Yamaha Tmax XP500 2016 Owner'S Manual Download Page 62

Page: 62 / 110

Periodic maintenance and adjustment

7-5

Drive pulley and

drive axle

• Lubricate.



Steering bearings

• Check bearing play and

steering for roughness.



• Lubricate with lithium-soap-

based grease.

Every 20000 km (12000 mi)

Chassis fasteners

• Make sure that all nuts, bolts

and screws are properly
tightened.



Front brake lever

pivot shaft

• Lubricate with silicone grease.



Rear brake lever

pivot shaft

• Lubricate with silicone grease.



Sidestand,

centerstand

• Check operation.
• Lubricate with lithium-soap-

based grease.



Sidestand switch

• Check operation.



Front fork

• Check operation and for oil

leakage.



Shock absorber

assembly

• Check operation and shock

absorber for oil leakage.



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)



Engine oil filter

cartridge

• Replace.



Cooling system

• Check coolant level and vehicle

for coolant leakage.



• Change coolant.

Every 3 years

V-belt

• Replace.

When the V-belt replacement

indicator flashes [every 20000

km (12500 mi)]

Front and rear

brake switches

• Check operation.



NO.

ITEM

X 1000 km

CHECK OR

MAINTENANCE JOB

X 1000 mi

ODOMETER

READINGS

ANNU

AL CHECK

0.6

2PW-9-E1.book 5 ページ２０１５年９月１０日　木曜日　午後５時１７分

Summary of Contents for Tmax XP500 2016

Page 1: ...XP500 MOTORCYCLE 2PW 28199 E1 OWNER S MANUAL Read this manual carefully before oper ating this vehicle XP500 XP500A ...

Page 2: ...Q Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold EAU72660 ...

Page 3: ...e and injury In addition the many tips given in this manual will help keep your scooter in the best possible condition If you have any further questions do not hesitate to con tact your Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality There fore while this manual contains the mo...

Page 4: ...death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make proce dures easier or clearer XP500 XP500A OWNER S MANUAL 2015 by Yamaha Motor Co Ltd 1st edition August 2015 All rights reserved Any reprinting ...

Page 5: ...ssembly 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 m...

Page 6: ... 7 28 Replacing the fuses 7 29 Headlights 7 31 Auxiliary lights 7 32 Tail brake light 7 32 Replacing a front turn signal light bulb 7 33 Rear turn signal light bulb 7 33 Replacing the license plate light bulb 7 34 Troubleshooting 7 34 Troubleshooting charts 7 36 Emergency mode 7 38 Scooter care and storage 8 1 Matte color caution 8 1 Care 8 1 Storage 8 4 Specifications 9 1 Consumer information 10 ...

Page 7: ...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...

Page 8: ... It is not suitable for off road use Protective Apparel The majority of fatalities from scooter accidents are the result of head inju ries The 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 could contribute to an impairment of vision that could dela...

Page 9: ... could cause an accident When loading within this weight limit keep the following in mind Cargo and accessory weight should be kept as low and close to the scooter as possible Securely pack your heaviest items as close to the center of the vehicle as 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 we...

Page 10: ...travel or control operation or obscure lights or reflectors Accessories fitted to the handle bar or the front fork area can cre ate instability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability o...

Page 11: ... can be extremely difficult on a wet road Avoid hard braking because the scooter could slide Apply the brakes slowly when stopping on a wet surface Slow down as you approach a cor ner or turn 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 constructio...

Page 12: ...r storage compartment page 4 18 4 Grab bar page 6 3 5 Engine oil filler cap page 7 10 6 Sidestand page 4 22 7 Engine oil drain bolt page 7 10 8 Engine oil level check window page 7 10 9 Oil filter cartridge page 7 10 10 Coolant level check window page 7 13 3 5 9 8 7 6 10 1 4 2 2PW 9 E1 book 1 ページ２０１５年９月１０日木曜日午後５時１７分 ...

