2003 YAMAHA TMAX oil

6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EW000119
w
Headlight bulbs get very hot.
Therefore, keep flammable prod-
ucts away from a lit headlight bulb,
and do not touch the bulb until it
has cooled down.
3. Place a new bulb into position,
and then secure it with the bulb
holder.
a
a. Do not touch the glass part of the bulb.
EAU03087
TroubleshootingTroubleshooting
Although Yamaha scooters receive a
thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition sys-
tems, for example, can cause poor
starting and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your scooter
require any repair, take it to a
Yamaha dealer, whose skilled techni-
cians have the necessary tools,
experience, and know-how to service
the scooter properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life
and can lead to expensive repair
bills.
EC000105
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Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the
bulb, and the bulb life will be
adversely affected. Thoroughly
clean off any dirt and fingerprints
on the headlight bulb using a cloth
moistened with alcohol or thinner.
4. Install the bulb cover, and then
connect the coupler.
5. Have a Yamaha dealer adjust
the headlight beam if necessary.
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7-1
EAU03873
SCOOTER CARE AND STORAGE
7
CareCare
While the open design of a scooter
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go
unnoticed on a car, however, it
detracts from the overall appearance
of a scooter. Frequent 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 perfor-
mance.Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and cov-
ers as well as all electrical cou-
plers and connectors, including
the spark plug cap, are tightly
installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such
products onto seals, gaskets and
wheel axles. Always rinse the dirt
and degreaser off with water.CleaningECA00011
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8
8
Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If such prod-
ucts are used on hard-to-
remove dirt, do not leave the
cleaner on the affected area
any longer than instructed.
Also, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection spray.
8 8
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent
and water to clean plastic.
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7-3
SCOOTER CARE AND STORAGE
7After cleaning
1. Dry the scooter with a chamois
or an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, includ-
ing chrome- and nickel-plated,
surfaces.
4. Use spray oil as a universal
cleaner 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
before storing or covering it.
EWA00002
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8 8
Make sure that there is no oil
or wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
8 8
Before operating the scooter
test its braking performance
and cornering behavior.
ECA00013
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8
8
Apply spray oil and wax spar-
ingly and make sure to wipe
off any excess.
8 8
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
8 8
Avoid using abrasive polish-
ing compounds as they will
wear away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
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7-4
SCOOTER CARE AND STORAGE
7
Storage
Storage
Short-term
Always store your scooter in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00015
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8
8
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.
8 8
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 for sever-
al months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Drain the carburetor float cham-
bers by loosening the drain bolts;
this will prevent fuel deposits
from building up. Pour the
drained fuel into the fuel tank.
3. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
4. Perform the following steps to
protect the cylinders, piston
rings, etc. from corrosion.a. Remove the spark plug caps
and the spark plugs.
b. Pour a teaspoonful of engine
oil into the spark plug bores.
c. Install the spark plug caps
onto the spark plugs, and then
place the spark plugs on the
cylinder head so that the elec-
trodes are grounded. (This will
limit sparking 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.
EWA00003
w
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turn-
ing the engine over.
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8-1
EAU01038
SPECIFICATIONS
8
Specifications
SpecificationsModel XP500
Dimensions
Overall length 2,235 mm
Overall width 775 mm
Overall height 1,410 mm
Seat height 795 mm
Wheelbase 1,575 mm
Ground clearance 130 mm
Minimum turning radius 2,800 mm
Basic weight (with oil and full
fuel tank)217 kg
Engine
Engine type Liquid-cooled 4-stroke, DOHC
Cylinder arrangement Forward inclined 2–cylinder
Displacement 499 cm
3
Bore ×Stroke 66.0 ×73.0 mm
Compression ratio 10.1:1
Starting system Electric starter
Lubrication system Dry sumpEngine oil
Type SAE 10W-30 or 10W-40
Recommended engine oil
classification API Service SE, SF, SG
type or higher
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In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a
higher quality than specified. In addition, do not use oils
labeled “ENERGY CONSERVING
II” or higher.
