2009 YAMAHA TMAX brake

PERIODIC MAINTENANCE AND ADJUSTMENT
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 dam-
age.

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 lith-
ium-soap-based grease.Every 20000 km (12000 mi)
14

*
Chassis fasteners

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

Front brake lever
pivot shaft

Lubricate with silicone grease.
√√√√√
16

Rear brake lever
pivot shaft

Lubricate with silicone grease.
√√√√√
17

Sidestand, center-
stand

Check operation.

Lubricate.
√√√√√
18

*
Sidestand switch

Check operation.
√√√√√√
19

*
Front fork

Check operation and for oil leak-
age.
√√√√
20

*
Shock absorber
assembly

Check operation and shock
absorber for oil leakage.
√√√√
21

*
Fuel injection

Adjust engine idling speed and
synchronization.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
1
2
3
4
5
6
7
8
9

22

Engine oil

Change. (See pages 3-8 and
6-11.)
√
When the oil change indicator flashes

Check oil level and vehicle for oil
leakage.Every 5000 km (3000 mi)
√
23

Engine oil filter car-
tridge

Replace.
√√√
24

*
Cooling system

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

Change. Every 3 years
25

Chain drive oil

Check vehicle for oil leakage.

Change.
√√√√
26

*
V-belt

Replace. When the V-belt replacement indicator flashes [every 20000 km (12000 mi)]
27

*
Front and rear brake
switches

Check operation.
√√√√√√
28

Moving parts and
cables

Lubricate.
√√√√√
29

*
Throttle grip hous-
ing and cable

Check operation and free play.

Adjust the throttle cable free play
if necessary.

Lubricate the throttle grip housing
and cable.
√√√√√
30

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

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

EAU38262
TIP


Engine air filter and V-belt air filters

This model’s engine air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with
compressed air to avoid damaging it.

The engine air filter element needs to be replaced and the V-belt air filter elements need to be serviced more frequent-
ly when riding in unusually wet or dusty areas.

Hydraulic brake service

After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid
levels and fill the reservoirs as required.

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.

Replace the brake hoses every four years and if cracked or damaged.

PERIODIC MAINTENANCE AND ADJUSTMENT
6-20
2
3
4
5
67
8
9 Tire information
This model is equipped with tubeless
tires.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING

EWA10470

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.

The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to aYamaha dealer, who has the
necessary professional knowl-
edge and experience.
EAU21960
Cast wheels
To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.

The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
Front tire:
Size:
120/70R15 M/C 56H
Manufacturer/model:
DUNLOP/GPR-100F
BRIDGESTONE/BT011F
Rear tire:
Size:
160/60R15 M/C 67H
Manufacturer/model:
DUNLOP/GPR-100L
BRIDGESTONE/BT012R

PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
1
2
3
4
5
6
7
8
9

EAU33453
Front and rear brake lever free
play
Front
Rear
There should be no free play at the
brake lever ends. If there is free play,
have a Yamaha dealer inspect the
brake system.
WARNING

EWA14211
A soft or spongy feeling in the brake
lever can indicate the presence of air
in the hydraulic system. If there is air
in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the vehicle. Air in the
hydraulic system will diminish the
braking performance, which may re-
sult in loss of control and an acci-
dent.
EAU33473
Adjusting the rear brake lock
lever cable
Rear brake lock lever cable adjustment
may be required if the rear brake lock
lever does not hold properly. When the
rear brake lock lever is not in use, the
rear brake lock lever cable length
should measure 45 mm to 47 mm (1.77
in to 1.85 in) at the rear brake caliper.
Periodically check the rear brake lock
lever cable length and, if necessary,
adjust it as follows.
To increase the rear brake lock lever
cable length, turn the adjusting nut at
the rear brake caliper in direction (a).
1. Front brake lever free play
1. Rear brake lever free play
1
1

1. Adjusting nut
2. Rear brake lock lever cable length
2
1
(b)
(a)

PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
2
3
4
5
67
8
9
To decrease the rear brake lock lever
cable length, turn the adjusting nut in
direction (b).
WARNING

EWA10650
If proper adjustment cannot be ob-
tained as described, have a Yamaha
dealer make this adjustment.
EAU22390
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22410
Front brake pads
Each front brake pad is provided with a
wear indicator, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicator while applying the
brake. If a brake pad has worn to thepoint that the wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.
EAU22493
Rear brake pads
1. Remove the rear brake caliper by
removing the bolts.
2. Check each rear brake pad for
damage and measure the lining
thickness. If a brake pad is dam-
aged or if the lining thickness is
less than 0.8 mm (0.03 in), have a
Yamaha dealer replace the brake
pads as a set.
3. Install the rear brake caliper by in-
1. Wear indicator
1

1. Brake caliper bolt
2. Lining thickness
1
2

PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
1
2
3
4
5
6
7
8
9
stalling the bolts, then tightening
them to the specified torque.
NOTICE

ECA12822
Do not apply the rear brake or rear
brake lock after the brake caliper
has been removed, otherwise the
brake caliper piston will be forced
out.
EAU40260
Checking the brake fluid level
Front brake
Rear brake
Insufficient brake fluid may allow air toenter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:

When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.

Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.

Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.

Be careful that water or dust does
not enter the brake fluid reservoir
Tightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf, 28.9 ft·lbf)
1. Minimum level mark
1. Minimum level mark
1
1

Recommended brake fluid:
DOT 4

PERIODIC MAINTENANCE AND ADJUSTMENT
6-24
2
3
4
5
67
8
9
when refilling. Water will signifi-
cantly lower the boiling point of the
fluid and may result in vapor lock,
and dirt may clog the ABS hydrau-
lic unit valves.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.

As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22731
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the master cylinders and
calipers as well as the brake hoses re-
placed at the intervals listed below or
whenever they are damaged or leak-
ing.

Oil seals: Replace every two
years.

Brake hoses: Replace every four
years.
EAU23111
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.