Page 13: ... 11 12 13 14 EAU63391 Right view 1 Owner s tool kit page 7 2 2 Fuel tank cap page 4 14 3 Air filter element page 7 15 4 Windshield page 4 19 5 Fuses page 7 29 6 Centerstand page 7 26 3 6 1 5 4 2 2PW 9 E1 book 2 ページ２０１５年９月１０日木曜日午後５時１７分 ...

Page 14: ... lever page 4 12 4 Speedometer page 4 2 5 Multi function display page 4 3 6 Tachometer page 4 3 7 Right handlebar switches page 4 10 8 Front brake lever page 4 11 9 Throttle grip page 7 16 10 Front storage compartment page 4 18 11 Smart key system switches page 3 1 12 Auxiliary DC jack page 4 24 4 2 3 6 7 8 1 11 9 5 10 12 2PW 9 E1 book 3 ページ２０１５年９月１０日木曜日午後５時１７分 ...

Page 15: ...ustration Radio waves transmitted by the antenna may affect the opera tion of such devices when close by If you have an electric medical device consult a doctor or the device manufacturer before us ing this vehicle In addition to the vehicle mounted an tenna the smart key system consists of the smart key smart key system indica tor light ON switch and the OFF LOCK and SEAT OPEN switches 1 Vehicle ...

Page 16: ...move the smart key to another location and perform the operation again If it still does not work use the mechanical key to carry out the operation in emergen cy mode See page 7 38 EAU61582 Operating range of the smart key system The operating range of the smart key system is about 80 cm 31 5 in from the center of the handlebars TIP As the smart key system uses weak radio waves the operating range ...

Page 17: ...ot store it on the vehicle When the smart key is within op erating range exercise due care because other people not carry ing the smart key can start the engine and operate the vehicle Included with the vehicle is one smart key with a built in mechanical key and one spare mechanical key with an iden tification tag Keep the spare mechani cal key and tag separate from the smart key Should you lose o...

Page 18: ...etic fields and mag netic objects such as key hold ers TVs and computers Keep the smart key away from electric medical equipment Do not allow oils polishing agents fuel or any strong chemicals to come in contact with the smart key The smart key body may become discol ored or cracked TIP The smart key battery life is ap proximately two years but this may vary according to operating conditions The s...

Page 19: ...n the smart key on or off press and hold the ON OFF switch for ap proximately one second When the smart key is turned off the vehicle can not be operated even if the smart key is brought within operating range of the vehicle Turn the smart key on and bring it within range to operate the vehi cle See page 3 2 TIP To preserve battery power the smart key will turn off automatically about a week after...

Page 20: ... about 20 seconds when the power of the vehicle is turned on When the smart key indicator light does not come on when the ON OFF switch is pushed WARNING EWA14724 The battery and other remov able parts may cause injury if swallowed Keep the battery and other removable parts away from children Do not expose the battery to di rect sunlight or other heat sources NOTICE ECA15784 Use a cloth when openi...

Page 21: ... 1 Open the smart key case as shown 2 Remove the switch plate and con trol unit from the smart key case 3 Remove the battery cover 4 Remove the battery TIP Dispose of the removed battery in ac cordance with local regulations 5 Install a new battery as shown Note the polarity of the battery 6 Install the battery cover 7 Install the switch plate and control unit into the smart key case 8 Gently snap...

Page 22: ...ess the ON switch If the steering continues to be locked and will not release the smart key system indicator light will flash 16 times and the steering lock release operation will stop midway Move the handlebar gen tly to the left and right to help re lease the steering lock and then press the ON switch again NOTICE ECA15825 If the steering lock will not release and the smart key system indicator ...

Page 23: ...at the power was not successfully turned off Confirm the location and condition of the smart key and try pow ering off the vehicle again TIP The rider must turn off the power of the vehicle manually The power of the vehicle will not turn off automatically even if the smart key is moved out of operat ing range of the smart key system The power of the vehicle cannot be turned off via the OFF LOCK sw...

