Yamaha TMax XP500 2012 Owner'S Manual Download

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PERIODIC MAINTENANCE AND ADJUSTMENT

6-31

For XP500

For XP500A

3. Turn the key to “ON” and turn on

the electrical circuit in question to
check if the device operates.

4. If the fuse immediately blows

again, have a Yamaha dealer
check the electrical system.

1. Spare fuse

2. Parking lighting fuse

3. Signaling system fuse

4. Ignition fuse

5. Backup fuse

6. Radiator fan fuse

7. Fuel injection system fuse

8. Headlight fuse

9. Spare fuse

4
5
6
7
8

1. Spare fuse

2. ABS control unit fuse

3. Signaling system fuse

4. Ignition fuse

5. Backup fuse

6. Radiator fan fuse

7. Fuel injection system fuse

8. Headlight fuse

9. Spare fuse

10.Parking lighting fuse

2 1

9 1 8

Specified fuses:

Main fuse:

40.0 A

Headlight fuse:

20.0 A

Signaling system fuse:

15.0 A

Ignition fuse:

7.5 A

Radiator fan fuse:

15.0 A

Fuel injection system fuse:

7.5 A

Parking lighting fuse:

10.0 A

ABS control unit fuse:

XP500A 5.0 A

ABS motor fuse:

XP500A 30.0 A

ABS solenoid fuse:

XP500A 20.0 A

Backup fuse:

7.5 A

59C-9-E1.book 31 ページ２０１２年６月２６日　火曜日　午前１１時３３分

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Summary of Contents for TMax XP500 2012

Page 1: ...NER S MANUAL XP500 XP500A 59C 28199 E1 q Read this manual carefully before operating this vehicle U59CE1_Hyoshi indd 1 2012 07 09 16 All manuals and user guides at all guides com a l l g u i d e s c o...

Page 2: ...re that the product Type designation 5SL 00 is in compliance with following norm s or documents R TTE Directive 1999 5 EC EN300 330 2 v1 3 1 2006 01 EN300 330 2 v1 5 1 2010 02 EN60950 1 2006 A11 2009...

Page 3: ...y In addition the many tips given in this manual will help keep your scooter in the best possible condition If you have any fur ther questions do not hesitate to contact your Yamaha dealer The Yamaha...

Page 4: ...personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serio...

Page 5: ...L 2012 by Yamaha Motor Co Ltd 1st edition June 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japa...

Page 6: ...ing 5 5 PERIODIC MAINTENANCE AND ADJUSTMENT 6 1 Owner s tool kit 6 2 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installin...

Page 7: ...the license plate light bulb 6 34 Replacing an auxiliary light bulb 6 35 Troubleshooting 6 35 Troubleshooting charts 6 37 SCOOTER CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPEC...

Page 8: ...he possibility of an accident or equipment damage See page 4 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...

Page 9: ...use of a safety helmet is the single most critical factor in the preven tion or reduction of head injuries Always wear an approved helmet Wear a face shield or goggles Wind in your unprotected eyes co...

Page 10: ...s pos sible and make sure to distribute the weight as evenly as possible on both sides of the scooter to min imize imbalance or instability Shifting weights can create a sud den imbalance Make sure th...

Page 11: ...arge accessories may seriously affect the stability of the scooter due to aerodynamic effects Wind may attempt to lift the scooter or the scooter may become unstable in cross winds These accessories m...

Page 12: ...Once you have com pleted a turn accelerate slowly Be careful when passing parked cars A driver might not see you and open a door in your path Railroad crossings streetcar rails iron plates on road con...

Page 13: ...e 3 21 4 Rear storage compartment page 3 22 5 Grab bar page 5 2 6 Engine oil filler cap page 6 11 7 Sidestand page 3 26 8 Engine oil drain bolt page 6 11 9 Engine oil level check window page 6 11 10 O...

Page 14: ...7 1 5 4 2 1 Owner s tool kit page 6 2 2 Fuel tank cap page 3 17 3 Air filter element page 6 15 4 Windshield page 3 24 5 Fuses page 6 30 6 V belt air filter element right 7 Centerstand page 6 26 59C 9...

Page 15: ...page 3 15 4 Speedometer page 3 5 5 Multi function display page 3 5 6 Tachometer page 3 5 7 Right handlebar switches page 3 12 8 Front brake lever page 3 14 9 Throttle grip page 6 17 10 Front storage...

Page 16: ...s lost regis tering new codes in the stan dard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made...

Page 17: ...ight li cense plate light and auxiliary light come on and the engine can be start ed The key cannot be removed TIP The headlight comes on automatically when the engine is started and stays on until th...

Page 18: ...indicator light comes on when the high beam of the headlight is switched on EAU43023 Engine trouble warning light This warning light comes on if an elec trical circuit monitoring the engine is not wo...

Page 19: ...ts as soon as possible TIP If the start switch is pushed while the engine is running the ABS warning light will come on but this is not a malfunction The ABS warning light may come on while accelerati...

