Yamaha Tmax XP500Z Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

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EAU17391

Owner’s tool kit

The owner’s tool kit is located under the
seat. (See page 4-14.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.

TIP

If you do not have the tools or experi-
ence required for a particular job, have

a Yamaha dealer perform it for you.

1. Helmet holding cable

2. Owner’s tool kit

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2

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Summary of Contents for Tmax XP500Z

Page 1: ...OWNER S MANUAL 4B5 28199 11 XP500Z LIT 11626 23 72 Read this manual carefully before operating this vehicle...

Page 2: ...EAU10042 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold Q Q Q Q...

Page 3: ...high standards it is important that you and your Yamaha dealer pay close attention to the rec ommended maintenance schedules and operating instructions contained within this manual Yamaha continually...

Page 4: ...ersonal 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 seriou...

Page 5: ...MANUAL 2009 by Yamaha Motor Corporation U S A 1st edition August 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expres...

Page 6: ...DIC MAINTENANCE AND ADJUSTMENT 7 1 Owner s tool kit 7 2 Periodic maintenance chart for the emission control system 7 3 General maintenance and lubrication chart 7 4 Removing and installing panels 7 8...

Page 7: ...OTER CARE AND STORAGE 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 Scooter noise regulation 10 3 Maintenance record 10 4 YA...

Page 8: ...e labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a...

Page 9: ...LOCATION OF IMPORTANT LABELS 1 2 1 2 3 4 5 6 7 8 9 1 2 3 4 4B5 21686 00 5RU 24877 A0 WARNING AVERTISSEMENT 6 5 3LD 24877 A0 7 8 9...

Page 10: ...LOCATION OF IMPORTANT LABELS 1 3 1 2 3 4 5 6 7 8 9 1 2...

Page 11: ...LOCATION OF IMPORTANT LABELS 1 4 1 2 3 4 5 6 7 8 9 1 2 5RU 24877 A0 LOAD LIMIT 2 kg 4 lbs 225 2 25 33 250 2 50 36 225 2 25 33 280 2 80 41 5VU 21668 00...

Page 12: ...senger The failure of motorists to detect and recognize scooters in traffic is the predominating cause of auto mobile scooter accidents Many accidents have been caused by an automobile driver who did...

Page 13: ...a hazard The use of a jacket substantial shoes trousers gloves etc is ef fective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the...

Page 14: ...nd cargo are securely attached to the scooter before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and c...

Page 15: ...area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the scooter due to aerodynamic effects Wind may attempt t...

Page 16: ...s iron plates on road construction sites and manhole covers be come extremely slippery when wet Slow down and cross them with caution Keep the scooter up right otherwise it could slide out from under...

Page 17: ...ir filter element left 3 Helmet holder page 4 15 4 Rear storage compartment page 4 16 5 Grab bar page 6 2 6 Chain drive oil filler cap page 7 15 7 Engine oil filler cap page 7 12 8 Sidestand page 4 18...

Page 18: ...9 EAU10420 Right view 2 6 5 7 1 3 4 1 Owner s tool kit page 7 2 2 Air filter element page 7 18 3 Battery page 7 28 4 Fuses page 7 29 5 Coolant level check window page 7 16 6 V belt air filter element...

Page 19: ...Rear brake lock lever page 4 10 4 Coolant temperature gauge page 4 3 5 Speedometer page 4 2 6 Multi function display page 4 4 7 Fuel gauge page 4 2 8 Right handlebar switches page 4 8 9 Front brake l...

Page 20: ...CK while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of control or an accident EAU10683 LOCK The steering is locked and all electrical systems...

Page 21: ...when the key is turned to ON and the start switch is pushed but this does not indi cate a malfunction EAU11601 Speedometer The speedometer shows the riding speed When the key is turned to ON the speed...

Page 22: ...key is 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...

Page 23: ...uel in the fuel tank reaches approximately 3 0 L 0 79 US gal 0 66 Imp gal a self diagnosis device a clock an oil change tripmeter which shows the distance traveled since the last engine oil change a V...