Page 24: ...or light will flash Turn the handlebar fully to the left one more time and press the OFF LOCK switch again for one second WARNING EWA14742 Do not operate the steering lock while the vehicle is moving EAU61683 Seat opening and closing To open the seat 1 Place the vehicle on the center stand 2 With the smart key on and in oper ating range press the SEAT OPEN switch 3 The seat lock will release upon ...

Page 25: ...SEAT OPEN switch for at least one second 3 Upon authentification of the smart key the beeper will sound twice and the smart key system will change to parking mode and the smart key system indicator light will come on TIP The seat cannot be opened while in parking mode NOTICE ECA21990 Do not use the hazard lights for an extended length of time otherwise the battery may discharge To exit parking mod...

Page 26: ...indi cate a malfunction EAU63532 ABS warning light for ABS models In normal operation the ABS warning light comes on when the vehicle power is turned on and goes off after traveling at a speed of 10 km h 6 mi h or higher If the ABS warning light does not come on when the vehi cle power is turned on comes on or flashes while riding does not go off after traveling at a speed of 10 km h 6 mi h or hig...

Page 27: ...ndicator light will be off If there is an error in the smart key sys tem the indicator light will flash The in dicator light will also flash when communication between the vehicle and smart key takes place and when certain smart key system operations are carried out See page 3 1 TIP When the start switch is pushed the in dicator light will come on for about one second and then go off If the indica...

Page 28: ...ne Red zone 8250 r min and above EAU63564 Multi function display WARNING EWA12313 Be sure to stop the vehicle before making any setting changes to the multi function display Changing settings while riding can distract the operator and increase the risk of an accident 1 Tachometer 2 Tachometer red zone 1 2 1 SELECT button 2 Fuel meter 3 Fuel level warning indicator 4 Odometer 5 Coolant temperature ...

Page 29: ...ay segments of the multi function display will ap pear one after the other and then disappear in order to test the elec trical circuits Clock The clock uses a 24 hour time system The clock displays when the key is turned to ON To set the clock 1 Push the SELECT and RESET buttons together for at least two seconds 2 When the hour digits start flashing push the RESET button to set the hours 3 Push th...

Page 30: ...imately 3 0 L 0 79 US gal 0 66 Imp gal of fuel remains in the fuel tank the display will automatically change to the fuel reserve tripmeter mode Trip F and start counting the distance traveled from that point In that case pushing the SELECT button switches the display between the vari ous tripmeter and odometer modes in the following order Odo Trip 1 Trip 2 Trip F V Belt Trip Oil Trip Odo To reset...

Page 31: ...eating 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 SE LECT button at least ...

Page 32: ...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 vehicle on and make sure that the engine stop switch is set to 2 Check that the V belt replacement indicator comes on...

Page 33: ...ion mode Since it was last reset this mode calcu lates the average fuel consumption rate of the vehicle For the UK The average fuel consumption is dis played AVE_ _ _ MPG When the display is set to AVE_ _ _ km L the average distance that can be traveled on 1 0 L of fuel is shown When the display is set to AVE_ _ _ L 100 km the average amount of fuel necessary to travel 100 km is shown For the UK W...

Page 34: ... shown To switch between the instantaneous fuel consumption displays push the RESET button for one second when one of the displays is shown except for the UK TIP If traveling at speeds under 10 km h 6 mi h _ _ _ is displayed Self diagnosis device This model is equipped with a self diag nosis device for various electrical cir cuits If a problem is detected in any of those circuits the engine troubl...

Page 35: ...e vehicle overturns or when the throttle cable is stuck EAU63631 ON switch With the smart key turned on and within range press this switch to turn on the power to the vehicle Then with the sid estand up and while applying the front or rear brake push this switch to crank the engine with the starter See page 6 2 for starting instructions prior to starting the engine EAU63571 The engine trouble warn...