Page 20: ...then return to zero r min in order to test the electri cal circuit NOTICE ECA10031 Do not operate the engine in the ta chometer red zone Red zone 8250 r min and above EAU52242 Multi function display...

Page 21: ...ich shows the distance trav eled since the last V belt replace ment TIP Be sure to turn the key to ON be fore using the left and right set but tons When the key is turned to ON all of the display segm...

Page 22: ...he various trip meter and odometer modes in the following order Odo Trip 1 Trip 2 Trip F V Belt Trip Oil Trip Odo To reset a tripmeter select it by push ing the left set button until Trip F Trip 1 or...

Page 23: ...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 indicato...

Page 24: ...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 swi...

Page 25: ...or the UK only The average fuel consumption is dis played AVE_ _ _ MPG This display shows the average fuel consumption since it was last reset When the display is set to AVE_ _ _ km L the average dist...

Page 26: ...self diag nosis device for various electrical cir cuits If a problem is detected in any of those circuits the engine trouble warning light comes on and the display indicates an error code If the displ...

Page 27: ...stan dard keys re registered NOTICE ECA11590 If the display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage EAU12331 Anti theft alarm optional...

Page 28: ...EAU12721 Start switch With the sidestand up push this switch while applying the front or rear brake to crank the engine with the starter See page 5 1 for starting instructions prior to starting the e...

Page 29: ...ke lever The rear brake lever is located at the left handlebar grip To apply the rear brake pull this lever toward the handle bar grip The rear brake lever is equipped with a position adjusting dial T...

Page 30: ...r brake lock lever back to the original position TIP Be sure to check that the rear wheel does not move when the rear brake lock lever is applied To provide secure locking of the rear wheel apply the...

Page 31: ...aking if a malfunction occurs TIP The ABS performs a self diagno sis test each time the vehicle first starts off after the key is turned to ON and the vehicle has traveled at a speed of 10 km h 6 mi h...

Page 32: ...fuel tank cap 1 Align the match marks insert the fuel tank cap into the tank opening and then push down on the cap 2 Turn the key counterclockwise to the original position and then re move it 3 Close...

Page 33: ...painted surfaces or plastic parts ECA10071 4 Be sure to securely close the fuel tank cap WARNING EWA15151 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon ga...

Page 34: ...tic converter in the exhaust system WARNING EWA10862 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 ot...

Page 35: ...at down and then push it down to lock it in place 2 Remove the key from the main switch if the scooter will be left un attended TIP Make sure that the seat is properly se cured before riding EAU14270...

Page 36: ...kle on the helmet strap as shown and then hook the cable loop over the helmet holder 3 Make sure the helmet holding ca ble is not touching the shaded pro jection and securely close the seat WARNING Ne...

Page 37: ...ver while pushing the lever up To close the storage compartment push the lid into the original position To lock the storage compartment push the lid into the original position insert the key in the lo...

Page 38: ...wise the light may cause the battery to discharge ECA16082 NOTICE The shaded area is not a storage compartment To prevent damaging the seat hinges do not place any items in this area ECA16091 TIP Some...

Page 39: ...s covers by removing the quick fasteners 2 Remove the windshield by remov ing the screws 3 Remove the rubber caps 4 Install the rubber caps in the de sired position 5 Install the windshield to the de...

Page 40: ...Rear view mirrors The rear view mirrors of this vehicle can be folded forward or backward for park ing in narrow spaces Fold the mirrors back to their original position before riding WARNING EWA14371...

Page 41: ...located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright TIP The built in sidestand switch is part of the ignition circuit cut off system...

Page 42: ...ing 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...

Page 43: ...the engine stall The system is OK The scooter can be ridden The sidestand switch may not be working correctly The scooter should not be ridden until checked by a Yamaha dealer The sidestand switch may...

Page 44: ...points ITEM CHECKS PAGE 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 h...

Page 45: ...ls and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 17 6 19 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if...

Page 46: ...p system The engine stops automatically if left idling for 20 minutes If the engine stops simply push the start switch to restart the engine EAU54010 Starting the engine NOTICE ECA10250 See page 5 4 f...

Page 47: ...or rear brake If the engine does not start re lease the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to preserve the bat tery Do not crank th...

Page 48: ...de otherwise the scooter may skid or overturn Railroad crossings streetcar rails iron plates on road con struction sites and manhole covers become extremely slip pery when wet Therefore slow down when...

Page 49: ...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 op...

Page 50: ...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 over...

Page 51: ...ance 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 l...

Page 52: ...l 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 c...

Page 53: ...they require special tools data and technical skills EAU46910 Periodic maintenance chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 1...

Page 54: ...id 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 Rear brake...

Page 55: ...silicone grease 16 Rear brake lever pivot shaft Lubricate with silicone grease 17 Sidestand centerstand Check operation Lubricate with lithium soap based grease 18 Sidestand switch Check operation 19...

