Yamaha TMAX TECH MAX 2020 Manuals

Manuals and User Guides for Yamaha TMAX TECH MAX 2020. We have 1 Yamaha TMAX TECH MAX 2020 manual available for free PDF download: Service Manual

Yamaha TMAX TECH MAX 2020 Service Manual

Yamaha TMAX TECH MAX 2020 Service Manual (688 pages)

Brand: Yamaha | Category: Motorcycle | Size: 18.97 MB

Table of Contents

Table of Contents

7
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Multi-Function Display
    11
    
    Canceling the Sidestand Alarm Beeper
    20
  - Special Tools
    21
Specifications

29
- General Specifications
  30
- Engine Specifications
  31
- Chassis Specifications
  36
- Electrical Specifications
  38
- Tightening Torques
  40
  - Engine Tightening Torques
    40
  - Chassis Tightening Torques
    40
- Cable Routing
  42
Periodic Checks and Adjustments

91
- General Maintenance and Lubrication Chart
  93
- Introduction
  93
- Periodic Maintenance
  93
- Periodic Maintenance Chart for the Emission Control System
  93
- Checking the Fuel Line
  96
- Checking the Vehicle Using the Yamaha Diagnostic Tool
  96
- Adjusting the Valve Clearance
  97
- Checking the Spark Plugs
  97
- Checking the Engine Idling Speed
  100
- Synchronizing the Throttle Bodies
  101
- Checking the Throttle Body Joints
  102
- Checking the Cylinder Head Breather Hose
  103
- Checking the Exhaust System
  103
- Adjusting the Exhaust Gas Volume
  104
- Checking the Canister
  104
- Replacing the Air Filter Element and Cleaning the Check Hose
  104
- Cleaning the V-Belt Case Air Filter Element
  105
- Adjusting the Front Disc Brake
  106
- Checking the Brake Fluid Level
  106
- Checking the Brake Operation
  106
- Adjusting the Rear Disc Brake
  107
- Checking the Front Brake Pads
  107
- Bleeding the Hydraulic Brake System
  108
- Checking the Front Brake Hoses
  108
- Checking the Rear Brake Hose
  108
- Checking the Rear Brake Pads
  108
- Adjusting the Rear Brake Lock Cable
  109
- Checking the Rear Brake Lock
  110
- Checking the Rear Brake Lock Pads
  110
- Checking the Tires
  111
- Checking the Wheels
  111
- Checking the Drive Belt
  112
- Checking the Swingarm Operation
  112
- Checking the Wheel Bearings
  112
- Drive Belt Tension
  113
- Lubricating the Drive Pulley and Drive Axle
  114
- Checking and Adjusting the Steering Head
  115
- Lubricating the Steering Head
  116
- ADJUSTING the REAR SHOCK ABSORBER ASSEMBLY (for XP560D)
  117
- Checking the Centerstand
  117
- Checking the Chassis Fasteners
  117
- Checking the Front Fork
  117
- Checking the Rear Shock Absorber Assembly
  117
- Checking the Sidestand
  117
- Checking the Sidestand Switch
  117
- Lubricating the Centerstand
  117
- Lubricating the Levers
  117
- Lubricating the Sidestand
  117
- Checking the Connecting Arm and Relay Arm
  118
- Changing the Engine Oil
  119
- Checking the Engine Oil Level
  119
- Checking the Coolant Level
  121
- Measuring the Engine Oil Pressure
  121
- Checking the Cooling System
  122
- Changing the Coolant
  123
- Replacing the V-Belt
  124
- Checking and Lubricating the Cables
  125
- Checking the Brake Light Switches
  125
- Checking the Throttle Grip
  125
- Adjusting the Headlight Beams
  126
- Checking and Charging the Battery
  126
- Checking the Fuses
  126
Chassis

127
- General Chassis (1)
  
  130
  - ADJUSTING the WINDSHIELD HEIGHT (for XP560E)
    136
  - Removing the Front Cover
    136
  - Removing the Side Panel
    137
  - Installing the Side Panel
    138
  - Removing the Inner Panel
    138
  - Removing the Battery Cover
    139
- General Chassis (2)
  
  140
  - Removing the Side Cover
    144
  - Removing the Rear Side Cowling
    144
  - Removing the Footboard
    144
  - Removing the Rear Cover
    145
- General Chassis (3)
  