Page 36: ...of the handlebar To apply the front brake pull this lever toward the throttle grip The front brake lever is equipped with a position adjusting dial To adjust the distance between the front brake lever and the throttle grip turn the adjusting dial while holding the front brake lever pushed away from the throttle grip Make sure that the appropriate setting on the adjusting dial is aligned with the m...

Page 37: ...a rear brake lock lever to prevent the rear wheel from moving while stopped at traffic signals railroad crossings etc To lock the rear wheel Push the rear brake lock lever to the left until it snaps into place To unlock the rear wheel Push the rear 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 WARNING...

Page 38: ...istance may be longer with the ABS than without The ABS is monitored by an ECU which will revert the system to conven tional braking if a malfunction occurs TIP The ABS performs a self diagno sis test each time the vehicle is turned on and travels at a speed of 10 km h 6 mi h or higher During this test a clicking noise can be heard and if either brake lever is even slightly applied a vibration can...

Page 39: ...moved To install the 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 the lid WARNING EWA11263 Make sure that the fuel tank cap is properly installed and locked in place before operating the vehicle Leaking fuel is a fire hazard 1 Opening lever 2 Li...

Page 40: ...an dry soft cloth since fuel may deteri orate painted surfaces or plastic parts ECA10072 4 Be sure to securely close the fuel tank cap WARNING EWA15152 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If ...

Page 41: ...his 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 sy...

Page 42: ...der To secure a helmet to the helmet holder 1 Open the seat See page 3 10 2 Pass the helmet holding cable through the buckle 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 Never ride with a helmet attached to the helmet holder since the helmet may hit o...

Page 43: ...g and closing information To store a helmet in the rear storage compartment place the helmet upside down with the front fac ing to the left side NOTICE The shad ed area is not a storage compartment To prevent damaging the seat hinges do not place any items in this area ECA16092 TIP Some helmets cannot be stored in the rear storage compartment be cause of their size or shape Do not leave your scoot...

Page 44: ...ng valuable or breakable in the storage com partment Since the storage compartment accumulates heat from the en gine and from direct sunlight do not store anything suscepti ble to heat such as food or flammable items inside the compartment WARNING EWA15861 Do not exceed the following loading limits Front storage compartment 1 kg 2 lb Rear storage compartment 5 kg 11 lb Maximum load for the vehicle...

Page 45: ...ews 6 Tighten the screws to the specified torque WARNING A loose wind shield could cause an accident Be sure to tighten the screws to the specified torque EWA15511 7 Place the screw access covers and then install the quick fasten ers 1 Screw 1 Rubber cap 1 Rubber cap 1 1 1 1 1 1 1 Screw Tightening torque Windshield screw 10 Nm 1 0 m kgf 7 2 ft lbf 1 Screw access cover 1 1 1 2PW 9 E1 book 20 ページ２０...

Page 46: ...essurized 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 resu...

Page 47: ...erator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly and have a Yamaha dealer repair it if it does not function properly EAU66770 Ignition circuit cut off system The ignition circuit cut off system com pris...

Page 48: ...Move the sidestand down Does 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 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 ...

Page 49: ...herwise the fuse may blow or the battery may discharge This vehicle is equipped with an auxilia ry DC jack A 12 V accessory connected to the auxiliary DC jack can be used when the key is in the ON position and should only be used when the engine is run ning To use the auxiliary DC jack 1 Turn the key to OFF 2 Remove the auxiliary DC jack cap 3 Turn the accessory off 4 Insert the accessory plug int...

Page 50: ...nections 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 recommended 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 ne...

Page 51: ...ssary 7 25 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 7 26 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha de...

Page 52: ...EAU63621 TIP This model is equipped with a lean angle sensor to stop the en gine in case of a turnover In this case the display will indicate error code 30 but this is not a malfunc tion Turn the vehicle power off and then on to clear the error code Failing to do so will prevent the en gine from starting even though the engine will crank when pushing the start switch an engine auto stop system The...

