YAMAHA TMAX 2002 Service Manual

5-3
OPERATION AND IMPORTANT RIDING POINTS
5
EAU00435
BrakingBraking1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually
increasing the pressure.
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.
EAU03093
Tips for reducing fuel
consumptionFuel consumption, tips for reducingFuel 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).
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5-4
OPERATION AND IMPORTANT RIDING POINTS
5
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Engine break-inEngine 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.
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.
EAU00460
ParkingParkingWhen 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 ..................................................... 6-15
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 .......................................................... 6-29
Checking the front fork ........................................ 6-30Checking the steering ......................................... 6-31
Checking the wheel bearings .............................. 6-31
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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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.
EAU03846
Owner’s tool kitTool kitThe owner’s tool kit is located under
the seat. (See page 3-11 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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6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
If you do not have the tools or experi-
ence required for a particular job,
have a Yamaha dealer perform it for
you.
EW000063
wModifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any
changes.
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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Periodic maintenance and lubrication chart
Periodic maintenance and lubrication chartNOTE:
8The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line•Check fuel hoses and vacuum hose for cracks or damage.√√√√ √
2*Fuel filter•Check condition.√√
3 Spark plugs•Check condition.
•Clean and regap.√√
•Replace.√√
4*Valves•Check valve clearance.
•Adjust.Every 40,000 km
5 Air filter element•Clean.√√
•Replace.√√
6*V-belt case air filter
elements•Clean.√√
•Replace.√√
7*Front brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
8
*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 hoses•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 grease.Every 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*Shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√
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
6
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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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6-6
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01139
Removing and installing
cowlings and panelsCowlings and panels, removing and installingThe cowlings and panels shown
above need to be removed to per-
form some of the maintenance jobs
described in this chapter. Refer to
this section each time a cowling or
panel needs to be removed and
installed.
4
3
1 2
1. Panel A
2. Panel B
3. Panel C
4. Cowling A
EAU03878
Panels A and D
To remove one of the panels1. Remove panel C (right side) or
panel E (left side).
2. Remove the panel screws.
3. Pull outward on the front of the
panel.
1
1. Screw (×3)
1
23
4
5
1. Panel D
2. Cowling B
3. Panel E
4. Cowling C
5. Panel F
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