brake pads YAMAHA VMAX 2001 Owners Manual

6
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 .................................... 6-7
Engine oil and oil filter cartridge .......................... 6-9
Final gear oil ...................................................... 6-13
Coolant .............................................................. 6-14
Cleaning the air filter element ............................ 6-19
Adjusting the carburetors ................................... 6-20
Adjusting the engine idling speed ...................... 6-20
Adjusting the throttle cable free play .................. 6-21
Adjusting the valve clearance ............................ 6-21
Tires ................................................................... 6-21
Cast wheels ....................................................... 6-24
Clutch lever free play ......................................... 6-24
Adjusting the brake lever free play ..................... 6-25
Adjusting the brake pedal position ..................... 6-25
Adjusting the rear brake light switch .................. 6-26
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 cables .................. 6-28Checking and lubricating the throttle
grip and cable ................................................. 6-29
Checking and lubricating the brake and
shift pedals ...................................................... 6-29
Checking and lubricating the brake and
clutch levers .................................................... 6-30
Checking and lubricating the centerstand and
sidestand......................................................... 6-30
Lubricating the rear suspension ........................ 6-31
Checking the front fork ...................................... 6-31
Checking the steering ....................................... 6-32
Checking the wheel bearings ............................ 6-33
Battery ............................................................... 6-33
Replacing the fuses .......................................... 6-37
Replacing the headlight bulb ............................. 6-38
Replacing a turn signal light bulb or the tail/
brake light bulb ................................................ 6-39
Front wheel ....................................................... 6-40
Rear wheel ........................................................ 6-41
Troubleshooting ................................................. 6-44
Troubleshooting charts ...................................... 6-45
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
EAU03540
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-01ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
•Replace.ÖÖ
4*Valves• Check valve clearance.
• Adjust.ÖÖ
5 Air filter element• Clean.ÖÖ
•Replace.ÖÖ
6*Battery• Check electrolyte level and specific gravity.
• Make sure that the breather hose is properly routed.ÖÖÖÖ Ö
7*Clutch• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)ÖÖÖÖÖ
8*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
9*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EW000109
WARNING
@ A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident. @
EAU00713
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction
a. To
make the brake light come on later,
turn the adjusting nut in direction
b.
EAU00715
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. Each brake pad is
provided with a wear indicator, which
allows you to check the brake pad wear
without having to disassemble the
brake. To check the brake pad wear,
check the position of the wear indicator
while applying the brake. If a brake pad
has worn to the point that the wear indi-
cator almost touches the brake disc,
have a Yamaha dealer replace the
brake pads as a set.
1. Brake light switch
2. Adjusting nut
1. Wear indicator (´ 2)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU03418
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake or clutch systems, pos-
sibly causing them to become ineffec-
tive.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.
NOTE:@ To check the rear brake fluid level, re-
move panel B. (See page 6-7 for panel
removal and installation procedures.) @Observe these precautions:l
When checking the fluid level,
make sure that the top of the mas-
ter cylinder is level by turning the
handlebars.
l
Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking or clutch
performance.
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking or clutch per-
formance.
l
The diaphragm will lose its shape
from the negative pressure if the
brake fluid level goes down too far.
Be sure to put the diaphragm back
in its original shape before install-
ing it into the master cylinder.
l
Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
1. Minimum level markFront brake
1. Minimum level mark
Recommended brake fluid: DOT 4Clutch
1. Panel B
2. Minimum level mark
Rear brake
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU03238
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the brake master cylinder and caliper
as well as the brake hose replaced at
the intervals listed below or whenever
they are damaged or leaking.l
Oil seals: Replace every two
years.
l
Brake hose: Replace every four
years.
EAU02962
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
@ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. @Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-40
6
EAU03419
Front wheel To remove the front wheel
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
@1. Place the motorcycle on the cen-
terstand.
2. Disconnect the speedometer ca-
ble from the front wheel.
3. Remove the brake caliper by re-
moving the bolts.
ECA00047
CAUTION:@ Do not pull the brake lever after the
brake caliper has been removed,
otherwise the brake pads will be
forced shut. @4. Loosen the front wheel axle pinch
bolt, then the wheel axle.
5. Pull the wheel axle out, and then
remove the wheel.
EAU03420
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
1. Speedometer cable
2. Bolt (´ 2)
3. Pinch bolt
4. Wheel axle
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-41
62. Lift the wheel up between the fork
legs.
NOTE:@ Make sure that the slot in the speedom-
eter gear unit fits over the retainer on
the fork leg. @3. Insert the wheel axle.
4. Take the motorcycle off the cen-
terstand so that the front wheel is
on the ground.5. Install the brake calipers by install-
ing the bolts.
NOTE:@ Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs. @6. Tighten the front wheel axle pinch
bolt, then the wheel axle, and the
brake caliper bolts to the specified
torques.
