Yamaha Tmax 500 Periodic maintenance and Adjustment

Periodic maintenance chart for the emission control system

No. ITEM ROUTINE INITIAL ODOMETER READINGS
x1000mi 0.6 4 8 12 16 20
x1000km 1 7 13 19 25 31
month 1 6 12 18 24 30
1 * Fuel line Check fuel hoses for cracks or damage.
Replace if necessary.		 ● ● ● ● ●
2 * Spark plugs Check condition.
Adjust gap and clean.		 ● ●
Replace. Every 12000 mi (19000 km) or
18 months
3 * Valve clearance Check and adjust valve clearance when engine is cold. Every 26600 mi (42000 km)
4 * Crankcase breather system Check breather hose for cracks or damage.
Replace if necessary.		 ● ● ●
5 * Fuel injection Adjust synchronization. ● ● ● ● ● ●
6 * Evaporative emission control system (for California only) Check control system for damage.
Replace if necessary.		 ● ●

General maintenance and lubrication chart

No. ITEM ROUTINE INITIAL ODOMETER READINGS
x1000mi 0.6 4 8 12 16 20
x1000km 1 7 13 19 25 31
month 1 6 12 18 24 30
1 Air filter element Replace. Every 12000 mi (19000 km)
2 * V-belt case air filter elements Clean. ● ● ● ● ●
3 * Front brake Check operation, fluid level, and for fluid leakage.
Replace brake pads if necessary.		 ● ● ● ● ● ●
4 * Rear brake Check operation, fluid level, and for fluid leakage.
Replace brake pads if necessary.		 ● ● ● ● ● ●
5 * Brake hoses Check for cracks or damage.
Check for correct routing and clamping.		 ● ● ● ● ●
Replace. Every 4 years
6 * Brake fluid Every 2 years
7 Rear brake lock cable Check cable length.
Adjust if necessary.		 ● ● ● ● ● ●
8 * Rear brake lock Check operation.
Check rubber boot.
Check wear indicator.
Adjust if necessary.		 ● ● ● ● ● ●
9 * Wheels Check runout and for damage.
Replace if necessary.		 ● ● ● ● ●
10 * Tires Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.		 ● ● ● ● ●
11 * Wheel bearings Check bearings for smooth operation.
Replace if necessary.		 ● ● ● ● ●
12 * Drive belt Check belt condition.
Replace if damaged.
Check belt tension.
Adjust if necessary.		 ● ● ● ● ● ●
13 * Drive pulley and drive axle Lubricate. Every 12000 mi (19000 km)
14 * Steering bearings Check bearing assemblies for looseness. ● ● ● ● ● ●
Moderately repack with lithium- soap-based grease. Every 12000 mi (19000 km)
15 * Chassis fasteners Check all chassis fitting and fasteners.
Correct if necessary.		 ● ● ● ● ●
16 Front brake lever pivot shaft Apply silicone grease lightly. ● ● ● ● ●
17 Rear brake lever pivot shaft Apply silicone grease lightly. ● ● ● ● ●
18 Centerstand and sidestand pivots Check operation.
Apply lithium-soap-based grease lightly.		 ● ● ● ● ●
19 * Sidestand switch Check operation and replace if necessary. ● ● ● ● ● ●
20 * Front fork Check operation and for oil leakage.
Replace if necessary.		 ● ● ● ● ●
21 * Shock absorber assembly Check operation and for oil leakage.
Replace if necessary.		 ● ● ● ● ●
22 Engine oil Change. (See pages 5-3 and 8-10.) ● When the oil change indicator flashes
Check oil level and vehicle for oil leakage. ● ● ● ● ● ●
23 Engine oil filter cartridge Replace. ● At 12500 mi (20000 km)
and thereafter every 12500 mi (20000 km)
24 * Cooling system Check coolant level and vehicle for coolant leakage. ● ● ● ● ●
Change coolant. Every 3 years
25 * V-belt Replace. When the V-belt replacement indicator flashes (every 12500 mi (20000 km)).
26 * Front and rear brake switches Check operation. ● ● ● ● ● ●
27 Control cables Apply Yamaha cable lubricant or other suitable cable lubricant thoroughly. ● ● ● ● ●
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.		 ● ● ● ● ● ●

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