maintenance YAMAHA VMAX 2009 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2009, Model line: VMAX, Model: YAMAHA VMAX 2009Pages: 102, PDF Size: 2.56 MB
Page 6 of 102
TABLE OF CONTENTS
SAFETY INFORMATION
...................1-1
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 unit ............................3-5
Multi-function display .......................3-6
Anti-theft alarm (optional) ..............3-14
Handlebar switches .......................3-15
Clutch lever ....................................3-16
Shift pedal ......................................3-17
Brake lever ....................................3-17
Brake pedal ...................................3-18
ABS ...............................................3-18
Fuel tank cap .................................3-19
Fuel ................................................3-20
Catalytic converters .......................3-22
Seats .............................................3-22
Adjusting the front fork ...................3-24
Adjusting the shock absorber
assembly ....................................3-26
Luggage strap holders ...................3-28
EXUP system ................................3-28
Sidestand .......................................3-29Ignition circuit cut-off system ......... 3-29
FOR YOUR SAFETY –
PRE-OPERATION CHECKS
.............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
Starting the engine .......................... 5-1
Shifting ............................................ 5-2
Engine break-in ............................... 5-3
Parking ............................................ 5-3
PERIODIC MAINTENANCE AND
ADJUSTMENT
.................................... 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance and
lubrication chart ........................... 6-2
Removing and installing the
cowling and panels ...................... 6-6
Checking the spark plugs ................ 6-8
Engine oil and oil filter cartridge ...... 6-9
Final gear oil .................................. 6-12
Coolant .......................................... 6-14
Air filter element ............................ 6-17
Checking the engine idling
speed ......................................... 6-17
Checking the throttle cable free
play ............................................ 6-17
Valve clearance ............................. 6-18
Tires .............................................. 6-18
Cast wheels ................................... 6-20Clutch lever ................................... 6-21
Checking the front brake lever
free play ..................................... 6-21
Adjusting the rear brake light
switch ......................................... 6-22
Checking the front and rear brake
pads ........................................... 6-22
Checking the brake fluid level ....... 6-23
Changing the brake and clutch
fluids .......................................... 6-24
Checking and lubricating the
cables ........................................ 6-24
Checking and lubricating the
throttle grip and cable ................ 6-24
Checking and lubricating the
brake and clutch levers .............. 6-25
Checking and lubricating the
brake pedal ................................ 6-25
Checking and lubricating the
shift pedal .................................. 6-26
Checking and lubricating the
sidestand ................................... 6-26
Checking the front fork .................. 6-26
Checking the steering ................... 6-27
Checking the wheel bearings ........ 6-28
Battery ........................................... 6-28
Replacing the fuses ...................... 6-31
Replacing the headlight bulb ........ 6-32
Tail/brake light ............................... 6-34
Replacing a turn signal light
bulb ............................................ 6-34
Page 22 of 102
INSTRUMENT AND CONTROL FUNCTIONS
3-8
1
2
3
4
5
6
7
8
9
clock
stopwatch
countdown clock
system status
maintenance counters
TIP
To return to the Normal mode, push
“SELECT” to scroll to “”, then push
“RESET”.
Adjusting the brightness
This function allows you to adjust the
brightness of the tachometer unit panel
(“Meter panel”), the tachometer needle
(“Needle”), and the speedometer and
multi-function displays (“Display”) to
suit the outside lighting conditions.
1. Push “SELECT” to highlight
“Brightness”.
2. Push “RESET”, then push “SE-
LECT” to scroll through the func-
tions and to highlight an item.3. Push “RESET”; the brightness lev-
el segments for the selected item
starts flashing.
4. Push “SELECT” to highlight the
desired brightness level.
5. Push “RESET” to set the bright-
ness level.
6. Push “SELECT” to scroll to “”,
then push “RESET” to return to the
previous menu.