  146
  - INSTALLING the WINDSHIELD DRIVE UNIT (for XP560D)
    150
- Front Wheel
  
  151
- Rear Wheel
  
  159
- Front Brake
  
  167
- Rear Brake
  
  179
- ABS (Anti-Lock Brake System)
  
  196
- Handlebar
  
  203
  - Removing the Handlebar
    207
  - Checking the Handlebar
    207
  - Installing the Handlebar
    207
  - Adjusting the Accelerator Position Sensor
    209
- Front Fork
  
  210
  - Removing the Front Fork Legs
    212
  - Disassembling the Front Fork Legs
    212
  - Checking the Front Fork Legs
    213
  - Assembling the Front Fork Legs
    214
  - Installing the Front Fork Legs
    218
- Steering Head
  
  219
  - Removing the Lower Bracket
    221
  - Checking the Steering Head
    221
  - Installing the Steering Head
    221
- Belt Drive
  
  223
  - Checking the Drive Belt
    224
  - Installing the Drive Belt and Drive Pulley
    224
- Rear Shock Absorber Assembly
  
  225
- Swingarm
  
  229
  - Removing the Swingarm
    231
  - Checking the Swingarm
    231
  - Installing the Swingarm
    231
Engine

233
- Lubrication System Chart and Diagrams
  
  236
  - Engine Oil Lubrication Chart
    236
  - Lubrication Diagrams
    237
- Engine Inspection
  
  241
  - Measure the Compression Pressure
    241
- Engine Removal
  
  242
  - Installing the Engine
    246
- Camshafts
  
  247
  - Removing the Camshafts
    249
  - Checking the Camshafts
    249
  - Checking the Camshaft Sprockets
    251
  - Checking the Timing Chain Guides
    251
  - Checking the Timing Chain Tensioner
    251
  - Installing the Camshafts
    252
- Cylinder Head
  
  255
  - Removing the Cylinder Head
    256
  - Checking the Cylinder Head
    256
  - Installing the Cylinder Head
    256
- Valves and Valve Springs
  
  258
  - Removing the Valves
    259
  - Checking the Valves and Valve Guides
    259
  - Checking the Valve Seats
    261
  - Checking the Valve Springs
    262
  - Checking the Valve Lifters
    263
  - Installing the Valves
    263
- Cylinder and Pistons
  
  265
  - Removing the Piston
    266
  - Checking the Cylinders and Pistons
    266
  - Checking the Piston Rings
    267
  - Checking the Piston Pins
    268
  - Installing the Piston and Cylinder
    268
- Electric Starter
  
  270
  - Checking the Starter Motor
    272
  - Assembling the Starter Motor
    273
  - Installing the Starter Motor
    273
- V-Belt Automatic Transmission
  
  274
- Generator and Starter Clutch
  
  284
  - Removing the Generator
    287
  - Removing the Starter Clutch
    287
  - Checking the Starter Clutch
    288
  - Checking the Oil Strainer
    288
  - Assembling the Oil Tank
    288
  - Installing the Starter Clutch
    288
  - Installing the Generator
    288
- Clutch
  
  290
  - Removing the Clutch
    293
  - Disassembling the Clutch
    293
  - Checking the Friction Plates
    294
  - Checking the Clutch Plates
    294
  - Checking the Clutch Damper Springs
    294
  - Checking the Clutch Spring Plate
    295
  - Checking the Clutch Springs
    295
  - Checking the Clutch Housing
    295
  - Checking the Clutch Boss
    295
  - Checking the Pressure Plate and Thrust Plate
    295
  - Assembling the Clutch
    295
  - Installing the Clutch
    296
- Oil Pump
  
  298
  - Checking the Oil Pump
    300
  - Checking the Relief Valve
    300
  - Checking the Oil Pipes
    300
  - Checking the Oil Pump Drive Chain
    300
  - Assembling the Oil Pump
    300
  - Installing the Oil Pump
    300
- Crankcase
  
  301
  - Assembling the Centerstand
    305
  - Disassembling the Crankcase
    306
  - Checking the Crankcase
    306
  - Checking the Timing Chain
    306
  - Assembling the Crankcase
    306
- Crankshaft
  
  308
- Transmission
  
  318
  - Checking the Transmission
    319
Cooling System

321
- Cooling System Diagrams
  
  322
- Radiator
  
  324
  - Checking the Radiator
    326
  - Installing the Radiator
    326
- Oil Cooler
  
