2006 YAMAHA TMAX engine

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
2
3
4
5
67
8
9 Engine overheating
WARNING

EWA10400

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.

After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing
sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
NOTE:

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.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.

7-1
1
2
3
4
5
6
7
8
9

SCOOTER CARE AND STORAGE
EAU37831
Matte black caution
CAUTION:

ECA15191
Some models are equipped with
matte black finished parts. Be sure
to consult a Yamaha dealer for ad-
vice on what products to use before
cleaning the vehicle. Using a brush,
harsh chemical products or clean-
ing compounds when cleaning
these parts will scratch or damage
their surface. Wax also should not
be applied to any matte black fin-
ished parts.
EAU26100
Care
While the open design of a scooter re-
veals the attractiveness of the technol-
ogy, it also makes it more vulnerable.
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. 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, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:

ECA10780

Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.

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.

Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or

SCOOTER CARE AND STORAGE
7-4
2
3
4
5
6
78
9
fuel from deteriorating.
3. Perform the following steps to pro-
tect 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 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

EWA10950
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
4. Lubricate all control cables and thepivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place
[less than 0 °C (30 °F) or more
than 30 °C (90 °F)]. For more in-
formation on storing the battery,
see page 6-28.
NOTE:

Make any necessary repairs before
storing the scooter.

8-1
1
2
3
4
5
6
7
8
9

SPECIFICATIONS
EAU2633E
Dimensions:
Overall length:
2235 mm (88.0 in)
Overall width:
775 mm (30.5 in)
Overall height:
1410 mm (55.5 in)
Seat height:
795 mm (31.3 in)
Wheelbase:
1575 mm (62.0 in)
Ground clearance:
130 mm (5.12 in)
Minimum turning radius:
2800 mm (110.2 in)
Weight:
With oil and fuel:
XP500 225.0 kg (496 lb)
XP500A 230.0 kg (507 lb)
Engine:
Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward-inclined parallel 2-cylinder
Displacement:
499.0 cm
3

(30.45 cu.in)
Bore
×
stroke:
66.0
×
73.0 mm (2.60
×
2.87 in)
Compression ratio:
11.00 :1
Starting system:
Electric starterLubrication system:
Dry sump

Engine oil:
Type:
SAE10W30 or SAE10W40
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Without oil filter cartridge replacement:
2.80 L (2.96 US qt) (2.46 Imp.qt)
With oil filter cartridge replacement:
2.90 L (3.07 US qt) (2.55 Imp.qt)
Chain drive oil:
Type:
SAE80 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 level mark):
0.35 L (0.37 US qt) (0.31 Imp.qt)
Radiator capacity (including all routes):
1.50 L (1.59 US qt) (1.32 Imp.qt)
Air filter:
Air filter element:
Dry element
Fuel:
Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
14.0 L (3.70 US gal) (3.08 Imp.gal)
Fuel injection:
Manufacturer:
AISAN
Model/quantity:
1100-87B60/1100-87B70
Spark plug (s):
Manufacturer/model:
NGK/CR7E
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Clutch:
Clutch type:
Wet, multiple-disc automatic
Transmission:
Primary reduction system:
Spur gear/helical gear
Primary reduction ratio:
52/32
×
36/22 (2.659)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
41/25
×
40/29 (2.262)
Transmission type:
V-belt automatic
Operation:
Centrifugal automatic type

Chassis:
Frame type:
Diamond
Caster angle:
28.00 °
Trail:
95.0 mm (3.74 in)

SPECIFICATIONS
8-3
1
2
3
4
5
6
7
8
9

Tail/brake light:
12 V, 5.0 W/21.0 W
×
2
Front turn signal/position light:
12 V, 21 W/5.0 W
×
2
Rear turn signal light:
12 V, 21.0 W
×
2
Auxiliary light:
12 V, 5.0 W
×
2
License plate light:
12 V, 5.0 W
×
1
Meter lighting:
14 V, 2.0 W
×
3
High beam indicator light:
14 V, 1.4 W
×
1
Turn signal indicator light:
14 V, 1.4 W
×
2
Engine trouble warning light:
14 V, 1.4 W
×
1
ABS warning light:
XP500A 14 V, 1.4 W
×
1
Immobilizer system indicator light:
LED

