check engine YAMAHA VMAX 2001 Owners Manual

DESCRIPTION
2-2
2
Right view11. Fuel tank cap (page 3-7)
12. Battery (page 6-33)
13. Coolant reservoir (page 6-14)
14. Front brake master cylinder reservoir (page 6-27)
15. Main switch (page 3-1)
16. Radiator cap (page 6-16)
17. Radiator (page 6-16)
18. Engine oil filter cartridge (page 6-9)
19. Engine oil level check window (page 6-9)
20. Brake pedal (page 3-6)
21. Rear brake fluid reservoir (page 6-27)
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INSTRUMENT AND CONTROL FUNCTIONS
3-2
3
EAU00083
Fuel level warning light “ ”
This warning light comes on when the
fuel level drops below approximately
3 L. When this occurs, set the fuel re-
serve switch to the “RES” position and
refuel as soon as possible.
EAU00063
High beam indicator light “ ”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU03285
Oil level warning light “ ”
This warning light comes on when the
engine oil level is low.
The electrical circuit of the warning light
can be checked according to the fol-
lowing procedure.
1. Turn the key to “ON”.
2. If the warning light does not come
on, have a Yamaha dealer check
the electrical circuit.NOTE:@ Even if the oil level is sufficient, the
warning light may flicker when riding on
a slope or during sudden acceleration
or deceleration, but this is not a mal-
function. @
EAU00095
Speedometer unit The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset knob.
The tripmeter can be used to estimate
the distance that can be traveled with a
full tank of fuel. This information will en-
able you to plan future fuel stops.1. Tripmeter reset knob
2. Odometer
3. Tripmeter
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INSTRUMENT AND CONTROL FUNCTIONS
3-16
3
EAU00330
Sidestand The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
motorcycle upright.NOTE:@ The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.) @
EW000044
WARNING
@ The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up), oth-
erwise the sidestand could contact
the ground and distract the opera-
tor, resulting in a possible loss of
control. Yamaha’s ignition circuit
cut-off system has been designed to
assist the operator in fulfilling the
responsibility of raising the side-
stand before starting off. Therefore,
check this system regularly as de-
scribed below and have a Yamaha
dealer repair it if it does not function
properly. @
EAU00332
Ignition circuit cut-off system The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.l
It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is
not pulled.
l
It prevents starting when the trans-
mission is in gear and the clutch
lever is pulled, but the sidestand is
still down.
l
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.
EW000046
WARNING
@ l
The vehicle must be placed on
the centerstand during this in-
spection.
l
If a malfunction is noted, have a
Yamaha dealer check the sys-
tem before riding.
@
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INSTRUMENT AND CONTROL FUNCTIONS
3-17
3
CD-01E
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “ ”.
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
NOTE:This check is most reliable if performed with
a warmed-up engine.
YESYES NO
The system is OK.
The motorcycle can be ridden.
YES NO
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4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03328
Pre-operation check list
ITEM CHECKS PAGE
Front brake
• Check operation, free play, fluid level, and for fluid leakage.
• Fill with DOT 4 brake fluid if necessary.6-25–6-28
Rear brake6-25–6-28
Clutch• Check operation, fluid level, and for fluid leakage.
• Fill with DOT 4 brake fluid if necessary.6-24, 6-27
Throttle grip and housing• Check operation.
• Lubricate if necessary.6-21, 6-29
Engine oil• Check oil level.
• Add oil if necessary.6-9–6-12
Coolant• Check coolant level.
• Add coolant if necessary.6-14–6-18
Final gear oil• Check vehicle for leakage. 6-13
Wheels and tires• Check tire air pressure, for wear and damage. 6-21–6-24
Control cables• Check operation.
• Lubricate if necessary.6-28
Brake and shift pedal
shafts• Check operation.
• Lubricate if necessary.6-29
Brake and clutch lever
pivots• Check operation.
• Lubricate if necessary.6-30
Center and sidestand
pivots• Check operation.
• Lubricate if necessary.6-30
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5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373
WARNING
@ l
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
l
Never 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.
l
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
@
EAU01627
Starting a cold engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:l
The transmission is in the neutral
position.
l
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
WARNING
@ l
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-16.
l
Never ride with the sidestand
down.
@1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
EC000035
CAUTION:@ If the fuel level warning light comes
on, check the fuel level, and, if nec-
essary, refuel as soon as possible. @2. Shift the transmission into the neu-
tral position.NOTE:@ When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-
cuit. @3. Turn the starter (choke) on and
completely close the throttle. (See
page 3-8 for starter (choke) opera-
tion.)
4. Start the engine by pushing the
start switch.
E_3lr.book Page 1 Wednesday, November 22, 2000 4:10 PM

