2016 YAMAHA TMAX brake fluid

Table of contents
Safety information............................ 1-1
Further safe-riding points ................ 1-5
Description ........................................ 2-1
Left view .......................................... 2-1
Right view ........................................ 2-2
Controls and instruments ................ 2-3
Smart key system ............................. 3-1
Smart key system ............................ 3-1
Operating range of the smart key system............. ....................... ...... 3-2
Handling of the smart key and
mechanical key ............................ 3-3
Smart key ........................................ 3-5
Replacing the smart key battery ...... 3-6
Vehicle power on and steering lock release .................................. 3-8
Powering off the vehicle .................. 3-9
How to lock the steering ................ 3-10
Seat opening and closing .............. 3-10
Parking mode ................................ 3-11
Instrument and control functions ... 4-1
Indicator lights and warning lights ... 4-1
Speedometer .............. ..................... 4-2
Tachometer ..................................... 4-3
Multi-function display ....................... 4-3
Handlebar switches ....................... 4-10
Front brake lever ........................... 4-11
Rear brake lever ............................ 4-12
Rear brake lock lever .................... 4-12
ABS (for ABS models) ................... 4-13
Fuel tank cap ................................. 4-14
Fuel ............................................... 4-15
Catalytic converter......................... 4-16
Adjusting the rider backrest ........... 4-17
Helmet holder ................................ 4-17
Storage compartments .................. 4-18
Windshield ..................................... 4-19
Rear view mirrors .......................... 4-21
Shock absorber assembly ............. 4-21
Sidestand ...................................... 4-22
Ignition circuit cut- off system ......... 4-22
Auxiliary DC jack ........................... 4-24 For your safety – pre-operation
checks
............................................... 5-1
Operation and important riding
points ................................................. 6-1
Starting the engine .......................... 6-2
Starting off....................................... 6-3
Acceleration and deceleration......... 6-3
Braking ............................................ 6-4
Tips for reducing fuel
consumption ................................ 6-5
Engine break-in ............................... 6-5
Parking ............................................ 6-6
Periodic maintenance and
adjustment ........................................ 7-1
Owner’s tool kit ............................... 7-2
Periodic maintenance chart for the emission control system ........ 7-3
General maintenance and lubrication chart ........................... 7-4
Removing and installing panels ...... 7-7
Checking the spark plugs................ 7-9
Engine oil and oil filter cartridge .... 7-10
Coolant.......................................... 7-13
Replacing the air filter element ..... 7-15
Adjusting the engine idling speed ......................................... 7-16
Checking the throttle grip free play ............................................ 7-16
Valve clearance ............................ 7-17
Tires .............................................. 7-17
Cast wheels .................................. 7-19
Checking the front and rear brake lever free play .................. 7-20
Adjusting the rear brake lock
cable .......................................... 7-21
Checking the rear brake lock ........ 7-21
Checking the front and rear
brake pads ................................. 7-22
Checking the brake fluid level ....... 7-22
Changing the brake fluid ............... 7-23
Drive belt slack.............................. 7-24
Checking and lubricating the cables ........................................ 7-24
2PW-9-E1.book 1 ページ ２０１５年９月１０日　木曜日　午後５時１７分

5-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
For your safety – pre-operation checks
EAU63440
Inspect your vehicle each time you use it to make sure the vehicle is in safe oper-
ating condition. Always follow the inspection and maintenance procedures and
schedules described in the Owner’s Manual.
WARNING
EWA11152
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
in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKSPAGE
Fuel Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check fuel tank breather hose and overflow hose for
obstructions, cracks or damage, and check hose
connections. 4-15
Engine oil Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage. 7-10
Coolant Check coolant level in reservoir.
If necessary, add recomm
ended coolant to specified
level.
Check cooling system for leakage. 7-13
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 brake fluid to specified level.
Check hydraulic system for leakage. 7-20,
7-22
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 specified brake fluid to specified level.
Check hydraulic system for leakage. 7-20,
7-22
Throttle grip Make sure that operation is smooth.
Check throttle grip free play.
If necessary, have Yamaha dealer adjust throttle grip
free play and lubricate cable and grip housing. 7-16,
7-25
2PW-9-E1.book 1 ページ ２０１５年９月１０日　木曜日　午後５時１７分

Periodic maintenance and adjustment
7-4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU64031
General maintenance and lubrication chart
NO. ITEM
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 *Brake fluid Change. Every 2 years
7 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
8 *Rear brake lock Check operation.
Check rubber boot.
Check wear indicator.
Adjust if necessary. 
9 *Wheels Check runout and for damage. 
10 *Tires Check tread depth and for
damage.
Replace if necessary.
Check air pressure.
Correct if necessary. 
11 *Wheel bearings Check bearings for looseness
or damage. 
12 *Drive belt Check belt condition.
Replace if damaged.
Check belt tension.
Adjust if necessary. Every 10000 km (6000
mi) until 40000 km (24000 mi), and every 5000 km (3000 mi) thereafterX 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER READINGS
ANNUAL CHECK
110203040
0.66121824
2PW-9-E1.book 4 ページ ２０１５年９月１０日　木曜日　午後５時１７分

Periodic maintenance and adjustment
7-6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU38263
TIP
Engine air filter and V-belt air filters This model’s engine air fi lter is equipped with a disposable oil-coated paper
element, which must not be cleaned wi th compressed air to avoid damaging
it.
The engine air filter element needs to be replaced and the V-belt air filter el- ements need to be serviced more frequently 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 cylin-
ders and calipers, and change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
27 Moving parts and
cables Lubricate.