  328
  - Checking the Oil Cooler
    329
  - Installing the Oil Cooler
    329
- Thermostat
  
  330
  - Checking the Thermostat
    331
  - Installing the Thermostat Assembly
    331
- Water Pump
  
  332
  - Disassembling the Water Pump
    334
  - Checking the Water Pump
    334
  - Assembling the Water Pump
    334
  - Installing the Water Pump
    335
Fuel System

337
- Fuel Tank
  
  340
  - Checking the Fuel Pump Body
    340
  - Checking the Fuel Pump Operation
    340
  - Removing the Fuel Pump
    340
  - Removing the Fuel Tank
    340
  - Checking the Rollover Valve
    341
  - Installing the Fuel Pump
    341
  - Installing the Fuel Tank
    341
- Throttle Body
  
  344
  - Checking the Injectors (before Removing)
    346
  - Removing the Fuel Hose (Fuel Rail Side)
    346
  - Removing the Injectors
    346
  - Checking the Injectors
    346
  - Checking and Cleaning the Throttle Bodies
    347
  - Replacing the Throttle Bodies
    348
  - Installing the Injectors
    348
  - Checking the Injector Pressure
    349
  - Checking the Fuel Pressure
    349
  - Installing the Fuel Hose (Fuel Rail Side)
    350
  - Adjusting the Throttle Position Sensor
    350
Electrical System

353
- Ignition System
  
  356
  - Circuit Diagram
    356
  - Troubleshooting
    360
- Electric Starting System
  
  362
  - Circuit Diagram
    362
  - Starting Circuit Cut-Off System Operation
    366
  - Troubleshooting
    368
- Charging System
  
  372
  - Circuit Diagram
    372
  - Troubleshooting
    376
- Lighting System
  
  378
  - Circuit Diagram
    378
  - Troubleshooting
    382
- Signaling System
  
  384
  - Circuit Diagram
    384
  - Troubleshooting
    388
- Cooling System
  
  394
  - Circuit Diagram
    394
  - Troubleshooting
    398
- Fuel Pump System
  
  400
  - Circuit Diagram
    400
  - Troubleshooting
    404
- WINDSHIELD DRIVE SYSTEM (for XP560D)
  
  406
  - Circuit Diagram
    406
  - Troubleshooting
    408
- GRIP WARMER SYSTEM (for XP560D)
  
  410
  - Circuit Diagram
    410
  - Troubleshooting
    412
- SEAT HEATER SYSTEM (for XP560D)
  
  416
  - Circuit Diagram
    416
  - Troubleshooting
    418
- Smart Key System
  
  422
  - Circuit Diagram
    422
  - Troubleshooting
    426
  - Smart Key System Self-Diagnosis
    433
  - Smart Key System Emergency Mode
    435
  - Registering a Smart Key
    437
  - Disabling a Smart Key
    439
  - Replacing the Remote Control Unit, Steering Lock, and Ecu
    440
  - Replacing the Remote Control Unit
    440
  - Replacing the Steering Lock Unit
    440
  - Replacing the Ecu
    440
  - Replacement Parts List
    441
- Electrical Components
  
  443
Self Diagnostic

469
- Self-Diagnostic Function
  
  475
  - Glossary
    475
  - Outline
    475
  - Checking the Warning Light
    476
  - Ydt
    477
  - Parts Connected to the Ecu
    477
  - Parts Connected to the Abs Ecu
    478
  - Precautions for Road Test
    478
- System Diagram
  
  479
  - Ecu Circuit Diagram
    479
  - Ecu Coupler Layout
    482
- Fuel Injection System
  
  486
- CRUISE CONTROL SYSTEM (for XP560D)
  
  492
- ABS (Anti-Lock Brake System)
  
  500
  - Circuit Diagram
    500
  - Abs Components Chart
    504
  - Abs Coupler Location Chart
    505
  - Maintenance of the Abs Ecu
    506
  - Abs Troubleshooting Outline
    506
  - Basic Instructions for Troubleshooting
    507
  - [A] Checking the Abs Warning Light
    509
  - [A-1] Only the Abs Warning Light Fails to Come on
    509
  - [A-2] All Indicator Lights Fail to Come on
    509
  - [A-3] the Abs Warning Light Comes on
    509
  - [A-4] Only the Abs Ecu Fails to Communicate
    509

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