2004 YAMAHA TMAX Owners Manual

5VU-28199-E0
XP500
PRINTED ON RECYCLED PAPER
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2003.9–0.1×1 !
(E)
OWNER’S MANUAL
5VU-9-E0_hyoushi 9/4/03 11:30 AM Page 1

EAU26941
DECLARATION of CONFORMITY
We
Hereby declare that the product:
is in compliance with following norm(s) or documents: Type-designation:
5SL-00, 5VS-00, 5VX-00, 3HT-00, 5UX-00, 5UX-10, 5KS-00 and 5KS-10
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950(2000)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Place of issue: Shizuoka, Japan
Date of issue: Aug. 1
st 2002 Kind of equipment: IMMOBILIZER Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Company: MORIC CO., LTD.
Kazuji Kawai
representative name and signature
5VU-9-E0_hyoushi2&3 8/19/03 4:16 PM Page 1

INTRODUCTION
EAU10110
Welcome to the Yamaha world of motorcycling!
As the owner of the XP500, you are benefiting from Yamaha’s vast experience and newest technology regarding the design
and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XP500. The owner’s manual does
not only instruct you in how to operate, inspect and maintain your scooter, but also in how to safeguard yourself and others
from trouble 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 fur-
ther questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

IMPORTANT MANUAL INFORMATION
EAU10150
Particularly important information is distinguished in this manual by the following notations:
NOTE:


This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is sub-
sequently sold.

Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your scooter and
this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
WARNING

EWA10030
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER.The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in se
vere injur
y or death
to the
scooter operator, a bystander, or a person inspecting or repairing the scooter.
A CAUTION indicates special precautions that must be taken to avoid damage to
the scooter.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:NOTE:

IMPORTANT MANUAL INFORMATION
EAU10200
XP500
OWNER’S MANUAL
©2003 by Yamaha Motor Co., Ltd.
1st edition, August 2003
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.

TABLE OF CONTENTS
SAFETY INFORMATION ............. 1-1
Further safe-riding points .......... 1-4
DESCRIPTION ............................. 2-1
Left view ..................................... 2-1
Right view................................... 2-2
Controls and instruments ........... 2-3
INSTRUMENT AND CONTROL
FUNCTIONS ................................ 3-1
Immobilizer system ................... 3-1
Main switch/steering lock .......... 3-2
Indicator and warning lights ...... 3-3
Speedometer ............................. 3-4
Tachometer ............................... 3-4
Multi-function display ................. 3-5
Anti-theft alarm (optional) .......... 3-8
Handlebar switches ................... 3-8
Front brake lever ..................... 3-10
Rear brake lever ...................... 3-10
Parking brake .......................... 3-10
Fuel tank cap ........................... 3-11
Fuel ......................................... 3-12
Catalytic converter .................. 3-12
Seat ......................................... 3-13
Adjusting the rider backrest ..... 3-13
Helmet holder .......................... 3-14
Storage compartments ............ 3-15Shock absorber ....................... 3-15
Sidestand ................................ 3-16
Ignition circuit cut-off system ... 3-16
PRE-OPERATION CHECKS ....... 4-1
Pre-operation check list ............ 4-2
OPERATION AND IMPORTANT
RIDING POINTS ........................... 5-1
Starting the engine .................... 5-1
Starting off ................................. 5-2
Acceleration and
deceleration ............................ 5-2
Braking ...................................... 5-2
Tips for reducing fuel
consumption ............................ 5-3
Engine break-in ......................... 5-4
Parking ...................................... 5-4
PERIODIC MAINTENANCE
AND MINOR REPAIR ................... 6-1
Owner’s tool kit ......................... 6-1
Periodic maintenance and
lubrication chart ....................... 6-3
Removing and installing
cowlings and panels ................ 6-6
Checking the spark plugs .......... 6-9Engine oil and oil filter
cartridge ................................ 6-10
Chain drive oil ......................... 6-13
Coolant .................................... 6-14
Cleaning the air filter
element ................................. 6-16
Adjusting the engine idling
speed .................................... 6-17
Adjusting the throttle cable free
play ....................................... 6-18
Adjusting the valve
clearance .............................. 6-18
Tires ........................................ 6-18
Cast wheels ............................ 6-20
Front and rear brake lever
free play ................................ 6-21
Adjusting the parking brake
cable ..................................... 6-21
Checking the front and rear
brake pads ............................ 6-22
Checking the brake fluid
level ....................................... 6-23
Changing the brake fluid ......... 6-24
Checking and lubricating the
throttle grip and cable ........... 6-24
Lubricating the front and rear
brake levers .......................... 6-24

TABLE OF CONTENTS
Checking and lubricating the
centerstand and sidestand .... 6-25
Checking the front fork ............ 6-25
Checking the steering ............. 6-26
Checking the wheel
bearings ................................ 6-27
Battery ..................................... 6-27
Replacing the fuses ................. 6-28
Replacing the headlight
bulb ....................................... 6-30
Troubleshooting ...................... 6-31
Troubleshooting charts ............ 6-32
SCOOTER CARE AND
STORAGE .................................... 7-1
Care .......................................... 7-1
Storage ...................................... 7-3
SPECIFICATIONS ....................... 8-1
CONSUMER INFORMATION ....... 9-1
Identification numbers ............... 9-1

1-1
1
SAFETY INFORMATION
EAU10260
SCOOTERS ARE SINGLE TRACK
VEHICLES. THEIR SAFE USE AND
OPERATION ARE DEPENDENT
UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERA-
TOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIRE-
MENTS BEFORE RIDING THIS
SCOOTER.
HE OR SHE SHOULD:

OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
SCOOTER OPERATION.

OBSERVE THE WARNINGS
AND MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S MAN-
UAL.

OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.

OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECES-SARY BY MECHANICAL CONDI-
TIONS.
Safe riding

Always make pre-operation
checks. Careful checks may help
prevent an accident.

This scooter is designed to carry
the operator and 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 who did not see
the scooter. Making yourself con-
spicuous appears to be very effec-
tive in reducing the chance of this
type of accident.

Therefore:

Wear a brightly colored jacket.

Use extra caution when ap-
proaching and passing through
intersections, since intersec-
tions are the most likely places
for scooter accidents to occur.

Ride where other motorists cansee you. Avoid riding in another
motorist’s blind spot.

Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent driver’s license.

Make sure that you are qualified
and that you only lend your
scooter to other qualified opera-
tors.

Know your skills and limits.
Staying within your limits may
help you to avoid an accident.

We recommend that you prac-
tice riding your scooter where
there is no traffic until you have
become thoroughly familiar with
the scooter and all of its con-
trols.

Many accidents have been caused
by error of the scooter operator. A
typical error made by the operator
is veering wide on a turn due to
EXCESSIVE SPEED or undercor-
nering (insufficient lean angle for