7. Connect the speedometer cable.
8. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU03421
Rear wheel To remove the rear wheel
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
@
Tightening torques:
Wheel axle:
58 Nm (5.8 m·kg,)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kg)
Brake caliper bolt:
40Nm (4.0 m·kg)
1. Axle nut
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-42
6 1. Loosen the rear wheel axle pinch
bolt, then the axle nut.
2. Place the motorcycle on the cen-
terstand.
3. Remove the brake caliper bolts
and the axle nut.
4. Disconnect the brake torque rod
from the brake caliper bracket by
removing the cotter pin, the nut,
and the bolt.5. While supporting the brake cali-
per, pull the wheel axle out.
6. Remove the brake caliper bracket
and spacer.
7. Pull the wheel to the right to sepa-
rate it from the final gear case, and
then remove it.
ECA00062
CAUTION:@ Do not push the brake pedal after
the wheel has been removed togeth-
er with the brake disc, otherwise the
brake pads will be forced shut. @
1. Pinch bolt
1. Nut
2. Cotter pin
3. Brake torque rod
4. Bolt (´3)
5. Brake caliper bracket
6. Spacer
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-43
6
EAU03422
To install the rear wheel
1. Apply a light coating of lithium-
soap-based grease to the splines
of the final gear case and wheel
hub.
2. Install the wheel, brake caliper
bracket, spacer and wheel axle.
3. Install the brake caliper by install-
ing the bolts.NOTE:@ Make sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brake
disc. @
4. Install the brake torque rod bolt
and nut at the brake caliper brack-
et.
5. Install the rear wheel axle nut.
6. Take the motorcycle off the cen-
terstand so that the rear wheel is
on the ground.
7. Tighten the axle nut, brake caliper
bolts, brake torque rod nut, and
pinch bolt to the specified torques.
8. Install the brake torque rod cotter
pin.
EW000124
WARNING
@ Always use a new cotter pin. @
Tightening torques:
Axle nut:
150 Nm (15.0 m·kg)
Brake caliper bolt:
40 Nm (4.0 m·kg)
Brake torque rod nut:
48 Nm (4.8 m·kg)
Rear wheel axle pinch bolt:
16 Nm (1.6 m·kg)
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10-INDEXAAir filter element, cleaning ...................... 6-19
Anti-theft alarm ........................................3-3BBattery ................................................... 6-33
Brake and clutch levers, checking and
lubricating ............................................ 6-30
Brake and shift pedals, checking and
lubricating ............................................ 6-29
Brake fluid, changing ............................. 6-28
Brake fluid level, checking...................... 6-27
Brake lever...............................................3-6
Brake lever free play, adjusting .............. 6-25
Brake light switch (rear), adjusting ......... 6-26
Brake pads, checking............................. 6-26
Brake pedal..............................................3-6
Brake pedal position, adjusting .............. 6-25CCables, checking and lubricating............ 6-28
Carburetors, adjusting............................ 6-20
Care.........................................................7-1
Centerstand and sidestand, checking
and lubricating ..................................... 6-30
Clutch lever ..............................................3-5
Clutch lever free play ............................. 6-24
Conversion table ......................................8-5
Coolant .................................................. 6-14
Changing .......................................... 6-15
Checking .......................................... 6-14
Coolant temperature gauge .....................3-3
Cowlings and panels, removing and
installing................................................ 6-6DDimmer switch ......................................... 3-4EEngine break-in ....................................... 5-4
Engine oil and oil filter cartridge ............... 6-9
Engine stop switch................................... 3-4FFinal gear oil .......................................... 6-13
Front fork, adjusting ............................... 3-11
Front fork, checking ............................... 6-31
Fuel ......................................................... 3-8
Fuel consumption, tips for reducing ......... 5-4
Fuel level warning light ............................ 3-2
Fuel reserve switch.................................. 3-5
Fuel tank cap ........................................... 3-7
Fuses, replacing .................................... 6-37HHandlebar switches ................................. 3-4
Headlight bulb, replacing ....................... 6-38
Helmet holder ........................................ 3-10
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-4IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-20
Ignition circuit cut-off system.................. 3-16
Indicator and warning lights ..................... 3-1
KKey identification number .........................9-1LLight switch ..............................................3-4MMain switch ..............................................3-1
Maintenance and lubrication, periodic ......6-3
Model label ..............................................9-2NNeutral indicator light ...............................3-1OOil level warning light ...............................3-2
Operation .................................................5-1PParking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-4
Pre-operation check list ............................4-1RRider seat ................................................3-9SSafety information ....................................1-1
Shifting .....................................................5-3
Shift pedal ................................................3-6
Shift points (for Switzerland only) .............5-4
Shock absorber assemblies, adjusting ...3-12
Sidestand ...............................................3-16
Spark plugs, checking ..............................6-7
Specifications ...........................................8-1
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