Page 53: ...for a few seconds and then go off For ABS models 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 ECA21980 If the engine warning light or the ABS warning light for ABS equipped models does not come on and then go off as explained above see page 4 1 for the warning light circuit...

Page 54: ...ad just the rear view mirrors 3 Switch the turn signals on 4 Check for oncoming traffic and then slowly turn the throttle grip on the right in order to take off 5 Switch the turn signals off EAU16782 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 d...

Page 55: ...es on road con struction sites and manhole covers become extremely slip pery when wet Therefore slow down when approaching such areas and cross them with cau tion Keep in mind that braking on a wet road is much more difficult Ride slowly down a hill as brak ing downhill can be very diffi cult 1 Close the throttle completely 2 Apply both front and rear brakes simultaneously while gradually in creas...

Page 56: ... 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 4100 r min NOTICE After 1000 km ...

Page 57: ...ed 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 park near grass or other flammable materials which might catch fire TIP Even when the vehicle is parked in a lo cation partitioned by a fence or the glass window of a shop if the smart key is within operating range other people will be able to start the engine and op er...

Page 58: ...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 ...

Page 59: ...ment 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 addit...

Page 60: ...isk 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 synchroniza...

Page 61: ...y 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...

Page 62: ...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...

Page 63: ...ke 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 thrott...

Page 64: ... To remove the panel 1 Remove the quick fasteners 2 Remove the panel by pulling it out ward as shown To install the panel Place the panel in the original position and then install the quick fasteners Panel B To remove the panel 1 Remove the quick fastener 2 Release the sides of the panel by pulling its upper left and right sides to unhook them as shown 1 Panel A 2 Panel B 3 Panel C 1 Panel D 2 3 1...

Page 65: ... projec tions and then push the panel into its original position 3 Install the quick fastener 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 the original position and then install the screws Panel D To remove the panel Remove the screws and then pull the panel outward 1 Screw 2 Panel C 2 1 2PW 9 E1 book 8 ページ２０１５年９...

Page 66: ...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 deale...

Page 67: ... 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 NOTICE ECA11291 The engine must be cold before pro ceeding with the oil level check oth erwise the check will result in...

Page 68: ... Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap the engine oil drain bolt and its gasket to drain the oil from the crankcase 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 1 Engine oil level check window 2 Maximum ...

Page 69: ...ll 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 1 Oil filter wrench 2 Oil filter cartridge 1 O ring 2 1 1 1 Torque wrench Tightening torque Oil filter cartridg...

Page 70: ...eached the indicator must be reset after the oil change for the next periodic oil change to be indicated at the correct time EAU20071 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU52024 To check the coolant level 1 Place the vehicle on the center stand TIP The coo...

Page 71: ...er has been used instead of coolant replace it with cool ant 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 ECA10473 6 Install the coolant reservoir cover by insta...

Page 72: ... page 7 7 2 Remove the air filter case cover by removing the screws 3 Pull the air filter element out 4 Insert a new air filter element into the air filter case NOTICE Make sure that the air filter element is properly seated in the air filter case The engine should never be operated without the air filter element installed otherwise the piston s and or cylinder s may become excessively worn ECA104...

Page 73: ... adjust ing screw To increase the engine idling speed turn the screw in di rection a To decrease the en gine idling speed turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment 3 Install the panel EAU21386 Checking the throttle grip free play Measure the throttle grip free play as shown Periodically check the t...

Page 74: ...t Therefore it is essential to maintain the tires in good condition at all times and replace them at the appropriate time with the speci fied tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10504 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire air pressure mu...

Page 75: ...he 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...

Page 76: ... warpage or oth er damage before each ride If any damage is found have a Yamaha dealer replace 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 tir...

Page 77: ...ke 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 ...

Page 78: ...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 pr...

Page 79: ...o 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...

Page 80: ...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 Cha...

