Yamaha Tmax 500 Owner'S Manual Download

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Summary of Contents for Tmax 500

Page 1: ...OWNER S MANUAL 4B5 28199 E2 XP500A Read this manual carefully before operating this vehicle XP500 ...

Page 2: ...EAU26945 ng this vehicle This manual should stay with this vehicle if it is sold Feb 2006 ar 2007 e un 2005 MC 92 Japan ...

Page 3: ...spect and maintain your scooter but also in how to safeguard yourself help keep your scooter in the best possible condition If you have any fur maha dealer easant rides So remember to put safety first uct design and quality Therefore while this manual contains the most cur nting there may be minor discrepancies between your motorcycle and this manual please consult a Yamaha dealer EWA12411 tely be...

Page 4: ...t you to potential personal injury safety messages that follow this symbol to avoid possible injury ates a hazardous situation which if not avoided could result in njury es special precautions that must be taken to avoid damage to the roperty information to make procedures easier or clearer ...

Page 5: ...TION EAU10200 XP500 XP500A OWNER S MANUAL 8 by Yamaha Motor Co Ltd 1st edition June 2008 All rights reserved printing or unauthorized use ut the written permission of Yamaha Motor Co Ltd s expressly prohibited Printed in Japan ...

Page 6: ...lay 6 18 Valve clearance 6 18 Tires 6 19 Cast wheels 6 20 Front and rear brake lever free play 6 21 Adjusting the rear brake lock lever cable 6 21 Checking the front and rear brake pads 6 22 Checking the brake fluid level 6 23 Changing the brake fluid 6 24 Checking and lubricating the throttle grip and cable 6 24 Lubricating the front and rear brake levers 6 25 Checking and lubricating the centers...

Page 7: ...TABLE OF CONTENTS ...

Page 8: ...es for scooter accidents to ccur Ride where other motorists can ee you Avoid riding in another motorist s blind spot 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 Sta...

Page 9: ... Monoxide Poisoning gine exhaust contains carbon monoxide a deadly gas Breathing car bon monoxide can cause headaches dizziness drowsiness nausea confu sion and eventually death Carbon Monoxide is a colorless odor less tasteless gas which may be present even if you do not see or smell any engine exhaust Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable...

Page 10: ...ailer or to be attached to idecar Genuine Yamaha Accessories Choosing accessories for your vehicle is an important decision Genuine Yamaha accessories which are avail able only from a Yamaha dealer have been designed tested and approved by Yamaha for use on your vehicle Many companies with no connection to Yamaha manufacture parts and acces sories or offer other modifications for Yamaha vehicles Y...

Page 11: ...ts the free dom of movement of the opera or and may limit control ability herefore such accessories are not recommended e caution when adding electri accessories If electrical acces ries exceed the capacity of the ooter s electrical system an ectric failure could result which uld cause a dangerous loss of hts or engine power Aftermarket Tires and Rims The tires and rims that came with your scooter...

Page 12: ...ored jacket not carry too much luggage on scooter An overloaded scoot s unstable Use a strong cord to ure any luggage to the carrier equipped A loose load will af t the stability of the scooter and uld divert your attention from the d See page 1 1 ...

Page 13: ...2 1 2 3 4 5 6 7 8 9 DESCRIPTION EAU10410 3 5 10 9 8 7 6 11 1 4 2 9 Engine oil drain bolt page 6 11 10 Engine oil level check window page 6 11 11 Oil filter cartridge page 6 11 ...

Page 14: ...2 2 EAU10420 2 6 5 7 3 4 ...

Page 15: ...3 4 5 6 7 8 9 EAU10430 5 4 7 8 9 12 10 6 11 9 Front brake lever page 3 12 10 Throttle grip page 6 18 11 Front storage compartment B page 3 20 12 Main switch steering lock page 3 2 13 Front storage compartment A page 3 20 ...

Page 16: ...ew standard key is de or all keys are lost the en immobilizer system must be laced Therefore it is highly ommended to use either ndard key and keep the code re registering key in a safe place Do not submerse any key in wa ter Do not expose any key to exces sively high temperatures Do not place any key close to magnets this includes but not limited to products such as speakers etc Do not place item...