Page 24: ...set the minutes 5 Push the SELECT button and then release it to start the clock Odometer and tripmeter modes Pushing the SELECT button switches the display between the odometer mode and the tripmeter...

Page 25: ...t 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 second When pushing the RESET...

Page 26: ...lt 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...

Page 27: ...itch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or wh...

Page 28: ...rk on the front brake le ver EAU44921 Rear brake 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 leve...

Page 29: ...ock 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 To provide secure locki...

Page 30: ...can be removed 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 positi...

Page 31: ...ed fuel with a clean dry soft cloth since fuel may deteri orate painted surfaces or plastic parts ECA10071 4 Be sure to securely close the fuel tank cap WARNING EWA15151 Gasoline is poisonous and can...

Page 32: ...model is equipped with a catalytic 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 f...

Page 33: ...seat up To close the seat 1 Fold the seat 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 p...

Page 34: ...helmet to the helmet holder 1 Open the seat See page 4 14 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 Securel...

Page 35: ...ore a helmet in the rear storage compartment place the helmet upside down with the front fac ing the left side NOTICE Keep the following points in mind when using the storage compartment Since the sto...

Page 36: ...CA16091 TIP Some helmets cannot be stored in the rear storage compartment be cause of their size or shape Do not leave your scooter unat tended with the seat open WARNING EWA11241 Do not exceed the lo...

Page 37: ...any service EAU15303 Sidestand The sidestand is 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 switc...

Page 38: ...e light 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...

Page 39: ...engine start With the engine still running 9 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 shou...

Page 40: ...amaha dealer Before using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 12 Engine oil Check oil level in...

Page 41: ...and grip housing 7 19 7 25 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 19 7 21 Brake levers Make sure that operation is smooth Lub...

Page 42: ...o so will prevent the engine from starting even though the engine will crank when pushing the start switch EAU45952 Starting the engine NOTICE ECA10250 See page 6 3 for engine break in in structions p...

Page 43: ...re than 10 seconds on any one at tempt EAU45091 Starting off 1 While pulling the rear brake lever with your left hand and holding the grab bar with your right hand push the scooter off the centerstand...

Page 44: ...gradually in creasing the pressure Front Rear EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason y...

Page 45: ...a Yamaha dealer check the vehi cle 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 p...

Page 46: ...e unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead...

Page 47: ...ls provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perf...

Page 48: ...or 6 months 8000 mi 13000km or 12 months 12000 mi 19000km or 18 months 16000 mi 25000km or 24 months 20000 mi 31000km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessa...

Page 49: ...km 2 V belt case air filter elements Clean 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakag...

Page 50: ...and pivots Check operation Apply lithium soap based grease lightly 15 Sidestand switch Check operation and replace if necessary 16 Front fork Check operation and for oil leakage Replace if necessary 1...

Page 51: ...Front and rear brake switches Check operation 24 Control cables Apply Yamaha chain and cable lube or engine oil thoroughly 25 Throttle grip housing and cable Check operation and free play Adjust the...

Page 52: ...to be replaced and the V belt air filter elements need to be serviced more frequent ly when riding in unusually wet or dusty areas Hydraulic brake service After disassembling the brake master cylinde...

Page 53: ...a panel needs to be removed and installed EAU48621 Panel A To remove the panel 1 Remove the quick fasteners 2 Remove the panel by pulling its upper left and right sides to un hook them then pulling t...

Page 54: ...and then install the screws 2 Install the rear view mirrors by in stalling the nuts and then place the rubber cover on each mirror in the original position 3 Install panel A Panel C To remove the pane...

Page 55: ...removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator aro...

Page 56: ...e 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 EAU36110 Canister This model is equipped with a canister to p...

Page 57: ...false reading 3 Wait two minutes until the oil set tles and then check the oil level through the check window located at the bottom left side of the crank case TIP The engine oil should be between th...

Page 58: ...dge is not being replaced 6 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a Yamaha dealer 7 Apply a thin coat of clean engine oil to the O ring of...

Page 59: ...cooled down NOTICE ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD o...

