check engine YAMAHA TMAX 2006 Owners Manual

TABLE OF CONTENTS
SAFETY INFORMATION
...................1-1
Further safe-riding points .................1-4
DESCRIPTION
...................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS
........................................3-1
Immobilizer system ..........................3-1
Main switch/steering lock .................3-2
Indicator and warning lights .............3-3
Speedometer ...................................3-4
Tachometer .....................................3-4
Multi-function display .......................3-5
Anti-theft alarm (optional) ................3-8
Handlebar switches .........................3-8
Front brake lever ...........................3-10
Rear brake lever ............................3-10
Rear brake lock lever .....................3-10
ABS (for ABS models) ...................3-11
Fuel tank cap .................................3-12
Fuel ................................................3-13
Catalytic converter .........................3-13
Seat ...............................................3-14
Adjusting the rider backrest ...........3-14
Helmet holder ................................3-15
Storage compartments ..................3-16
Shock absorber .............................3-17
Sidestand .......................................3-17Ignition circuit cut-off system ......... 3-18
PRE-OPERATION CHECKS
.............. 4-1
Pre-operation check list ................... 4-2
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 ................................ 5-4
Engine break-in ............................... 5-4
Parking ............................................ 5-5
PERIODIC MAINTENANCE AND
MINOR REPAIR
.................................. 6-1
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 .... 6-11
Chain drive oil ............................... 6-14
Coolant .......................................... 6-15
Cleaning the air filter element ....... 6-16
Adjusting the engine idling
speed ......................................... 6-17Checking the throttle cable free
play ............................................ 6-18
Valve clearance ............................ 6-18
Tires .............................................. 6-19
Cast wheels .................................. 6-21
Front and rear brake lever free
play ............................................ 6-21
Adjusting the rear brake lock lever
cable .......................................... 6-22
Checking the front and rear brake
pads ........................................... 6-22
Checking the brake fluid level ....... 6-23
Changing the brake fluid ............... 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 ........ 6-25
Checking the front fork .................. 6-26
Checking the steering ................... 6-27
Checking the wheel bearings ........ 6-27
Battery ........................................... 6-28
Replacing the fuses ...................... 6-29
Replacing the headlight bulb ........ 6-31
Troubleshooting ............................ 6-32
Troubleshooting charts ................. 6-33
SCOOTER CARE AND
STORAGE
........................................... 7-1
Matte black caution ......................... 7-1

SAFETY INFORMATION
1-3
1
When loading within this weight limit,
keep the following in mind:

Cargo and accessory weight
should be kept as low and close to
the scooter as possible. Make sure
to distribute the weight as evenly
as possible on both sides of the
scooter to minimize imbalance or
instability.

Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the scooter before
riding. Check accessory mounts
and cargo restraints frequently.

Never attach any large or heavy
items to the handlebar, front fork,
or front fender. Such items can
create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this scooter. Since Yamaha cannot test
all other accessories that may be avail-
able, you must personally be responsi-
ble for the proper selection, installationand use of non-Yamaha accessories.
Use extreme caution when selecting
and installing any accessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.


Never install accessories or carry
cargo that would impair the perfor-
mance of your scooter. Carefully
inspect the accessory before using
it to make sure that it does not in
any way reduce ground clearance
or cornering clearance, limit sus-
pension travel, steering travel or
control operation, or obscure lights
or reflectors.

Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.

Bulky or large accessories may
seriously affect the stability of
the scooter due to aerodynamiceffects. Wind may attempt to lift
the scooter, or the scooter may
become unstable in cross
winds. These accessories may
also cause instability when
passing or being passed by
large vehicles.

Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.

Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
scooter’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas

GASOLINE IS HIGHLY FLAMMA-
BLE:

Always turn the engine off when
refueling.

SAFETY INFORMATION
1-4
1

Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.

Never refuel while smoking or in
the vicinity of an open flame.

Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
scooter in an area that has ade-
quate ventilation.

Always turn the engine off before
leaving the scooter unattended
and remove the key from the main
switch. When parking the scooter,
note the following:

The engine and exhaust system
may be hot, therefore, park the
scooter in a place where pedes-
trians or children are not likely to
touch these hot areas.