Quantity
Without oil filter cartridge
replacement 2.8 L
With oil filter cartridge
replacement 2.9 L
Total amount (dry engine) 3.6 L
Chain drive oil
Type SAE 80API “GL-4” hypoid
gear oil
Total amount 0.7 L
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8-3
SPECIFICATIONS
8
Wheels
Front
Type Cast wheel
Size 14 M/C ×MT3.50
Rear
Type Cast wheel
Size 14 M/C ×MT4.50
Brakes
Front
Type Single disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Single disc brake
Operation Left hand
Fluid DOT 4Suspension
Front Telescopic fork
Rear Swingarm
Spring/shock absorbers
Front Coil spring/oil damper
Rear Coil spring/gas-oil damper
Wheel travel
Front 120 mm
Rear 120 mm
Electrical
Ignition system Transistorized coil ignition
(digital)
Charging system
Type A.C. magneto
Standard output 14 V, 310W @ 5,000 r/min
Battery
Type GT9B-4
Voltage, capacity 12 V, 8 Ah
Headlight bulb typeHalogen
Bulb voltage, wattage ×quantity
Headlight 12 V, 60/55 W ×1
12 V, 55 W ×1
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8-4
SPECIFICATIONS
8
Tail/brake light 12 V, 5/21 W ×2
Front turn signal light 12 V, 5/21 W ×2
Rear turn signal light 12 V, 21 W ×2
Auxiliary light 12 V, 5 W ×2
License plate light 12 V, 5 W ×1
Meter lighting 12 V, 1.7 W ×3
High beam indicator light 12 V, 1.7 W ×1
Oil change indicator light 12 V, 1.7 W ×1
Turn indicator light 12 V, 3.4 W ×2
V-belt replacement
indicator light 12 V, 1.7 W ×1
Fuses
Main fuse 30 A
Signaling system fuse 15 A
Headlight fuse 15 A
Ignition fuse 10 A
Radiator fan fuse 15 A
Hazard fuse 10 A
Clock fuse (backup fuse) 10 A
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INDEX
F
Front and rear brake levers ..................6-25
Front and rear brake pads, checking ....6-26
Front fork, checking ..............................6-30
Fuel ......................................................3-10
Fuel consumption, tips for reducing .......5-3
Fuel gauge .............................................3-4
Fuel tank cap ..........................................3-9
Fuses, replacing ...................................6-34
H
Handlebar switches ................................3-6
Dimmer switch .....................................3-6
Engine stop switch ...............................3-7
Hazard switch ......................................3-7
Horn switch ..........................................3-7
Pass switch ..........................................3-6
Start switch ..........................................3-7
Turn signal switch ................................3-7
Headlight bulb, replacing ......................6-35
Headlight variations ................................3-8
Helmet holder .......................................3-13
I
Identification numbers ............................9-1
Ignition circuit cut-off system ................3-15
Indicator lights ........................................3-2
High beam indicator light .....................3-3
Oil change indicator light .....................3-2
Turn signal indicator lights ...................3-3
V-belt replacement indicator light ........3-3K
Key identification number .......................9-1
M
Main switch/steering lock .......................3-1
Model label .............................................9-2
P
Parking ...................................................5-4
Part locations ..........................................2-1
Periodic maintenance and lubrication
chart .....................................................6-3
Pre-operation check list ..........................4-1
R
Rider backrest, adjusting ......................3-12
S
Safe-riding points ...................................1-2
Seat ......................................................3-11
Self-diagnosis device .............................3-6
Sidestand .............................................3-14
Spark plugs, checking ............................6-9
Specifications .........................................8-1
Speedometer unit ...................................3-4
Starting off ..............................................5-2
Starting the engine .................................5-1
Steering, checking ................................6-31
Storage ...................................................7-4
Storage compartments .........................3-14A
Acceleration and deceleration ................5-2
Air filter element, cleaning ....................6-19
Anti-theft alarm (optional) .......................3-6
B
Battery ..................................................6-32
Brake fluid level, checking ....................6-27
Brake fluid, changing ............................6-28
Brake lever, front ....................................3-9
Brake lever, rear .....................................3-9
Brake levers, lubricating .......................6-29
Braking ...................................................5-3
C
Carburetors, adjusting ..........................6-21
Care ........................................................7-1
Centerstand and sidestand, checking and
lubricating ..........................................6-29
Chain drive oil .......................................6-15
Clock ......................................................3-5
Conversion table ....................................8-5
Coolant ..................................................6-17
Coolant temperature gauge ....................3-5
Cowlings and panels, removing and
installing ...............................................6-6
E
Engine break-in ......................................5-4
Engine idling speed ..............................6-21
Engine oil and oil filter cartridge ...........6-12
5GJ-28199-E2 9/9/02 9:15 AM Page 98