Page 60: ...ic maintenance and lubrica tion chart 1 Place the vehicle on a level sur face 2 Remove panel E See page 7 8 3 Place an oil pan under the chain drive case to collect the used oil 4 Remove the chain dri...

Page 61: ...ause 11 Install the panel EAU20070 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 lubr...

Page 62: ...it is harmful to the engine If water 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 w...

Page 63: ...ews 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 shoul...

Page 64: ...ic maintenance and lubrication chart EAU36132 Tires To maximize the performance durabil ity and safe operation of your vehicle note the following points regarding the specified tires Tire air pressure...

Page 65: ...erating the scooter with exces sively worn tires decrease riding stability and can lead to loss of con trol Have excessively worn tires re placed by a Yamaha dealer immediately Brakes tires and relat...

Page 66: ...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...

Page 67: ...lock lever cable Rear brake lock lever cable adjustment may be required if the rear brake lock le ver does not hold properly When the rear brake lock lever is not in use the rear brake lock lever cabl...

Page 68: ...r 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 dama...

Page 69: ...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...

Page 70: ...maged or leak ing Oil seals Replace every two years Brake hoses Replace every four years EAU23112 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be chec...

Page 71: ...ts and met al to metal contact surfaces should be lubricated if necessary WARNING EWA10741 If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it O...

Page 72: ...push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly NOTICE ECA10590 If any damage is found or the front fork does not operate smoothly have a Ya...

Page 73: ...60 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 batteri...

Page 74: ...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 necessary 3 Fully...

Page 75: ...ler check the electrical system 1 Main fuse 2 Spare main fuse 1 Fuse box 1 2 1 1 Headlight fuse 2 Ignition fuse 3 Backup fuse for clock and rear storage compartment light 4 Radiator fan fuse 5 Fuel in...

Page 76: ...prints on the headlight 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 wat...

Page 77: ...gnal light bulb 1 Remove the front turn signal light lens by removing the screw 2 Remove the burnt out bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push i...

Page 78: ...ate light bulb 1 Remove the license 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 in...

Page 79: ...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...

Page 80: ...ession Check the ignition Have a Yamaha dealer check 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 spa...

Page 81: ...When the hissing 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 t...

Page 82: ...ng 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 including the spark plug cap ar...

Page 83: ...gent and a soft clean sponge and then rinse thoroughly 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 cover...

Page 84: ...m with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid...

Page 85: ...age 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 as we...

Page 86: ...dge replacement 2 90 L 3 07 US qt 2 55 Imp qt Chain drive oil Type SAE 80 API GL 4 Hypoid gear oil Quantity 0 70 L 0 74 US qt 0 62 Imp qt Cooling system Coolant reservoir capacity up to the maxi mum l...

Page 87: ...l type Cast wheel Rim size 15M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 15M C x MT5 00 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Ty...

Page 88: ...er lighting LED High beam indicator light LED Turn signal indicator light LED x 2 Engine trouble warning light LED Fuses Main fuse 30 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system f...

Page 89: ...HICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EAU26381 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for...

Page 90: ...This in formation will be needed when ordering spare parts from a Yamaha dealer EAU48270 Vehicle Emission Control Informa tion label The Vehicle Emission Control Informa tion label is affixed at the...

Page 91: ...incorporated into any new ve hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or elem...

Page 92: ...rt below is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address R...

Page 93: ...CONSUMER INFORMATION 10 5 2 3 4 5 6 7 8 9 10 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks...

Page 94: ...ine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 day...

Page 95: ...sale and upon your request at any later date Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The rem...

Page 96: ...t have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation In...

Page 97: ...ng you ll have strong factory backed protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your...

Page 98: ...icator and warning lights 4 1 K Key identification number 10 1 L Labels location 1 1 License plate light bulb replacing 7 33 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 4 Ma...

Page 99: ...INDEX Vehicle Emission Control Information label 10 2 Vehicle identification number 10 1 W Warranty extended 10 8 Warranty limited 10 6 Wheel bearings checking 7 28 Wheels 7 21...

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Page 102: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2009 09 0 1 1 E...

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