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Yamaha TMAX 2020 Service Manual

Yamaha TMAX 2020
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4-69
ABS (Anti-lock Brake System)
EAS30198
CHECKING THE HYDRAULIC UNIT
ASSEMBLY
1. Check:
Hydraulic unit assembly
Cracks/damage Replace the hydraulic unit
assembly and the brake hoses that are con-
nected to the assembly as a set.
EAS30200
INSTALLING THE HYDRAULIC UNIT
ASSEMBLY
1. Install:
Hydraulic unit assembly
NOTICE
ECA21371
Do not remove the rubber plugs or bolts
(M10 1.0) installed in the brake hose union
bolt holes before installing the hydraulic unit
assembly.
TIP
Do not allow any foreign materials to enter the
hydraulic unit assembly or the brake hoses
when installing the hydraulic unit assembly.
2. Remove:
Rubber plugs or bolt (M10 1.0)
3. Install:
Rear brake hose (hydraulic unit to rear brake
caliper) “1”
Front brake hose (front brake master cylinder
to hydraulic unit) “2”
Front brake hose (hydraulic unit to front brake
caliper) “3”
Rear brake hose (rear brake master cylinder
to hydraulic unit) “4”
•Gasket
Brake hose union bolt
NOTICE
ECA21121
If the brake hose union bolt does not turn
easily, replace the hydraulic unit assembly,
brake hoses, and related parts as a set.
TIP
To route the brake hose, refer to “CABLE
ROUTING” on page 2-13.
4. Connect:
ABS ECU coupler “1”
TIP
Connect the ABS ECU coupler, and then push
the lock lever of the coupler in the direction of the
arrow shown.
5. Fill:
Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)
WARNING
EWA13090
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake hose union bolt
30 N·m (3.0 kgf·m, 22 lb·ft)
New
T
R
.
.
Specified brake fluid
DOT 4
4
1
3
2
1

Table of Contents

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Yamaha TMAX 2020 Specifications

General IconGeneral
Displacement562cc
Bore x Stroke70.0 mm x 73.0 mm
Compression Ratio10.9:1
Fuel SystemFuel Injection
Ignition SystemTCI
TransmissionV-Belt Automatic
Rear SuspensionSwingarm
Front BrakeHydraulic dual disc, Ø267 mm
Rear BrakeHydraulic single disc, Ø282 mm
Front Tyre120/70R15M/C 56H
Rear Tyre160/60R15M/C 67H
Overall Length2, 200 mm
Overall Width765 mm
Seat Height800 mm
Wheelbase1, 575 mm
Wet Weight218 kg
Fuel Tank Capacity15 litres
Engine TypeLiquid-cooled, 4-stroke, DOHC, 4-valve
Maximum Torque55.7 Nm @ 5, 250 rpm
Front SuspensionTelescopic fork
Overall Height1, 420mm

Summary

GENERAL INFORMATION

IDENTIFICATION

Details on vehicle and model identification numbers.

FEATURES

Overview of multi-function display, fuel meter, and coolant temperature meter.

SPECIAL TOOLS

Lists necessary special tools, their part numbers, and reference pages.

SPECIFICATIONS

GENERAL SPECIFICATIONS

Provides dimensions, weight, loading capacity, and model information.

ENGINE SPECIFICATIONS

Details engine parameters like combustion cycle, displacement, bore, stroke, and oil specifications.

CHASSIS SPECIFICATIONS

Covers frame, wheels, tires, brakes, and suspension specifications.

ELECTRICAL SPECIFICATIONS

Lists voltage, ignition system, coils, charging system, and battery specifications.

TIGHTENING TORQUES

Specifies torque values for engine and chassis components.

CABLE ROUTING

Illustrates and describes the proper routing of various wires and cables.

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE

Outlines recommended maintenance checks and adjustments for emissions control and general lubrication.

CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL

Explains the procedure for using the YDT to check the vehicle and diagnose malfunctions.

CHECKING THE FUEL LINE

Details the procedure for checking fuel, breather, and overflow hoses for cracks or loose connections.

ADJUSTING THE VALVE CLEARANCE

Provides step-by-step instructions for adjusting valve clearance on a cold engine.

CHANGING THE ENGINE OIL

Details the procedure for draining and replacing engine oil and oil filter.