Page 81: ...ndition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING Damage to the outer housing of cables may result in in ternal rusting and cause interfer ence with cable movement Replace damaged cables as soon as possi ble to prevent unsafe cond...

Page 82: ... 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 front and rear brake levers Front brake lever Rear brake lever The pivoting points of th...

Page 83: ...e 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 ther...

Page 84: ...urely support the vehicle so there is no danger of it falling over EWA10752 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23292 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tio...

Page 85: ...ro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories NOTICE ECA16522 To charge a VRLA ...

Page 86: ... EAU54025 Replacing the fuses The main fuse box and the fuse box which contains the fuses for the individ ual circuits are located under panel B See page 7 7 If a fuse is blown replace it as follows 1 Turn the vehicle power off 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 extens...

Page 87: ...ing system fuse 5 Ignition fuse 6 Parking lighting fuse 7 Radiator fan motor fuse 8 Fuel injection system fuse 9 Backup fuse 10 Spare fuse 1 2 3 4 5 6 7 7 7 8 9 7 2 3 4 5 6 7 8 9 10 1 1 Spare fuse 2 ABS solenoid fuse 3 ABS motor fuse 4 Headlight fuse 5 ABS control unit fuse 6 Auxiliary DC jack fuse Specified fuses Main fuse 40 0 A Headlight fuse 10 0 A Signaling system fuse 15 0 A Ignition fuse 7 ...

Page 88: ...ck the electrical system EAU64070 Headlights This model is equipped with LED type headlights If a headlight does not come on have a Yamaha dealer check its electrical cir cuit NOTICE ECA16581 Do not affix any type of tinted film or stickers to the headlight lens 2PW 9 E1 book 31 ページ２０１５年９月１０日木曜日午後５時１７分 ...

Page 89: ...l 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 2PW 9 E1 book 32 ページ２０１５年９月１０日木曜日午後５時１７分 ...

Page 90: ...ushing it in and turning it counter clockwise 4 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 5 Install the socket together with the bulb by turning it clockwise EAUT1331 Rear turn signal light bulb If a rear turn signal light does not come on have a Yamaha dealer check the electrical circuit or replace the bulb 1 Turn signal light bulb socket 1 Turn signa...

Page 91: ...cking these vital systems your self However should your scooter re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the scooter prop erly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills...

Page 92: ... the vehicle Is the vehicle battery discharged When the vehicle battery is dis charged the smart key system will not operate Please have the vehi cle battery charged or replaced See page 7 28 If the smart key system does not work after checking the above mentioned items have a Yamaha dealer check the smart key system TIP Refer to emergency mode on page 7 38 on how to start the engine without using...

Page 93: ...lead connections and have a Yamaha dealer charge the battery if necessary 2 Battery The battery is good The engine does not start Check the ignition 3 Ignition Wet Operate the electric starter Dry There is compression There is no compression The engine does not start Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle The engine does not start Check the compression Have a...

Page 94: ...ssing sound has stopped 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 recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator Add coolant See TIP The coolant level is OK There is no leak...

Page 95: ...e seat and check that the trunk light comes on 4 Push the ON switch once 5 Without completely shutting the seat raise and lower it three times within 10 seconds TIP Use the rear storage compartment light as a guide when raising and lowering the seat The smart key system indicator light on the speedometer will come on for three seconds to indicate the transition to emergency mode 6 After the smart ...

Page 96: ...en either one of the following situa tions apply In this case start over again from step 4 When there are no SEAT OPEN switch operations for 10 seconds during the identifica tion number input process When the smart key system indi cator light is allowed to flash 10 or more times 8 Press the ON switch while the smart key system indicator light is flashing to turn on the power to the vehicle The eng...

Page 97: ...cts from the overall appearance of a scooter Fre quent and proper care does not only comply with the terms of the warranty but it will also keep your scooter looking good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors in...

Page 98: ...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...

