2006 YAMAHA TMAX engine coolant

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
Rear brake lock lever .....................3-10
ABS (for ABS models) ...................3-11
Fuel tank cap .................................3-12
Fuel ................................................3-13
Catalytic converter .........................3-13
Seat ...............................................3-14
Adjusting the rider backrest ...........3-14
Helmet holder ................................3-15
Storage compartments ..................3-16
Shock absorber .............................3-17
Sidestand .......................................3-17Ignition circuit cut-off system ......... 3-18
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 ............................................ 5-3
Tips for reducing fuel
consumption ................................ 5-4
Engine break-in ............................... 5-4
Parking ............................................ 5-5
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 ................ 6-9
Engine oil and oil filter cartridge .... 6-11
Chain drive oil ............................... 6-14
Coolant .......................................... 6-15
Cleaning the air filter element ....... 6-16
Adjusting the engine idling
speed ......................................... 6-17Checking the throttle cable free
play ............................................ 6-18
Valve clearance ............................ 6-18
Tires .............................................. 6-19
Cast wheels .................................. 6-21
Front and rear brake lever free
play ............................................ 6-21
Adjusting the rear brake lock lever
cable .......................................... 6-22
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 ............................ 6-25
Lubricating the front and rear brake
levers ......................................... 6-25
Checking and lubricating the
centerstand and sidestand ........ 6-25
Checking the front fork .................. 6-26
Checking the steering ................... 6-27
Checking the wheel bearings ........ 6-27
Battery ........................................... 6-28
Replacing the fuses ...................... 6-29
Replacing the headlight bulb ........ 6-31
Troubleshooting ............................ 6-32
Troubleshooting charts ................. 6-33
SCOOTER CARE AND
STORAGE
........................................... 7-1
Matte black caution ......................... 7-1

INSTRUMENT AND CONTROL FUNCTIONS
3-6
1
2
3
4
5
6
7
8
9
automatically change to the fuel re-
serve tripmeter mode “TRIP F” and
start counting the distance traveled
from that point. In that case, pushing
the “SELECT” button switches the dis-
play between the various tripmeter and
odometer modes in the following order:
TRIP F
→
TRIP (top)
→
TRIP (bottom)
→
ODO
→
TRIP F
To reset a tripmeter, select it by push-
ing the “SELECT” button until “TRIP” or
“TRIP F” begins flashing (“TRIP” or
“TRIP F” will only flash for five sec-
onds). While “TRIP” or “TRIP F” is
flashing, push the “RESET” button for
at least one second. If you do not reset
the fuel reserve tripmeter manually, itwill reset itself automatically and the
display will return to the prior mode af-
ter refueling and traveling 5 km (3 mi).
NOTE:

The display cannot be changed back to
“TRIP F” after pushing the “RESET”
button.
Fuel meter
With the key in the “ON” position, the
fuel meter indicates the amount of fuel
in the fuel tank. The display segments
of the fuel meter disappear towards “E”
(Empty) as the fuel level decreases.
When the fuel level reaches the bottom
segment near “E”, the fuel level warn-
ing indicator and the bottom segment
will flash. Refuel as soon as possible.
Coolant temperature meter
With the key in the “ON” position, the
coolant temperature meter indicates
the temperature of the coolant. The
coolant temperature varies with chang-
es in the weather and engine load. If
the top segment and coolant tempera-
ture warning indicator flash, stop the
vehicle and let the engine cool. (Seepage 6-33.)
CAUTION:

ECA10020
Do not operate the engine if it is
overheated.
Oil change indicator “OIL”
This indicator flashes at the initial 1000
km (600 mi), then at 5000 km (3000 mi)
and every 5000 km (3000 mi) thereafter
to indicate that the engine oil should be
changed.
After changing the engine oil, reset the
oil change indicator. (See page 6-11.)
If the engine oil is changed before the
oil change indicator comes on (i.e. be-
fore the periodic oil change interval has
been reached), the indicator must be
1. Fuel reserve tripmeter
1

PRE-OPERATION CHECKS
4-2
2
3
45
6
7
8
9

EAU15603
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-13
Engine oil

Check oil level in engine.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.6-11
Chain drive oil

Check vehicle for oil leakage. 6-14
Coolant

Check coolant level in reservoir.

If necessary, add recommended coolant to specified level.

Check cooling system for leakage.6-15
Front brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-22, 6-23
Rear brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-22, 6-23
Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-18, 6-25

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

9*
Brake hoses

Check for cracks or damage.
√√√√ √

Replace. Every 4 years
10

*
Wheels

Check runout and for damage.
√√√√
11

*
Tires

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
√√√√ √
12

*
Wheel bearings

Check bearing for looseness or damage.
√√√√
13

*
Steering bearings

Check bearing play and steering for roughness.
√√√√√

Lubricate with lithium-soap-based grease. Every 20000 km
14

*
Chassis fasteners

Make sure that all nuts, bolts and screws are properly
tightened.
√√√√ √
15

Sidestand, centerstand

Check operation.

Lubricate.
√√√√ √
16

*
Sidestand switch

Check operation.
√√√√√ √
17

*
Front fork

Check operation and for oil leakage.
√√√√
18

*
Shock absorber assem-
bly

Check operation and shock absorber for oil leakage.
√√√√
19

*
Fuel injection

Adjust engine idling speed and synchronization.
√√√√√ √
20

Engine oil

Change. (See pages 3-5 and 6-11.)
√
When the oil change indicator flashes (every
5000 km)

Check oil level and vehicle for oil leakage. Every 5000 km
√
21

Engine oil filter cartridge

Replace.
√√√
22

*
Cooling system

Check coolant level and vehicle for coolant leakage.
√√√√ √

Change. Every 3 years
23

Chain drive oil

Check vehicle for oil leakage.

Change.
√√√√
24

*
V-belt

Replace.When the V-belt replacement indicator flashes (every
20000 km)
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
1
2
3
4
5
6
7
8
9

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 lubrication chart.
EAU20122
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:


The coolant level must be checked
on a cold engine since the level
varies with engine temperature.

Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Remove the coolant reservoir cov-
er by removing the screw.3. Check the coolant level in the cool-
ant reservoir.
NOTE:

The coolant should be between the
minimum and maximum level marks.4. If the coolant is at or below the
minimum level mark, open the res-
ervoir cap, add coolant to the max-
imum level mark, and then close
the reservoir cap.
1. Coolant reservoir cover
2. Screw
1
2
1. Maximum level mark
2. Minimum level mark
12

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
2
3
4
5
67
8
9
CAUTION:

ECA10470

If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since 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 engine may not be
sufficiently cooled and the cool-
ing system will not be protectedagainst frost and corrosion.

If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
WARNING

EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
5. Install the coolant reservoir cover
by installing the screw.
NOTE:


The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.

If the engine overheats, see page
6-33 for further instructions.
EAU21120
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove cowling A. (See
page 6-6.)
2. Remove the windshield by remov-
ing the screws.
3. Remove the air filter case cover by
removing the screws, and then pull
the air filter element out.
1. Coolant reservoir cap
Coolant reservoir capacity (up to the
maximum level mark):
0.35 L (0.37 US qt) (0.31 Imp.qt)
1

1. Screw
1
1(×5)

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.

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)