Fuses:
Main fuse:
30.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
XP500 20.0 A
XP500A 15.0 A
Ignition fuse:
10.0 A
Parking lighting fuse:
10.0 ARadiator fan fuse:
15.0 A
Fuel injection system fuse:
10.0 A
ABS control unit fuse:
XP500A 5.0 A
ABS motor fuse:
XP500A 30.0 A
Backup fuse:
10.0 A

INDEX
A
ABS (for ABS models) .............................3-11
ABS warning light (for ABS models) ..........3-3
Acceleration and deceleration ...................5-2
Air filter element, cleaning .......................6-16
Anti-theft alarm (optional) ..........................3-8
B
Battery .....................................................6-28
Brake fluid, changing ...............................6-24
Brake fluid level, checking .......................6-23
Brake lever, front .....................................3-10
Brake lever, rear ......................................3-10
Brake levers, lubricating ..........................6-25
Braking ......................................................5-3
C
Care ...........................................................7-1
Catalytic converter ...................................3-13
Caution, matte black ..................................7-1
Centerstand and sidestand, checking and
lubricating ..............................................6-25
Chain drive oil ..........................................6-14
Coolant ....................................................6-15
Cowlings and panels, removing and
installing ..................................................6-6
D
Dimmer switch ...........................................3-9
E
Engine break-in .........................................5-4
Engine idling speed .................................6-17
Engine oil and oil filter cartridge ..............6-11
Engine stop switch.....................................3-9
Engine trouble warning light ......................3-3
F
Front and rear brake lever free play ........6-21Front and rear brake pads, checking....... 6-22
Front fork, checking ................................. 6-26
Fuel ......................................................... 3-13
Fuel consumption, tips for reducing .......... 5-4
Fuel tank cap ........................................... 3-12
Fuses, replacing ...................................... 6-29
H
Handlebar switches ................................... 3-8
Hazard switch ............................................ 3-9
Headlight bulb, replacing ......................... 6-31
Helmet holder .......................................... 3-15
High beam indicator light ........................... 3-3
Horn switch................................................ 3-9
I
Identification numbers ............................... 9-1
Ignition circuit cut-off system ................... 3-18
Immobilizer system.................................... 3-1
Immobilizer system indicator light ............. 3-3
Indicator and warning lights....................... 3-3
K
Key identification number .......................... 9-1
M
Main switch/steering lock .......................... 3-2
Model label ................................................ 9-2
Multi-function display ................................. 3-5
P
Parking ...................................................... 5-5
Part locations............................................. 2-1
Pass switch ............................................... 3-9
Periodic maintenance and lubrication
chart ........................................................ 6-3
Pre-operation check list ............................. 4-2
R
Rear brake lock lever .............................. 3-10Rear brake lock lever cable, adjusting .... 6-22
Rider backrest, adjusting......................... 3-14
S
Safe-riding points ...................................... 1-4
Safety information ..................................... 1-1
Seat ......................................................... 3-14
Shock absorber ....................................... 3-17
Sidestand ................................................ 3-17
Spark plugs, checking ............................... 6-9
Specifications ............................................ 8-1
Speedometer............................................. 3-4
Starting off ................................................. 5-2
Starting the engine .................................... 5-1
Start switch................................................ 3-9
Steering, checking................................... 6-27
Storage...................................................... 7-3
Storage compartments ............................ 3-16
T
Tachometer ............................................... 3-4
Throttle cable free play, checking ........... 6-18
Throttle grip and cable, checking and
lubricating ............................................. 6-25
Tires ........................................................ 6-19
Tool kit....................................................... 6-1
Troubleshooting ...................................... 6-32
Troubleshooting charts............................ 6-33
Turn signal indicator lights ........................ 3-3
Turn signal switch ..................................... 3-9
V
Valve clearance....................................... 6-18
Vehicle identification number .................... 9-1
W
Wheel bearings, checking ....................... 6-27
Wheels .................................................... 6-21