts
TIP
Items marked with an asterisk should be performed by your Yamaha dealer
because these items require special tools, data, and technical skills.
From 50000 km (30000 mi), repeat the maintenance intervals starting from
10000 km (6000 mi).
The annual checks must be performed every year, except if a distance-
based maintenance is performed instead.
EAU71071
Periodic maintenance chart for the emission control system
NO. ITEM
1 *Fuel line Check fuel hoses for cracks or
damage.
Replace if necessary. 
2 *Spark plugs Check condition.
Adjust gap and clean.

Replace. 
3 *Valve clearance Check and adjust. Every 40000 km (24000 mi)
4 *Fuel injection Check engine idle speed.

Check and adjust synchronization. 
5 *Exhaust system Check for leakage.
Tighten if necessary.
Replace gaskets if necessary. 
6 *Evaporative
emission control
system Check control system for
damage.
Replace if necessary. 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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13 *Drive belt Check belt condition.
Replace if damaged.
Check belt tension.
Adjust if necessary. At the initial interval and every
10000 km (6000 mi) until 40000 km (24000 mi), and every 5000 km (3000 mi) thereafter.
14 *Drive pulley and
drive axle Lubricate.

15 *Steering bearings Check bearing assemblies for
looseness.  
Moderately repack with lithium- soap-based grease. 
16 *Chassis fasteners Make sure that all nuts, bolts
and screws are properly
tightened. 
17 Front and 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 and replace if
necessary. 
20 *Front fork Check operation and for oil
leakage.
Replace if necessary. 
21 *Shock absorber
assembly Check operation and for oil
leakage.
Replace if necessary. 
22 *Rear suspension
relay arm and
connecting arm
pivoting points Check operation.

23 Engine oil Change (warm engine before
draining).
Check oil level and vehicle for oil leakage. At the initial interval and
when the oil change
indicator flashes or comes on. 
24 Engine oil filter
cartridge Replace.

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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EAU72781
TIP
Air filters
The engine air filter uses a disposable oil-coated paper element. This element
cannot be cleaned with compressed air, doing so will only damage it.
If you often ride in the rain or in dusty areas, have the engine air filter and V-
belt air filter elements serviced more frequently.
Hydraulic brake service
Regularly check the brake fluid levels in the reservoirs, and refill as necessary.
Replace the internal components of the brake master cylinders and calipers,
and change the brake fluid every 2 years.
Replace the brake hoses every 4 years, or sooner if cracked or damaged.
25*Cooling system Check coolant level and vehicle
for coolant leakage. 
Change. Every 3 years
26 *V- b e l t Replace. When the V-belt replacement
indicator flashes [every 20000 km (12000 mi)]
27 *Front and rear
brake switches Check operation.

28 *Moving parts and
cables Lubricate.

29 *Throttle grip
housing and cable Check operation and free play.
Adjust the throttle cable free
play if necessary.
Lubricate the throttle grip housing, cable and grip warmer
wire. 
30 *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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EAU19643
Checking the spark plugs
The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be operating im-
properly. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification. Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
TIP
If a torque wrench is not available when
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.
Specified spark plug:
NGK/CR7E
1. Spark plug gap
Spark plug gap:0.7–0.8 mm (0.028–0.031 in)
Tightening torque: Spark plug:
13 N·m (1.3 kgf·m, 9.6 lb·ft)
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Periodic maintenance and adjustment
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EAU36112
Canister
This model is equipped with a canister
to prevent the discharging of fuel vapor
into the atmosphere. Before operating
this vehicle, make sure to check the fol-
lowing:
Check each hose connection.
Check each hose and canister for
cracks or damage. Replace if dam-
aged.
Make sure that the canister breath-
er is not blocked, and if necessary,
clean it.
EAU77364
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.
3. Wait two minutes until the oil level settles.
4. Check the oil level through the check window located at the bot-
tom-left side of the crankcase.
TIP
The engine oil should be between the
minimum and maximum level marks.
5. 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.
1. Caniste
2. Canister breather
12
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
2
3
1
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Periodic maintenance and adjustment
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14 To change the engine oil (and re-
place the oil filter cartridge)
1. Place the vehicle on a level sur- face.
2. Start the engine, warm it up for several 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, and then the engine oil drain bolt
and its gasket.
5. Check the O-ring for damage and replace it if necessary.
TIP
Skip steps 6–8 if the oil filter cartridge is
not being replaced. 6. Remove the oil filter cartridge with
an oil filter wrench.
TIP
An oil filter wrench is available at a
Yamaha dealer.
7. Apply a thin coat of clean engine oil to the O-ring of the new oil filter
cartridge.
TIP
Make sure that the O-ring is properly
seated.
8. Install the new oil filter cartridge, and then tighten it to the specified
torque with a torque wrench.
1. Engine oil filler cap
1. Engine oil drain bolt
2. O-ring
3. Gasket
1
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3
1. Oil filter wrench
2. Oil filter cartridge
1. O-ring
1
2
1
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Periodic maintenance and adjustment
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9. Install the engine oil drain bolt and
its new gasket, and then tighten
the bolt to the specified torque.
10. Check the O-ring for damage and replace it if necessary.
11. Refill with the specified amount of the recommended engine oil, and
then install and tighten the oil filler
cap.
TIP
Be sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.
NOTICE
ECA11621
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.
12. 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.
13. Turn the engine off, and then check the oil level and correct it if
necessary.
14. Reset the oil change indicator. (See page 5-10.)
1. Torque wrench
Tightening torque:Oil filter cartridge:
17 N·m (1.7 kgf·m, 13 lb·ft)
Tightening torque: Engine oil drain bolt:43 N·m (4.3 kgf·m, 32 lb·ft)
1. Engine oil filler cap
2. O-ring
1
2
1
Engine oil:Recommended brand:
YAMALUBE
SAE viscosity grades: 10W-40
Recommended engine oil grade: API service SG type or higher,
JASO standard MA
Oil quantity: Oil change: 2.60 L (2.75 US qt, 2.29 Imp.qt)
With oil filter removal: 2.90 L (3.07 US qt, 2.55 Imp.qt)
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