2005 YAMAHA TMAX ECU

SAFETY INFORMATION
1-3
1
Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit of
XP500 190 kg (419 lb) XP500A 185 kg
(408 lb). 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. Make sure
to distribute the weight as evenly
as possible on both sides of the
scooter to minimize imbalance or
instability.

Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the scooter before
riding. Check accessory mounts
and cargo restraints frequently.

Never attach any large or heavy
items to the handlebar, front fork,
or front fender. Such items can
create unstable handling or a slow
steering response.Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this scooter. Since Yamaha cannot test
all other accessories that may be avail-
able, you must personally be responsi-
ble for the proper selection, installation
and use of non-Yamaha accessories.
Use extreme caution when selecting
and installing any accessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.


Never install accessories or carry
cargo that would impair the perfor-
mance of your scooter. Carefully
inspect the accessory before using
it to make sure that it does not in
any way reduce ground clearance
or cornering clearance, limit sus-
pension travel, steering travel or
control operation, or obscure lights
or reflectors.

Accessories fitted to the handle-
bar or the front fork area can
create instability due to improperweight 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 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 may
also cause instability when
passing or being passed by
large vehicles.

Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.

Use caution when adding electri-
cal accessories. If electrical acces-

3-1
2
34
5
6
7
8
9

INSTRUMENT AND CONTROL FUNCTIONS
EAU10972
Immobilizer system
This vehicle is equipped with an immo-
bilizer system to help prevent theft by
re-registering codes in the standard
keys. This system consists of the fol-
lowing.

a code re-registering key (with a
red bow)

two standard keys (with a black
bow) that can be re-registered with
new codes

a transponder (which is installed in
the code re-registering key)

an immobilizer unit

an ECU

an immobilizer system indicator
light (See page 3-3.)
The key with the red bow is used to reg-
ister codes in each standard key. Since
re-registering is a difficult process, take
the vehicle along with all three keys to
a Yamaha dealer to have them re-reg-
istered. Do not use the key with the red
bow for driving. It should only be used
for re-registering the standard keys. Al-
ways use a standard key for driving.
CAUTION:

ECA11820

DO NOT LOSE THE CODE
RE-REGISTERING KEY! CON-
TACT YOUR DEALER IMMEDI-
ATELY IF IT IS LOST! If the code
re-registering key is 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 or all keys are lost) the en-
tire immobilizer system must be
replaced. Therefore, it is highlyrecommended to use either
standard key and keep the code
re-registering key in a safe
place.

Do not submerse any key in wa-
ter.

Do not expose any key to exces-
sively high temperatures.

Do not place any key close to
magnets (this includes, but not
limited to, products such as
speakers, etc.).

Do not place heavy items on any
key.

Do not grind any key or alter its
shape.

Do not disassemble the plastic
part of any key.

Do not put two keys of any im-
mobilizer system on the same
key ring.

Keep the standard keys as well
as keys of other immobilizer
systems away from this vehi-
cle’s code re-registering key.

Keep other immobilizer system
1. Code re-registering key (red bow)
2. Standard keys (black bow)

INSTRUMENT AND CONTROL FUNCTIONS
3-11
2
34
5
6
7
8
9

EAU12900
Front brake lever
The front brake lever is located on the
right handlebar grip. To apply the front
brake, pull this lever toward the handle-
bar grip.
EAU12950
Rear brake lever
The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the handle-
bar grip.
EAU12962
Rear brake lock lever
This vehicle is equipped with 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.
NOTE:


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
1. Front brake lever
1

1. Rear brake lever
1

1. Rear brake lock lever
1

INSTRUMENT AND CONTROL FUNCTIONS
3-12
1
2
3
4
5
6
7
8
9
rear wheel, apply the rear brake le-
ver first before moving the rear

brake lock lever to the left.
WARNING

EWA12361
Never move the rear brake lock lever
to the left while the vehicle is mov-
ing, otherwise loss of control or an
accident may result. Make sure that
the vehicle is stopped before mov-
ing the rear brake lock lever to the
left.
EAU12991
ABS (for ABS models)
The Yamaha ABS (Anti-lock Brake
System) features a dual electronic con-
trol system, which acts on the front and
rear brakes independently. The ABS
securely controls wheel lockup during
emergency braking on changing road
surfaces and under various weather
conditions, thereby maximizing tire ad-
hesion and performance while provid-
ing a smooth braking action. The ABS
is monitored by an ECU (Electronic
Control Unit), which will have recourse
to manual braking if a malfunction oc-
curs.
WARNING

EWA10090

The ABS performs best on long
braking distances.