Page 17: ...auxiliary lights come on and the engine can be start ed The key cannot be removed TIP The headlights come on automatically when the engine is started and stay on until the key is turned to OFF or the sidestand is moved down EAU10661 OFF All electrical systems are off The key can be removed WARNING EWA10061 Never turn the key to OFF or LOCK while the vehicle is moving Otherwise the electrical syste...

Page 18: ...dealer check the self diagno sis system The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical circuit TIP This warning light will come on when the key is turned to ON and the start switch is pushed but this does not indi cate a malfunction EAU43031 ABS warning...

Page 19: ...icator l start flashing indicating the im er system is enabled After 24 have passed the indicator light p flashing however the immobi stem is still enabled odel is also equipped with a gnosis device for the immobiliz em See page 3 9 for an expla of the self diagnosis device EAU11601 Speedometer The speedometer shows the riding speed When the key is turned to ON the speedometer needle will sweep on...

Page 20: ... turned to ON the coolant temperature gauge needle will sweep once across the temperature range and then return to C in order to test the electrical circuit The coolant tempera ture varies with changes in the weather and engine load If the needle reaches or enters the red zone stop the vehicle and let the engine cool See page 6 35 1 Coolant temperature gauge 2 Red zone 2 1 ...

Page 21: ...s to the unction display Changing s while riding can distract the or and increase the risk of an nt The multi function display is equipped with the following a tachometer which shows engine speed ometer ometer red zone t replacement indicator V BELT meter tripmeters 1 2 3 1 Clock 2 Oil change indicator OIL 1 RESET button 2 SELECT button 1 2 1 2 ...

Page 22: ...bove he clock sh the SELECT button and ESET button together for at st two seconds en the hour digits start flashing sh the RESET button to set the urs sh the SELECT button and minute digits will start flashing sh the RESET button to set minutes sh the SELECT button and n release it to start the clock Odometer and tripmeter modes 1 Odometer tripmeters 1 Oil change tripmeter 1 1 ...

Page 23: ...SET but Oil change indicator OIL This indicator flashes at the initial 1000 km 600 mi then at 5000 km 3000 mi and every 5000 km 3000 mi thereafter to indicate that the engine oil should be changed After changing the engine oil reset the oil change indicator To reset the oil change indicator select it by pushing the SELECT button until OIL Trip is displayed and then push the RESET button at least 1...

Page 24: ...elt replacement indicator V BELT flashes i e before the periodic V belt change interval has been reached the indicator V BELT must be reset after the V belt change for the next periodic V belt change to be indicated at the correct time The electrical circuit of the indicator can be checked according to the following procedure 1 Turn the key to ON and make sure that the engine stop switch is set to...

Page 25: ...may cause signal interfer which may prevent the engine arting he engine starts turn it off and starting the engine with the andard keys one or both of the standard keys not start the engine take the hicle the code re registering y and both standard keys to a maha dealer and have the stan rd keys re registered splay indicates any error codes e code number and then have a a dealer check the vehicle ...

Page 26: ...12400 Dimmer switch Set this switch to for the high beam and to for the low beam EAU12460 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re switch PASS er switch ignal switch switch 1 3 4 1 Engine stop switch 2 Hazard switch 3 Start switch 1 2 3 ...

Page 27: ...th of time with the en ot running otherwise the bat ay discharge EAU44910 Front brake lever The front brake lever is located at the right handlebar grip To apply the front brake pull this lever toward the handle bar grip The front brake lever is equipped with a position adjusting dial To adjust the distance between the front brake lever and the handlebar grip turn the adjust ing dial while holding...

Page 28: ... with a adjusting dial To adjust the e between the rear brake lever handlebar grip turn the adjust while holding the rear brake le hed away from the handlebar ake sure that the appropriate setting on the adjusting dial is aligned with the mark on the rear brake le ver brake lever lever position adjusting dial mark nce between brake lever and ebar grip 1 3 2 ...

