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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