OPERATION AND IMPORTANT RIDING POINTS
5-2
5
NOTE:@ If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt. @
EC000038
CAUTION:@ l
The oil level warning light and
fuel level warning light should
come on when the start switch
is pushed, and they should go
off when the start switch is re-
leased.
l
If the oil level warning light flick-
ers or remains on after starting,
immediately stop the engine,
and then check the engine oil
level and the vehicle for oil leak-
age. If necessary, add engine
oil, and then check the warning
light again. If the warning light
does not come on when push-
ing the start switch, or if it doesnot go off after starting with suf-
ficient engine oil, have a
Yamaha dealer check the elec-
trical circuit.
l
If the fuel level warning light re-
mains on after starting, stop the
engine, and then check the fuel
level. If necessary, refuel as
soon as possible, and then
check the warning light again. If
the warning light does not come
on when pushing the start
switch, or if it does not go off af-
ter starting with sufficient fuel,
have a Yamaha dealer check the
electrical circuit.
@5. After starting the engine, move the
starter (choke) lever back halfway.
ECA00045
CAUTION:@ For maximum engine life, never ac-
celerate hard when the engine is
cold! @
6. When the engine is warm, turn the
starter (choke) off.NOTE:@ The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off. @
E_3lr.book Page 2 Wednesday, November 22, 2000 4:10 PM

OPERATION AND IMPORTANT RIDING POINTS
5-5
5
EAU00442
0–150 kml
Avoid prolonged operation above
4,500 r/min.
l
After every hour of operation, stop
the engine, and then let it cool for
five to ten minutes.
l
Vary the engine speed from time
to time. Do not operate the engine
at one set throttle position.
150–500 km
l
Avoid prolonged operation above
5,500 r/min.
l
Rev the engine freely through the
gears, but do not use full throttle at
any time.
500–1,000 km
l
Avoid prolonged full-throttle oper-
ation.
l
Avoid prolonged operation above
6,500 r/min.
EC000056
CAUTION:@ After 1,000 km of operation, the en-
gine oil and final gear oil must be
changed, and the oil filter cartridge
replaced.@1,000 km and beyond
The vehicle can now be operated
normally.
EC000053
CAUTION:@ l
Keep the engine speed out of
the tachometer red zone.
l
If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the
vehicle.
@
EAU00460
Parking When parking, stop the engine, and
then remove the key from the main
switch.
EW000058
WARNING
@ l
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.
l
Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
@
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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
E_3lr.book Page 1 Wednesday, November 22, 2000 4:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
10
*Brake hoses• Check for cracks or damage.ÖÖÖÖ Ö
• Replace. Every 4 years
11*Wheels• Check runout and for damage. ÖÖÖÖ
12*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖÖÖ
13*Wheel bearings• Check bearings for looseness or damage. ÖÖÖÖ
14*Swingarm• Check swingarm pivoting point for play.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease. Every 50,000 km
15*Steering bearings• Check bearing play and steering for roughness.ÖÖÖÖÖ
• Lubricate with lithium-soap-based grease. Every 50,000 km
16*Chassis fasteners• Make sure that all nuts, bolts and screws are properly
tightened.ÖÖÖÖ Ö
17 Sidestand/centerstand• Check operation.
• Lubricate.ÖÖÖÖ Ö
18*Sidestand switch• Check operation.ÖÖÖÖÖ Ö
19*Front fork• Check operation and for oil leakage.ÖÖÖÖ
20*Rear shock absorber
assemblies• Check operation and shock absorbers for oil leakage.ÖÖÖÖ
21*Carburetors• Check engine idling speed, synchronization and starter
operation.ÖÖÖÖÖ Ö
22 Engine oil• Change.ÖÖÖÖÖ Ö
23 Engine oil filter cartridge• Replace.ÖÖÖ
24*Cooling system• Check coolant level and vehicle for coolant leakage.ÖÖÖÖ Ö
• Change coolant. Every 3 years NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
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