CHASSIS

FRONT WHEEL

Covers removal, disassembly, checking, assembly, and installation of the front wheel and brake discs.

REAR WHEEL

Details the procedures for removing, disassembling, checking, and installing the rear wheel.

ABS (Anti-lock Brake System)

Explains the hydraulic unit assembly removal, checking, installation, and operation test.

HANDLEBAR

Covers handlebar cover removal, checking, installation, and accelerator position sensor adjustment.

FRONT FORK

Details the removal, disassembly, checking, and installation of front fork legs.

STEERING HEAD

Explains how to remove, check, and install the steering head components.

BELT DRIVE

Covers checking the drive belt and installing the drive belt and drive pulley.

REAR SHOCK ABSORBER ASSEMBLY

Details handling, disposal, removal, checking, assembly, and installation of the rear shock absorber.

SWINGARM

Covers swingarm removal, checking, and installation procedures.

ENGINE

LUBRICATION SYSTEM CHART AND DIAGRAMS

Provides diagrams and charts for the engine oil lubrication system.

ENGINE INSPECTION

Details how to measure compression pressure, including procedure and specifications.

ENGINE REMOVAL

Covers the step-by-step procedure for removing the engine assembly.

CAMSHAFTS

Details camshaft removal, checking, installation, and related components.

CYLINDER HEAD

Explains cylinder head removal, checking, and installation procedures, including warpage measurement.

VALVES AND VALVE SPRINGS

Covers valve and spring removal, checking, and installation, including valve guide and seat checks.

CYLINDER AND PISTONS

Details cylinder and piston removal, checking, and installation procedures.

ELECTRIC STARTER

Covers starter motor removal, disassembly, checking, assembly, and installation.

V-BELT AUTOMATIC TRANSMISSION

REMOVING THE V-BELT CASE COVER

Step-by-step instructions for removing the V-belt case cover and related components.

REMOVING THE V-BELT AND PRIMARY/SECONDARY SHEAVE

Details the removal of the V-belt, primary, and secondary sheaves.

DISASSEMBLY THE SECONDARY SHEAVE

Procedures for disassembling the secondary sheave, including spring compressor use.

CHECKING THE V-BELT

Explains how to check the V-belt for cracks, damage, wear, and measure its width.

CHECKING THE PRIMARY SHEAVE

Covers checking the primary sliding sheave and primary fixed sheave for damage.

CHECKING THE PRIMARY SHEAVE WEIGHTS

Details how to check primary sheave weights for cracks or wear and measure their outside diameter.

ASSEMBLING THE PRIMARY SHEAVE

Steps for cleaning, lubricating, and installing primary sheave components.

INSTALLING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY SHEAVE ASSEMBLY AND V-BELT

Step-by-step guide for installing the primary and secondary sheave assemblies and the V-belt.

GENERATOR AND STARTER CLUTCH

REMOVING THE GENERATOR ROTOR AND STARTER CLUTCH

Details the procedure for removing the generator rotor and starter clutch assembly.

REMOVING THE STATOR COIL AND OIL TANK

Steps for removing the stator coil and oil tank assembly.

CHECKING THE STARTER CLUTCH

How to check the starter clutch rollers, idle gears, and contacting surface for wear or damage.

INSTALLING THE STARTER CLUTCH

Steps for installing the starter clutch and its bolts, with torque specifications.

INSTALLING THE GENERATOR

Procedures for installing the generator rotor, spacer, and nut.

CLUTCH

REMOVING THE CLUTCH

Details the removal of the clutch assembly, including draining fluids and removing related parts.

DISASSEMBLING THE CLUTCH

Step-by-step instructions for disassembling the clutch, including components like plates, springs, and the clutch boss.

CHECKING THE FRICTION PLATES

How to check friction plates for damage/wear and measure their thickness.

CHECKING THE CLUTCH PLATES

Instructions on checking clutch plates for damage, warpage, and thickness.

ASSEMBLING THE CLUTCH

Steps for installing the clutch boss, primary drive gear, clutch boss nut, and tightening.

INSTALLING THE CLUTCH

Procedures for installing clutch weights, thrust plate, springs, plates, and the clutch assembly nut.

OIL PUMP

CHECKING THE OIL PUMP

How to check the oil pump driven gear, housing, and operation.

