2012 YAMAHA TMAX maintenance

TABLE OF CONTENTSSAFETY INFORMATION .................. 1-1
Further safe-riding points ................ 1-5
DESCRIPTION .................................. 2-1
Left view .......................................... 2-1
Right view ........................................ 2-2
Controls and instrument s................. 2-3
INSTRUMENT AND CONTROL
FUNCTIONS ....................................... 3-1
Immobilizer system .... ..................... 3-1
Main switch/steering lock ................ 3-2
Indicator lights and warning light .... 3-3
Speedometer .................................. 3-4
Tachometer .................................... 3-4
Multi-function display ...................... 3-5
Anti-theft alarm (opti onal) ............. 3-12
Handlebar switches ...................... 3-12
Front brake lever .......................... 3-13
Rear brake lever ........................... 3-14
Rear brake lock lever .................... 3-15
Fuel tank cap ................................ 3-15
Fuel ............................................... 3-16
Catalytic converter ........................ 3-18
Seat .............................................. 3-18
Adjusting the rider backrest .......... 3-19
Helmet holder ............................... 3-20
Storage compartments ................. 3-20
Windshield .................................... 3-22
Rear view mirrors ......................... 3-24
Shock absorber assembly ............ 3-24 Sidestand ..................................... 3-25
Ignition circuit cut-o
ff system ........ 3-25
FOR YOUR SAFETY –
PRE-OPERATION CHECKS ............. 4-1
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 ............................... 5-3
Engine break-in .............................. 5-4
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 6-1
Owner’s tool kit ............................... 6-2
Periodic maintenance chart for the emission contro l system ....... 6-3
General maintenance and
lubrication chart .......................... 6-4
Removing and installing panels ..... 6-8
Checking the spark plugs ............. 6-10
Engine oil and oil filter cartridge ... 6-11
Coolant ......................................... 6-14
Replacing the air filter element ..... 6-15
Adjusting the engine idling speed ........................................ 6-16 Checking the throttle grip free
play ............................................ 6-17
Valve clearance ............................ 6-17
Tires .............................................. 6-17
Cast wheels .................................. 6-19
Checking the front and rear brake lever free play .................. 6-20
Adjusting the rear brake lock
cable .......................................... 6-21
Checking the rear brake lock ........ 6-21
Checking the front and rear
brake pads ................................. 6-22
Checking the brake fluid level ....... 6-23
Changing the brake fluid ............... 6-24
Drive belt slack ............................. 6-24
Checking and lubricating the cables ........................................ 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 ........ 6-26
Checking the front fork .................. 6-26
Checking the steering ................... 6-27
Checking the wheel bearings ........ 6-27
Battery .......................................... 6-28
Replacing the fuses ...................... 6-30
Replacing the headlight bulb ........ 6-31
Tail/brake light .............................. 6-3259C-9-E0.book 1 ページ ２０１１年９月１１日　日曜日　午前９時２７分

INSTRUMENT AND CONTROL FUNCTIONS
3-17
1
23
4
5
6
7
8
93. Wipe up any spilled fuel immedi-
ately. NOTICE: Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plastic
parts.
[ECA10071]

4. Be sure to securely close the fuel tank cap.
WARNING
EWA15151
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline in your eyes, see your doctor immedi-
ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.
EAU53010
NOTICE
ECA11400
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,as well as to the exhaust system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug lifeand reduce maintenance costs.
Gasohol
There are two types of gasohol: gaso-
hol containing ethanol and that contain-
ing methanol. Gasohol containing
ethanol can be used if the ethanol con-
tent does not exceed 10% (E10). Gas-
ohol containing methanol is not
recommended by Yamaha because it
can cause damage to the fuel system
or vehicle performance problems.
1. Fuel tank filler tube
2. Maximum fuel level2
1
Recommended fuel:
Regular unleaded gasoline or gaso-
hol (E10)
Fuel tank capacity: 15.0 L (3.96 US gal, 3.30 Imp.gal)
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INSTRUMENT AND CONTROL FUNCTIONS
3-18
234
5
6
7
8
9
EAU13433
Catalytic converter This model is equipped with a catalytic
converter in the exhaust system.
WARNING
EWA10862
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:
Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.

Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.

Make sure that the exhaust sys-
tem has cooled down before do-
ing any maintenance work.

Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up ofheat.
NOTICE
ECA10701
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-
pairable damage to the catalytic
converter.
EAU13932
Seat To open the seat1. Place the scooter on the center- stand.
2. Insert the key into the main switch, and then turn it counterclockwise
to “OPEN”.TIPDo not push inward when turning thekey.
3. Fold the seat up.1. Open.
1
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4-1
1
2
34
5
6
7
8
9
FOR YOUR SAFETY – PRE-OPERATION CHECKS
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided inthis manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check fuel tank breather hose and overfl
ow hose for obstructions, cracks or
damage, and check hose connections. 3-16
Engine oil Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage. 6-11
Coolant Check coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage. 6-14
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 specified brak
e fluid to specified level.
Check hydraulic system for leakage. 6-20, 6-22, 6-23
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6-1
1
2
3
4
56
7
8
9
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17244
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer performservice.
WARNING
EWA15122
Turn off the engine when performing
maintenance unless otherwise
specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.

Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-2 for more in-
formation about carbon monox-ide.WARNING
EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool beforetouching them.
EAU17302
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replacement,
or repair of the emission control devic-
es and systems may be performed by
any repair establishment or individual
that is certified (if applicable). Yamaha
dealers are trained and equipped to
perform these particular services.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
2
3
4
567
8
9
EAU17391
Owner’s tool kit The owner’s tool kit is located under the
seat. (See page 3-18.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.TIPIf you do not have the tools or experi-
ence required for a particular job, havea Yamaha dealer perform it for you.1. Helmet holding cable
2. Owner’s tool kit
12
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
1
2
3
4
56
7
8
9
EAU46861
TIP
The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.

From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
EAU46910
Periodic maintenance chart for the emission control system NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
1* Fuel line Check fuel hoses for cracks or
damage. 
2* Spark plugs Check condition.
Clean and regap.

Replace. 
3* Va l v e s Check valve clearance.
Adjust. Every 40000 km (24000 mi)
4* Fuel injection Adjust engine idling speed and
synchronization. 
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
2
3
4
567
8
9
EAU1770E
General maintenance and lubrication chart NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
1 Air filter element Replace. 
2* V-belt case air filter
elements Clean.

Replace. 
3* Front brake Check operation, fluid level and
vehicle for fluid leakage. 
Replace brake pads. Whenever worn to the limit
4* Rear brake Check operation, fluid level and
vehicle for fluid leakage. 
Replace brake pads. Whenever worn to the limit
5* Brake hoses Check for cracks or damage.
Check for correct routing and
clamping. 
Replace. Every 4 years
6 Rear brake lock
cable Check cable length.
Adjust if necessary.
4000 km (2400 mi) after the initial 1000 km (600 mi) and every
5000 km (3000 mi) thereafter
7* Rear brake lock Check operation.
Check rubber boot.
Check wear indicator.
Adjust if necessary. 
8* Wheels Check runout and for damage. 
9* Tires Check tread depth and for
damage.
Replace if necessary.
Check air pressure.
Correct if necessary. 
10 * Wheel bearings Check bearing for looseness or
damage. 
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