Page 29: ... dual electronic con trol system which acts on the front and rear brakes independently The ABS securely controls wheel lockup during emergency braking on changing road surfaces and under various weather conditions thereby maximizing tire ad hesion and performance while provid ing a smooth braking action The ABS is monitored by an ECU Electronic Control Unit which will have recourse to manual braki...

Page 30: ... may be damaged result mproper performance of the stem EAU13175 Fuel tank cap To remove the fuel tank cap 1 Open the lid by pulling the lever up 2 Insert the key into the lock and turn it clockwise The lock will be re leased and the fuel tank cap can be removed wheel hub wheel hub 1 Opening lever 2 Lid 1 2 ...

Page 31: ...explosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or while in the vi cinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank Stop filling when the fuel ...

Page 32: ...evere e to internal engine parts s the valves and piston rings as to the exhaust system amaha engine has been de to use regular unleaded gaso h a research octane number of gher If knocking or pinging oc e a gasoline of a different brand ium unleaded fuel Use of un fuel will extend spark plug life and reduce maintenance costs mmended fuel GULAR UNLEADED GASOLINE LY ank capacity 0 L 3 96 US gal 3 30...

Page 33: ...9 e damage to the catalytic ter EAU13932 Seat To open the seat 1 Place the scooter on the center stand 2 Insert the key into the main switch and then turn it counterclockwise to OPEN TIP Do not push inward when turning the key 3 Fold the seat up 1 Open 1 ...

Page 34: ...d to e different positions shown he backrest as follows en the seat See page 3 18 move the backrest bolts 3 Slide the backrest forward or back ward to the desired position 4 Install and securely tighten the backrest bolts 5 Close the seat backrest 1 1 Rider backrest 2 Bolt 2 1 ...

Page 35: ... d possibly an accident EWA10161 ease the helmet from the hel older the seat remove the helmet cable from the helmet holder e helmet and then close the EAU44993 Storage compartments Front storage compartments A and B To open a front storage compartment slide the lever up and then pull on the lever WARNING Do not store heavy items in these compartments EWA14861 1 Storage compartment opening lever 2...

Page 36: ...bag before storing them in mpartment Since the storage compartment may get wet while the scooter is being washed wrap any articles stored in the compartment in a plastic bag Do not keep any thing valuable or breakable in the storage compartment Do not leave the seat open for an extended period of time otherwise the light may cause the battery to discharge ECA16081 NOTICE The shaded area is not a s...

Page 37: ... nitrogen gas Read and understand the fol lowing information before handling the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Do not subject the shock ab sorber assembly to an open flame or other high heat source This may cause the unit to ex plode due to excessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poo...

Page 38: ...ight switches has the following func tions It prevents starting when the side stand is up but neither brake is ap plied It prevents starting when either brake is applied but the sidestand is still down It cuts the running engine when the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure ...

Page 39: ...ntil checked by a Yamaha dealer The brake switch may not be working correctly The scooter should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The scooter should not be ridden until checked by a Yamaha dealer If a malfunction is noted have a Yamaha dealer check the system before riding WARNING ...

Page 40: ...equipment damage lem If a problem cannot be corrected by the procedures provided in amaha dealer ts CHECKS PAGE uel tank akage 3 16 gine commended oil to specified level leakage 6 11 leakage 6 14 in reservoir commended coolant to specified level m for leakage 6 15 ve Yamaha dealer bleed hydraulic system or wear y eservoir commended brake fluid to specified level tem for leakage 6 21 6 22 6 23 ...

Page 41: ... leakage 6 21 6 22 6 23 ration is smooth ay Yamaha dealer adjust cable free play and lubricate cable 6 18 6 24 n and tread depth y 6 19 6 20 ration is smooth ting points if necessary 6 25 ration is smooth ecessary 6 25 uts bolts and screws are properly tightened y y ignition circuit cut off system king correctly have Yamaha dealer check vehicle 3 23 CHECKS PAGE ...

Page 42: ...ng the ve hicle for the first time In order for the ignition circuit cut off system to enable starting the side stand must be up See page 3 23 for more information 1 Turn the key to ON and make sure that the engine stop switch is set to The following warning lights indi cator light and indicators should come on for a few seconds then go off Engine trouble warning light ABS warning light for ABS mo...