28 *Throttle grip Check operation.
Check throttle grip free play,
and adjust if necessary.
Lubricate cable and grip housing. 
29 *Lights, signals and
switches Check operation.
Adjust headlight beam.

NO. ITEM
X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER READINGS
ANNUAL CHECK
110203040
0.66121824
2PW-9-E1.book 6 ページ ２０１５年９月１０日　木曜日　午後５時１７分

Periodic maintenance and adjustment
7-22
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU22312
Checking the fr ont and rear
brake pads
Front brake
Rear brake
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. Each brake pad is
provided with a wear indicator, which
allows you to check the brake pad wear
without having 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 the point that the wear indi-
cator almost touches the brake disc,
have a Yamaha dealer replace the
brake pads as a set.
EAU22582
Checking the brake fluid level
Before riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake
Rear brake
WARNING
EWA15991
Improper maintenance can result in
loss of braking ability. Observe
these precautions:
Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.
1. Brake pad wear indicator
1. Brake pad wear indicator
1
1
1. Minimum level mark
1. Minimum level mark
Specified brake fluid: DOT 4
1
1
2PW-9-E1.book 22 ページ ２０１５年９月１０日　木曜日　午後５時１７分

Periodic maintenance and adjustment
7-23
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.
Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.
Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.
Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
NOTICE
ECA17641
Brake fluid may damage painted sur-
faces or plastic parts. Always clean
up spilled fluid immediately.
As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake sys-
tem leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brake
fluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
EAU22733
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the master cylinders and calipers as
well as the brake hoses replaced at the
intervals listed below or whenever they
are damaged or leaking.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
2PW-9-E1.book 23 ページ ２０１５年９月１０日　木曜日　午後５時１７分

Scooter care and storage
8-3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Cleaning the windshield
Avoid using any alkaline or strong acid
cleaner, gasoline, brake fluid, or any
other solvent. Clean the windshield with
a cloth or sponge dampened with a mild
detergent, and then wash it off thor-
oughly with water. For additional clean-
ing, use Yamaha Windshield Cleaner
or another high-quality windshield
cleaner. Some cleaning compounds for
plastics may leave scratches on the
windshield. Before using such clean-
ers, test an area of the windshield
which does not affect your visibility and
which cannot be easily recognized.
After cleaning
1. Dry the scooter with a chamois or an absorbing cloth.
2. Use a chrome polish to shine chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
3. To prevent corrosion, it is recom- mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean- er to remove any remaining dirt.
5. Touch up minor paint damage caused by stones, etc.
6. Wax all painted surfaces.
7. Let the scooter dry completely be- fore storing or covering it.
WARNING
EWA10943
Contaminants on the brakes or tires
can cause loss of control.
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.
Before operating the scooter
test its braking performance
and cornering behavior.
NOTICE
ECA10801
Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing
compounds as they will wear
away the paint.
TIP
Consult a Yamaha dealer for ad-
vice on what products to use.
Washing, rainy weather or humid
climates can cause the headlight
lens to fog. Turning the headlight
on for a short period of time will
help remove the moisture from the
lens.
2PW-9-E1.book 3 ページ ２０１５年９月１０日　木曜日　午後５時１７分

Specifications
9-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Front tire:
Type: Tubeless
Size: 120/70R15M/C 56H
Manufacturer/model:
DUNLOP/GPR-100F M
Rear tire:
Type:Tubeless
Size:
160/60R15M/C 67H
Manufacturer/model: DUNLOP/GPR-100 M
Loading:
Maximum load:
193 kg (425 lb) (XP500A)
196 kg (432 lb) (XP500)
* (Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Up to 90 kg (198 lb) load:Front:225 kPa (2.25 kgf/cm
2, 33 psi)
Rear:
250 kPa (2.50 kgf/cm
2, 36 psi)
90 kg (198 lb) load - maximum load: Front:
225 kPa (2.25 kgf/cm
2, 33 psi)
Rear: 280 kPa (2.80 kgf/cm
2, 41 psi)
Front wheel:
Wheel type:
Cast wheel
Rim size: 15M/C x MT3.50
Rear wheel:
Wheel type:
Cast wheel
Rim size: 15M/C x MT5.00
Front brake:
Type:Hydraulic dual disc brake
Specified brake fluid: DOT 4
Rear brake:
Type:Hydraulic single disc brake Specified brake fluid:
DOT 4
Front suspension:
Type:Telescopic fork
Spring:
Coil spring
Shock absorber: Hydraulic damper
Wheel travel: 120 mm (4.7 in)
Rear suspension:
Type:Swingarm
Spring: Coil spring
Shock absorber:
Gas-hydraulic damper
Wheel travel: 116 mm (4.6 in)
Electrical system:
System voltage:
12 V
Ignition system: TCI
Charging system: AC magneto
Battery:
Model:YTZ12S
Voltage, capacity: 12 V, 11.0 Ah (10 HR)
Bulb wattage  quantity:
Headlight:
LED
Brake/tail light: LED
Front turn signal light:
21.0 W  2
Rear turn signal light: 21.0 W  2
Auxiliary light:
LED
License plate light: 5.0 W  1
Meter lighting: LED
High beam indicator light:
LED
2PW-9-E1.book 2 ページ ２０１５年９月１０日　木曜日　午後５時１７分