engine YAMAHA TMAX 2001 User Guide

4-1
EAU01114
PRE-OPERATION CHECKS
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9The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-4, 3-8–3-9
Engine oil•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-12–6-14
Coolant•Check coolant level in reservoir.
•If necessary, add recommended coolant to specified level.
•Check cooling system for leakage.6-17–6-18
Front brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-7, 6-25–6-28
Rear brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-8, 6-25–6-28
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OPERATION AND IMPORTANT RIDING POINTS
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
5
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5-1
EAU03844
w8Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or func-
tion that you do not thorough-
ly understand.
8Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
8For safety, always start the
engine with the centerstand
down.
8When the centerstand is down
and the engine is idling, keep
your hands and feet away
from the rear wheel.
EAU03843
Starting the engine
EC000046
cCSee page 5-4 for engine break-in
instructions prior to operating the
vehicle for the first time.In order for the ignition circuit cut-off
system to enable starting, the side-
stand must be up.
EW000054
w8Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-14.
8Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch
is set to “#”.
2. Close the throttle completely.
3. Start the engine by pushing the
start switch while applying the
front or rear brake.NOTE:
If the engine does not start, release
the start switch, wait a few seconds,
and then try again. Each starting
attempt should be as short as possi-
ble to preserve the battery. Do not
crank the engine more than 10 sec-
onds on any one attempt. If the
engine does not start, try with the
throttle open 1/8 turn.
ECA00045
cCFor maximum engine life, never
accelerate hard when the engine is
cold!
EAU00372
OPERATION AND IMPORTANT RIDING POINTS
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2
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5-2
OPERATION AND IMPORTANT RIDING POINTS
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EAU00433
Starting offNOTE:
Before starting off, allow the engine
to warm up.1. While pulling the rear brake lever
with your left hand and holding
the grab bar with your right hand,
push the scooter off the center-
stand.
2. Sit astride the seat, and then
adjust the rear view mirrors.
3. Switch the turn signal on.4. Check for oncoming traffic, and
then slowly turn the throttle grip
(on the right) in order to take off.
5. Switch the turn signal off.
1
1. Grab bar
EAU00434
Acceleration and
decelerationThe speed can be adjusted by open-
ing and closing the throttle. To
increase the speed, turn the throttle
grip in direction a. To reduce the
speed, turn the throttle grip in direc-
tion b.
ab
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5-3
EW000057
w8Avoid braking hard or sudden-
ly (especially when leaning
over to one side), otherwise
the scooter may skid or over-
turn.
8Railroad crossings, streetcar
rails, iron plates on road con-
struction sites, and manhole
covers become extremely slip-
pery when wet. Therefore,
slow down when approaching
such areas and cross them
with caution.
8Keep in mind that braking on a
wet road is much more diffi-
cult.
8Ride slowly down a hill, as
braking downhill can be very
difficult.
OPERATION AND IMPORTANT RIDING POINTS
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3
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EAU03093
Tips for reducing fuel
consumptionFuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
8Thoroughly warm up the engine.
8Avoid high engine speeds during
acceleration.
8Avoid high engine speeds with
no load on the engine.
8Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad cross-
ings).
EAU00435
Braking1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually
increasing the pressure.
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5-4
EAU03845
0–1,000 km
Avoid prolonged operation above 1/3
throttle.
1,000–1,600 km
Avoid prolonged operation above 1/2
throttle.
ECA00080
cCAfter 1,000 km of operation, the
engine oil must be changed, and
the oil filter cartridge replaced.1,600 km and beyond
The vehicle can now be operated
normally.
EC000049
cCIf any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.OPERATION AND IMPORTANT RIDING POINTS
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2
3
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EAU01128
Engine break-inThere is never a more important peri-
od in the life of your engine than the
period between 0 and 1,600 km. For
this reason, you should read the fol-
lowing material carefully.
Since the engine is brand new, do
not put an excessive load on it for the
first 1,600 km. The various parts in
the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheat-
ing must be avoided.
EAU00460
ParkingWhen parking, stop the engine, and
then remove the key from the main
switch.
EW000058
w8Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely
to touch them.
8Do not park on a slope or on
soft ground, otherwise the
scooter may overturn.
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PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .......................................................6-1
Periodic maintenance and lubrication chart ............6-3
Removing and installing cowlings and panels ........6-6
Checking the spark plugs........................................6-9
Engine oil and oil filter cartridge ............................6-12
Chain drive oil .......................................................6-16
Coolant..................................................................6-17
Cleaning the air filter element ...............................6-19
Adjusting the carburetors ......................................6-21
Adjusting the engine idling speed .........................6-21
Adjusting the throttle cable free play .....................6-22
Adjusting the valve clearance ...............................6-22
Tires ......................................................................6-23
Cast wheels ..........................................................6-25
Front and rear brake levers...................................6-25
Checking the front and rear brake pads................6-26
Checking the brake fluid level ...............................6-27
Changing the brake fluid .......................................6-28
Checking and lubricating the throttle grip and
cable ...................................................................6-29
Lubricating the front and rear brake levers ...........6-29
Checking and lubricating the
centerstand and sidestand ..................................6-30
Checking the front fork ..........................................6-30Checking the steering ...........................................6-31
Checking the wheel bearings ................................6-32
Battery...................................................................6-32
Replacing the fuses ..............................................6-34
Replacing a headlight bulb....................................6-35
Troubleshooting ....................................................6-36
Troubleshooting charts .........................................6-37
6
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6-1
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. The most important
points of inspection, adjustment, and
lubrication are explained on the fol-
lowing pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, DEPENDING
ON THE WEATHER, TERRAIN,
GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTE-
NANCE INTERVALS MAY NEED TO
BE SHORTENED.
EW000060
wIf you are not familiar with scooter
maintenance work, have a Yamaha
dealer do it for you.
EAU00466
wThis scooter is designed for use
on paved roads only. If this scoot-
er is operated in abnormally dusty,
muddy or wet conditions, the air
filter element should be cleaned or
replaced more frequently, other-
wise rapid engine wear may result.
Consult a Yamaha dealer for prop-
er maintenance intervals.
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU03846
Owner’s tool kitThe owner’s tool kit is located under
the seat. (See page 3-9 for seat
opening and closing procedures.)
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 pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be nec-
essary to perform certain mainte-
nance work correctly.
2 1
1. Helmet holding cable
2. Owner’s tool kit
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
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*Rear brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
9*Brake hose•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-5.)Every 4 years
10*Wheels•Check runout and for damage.√√√√
11*Tires•Check tread depth and for damage.
•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 lithium-soap-based greaseEvery 20,000 km
14*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
15 Sidestand/centerstand•Check operation.
•Lubricate.√√√√ √
16*Sidestand switch•Check operation.√√√√√ √
17*Front fork•Check operation and for oil leakage.√√√√
18*Rear shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√
•Lubricate the pivoting points with lithium-soap-based
grease.√√
19*Carburetors•Adjust engine idling speed and synchronization.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
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6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU03884
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.20 Engine oil•Change. (See page 3-2 for more information about the oil
change indicator light.)√4,000 km after initial 1,000 km
When the oil change indicator light comes on
(every 5,000 km)
21 Engine oil filter cartridge•Replace.√√√
22
*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change.Every 3 years
23 Chain drive oil•Check vehicle for oil leakage.
•Change.√√√√
24*V-belt•Replace.When the V-Belt replacement indicator light comes on
(every 20,000 km)
25*Front and rear brake
switches•Check operation.√√√√√ √
26 Moving parts and cables•Lubricate.√√√√ √
27*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
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