Page 43: ...eat and then ad t the rear view mirrors witch the turn signals on eck for oncoming traffic and en slowly turn the throttle grip on e right in order to take off witch the turn signals off EAU16780 Acceleration and deceleration The speed can be adjusted by opening and closing the throttle To increase the speed turn the throttle grip in direction a To reduce the speed turn the throt tle grip in direc...

Page 44: ... 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 ...

Page 45: ...heck the vehi e EAU17213 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10311 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not par...

Page 46: ...e engine while ser ing can lead to eye injury rns fire or carbon monoxide soning possibly leading to ath See page 1 1 for more in mation about carbon monox ARNING EWA10330 ooter is designed for use on roads only If this scooter is ed in abnormally dusty mud et conditions the air filter el should be cleaned or d more frequently otherwise ngine wear may result Con Yamaha dealer for proper maintenanc...

Page 47: ...RIODIC MAINTENANCE AND ADJUSTMENT 6 2 2 3 4 5 6 7 8 9 ...

Page 48: ...vals starting from 10000 km 6000 mi rmed by a Yamaha dealer as they require special tools data and technical E JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi s or Every 40000 km 24000 mi and Whenever worn to the limit and Whenever worn to the limit ...

Page 49: ...4 2 3 4 5 6 7 8 9 ge Every 4 years age dam ss or eering Every 20000 km 12000 mi lts and ned ase ase il leak k d and E JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi ...

Page 50: ...or oil Every 5000 km 3000 mi hicle Every 3 years ge When the V belt replacement indicator flashes every 20000 km 12000 mi play e play ousing E JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi ...

Page 51: ...per element which must not be cleaned with placed and the V belt air filter elements need to be serviced more frequent eas ders and calipers always change the fluid Regularly check the brake fluid ponents of the brake master cylinders and calipers and change the brake and if cracked or damaged ...

Page 52: ...k fasteners 2 Remove the upper left and right side of the panel by pulling them upward and then pull the panel downward as shown To install the panel Place the panel in the original position and then install the quick fasteners F A fastener 1 2 1 1 Panel A 1 ...

Page 53: ...the nuts and then place e rubber cover on each mirror in e original position stall panel A C ove the panel e the screws and then pull the pward To install the panel Place the panel in the original position and then install the screws Panel D To remove the panel 1 Remove panel C 2 Remove the screws and then pull the panel backward and upward w l B 2 1 1 Screw 2 Panel C 2 1 ...

Page 54: ...the panel he panel in the original position n install the screws F ove the panel e the screws and then pull the utward To install the panel Place the panel in the original position and then install the screws 1 1 Screw 1 1 ...

Page 55: ...park plug and its mating surface and then f any grime from the spark plug s ue 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 k plug gap k plug gap 7 0 8 mm 0 028 0 031 in tening torque ark plug 12 5 Nm 1 25 m kgf 9 ft lbf ...

Page 56: ...l nge the engine oil with or t oil filter cartridge replace ce the vehicle on a level sur e rt 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 drain bolt to drain the oil from the crankcase e oil level check window mum level mark um level mark 1 3 2 1 Engine oil filler cap 1 ...

Page 57: ...n 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 ne oil drain bolt g her 2 3 1 Oil filter wrench 2 Oil filter cartridge 2 1 ...

Page 58: ...ral 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 TIP If the engine oil is changed before the oil change indicator comes on i e be fore the periodic oil change interval has been reached the indicator mu...

Page 59: ...e chain ve case stall the chain drive oil drain bolt d then tighten it to the specified torque 6 Refill with the specified amount of the recommended oil 7 Wipe the dipstick clean insert it into the oil filler hole without screwing it in and then remove it to check the oil level TIP The chain drive oil should be between the minimum and maximum level marks n drive oil filler cap n drive oil drain bo...

Page 60: ... 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 the side can result in a false reading 2 Check the coolant level through the check window TIP The coolant should be between the...

