light YAMAHA TMAX 2001 User Guide

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
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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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9To check the spark plugs
1. Check that the porcelain insula-
tor around the center electrode
on each spark plug is a medium-
to-light tan (the ideal color when
the scooter is ridden normally).
2. Check that all spark plugs
installed in the engine have the
same color.
NOTE:
If any spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead,
have a Yamaha dealer check the
scooter.3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and
replace it if necessary.To install a spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4–1/2 turn past finger tight.
However, the spark plug should be
tightened to the specified torque as
soon as possible.4. Install the spark plug cap.
Specified spark plug:
CR7E (NGK)
Spark plug gap:
0.7–0.8 mm
Tightening torque:
Spark plug:
12.5 Nm (1.25 m0kg)
a
a. Spark plug gap
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EAU03872
Engine oil and oil filter
cartridgeThe engine oil level should be
checked before each ride. In addition,
the oil must be changed and the oil
filter cartridge replaced at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
To check the engine oil level
1. Place the scooter on the center-
stand.
ECA00081
cCThe engine must be cold before
proceeding with the oil level
check, otherwise the check will
result in a false reading. NOTE:
Make sure that the scooter is posi-
tioned straight up when checking the
oil level. A slight tilt to the side can
result in a false reading.
32
1
4
1. Engine oil level check window
2. Maximum level
3. Minimum level
4. Engine oil drain bolt2. Start the engine, warm it up for
two minutes, and then turn it off.
3. Wait two minutes until the oil set-
tles, and then check the oil level
through the check window locat-
ed at the bottom-left side of the
crankcase.NOTE:
The engine oil should be between the
minimum and maximum level marks.4. If the engine oil is below the min-
imum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
1
1. Spark plug cover5. Place the spark plug cover in the
original position as shown, and
then install the cowling.
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1
To reset the oil change indicator
light
1. Turn the key to “ON”.
2. Hold the reset button pushed for
two to five seconds.
3. Release the reset button, and
the oil change indicator light will
go off.1. Reset button “Oil Change”
NOTE:
If the engine oil is changed before the
oil change indicator light comes on
(i.e. before the periodic oil change
interval has been reached), the indi-
cator light must be reset after the oil
change for the next periodic oil
change to be indicated at the correct
time. To reset the oil change indicator
light before the periodic oil change
interval has been reached, follow the
above procedure, but note that the
indicator light will come on for 1.4
seconds after releasing the reset but-
ton, otherwise repeat the procedure.
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EAU03850
CoolantTo check the coolant level
1. Place the scooter on a level sur-
face and hold it in an upright
position.NOTE:
8The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
8Make sure that the scooter is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
2. Remove the coolant reservoir
cover by removing the screw.
1
2
1. Coolant reservoir cover
2. Screw
3. Check the coolant level in the
coolant reservoir.NOTE:
The coolant should be between the
minimum and maximum level marks.
12
1. Maximum level mark
2. Minimum level mark
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EC000082
cC8Make sure that the air filter ele-
ment is properly seated in the
air filter case.
8The engine should never be
operated without the air filter
element installed, otherwise
the pistons and/or cylinders
may become excessively
worn.6. Install the air filter case cover by
installing the screws.
7. Install the windshield and the
cowling. 4. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as
shown. If the air filter element is
damaged, replace it.
5. Insert the air filter element into
the air filter case.
1
1. Air filter element
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1
EAU03875
Replacing the fusesThe main fuse box is located beside
the battery and can be accessed as
follows:
1. Open the seat. (See page 3-9 for
seat opening and closing proce-
dures.)
2. Remove the battery cover. (See
page 6-32 for battery cover
removal procedures.)1. Battery
12
3
3. Disconnect the negative battery
lead, and then lift the battery as
shown.
The fuse box, which contains the
fuses for the individual circuits, is
located under the battery cover and
can be accessed as follows:
1. Open the seat. (See page 3-9 for
seat opening and closing proce-
dures.)
2. Remove the battery cover by
removing the screws.1. Negative battery lead
2. Main fuse box
3. Fuse box
If a fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn
off the electrical circuit in ques-
tion.
2. Remove the blown fuse, and
then install a new fuse of the
specified amperage.
6
12345
1. Signaling system fuse
2. Headlight fuse
3. Ignition fuse
4. Radiator fan fuse
5. Clock fuse
6. Spare fuse (×2)
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EC000103
cCDo not use a fuse of a higher
amperage rating than recommend-
ed to avoid causing extensive
damage to the electrical system
and possibly a fire.3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system. Specified fuses:
Main fuse: 30 A
Signaling system fuse: 15 A
Headlight fuse: 15 A
Ignition fuse: 10 A
Radiator fan fuse: 15 A
Clock fuse: 10 A
1
2
EAU03874
Replacing a headlight bulbThis scooter is equipped with quartz
bulb headlights. If a headlight bulb
burns out, replace it as follows.
1. Disconnect the headlight cou-
pler, and then remove the head-
light bulb cover.1. Headlight coupler
2. Headlight bulb cover
2. Unhook the headlight bulb holder
as shown, and then remove the
defective bulb.
a
1
1. Headlight bulb holder
a. Unhook.
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EC000105
cCDo not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the
bulb, and the bulb life will be
adversely affected. Thoroughly
clean off any dirt and fingerprints
on the headlight bulb using a cloth
moistened with alcohol or thinner.4. Install the bulb cover, and then
connect the coupler.
5. Have a Yamaha dealer adjust
the headlight beam if necessary.
EW000119
wHeadlight bulbs get very hot.
Therefore, keep flammable prod-
ucts away from a lit headlight bulb,
and do not touch the bulb until it
has cooled down.3. Place a new bulb into position,
and then secure it with the bulb
holder.
a
a. Do not touch this area.
EAU03087
TroubleshootingAlthough Yamaha motorcycles
receive a thorough inspection before
shipment from the factory, trouble
may occur during operation. Any
problem in the fuel, compression, or
ignition systems, for example, can
cause poor starting and loss of
power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your scooter
require any repair, take it to a
Yamaha dealer, whose skilled techni-
cians have the necessary tools,
experience, and know-how to service
the scooter properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life
and can lead to expensive repair
bills.
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