Do not park the scooter on a
slope or soft ground, otherwise it
may fall over.

Do not park the scooter near a
flammable source (e.g., a kero-sene heater, or near an open
flame), otherwise it could catch
fire.

If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediate-
ly. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.
EAU10371
Further safe-riding points

Be sure to signal clearly when
making turns.

Braking can be extremely difficult
on a wet road. Avoid hard braking,
because the scooter could slide.
Apply the brakes slowly when
stopping on a wet surface.

Slow down as you approach a cor-
ner or turn. Once you have com-
pleted a turn, accelerate slowly.

Be careful when passing parked
cars. A driver might not see you
and open a door in your path.

Railroad crossings, streetcar rails,
iron plates on road construction
sites, and manhole covers be-
come extremely slippery when
wet. Slow down and cross them
with caution. Keep the scooter up-
right, otherwise it could slide out
from under you.

The brake pads could get wet
when you wash the scooter. After
washing the scooter, check the
brakes before riding.

Always wear a helmet, gloves,
trousers (tapered around the cuff

2-1
1
2
3
4
5
6
7
8
9

DESCRIPTION
EAU10410
Left view
1
2
3
4
9
8
7
6
5
10

1. Fuel tank cap (page 3-12)
2. Rear storage compartment (page 3-16)
3. Helmet holder (page 3-15)
4. Grab bar (page 5-2)
5. Chain drive oil filler cap (page 6-14)
6. Engine oil filler cap (page 6-11)
7. V-belt air filter element (left)
8. Engine oil drain bolt (page 6-11)9. Engine oil level check window (page 6-11)
10. Oil filter cartridge (page 6-11)

INSTRUMENT AND CONTROL FUNCTIONS
3-3
2
34
5
6
7
8
9

EAU11003
Indicator and warning lights
EAU11030
Turn signal indicator lights “” and
“”
The corresponding indicator light flash-
es when the turn signal switch is
pushed to the left or right.
EAU11080
High beam indicator light “”
This indicator light comes on when thehigh beam of the headlight is switched
on.
EAU11480
Engine trouble warning light “”
This warning light comes on when an
electrical circuit monitoring the engine
is defective. When this occurs, have a
Yamaha dealer check the self-diagno-
sis system.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.
EAU11551
ABS warning light “” (for ABS
models)
CAUTION:

ECA10830
If the ABS warning light comes on or
flashes while riding, the ABS may be
defective. If this occurs, have a
Yamaha dealer check the electrical
circuit.
See page 3-11 for an explanation of the
ABS.The electrical circuit of the warning light
can be checked by setting the engine
stop switch to “ ” and turning the key
to “ON”. The warning light should come
on for a few seconds, and then go off. If
the warning light does not come on or
remains on, have a Yamaha dealer
check the electrical circuit.
WARNING

EWA11350
When the ABS warning light comes
on or flashes while riding, the brake
system reverts to conventional brak-
ing. Therefore, be careful not to
cause the wheel to lock during emer-
gency braking.
NOTE:

The ABS warning light may come on
while pushing the start switch and while
accelerating the engine with the scoot-
er on its centerstand, but this does not
indicate a malfunction.
EAU26873
Immobilizer system indicator light
“”
The electrical circuit of the indicator
1. Turn signal indicator lights “ ” and “ ”
2. High beam indicator light “ ”
3. Immobilizer system indicator light “ ”
4. Engine trouble warning light “ ”
5. Anti-lock Brake System (ABS) warning
light “ ” (for ABS models)
1
2
3
4
5
ABS
ABS

INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
2
3
4
5
6
7
8
9
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
When the key is turned to “OFF” and 30
seconds have passed, the indicator
light will start flashing indicating the im-
mobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobi-
lizer system is still enabled.
This model is also equipped with a
self-diagnosis device for the immobiliz-
er system. (See page 3-5 for an expla-
nation of the self-diagnosis device.)