Page 61: ...ngine water has been used instead coolant replace it with cool t 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 i...

Page 62: ...e panels 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 F See page 6 7 2 Check the engine idling speed and if necessary adjust it to spec ification by turning the idle adjust ing ...

Page 63: ...heck the cable free play and if neces ave 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 tle cable free play 1 ...

Page 64: ...mmediately TIP The tire tread depth limits may differ from country to country Always comply with the local regulations ir pressure measured on cold 90 kg 0 198 lb Front 225 kPa 2 25 kgf cm2 33 psi Rear 250 kPa 2 50 kgf cm2 36 psi 500 90 194 kg 198 428 lb 500A 90 190 kg 198 419 lb Front 225 kPa 2 25 kgf cm2 33 psi Rear 280 kPa 2 80 kgf cm2 41 psi mum load 500 194 kg 428 lb 500A 190 kg 419 lb al wei...

Page 65: ...warpage be fore each ride If any damage is found have a Yamaha dealer re place 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 Ride at m...

Page 66: ...ci EAU33473 Adjusting the rear brake lock lever cable Rear brake lock lever 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 lever cable length should measure 45 mm to 47 mm 1 77 in to 1 85 in at the rear brake caliper Periodically check the rear brake lock lever cable length and if necessary adjus...

Page 67: ...ition wear indicator while applying the If a brake pad has worn to the point that the wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU22493 Rear brake pads 1 Remove the rear brake caliper by removing the bolts 2 Check each rear brake pad for damage and measure the lining thickness If a brake pad is dam aged or if the lining thickness is less tha...

Page 68: ... to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful che...

Page 69: ...of the master cylinders and s as well as the brake hoses re at the intervals listed below or ver they are damaged or leak seals Replace every two ars ake hoses Replace every four ars EAU23111 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 at the intervals specified in the periodi...

Page 70: ...Checking and lubricating the centerstand and sidestand The operation of the centerstand and sidestand should be checked before each ride and the pivots and met al to metal contact surfaces should be lubricated if necessary mmended lubricant cone grease ...

Page 71: ...and excessive oil leakage ck the operation ace the vehicle on a level sur ce and hold it in an upright posi n WARNING To avoid injury curely support the vehicle so ere is no danger of it falling er EWA10751 hile applying the front brake sh down hard on the handlebars veral times to check if the front k compresses and rebounds moothly NOTICE ECA10590 If any damage is found or the front fork does no...

Page 72: ... is no need to check the electro lyte or to add distilled water However the battery lead connections need to be checked and if necessary tightened WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fo...

Page 73: ...tery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place NOTICE When removing the battery be sure the key is turned to OFF then discon nect the negative lead before disconnecting the positive lead ECA16302 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if nece...

Page 74: ...JUSTMENT 6 29 ng than recommended to oid causing extensive dam e to the electrical system and ssibly a fire EWA15131 500 For XP500A For XP500 use main fuse 1 2 1 Main fuse 2 Spare main fuse 1 Fuse box 1 2 1 ...

Page 75: ...fuse njection system fuse aling system fuse e fuse ng lighting fuse 7 7 7 8 1 2 3 4 5 6 1 Headlight fuse 2 Ignition fuse 3 Backup fuse for odometer and clock 4 Radiator fan fuse 5 Fuel injection system fuse 6 Signaling system fuse 7 Spare fuse 8 ABS control unit fuse 9 Parking lighting fuse 10 Spare fuse 7 7 7 9 1 8 10 2 3 4 5 6 ...

Page 76: ...from erwise the transparency of ss the luminosity of the bulb bulb life will be adversely af Thoroughly clean off any dirt ngerprints on the headlight ing a cloth moistened with al r thinner connect the headlight coupler and then remove the headlight bulb cover 2 Unhook the headlight bulb holder and then remove the burnt out bulb t touch the glass part of the bulb 1 Headlight coupler 2 Bulb cover ...

Page 77: ...he bulb EAU43051 Replacing a front turn signal light bulb 1 Place the scooter on the center stand 2 Remove the socket together with the bulb by turning it counter clockwise 3 Remove the burnt out bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by turning it clockwise 1 Turn signal light bulb socket 1 ...