CHECKING THE RELIEF VALVE

Procedure for checking the relief valve body for damage or wear.

CHECKING THE OIL PIPES

Instructions on checking oil pipes for damage and obstructions.

CHECKING THE OIL PUMP DRIVE CHAIN

How to check the oil pump drive chain for cracks or stiffness.

INSTALLING THE OIL PUMP

Steps for installing the oil pump assembly.

CRANKCASE

SEPARATING THE CRANKCASE

Details the procedure for separating the crankcase halves.

CHECKING THE TIMING CHAIN

How to check the timing chain for damage and stiffness.

ASSEMBLING THE CRANKCASE

Steps for cleaning mating surfaces and assembling the crankcase halves.

CRANKSHAFT

REMOVING THE CRANKSHAFT ASSEMBLY

Details the procedure for removing the crankshaft assembly.

REMOVING THE CONNECTING RODS

Covers the removal of connecting rod caps, rods, and big end bearings.

CHECKING THE CRANKSHAFT AND CONNECTING RODS

Procedures for measuring crankshaft runout and checking journal/pin surfaces and bearings.

INSTALLING THE CONNECTING RODS

Steps for lubricating and installing connecting rods, caps, and bearings.

TRANSMISSION

REMOVING THE TRANSMISSION

Details the procedure for removing the transmission assembly.

CHECKING THE TRANSMISSION

Covers checking transmission gears, movement, and main axle for damage.

COOLING SYSTEM

COOLING SYSTEM DIAGRAMS

Provides diagrams illustrating the cooling system components and their connections.

RADIATOR

Covers radiator removal, checking, and installation procedures.

OIL COOLER

Details oil cooler removal, checking, and installation procedures.

THERMOSTAT

Explains thermostat removal, checking, and installation procedures.

WATER PUMP

Covers water pump disassembly, checking, assembly, and installation procedures.

FUEL SYSTEM

FUEL TANK

Covers fuel tank removal, fuel pump removal, checking, and installation.

THROTTLE BODY

Details air filter case removal, throttle body removal, checking, cleaning, and installation.

ELECTRICAL SYSTEM

IGNITION SYSTEM

Covers circuit diagram and troubleshooting for the ignition system.

ELECTRIC STARTING SYSTEM

Details circuit diagram, operation, and troubleshooting for the electric starting system.

CHARGING SYSTEM

Covers circuit diagram, troubleshooting, and checking of the charging system components.

LIGHTING SYSTEM

Provides circuit diagram and troubleshooting for the lighting system.

SIGNALING SYSTEM

Covers circuit diagram and troubleshooting for the signaling system.

COOLING SYSTEM

Provides circuit diagram and troubleshooting for the cooling system.

FUEL PUMP SYSTEM

Covers circuit diagram and troubleshooting for the fuel pump system.

WINDSHIELD DRIVE SYSTEM (for XP560D)

Details circuit diagram and troubleshooting for the windshield drive system.

GRIP WARMER SYSTEM (for XP560D)

Covers circuit diagram and troubleshooting for the grip warmer system.

SEAT HEATER SYSTEM (for XP560D)

Provides circuit diagram and troubleshooting for the seat heater system.

SMART KEY SYSTEM

Covers circuit diagram, troubleshooting, emergency mode, and key registration.

ELECTRICAL COMPONENTS

Illustrates and lists various electrical components and their locations.

SELF-DIAGNOSTIC FUNCTION

GLOSSARY

Defines terms used in self-diagnosis, like MIL, DTC, and YDT.

OUTLINE

Explains the self-diagnostic function and warning lights.

CHECKING THE WARNING LIGHT

Describes how warning lights indicate malfunctions and their lighting times.

YDT

Information on using the Yamaha Diagnostic Tool (YDT) for malfunction identification.

PARTS CONNECTED TO THE ECU

Lists components connected to the Engine Control Unit (ECU).

PARTS CONNECTED TO THE ABS ECU

Lists components connected to the ABS ECU.

PRECAUTIONS FOR ROAD TEST

Safety precautions to follow when test riding the vehicle.

SYSTEM DIAGRAM

Presents the overall ECU and ABS ECU circuit diagrams.

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Provides a table of DTCs, symptoms, probable causes, and fail-safe operations.

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