EAU11601
Speedometer
The speedometer shows the riding
speed.
When the key is turned to “ON”, the
speedometer needle will sweep once
across the speed range and then return
to zero in order to test the electrical cir-
cuit.
EAU11872
Tachometer
The electric tachometer allows the rider
to monitor the engine speed and keep it
within the ideal power range.
When the key is turned to “ON”, the ta-
chometer needle will sweep once
across the r/min range and then return
to zero r/min in order to test the electri-
cal circuit.
CAUTION:

ECA10031
Do not operate the engine in the ta-
chometer red zone.
Red zone: 8250 r/min and above
1. Speedometer
1

1. Tachometer
2. Tachometer red zone
12

INSTRUMENT AND CONTROL FUNCTIONS
3-7
2
34
5
6
7
8
9
reset after the oil change for the next
periodic oil change to be indicated at
the correct time. (See page 6-11.)
The electrical circuit of the indicator can
be checked according to the following
procedure.
1. Set the engine stop switch to “”
and turn the key to “ON”.
2. Check that the indicator comes on
for a few seconds and then goes
off.
3. If the indicator does not come on,
have a Yamaha dealer check the
electrical circuit.
NOTE:

The oil change indicator may flash
when the engine is revved with the
scooter on the centerstand, but this
does not indicate a malfunction.
V-belt replacement indicator
“V-BELT”
This indicator flashes every 20000 km
(12500 mi) when the V-belt needs to be
replaced.
The electrical circuit of the indicator can
be checked according to the following
procedure.1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
2. If the indicator does not come on,
have a Yamaha dealer check the
electrical circuit.
Self-diagnosis device
This model is equipped with a self-diag-
nosis device for various electrical cir-
cuits.
If any of those circuits are defective, the
multi-function display will indicate a
two-digit error code (e.g., 12, 13, 14).
If the multi-function display indicates
such an error code, note the code num-
ber, and then have a Yamaha dealer
check the vehicle.
CAUTION:

ECA11790
If the multi-function display indi-
cates an error code, the vehicle
should be checked as soon as pos-
sible in order to avoid engine dam-
age.
This model is also equipped with a
self-diagnosis device for the immobiliz-
er system.If any of the immobilizer system circuits
are defective, the immobilizer system
indicator light will flash, and then the
multi-function display will indicate a
two-digit error code (e.g., 51, 52, 53)
when the key is turned to “ON”.
NOTE:

If the multi-function display indicates er-
ror code 52, this could be caused by
transponder interference. If this error
appears, try the following.
1. Use the code re-registering key to
start the engine.
NOTE:

Make sure there are no other immobi-
lizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interfer-
ence, which may prevent the engine
from starting.
2. If the engine starts, turn it off, and
try starting the engine with the
standard keys.
3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering

INSTRUMENT AND CONTROL FUNCTIONS
3-18
1
2
3
4
5
6
7
8
9pair it if it does not function proper-

ly.
EAU15371
Ignition circuit cut-off system
The ignition circuit cut-off system (com-
prising the sidestand switch and brake
light switches) has the following func-
tions.

It prevents starting when the side-
stand is up, but neither brake is ap-
plied.

It prevents starting when either
brake is applied, but the sidestand
is still down.

It cuts the running engine when the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
WARNING

EWA10250
If a malfunction is noted, have a
Yamaha dealer check the system be-
fore riding.

INSTRUMENT AND CONTROL FUNCTIONS
3-19
2
34
5
6
7
8
9
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Keep the front or rear brake applied.
5. Push the start switch.
Does the engine start?
With the engine still off:
6. Move the sidestand up.
7. Keep the front or rear brake applied.
8. Push the start switch.
Does the engine start?
With the engine still running:
9. Move the sidestand down.
Does the engine stall?
The system is OK. The scooter can be ridden.
This check is most reliable if performed with
a warmed-up engine.The sidestand switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
The brake switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO NO YESNOTE:

PRE-OPERATION CHECKS
4-2
2
3
45
6
7
8
9

EAU15603
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-13
Engine oil

Check oil level in engine.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.6-11
Chain drive oil

Check vehicle for oil leakage. 6-14
Coolant

Check coolant level in reservoir.

If necessary, add recommended coolant to specified level.

Check cooling system for leakage.6-15
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 recommended brake fluid to specified level.

Check hydraulic system for leakage.6-22, 6-23
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 recommended brake fluid to specified level.

Check hydraulic system for leakage.6-22, 6-23
Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-18, 6-25