Page 78: ... socket together with bulb by pulling it out 3 Remove the burnt out bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by pushing it in 6 Install the license plate light unit by installing the screws 1 1 License plate light unit 2 License plate light bulb socket 1 2 ...

Page 79: ... your owever should your scooter re ny repair take it to a Yamaha whose skilled technicians have cessary tools experience and ow to service the scooter prop nly genuine Yamaha replace arts Imitation parts may look like a parts but they are often inferi e a shorter service life and can expensive repair bills ARNING EWA15141 checking the fuel system do oke and make sure there are en flames or sparks...

Page 80: ...a Yamaha dealer check the vehicle y cloth and correct the or replace the spark plugs dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery The battery is good Check the battery lead connections nd charge the battery if necessary Operate the electric starter ...

Page 81: ... de cape When the hissing sound has stopped press down on the cap en remove the cap arily used instead provided that it is changed to the recommended coolant The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See TIP Start the engine If the engine overheats again have a Yamaha dealer check and r...

Page 82: ...kcase h a degreasing agent and a sh but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the dirt and de greaser off with water Cleaning NOTICE ECA10782 Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the ar...

Page 83: ... in the ear the sea or on salt sprayed rayed 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 ECA10791 2 Apply a corrosion protection spray on all metal including chrome and nickel plated surfaces to prevent corrosion After cl...

Page 84: ...lace and if necessary protect it against dust with a porous cover NOTICE ECA10820 Storing the scooter in a poorly ventilated room or covering it with a tarp while it is still wet will allow water and humidity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your scooter...

Page 85: ... a little every onth in order to prevent the tires m becoming degraded in one ot ver the muffler outlet with a astic bag to prevent moisture m entering it move the battery and fully arge it Store it in a cool dry ace and charge it once a month not store the battery in an ex ssively cold or warm place less an 0 C 30 F or more than 30 90 F For more information storing the battery see page 27 any nec...

Page 86: ...US qt 1 30 Imp qt r r element coated paper element mended fuel ular unleaded gasoline only Fuel tank capacity 15 0 L 3 96 US gal 3 30 Imp gal Fuel reserve amount 3 0 L 0 79 US gal 0 66 Imp gal Fuel injection Throttle body Manufacturer MIKUNI Type quantity ACW31 10 1 Spark plug s Manufacturer model NGK CR7E Spark plug gap 0 7 0 8 mm 0 028 0 031 in Clutch Clutch type Wet multiple disc automatic Tran...

Page 87: ... M C x MT5 00 brake al disc brake tion ht hand operation mmended fluid T 4 Rear brake Type Single disc brake Operation Left hand operation Recommended fluid DOT 4 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 120 0 mm 4 72 in Rear suspension Type Swingarm Spring shock absorber type Coil spring gas oil damper Wheel travel 116 0 mm 4 57 in Elect...

Page 88: ...8 3 ght fuse A ng system fuse A fuse A g lighting fuse A or fan fuse A ection system fuse A ontrol unit fuse 00A 5 0 A otor fuse 00A 30 0 A olenoid fuse 00A 20 0 A p fuse A ...

Page 89: ...nce when ordering a new EAU26410 Vehicle identification number The vehicle identification number is stamped into the frame TIP The vehicle identification number is used to identify your vehicle and may be used to register it with the licensing authority in your area dentification number re registering key red bow dard keys black bow 1 Vehicle identification number 1 ...

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Page 91: ... and lubrication chart 6 3 R Rear brake lock lever 3 14 Rear brake lock lever cable adjusting 6 21 Rear view mirrors 3 22 Rider backrest adjusting 3 19 S Safe riding points 1 5 Safety information 1 1 Seat 3 18 Shock absorber assembly 3 22 Sidestand 3 23 Spark plugs checking 6 10 Specifications 8 1 Speedometer 3 4 Starting off 5 2 Starting the engine 5 1 Start switch 3 12 Steering checking 6 27 Sto...

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Yamaha Tmax 500, Owner'S Manual

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