Selecting the shift timing indicator light
settings
This function allows you to choose
whether or not the shift timing indicator
light is activated and whether it flashes
or stays on when activated.
1. Push “SELECT” to highlight “Shift
light”.
2. Push “RESET”.
3. Push “SELECT” to highlight “Oper-
ation selection”.
4. Push “RESET”.
Push “SELECT” and highlight “On”
to activate the indicator light; the
indicator light comes on and stays
on when activated.
Push “SELECT” and highlight
1. Shift timing indicator light
1
Page 27 of 102
INSTRUMENT AND CONTROL FUNCTIONS
3-13
2
34
5
6
7
8
9
in the following order:
(TRIP-F)
→
TRIP-1
→
TRIP-2
→
ODO
→
(TRIP-F)
Push “RESET” to reset a tripmeter.
TIP
For the U.K. only: Push “SELECT”
for at least two seconds to switch
between miles and kilometers.
Pushing “RESET” displays the
Normal mode for five seconds.
Pushing “SELECT” and “RESET”
for at least three seconds, chang-
es the display to the Normal mode.
To perform further multi-function
display settings, enter the Select
mode again by pushing and hold-
ing “SELECT” and “RESET” for at
least three seconds.
Resetting the maintenance counters
This function allows you to reset the
maintenance counters for the tires, theengine oil, and an item of your choice.
1. Push “SELECT” to highlight “Main-
tenance”, then push “RESET”.
2. Push “SELECT” to highlight the
item to reset.
3. Push “RESET” to reset the item.
TIP
The bottom area was left blank for an-
other item the rider cares to check the
distance of since it has been changed,
replaced or checked (i.e., air filter ele-
ment, engine parts, etc.).
4. Push “SELECT” to scroll to “”.
5. Push “RESET” to return to the pre-vious menu.
Self-diagnosis device
This model is equipped with a self-diag-
nosis device for various electrical cir-
cuits.
If a problem is detected in any of those
circuits, the engine trouble warning light
comes on and the display indicates a
two-digit error code.
NOTICE
ECA11590
If the display indicates an error
code, the vehicle should be checked
as soon as possible in order to avoid
engine damage.
The self-diagnosis device also detects
problems in the immobilizer system cir-
cuits.
If a problem is detected in any of the im-
1. Error code display
1
Page 35 of 102
INSTRUMENT AND CONTROL FUNCTIONS
3-21
2
34
5
6
7
8
9
3. Wipe up any spilled fuel immedi-
ately.
NOTICE:
Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plastic
parts.
[ECA10071]
4. Be sure to securely close the fuel
tank cap.
WARNING
EWA15151
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline inyour eyes, see your doctor immedi-
ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.
EAU43421
NOTICE
ECA11400
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been de-
signed to use premium unleaded gaso-
line with a research octane number of
95 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a differentbrand. Use of unleaded fuel will extend
spark plug life and reduce maintenance
costs.
1. Fuel tank filler tube
2. Fuel level
12
Recommended fuel:
PREMIUM UNLEADED GASOLINE
ONLY
Fuel tank capacity:
15.0 L (3.96 US gal, 3.30 Imp.gal)
Fuel reserve amount (when the fuel
level warning indicator flashes):
3.9 L (1.03 US gal, 0.86 Imp.gal)
Page 36 of 102
INSTRUMENT AND CONTROL FUNCTIONS
3-22
1
2
3
4
5
6
7
8
9
EAU13445
Catalytic converters
This vehicle is equipped with catalytic
converters in the exhaust system.
WARNING
EWA10862
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:
Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
Make sure that the exhaust sys-
tem has cooled down before do-
ing any maintenance work.
Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
NOTICE
ECA10701
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-pairable damage to the catalytic
converter.
EAU46840
Seats
Rider seat
To remove the rider seat
1. Pull the rider seat backrest release
lever on the left side of the vehicle
as shown. The backrest will slide
forward.