Page 99: ...tal including chrome and nickel plat ed surfaces 4 Use spray oil as a universal clean er to remove any remaining dirt 5 Touch up minor paint damage caused by stones etc 6 Wax all painted surfaces 7 Let the scooter dry completely be fore storing or covering it WARNING EWA10943 Contaminants on the brakes or tires can cause loss of control Make sure that there is no oil or wax on the brakes or tires ...

Page 100: ...k plugs and then place the spark plugs on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps WARNING To prevent damage or injury from sparking mak...

Page 101: ...Scooter care and storage 8 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 storing the scooter 2PW 9 E1 book 5 ページ２０１５年９月１０日木曜日午後５時１７分 ...

Page 102: ...e or higher JASO stan dard MA Engine oil quantity Oil change 2 70 L 2 85 US qt 2 38 Imp qt With oil filter removal 2 90 L 3 07 US qt 2 55 Imp qt Coolant quantity Coolant reservoir up to the maximum level mark 0 27 L 0 29 US qt 0 24 Imp qt Radiator including all routes 1 50 L 1 59 US qt 1 32 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasolin...

Page 103: ... wheel Wheel type Cast wheel Rim size 15M C x MT5 00 Front brake Type Hydraulic dual disc brake Specified brake fluid DOT 4 Rear brake Type Hydraulic single disc brake Specified brake fluid DOT 4 Front suspension Type Telescopic fork Spring Coil spring Shock absorber Hydraulic damper Wheel travel 120 mm 4 7 in Rear suspension Type Swingarm Spring Coil spring Shock absorber Gas hydraulic damper Whe...

Page 104: ...t LED Fuse s Main fuse 40 0 A Headlight fuse 10 0 A Signaling system fuse 15 0 A Ignition fuse 7 5 A Parking lighting fuse 10 0 A Radiator fan motor fuse 15 0 A Fuel injection system fuse 7 5 A ABS control unit fuse 7 5 A XP500A ABS motor fuse 30 0 A XP500A ABS solenoid fuse 15 0 A XP500A Auxiliary DC jack fuse 5 0 A Backup fuse 7 5 A 2PW 9 E1 book 3 ページ２０１５年９月１０日木曜日午後５時１７分 ...

Page 105: ...spare parts from a Yamaha dealer VEHICLE IDENTIFICATION NUM BER ENGINE SERIAL NUMBER MODEL LABEL INFORMATION EAU26411 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 EAU26442 Engine serial number The engine serial ...

Page 106: ...he model label is affixed to the inside of the rear storage compartment See page 4 18 Record the information on this label in the space provided This in formation will be needed when ordering spare parts from a Yamaha dealer 1 Model label 1 2PW 9 E1 book 2 ページ２０１５年９月１０日木曜日午後５時１７分 ...

Page 107: ...1 Helmet holder 4 17 High beam indicator light 4 1 Horn switch 4 10 How to lock the steering 3 10 I Identification numbers 10 1 Ignition circuit cut off system 4 22 Indicator lights and warning lights 4 1 K Key handling of smart and mechanical key 3 3 L License plate light bulb replacing 7 34 M Maintenance and lubrication periodic 7 4 Maintenance emission control system 7 3 Matte color caution 8 1...

Page 108: ...res 7 17 Tool kit 7 2 Troubleshooting 7 34 Troubleshooting charts 7 36 Turn signal indicator lights 4 1 Turn signal light bulb front replacing 7 33 Turn signal switch 4 10 V Valve clearance 7 17 Vehicle identification number 10 1 Vehicle power on and steering lock release 3 8 W Wheel bearings checking 7 27 Wheels 7 19 Windshield 4 19 2PW 9 E1 book 2 ページ２０１５年９月１０日木曜日午後５時１７分 ...

Page 109: ......

Page 110: ...PRINTED IN JAPAN 2015 10 0 5 1 E PRINTED ON RECYCLED PAPER Original instructions ...

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Yamaha Tmax XP500 2016, Owner'S Manual

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