2002 YAMAHA TMAX brake

6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
6 Tire inspection
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or
if the sidewall is cracked, have a
Yamaha dealer replace the tire imme-
diately.
NOTE:
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
Tire information
This scooter is equipped with cast
wheels and tubeless tires.
EW000078
w8The front and rear tires should
be of the same make and
design, otherwise the handling
characteristics of the scooter
cannot be guaranteed.
8After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor Co., Ltd.
EAU00683
w8Have a Yamaha dealer replace
excessively worn tires.
Besides being illegal, operat-
ing the scooter with exces-
sively worn tires decreases
riding stability and can lead to
loss of control.
8The replacement of all wheel-
and brake-related parts,
including the tires, should be
left to a Yamaha dealer, who
has the necessary profession-
al knowledge and experience.
1a
1. Tire sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
FRONT
Manufacturer Size Model
DUNLOP 120/70-14M/C 55S D305FABRIDGESTONE
120/70-14M/C 55S HOOP B03
REAR
Manufacturer Size Model
DUNLOP 150/70-14M/C 66S D305
BRIDGESTONE
150/70-14M/C 66S HOOP B02
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6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03773
Cast wheelsWheelsTo maximize the performance, dura-
bility, and safe operation of your
scooter, note the following points
regarding the specified wheels.
8The wheel rims should be
checked for cracks, bends or
warpage before each ride. If any
damage is found, have a
Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A
deformed or cracked wheel must
be replaced.
8The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.8Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for
it to develop its optimal charac-
teristics.
EAU03851
Front and rear brake leversFront and rear brake leversThere should be no free play at the
brake lever ends. If there is free play,
have a Yamaha dealer inspect the
brake system.FRONT
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6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00721
Checking the front and rear
brake padsFront and rear brake pads, checkingThe front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU03938
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear
without having to disassemble the
brake. To check the brake pad wear,
check the wear indicator grooves. If a
brake pad has worn to the point that
the wear indicator grooves have
almost disappeared, have a Yamaha
dealer replace the brake pads as a
set.
1 11 1
1. Brake pad wear indicator groove (×3)
REAR
FRONT
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6-27
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03294
Checking the brake fluid
levelBrake fluid level, checkingInsufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low
brake fluid 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 system for leak-
age.
1
1. Minimum level mark
EAU01248
Rear brake pads
1. Remove the rear brake caliper
by removing the bolts.
2. Check each rear brake pad for
damage and measure the lining
thickness. If a brake pad is dam-
aged or if the lining thickness is
less than 0.8 mm, have a
Yamaha dealer replace the
brake pads as a set.
3. Install the rear brake caliper by
installing the bolts, then tighten-
ing them to the specified torque.
a1
1. Bolt (×2)
a. Brake pad wear limit
Tightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf)
REAR
FRONT
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6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
6 Observe these precautions:
8When checking the fluid level,
make sure that the top of the
brake fluid reservoir is level.
8Use only the recommended qual-
ity brake fluid, otherwise the rub-
ber seals may deteriorate, caus-
ing leakage and poor braking
performance.
1
1. Minimum level mark
EAU03976
Changing the brake fluidBrake fluid, changingHave a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the master
cylinders and calipers as well as the
brake hoses replaced at the intervals
listed below or whenever they are
damaged or leaking.
8Oil seals: Replace every two
years.
8Brake hoses: Replace every four
years. 8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking perfor-
mance.
8Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8As 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
suddenly, have a Yamaha dealer
check the cause.
REARRecommended brake fluid:
DOT 4
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6-29
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04034
Checking and lubricating the
throttle grip and cableThrottle grip and cable, checking and lubricatingThe operation of the throttle grip
should be checked before each ride.
In addition, the cable should be lubri-
cated or replaced at the intervals
specified in the periodic maintenance
chart.
EAU03371
Checking and lubricating the
centerstand and sidestandCenterstand and sidestand, checking and lubricatingThe operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-
to-metal contact surfaces should be
lubricated if necessary.
EW000114
wIf the centerstand or sidestand
does not move up and down
smoothly, have a Yamaha dealer
check or repair it.
EAU03118
Lubricating the front and
rear brake leversBrake levers, lubricatingThe pivoting points of the front and
rear brake levers must be lubricated
at the intervals specified in the peri-
odic maintenance and lubrication
chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
6
To check the operation
1. Place the scooter on a level sur-
face and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
EC000098
cCIf any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU02939
Checking the front forkFront fork, checkingThe condition and operation of the
front fork must be checked as follows
at the intervals specified in the peri-
odic maintenance and lubrication
chart.
To check the condition
EW000115
wSecurely support the scooter so
that there is no danger of it falling
over.Check the inner tubes for scratches,
damage and excessive oil leakage. Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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7-2
SCOOTER CARE AND STORAGE
7 8Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra-
sive cleaning products, sol-
vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec-
trolyte.
8Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the
following areas: seals (of
wheel and swingarm bearings,
fork and brakes), electric com-
ponents (couplers, connec-
tors, instruments, switches
and lights), breather hoses
and vents.8For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it
does not leave any marks. If
the windshield is scratched,
use a quality plastic polishing
compound after washing.
After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottle-
brush for hard-to-reach areas.
Stubborn dirt and insects will come
off more easily if the area is covered
with a wet cloth for a few minutes
before cleaning.After riding in the rain, near the sea
or on salt-sprayed roadsSince sea salt or salt sprayed on
roads during winter are extremely
corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads.NOTE:
Salt sprayed on roads in the winter
may remain well into spring.1. Clean the scooter with cold water
and a mild detergent after the
engine has cooled down.
ECA00012
cCDo not use warm water since it
increases the corrosive action of
the salt.2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, sur-
faces to prevent corrosion.
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