On certain (rough or gravel)
roads, the braking distance may
be longer with than without the
ABS. Therefore, always keep a
sufficient distance to the vehi-
cle ahead to match the riding
speed.
NOTE:


When the ABS is activated, the
brakes are operated in the usual
way. A pulsating action may be felt
at the brake levers, but this does
not indicate a malfunction.

This ABS has a test mode which
allows the owner to experience the
pulsating at the brake levers when
the ABS is operating. However,
special tools are required, so
please consult your Yamaha deal-
er when performing this test.

INSTRUMENT AND CONTROL FUNCTIONS
3-16
1
2
3
4
5
6
7
8
9
3. Slide the backrest forward or back-
ward to the desired position.
4. Install and securely tighten the
backrest bolts.
5. Close the seat.

EAU14340
Helmet holder
The helmet holder is located under the
seat. A helmet holding cable is provid-
ed beside the owner’s tool kit to secure
a helmet to the helmet holder.
To secure a helmet to the helmet
holder
1. Open the seat. (See page 3-15.)
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. Securely close the seat.
WARNING

EWA10160
Never ride with a helmet attached tothe helmet holder, since the helmet
may hit objects, causing loss of con-
trol and possibly an accident.
To release the helmet from the hel-
met holder
Open the seat, remove the helmet
holding cable from the helmet holder
and the helmet, and then close the
seat.
1. Rider backrest
2. Bolt
1
2

1. Helmet holder
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
2
3
4
5
67
8
9

EAU33600
Tires
To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING

EWA10500

The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).

The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
WARNING

EWA11200
Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your vehicle, you should keep
the following precautions in mind.

NEVER OVERLOAD THE VEHI-
CLE! Operation of an overload-
ed vehicle may result in tire
damage, loss of control, or se-vere injury. Make sure that the
total weight of rider, passenger,
cargo, and accessories does
not exceed the specified maxi-
mum load for the vehicle.

Do not carry along loosely
packed items, which can shift
during a ride.

Securely pack the heaviest
items close to the center of the
vehicle and distribute the
weight evenly on both sides.

Adjust the tire air pressure with
regard to the load.

Check the tire condition and air
pressure before each ride.
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb) :
Front:
225 kPa (33 psi) (2.25 kgf/cm
2

)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2

)
XP500 90–190 kg (198–419 lb)
XP500A 90–185 kg (198–408 lb) :
Front:
225 kPa (33 psi) (2.25 kgf/cm
2

)
Rear:
280 kPa (41 psi) (2.80 kgf/cm
2

)
Maximum load*:
XP500 190 kg (419 lb)
XP500A 185 kg (408 lb)
* Total weight of rider, passenger,
cargo and accessories

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
1
2
3
4
5
6
7
8
9

EAU23271
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 condition
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
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.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
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.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
2
3
4
5
67
8
9

EAU23760
Replacing the headlight bulb
This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
1. Disconnect the headlight coupler,
and then remove the bulb cover.
2. Unhook the headlight bulb holder,
and then remove the defective
bulb.
WARNING

EWA10790
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
3. Place a new headlight bulb into po-
sition, and then secure it with the
bulb holder.
CAUTION:

ECA10660
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency ofthe glass, the luminosity of the bulb,
and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al-
cohol or thinner.
4. Install the headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Headlight coupler
2. Headlight bulb cover
1
2

1. Headlight bulb holder
2. Unhook.
1
2

1. Do not touch the glass part of the bulb.
1