Page 56: ...Check operation 26 Moving parts and cables Lubricate 27 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 28 Lights signals and swit...

Page 57: ...r elements need to be serviced more frequent ly when riding in unusually wet or dusty areas Hydraulic brake service After disassembling the brake master cylinders and calipers always change the fluid...

Page 58: ...er Refer to this section each time a panel needs to be removed and installed EAU52011 Panel A To remove the panel 1 Remove the panel by pulling its upper left and right sides to un hook them as shown...

Page 59: ...l Place the panel in the original position and then install the screws Panel C To remove the panel Remove the screws and then pull the panel backward and upward To install the panel Place the panel in...

Page 60: ...d 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 pro...

Page 61: ...nd 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 false reading 3 Wait two minutes until the oil set tles an...

Page 62: ...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...

Page 63: ...dition 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 fo...

Page 64: ...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...

Page 65: ...t 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...

Page 66: ...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 engi...

Page 67: ...t 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...

Page 68: ...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 b...

Page 69: ...wing 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...

Page 70: ...e 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 perfo...

Page 71: ...0 Check that the rear brake lock is re leased and then make sure that the rear wheel could rotate smoothly EAU52291 Checking the rear brake lock The rear brake lock must be checked at the intervals sp...

Page 72: ...or 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...

Page 73: ...ame 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...

Page 74: ...d adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EAU23095 Checking and lubricating the cables The operation of all control cables and the cond...

Page 75: ...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...

Page 76: ...23272 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 condit...

Page 77: ...stand WARNING To avoid inju ry securely support the vehicle so there is no danger of it falling over EWA10751 2 Hold the lower ends of the front fork legs and try to move them for ward and backward I...

Page 78: ...r the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt...

Page 79: ...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...

Page 80: ...cal circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive...

Page 81: ...5 6 7 8 2 1 1 Spare fuse 2 ABS control unit fuse 3 Signaling system fuse 4 Ignition fuse 5 Backup fuse 6 Radiator fan fuse 7 Fuel injection system fuse 8 Headlight fuse 9 Spare fuse 10 Parking lightin...

Page 82: ...bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specifi...

Page 83: ...r stand 2 Remove the socket together with the bulb by turning it counter clockwise 3 Remove the burnt out bulb by pushing it in and turning it counter clockwise 4 Insert a new bulb into the socket pus...

Page 84: ...nse plate light unit by removing the screws 2 Remove the license plate light bulb socket together with the bulb by pulling it out 3 Remove the burnt out bulb by pull ing it out 4 Insert a new bulb int...

Page 85: ...ng and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your scooter re quire any repair take it to a Ya...

Page 86: ...STMENT 6 36 1 2 3 4 5 6 7 8 9 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage 59C 9 E1 book 36 All manuals and user guides at all guides...

Page 87: ...k the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The...

Page 88: ...pped press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recomm...

Page 89: ...stic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug cap are tightly in stalled 3 Remove extremely...

Page 90: ...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 A...

Page 91: ...ll wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short...

Page 92: ...t damage or injury from sparking make sure to ground the spark plug elec trodes while turning the en gine over EWA10951 4 Lubricate all control cables and the pivoting points of all levers and pedals...

Page 93: ...e replacement 2 90 L 3 07 US qt 2 55 Imp qt Cooling system Coolant reservoir capacity up to the maxi mum level mark 0 27 L 0 29 US qt 0 24 Imp qt Radiator capacity including all routes 1 50 L 1 59 US...

Page 94: ...brake Operation Right hand operation Specified brake fluid DOT 4 Rear brake Type Single disc brake Operation Left hand operation Specified brake fluid DOT 4 Front suspension Type Telescopic fork Spri...

Page 95: ...0 A Headlight fuse 20 0 A Signaling system fuse 15 0 A Ignition fuse 7 5 A Parking lighting fuse 10 0 A Radiator fan fuse 15 0 A Fuel injection system fuse 7 5 A ABS control unit fuse XP500A 5 0 A AB...

Page 96: ...ehicle 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 E...

Page 97: ...numbers 9 1 Ignition circuit cut off system 3 27 Immobilizer system 3 1 Immobilizer system indicator light 3 4 Indicator lights and warning lights 3 3 L License plate light bulb replacing 6 34 M Main...

Page 98: ...INDEX V Valve clearance 6 17 Vehicle identification number 9 1 W Wheel bearings checking 6 27 Wheels 6 19 Windshield 3 24 59C 9 E1 book 3 All manuals and user guides at all guides com...

Page 99: ...U59CE1_Hyoshi indd 3 2012 07 09 16 All manuals and user guides at all guides com...

Page 100: ...PRINTED IN JAPAN 2012 07 0 4 1 E PRINTED ON RECYCLED PAPER U59CE1_Hyoshi indd 4 2012 07 09 16 All manuals and user guides at all guides com...

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