1. Rider seat backrest release lever
1
Page 45 of 102
4-1
2
3
45
6
7
8
9
FOR YOUR SAFETY – PRE-OPERATION CHECKS
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel
Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-20
Engine oil
Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-9
Final gear oil
Check vehicle for oil leakage. 6-12
Coolant
Check coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-14
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
Page 51 of 102
6-1
2
3
4
5
67
8
9
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17241
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, depending on the
weather, terrain, geographical location,
and individual use, the maintenance in-
tervals may need to be shortened.
WARNING
EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15121
Turn off the engine when performing
maintenance unless otherwise
specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more in-
formation about carbon monox-
ide.
EAU17341
Owner’s tool kit
The owner’s tool kit is located behind
panel A. (See page 6-6.)
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 preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIP
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
1. Owner’s tool kit
1
Page 52 of 102
PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
1
2
3
4
5
6
7
8
9
EAU1770A
Periodic maintenance and lubrication chart
TIP
The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.
From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
Items 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
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1*
Fuel line
Check fuel hoses for cracks or
damage.
√√√√√
2*
Spark plugs
Check condition.
Clean.
√√
Replace.
√√
3*
Valves
Check valve clearance.
Adjust.Every 40000 km (24000 mi)
4*
Air filter element
Replace.
√
5*
Clutch
Check operation, fluid level and
vehicle for fluid leakage.
√√√√√
6*
Front brake
Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√
Replace brake pads. Whenever worn to the limit
7*
Rear brake
Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√
Replace brake pads. Whenever worn to the limit
8*
Brake hoses
Check for cracks or damage.
√√√√√
Replace. Every 4 years
Page 53 of 102
PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
2
3
4
5
67
8
9
9*
Wheels
Check runout and for damage.
√√√√
10
*
Tires
Check tread depth and for dam-
age.
Replace if necessary.
Check air pressure.
Correct if necessary.
√√√√√
11
*
Wheel bearings
Check bearing for looseness or
damage.
√√√√
12
*
Swingarm
Check operation and for exces-
sive play.
√√√√
Lubricate with lith-
ium-soap-based grease.Every 50000 km (30000 mi)
13
*
Steering bearings
Check bearing play and steering
for roughness.
√√√√√
Lubricate with lith-
ium-soap-based grease.Every 50000 km (30000 mi)
14
Brake lever pivot
shaft
Lubricate with silicone grease.
√√√√√
15
Brake pedal pivot
shaft
Lubricate with lith-
ium-soap-based grease.
√√√√√
16
Clutch lever pivot
shaft
Lubricate with silicone grease.
√√√√√
17
Shift pedal pivot
shaft
Lubricate with lith-
ium-soap-based grease.
√√√√√
18
Sidestand
Check operation.
Lubricate.
√√√√√
19
*
Sidestand switch
Check operation.
√√√√√√
20
*
Front fork
Check operation and for oil leak-
age.
√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
Page 54 of 102
PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
1
2
3
4
5
6
7
8
9
21
*
Shock absorber
assembly
Check operation and shock
absorber for oil leakage.
√√√√
22
*
Rear suspension
relay arm and con-
necting arm pivoting
points
Check operation.
√√√√
23
*
Fuel injection sys-
tem
Adjust synchronization.
√√√√√
24
Engine oil
Change.
Check oil level and vehicle for oil
leakage.
√√√√√√
25
Engine oil filter car-
tridge
Replace.
√√√
26
*
Cooling system
Check coolant level and vehicle
for coolant leakage.
√√√√√
Change. Every 3 years
27
Final gear oil
Check oil level and vehicle for oil
leakage.
√√ √
Change.
√√√
28
*
Front and rear brake
switches
Check operation.
√√√√√√
29
Moving parts and
cables
Lubricate.
√√√√√
30
*
Throttle grip hous-
ing and cable
Check operation and free play.
Adjust the throttle cable free play
if necessary.
Lubricate the throttle grip housing
and cable.
√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)