2002 YAMAHA TMAX check engine

6-14
PERIODIC MAINTENANCE AND MINOR REPAIR
6 6. Install the new oil filter cartridge,
and then tighten it to the speci-
fied torque with a torque wrench.
7. Install the engine oil drain bolt,
and then tighten it to the speci-
fied torque.
1
1. Torque wrench
ECA00105
cC8In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives
with the oil or use oils of grade
“CD” or higher. In addition, do
not use oils labeled “ENERGY
CONSERVING
II” or higher.
8Make sure that no foreign
material enters the crankcase.
9. Start the engine, and then let it
idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the
engine off and check for the
cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary. 8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil
filler cap.
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
SAE 10W-30 or SAE 10W-40
(API SE, SF, SG or higher)
Oil quantity:
Without oil filter cartridge
replacement:
2.8 L
With oil filter cartridge
replacement:
2.9 L
Total amount (dry engine):
3.6 L
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6-16
PERIODIC MAINTENANCE AND MINOR REPAIR
6 4. Install the chain drive oil drain
bolt, and then tighten it to the
specified torque.
5. Add the specified amount of the
recommended oil.
6. Wipe the dipstick clean, insert it
into the oil filler hole (without
screwing it in), and then remove
it to check the oil level.
ECA00078
cCMake sure that no foreign material
enters the chain drive case.
NOTE:
The engine oil should be between the
minimum and maximum level marks.7. If the engine oil is below the min-
imum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
8. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
1
2
1. Maximum level mark
2. Minimum level mark
Tightening torque:
Chain drive oil drain bolt:
20 Nm (2.0 m·kgf)Recommended chain drive oil:
See page 8-1.
Oil quantity:
0.7 L
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6-17
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03850
CoolantCoolantTo check the coolant level
1. Place the scooter on a level sur-
face and hold it in an upright
position.NOTE:
8The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
8Make sure that the scooter is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
3. Check the coolant level in the
coolant reservoir.NOTE:
The coolant should be between the
minimum and maximum level marks.
12
1. Maximum level mark
2. Minimum level mark
2. Remove the coolant reservoir
cover by removing the screw.
1
2
1. Coolant reservoir cover
2. Screw
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6-18
PERIODIC MAINTENANCE AND MINOR REPAIR
6 4. If the coolant is at or below the
minimum level mark, open the
reservoir cap, add coolant to the
maximum level mark, and then
close the reservoir cap.
1
1. Coolant reservoir cap
EW000067
wNever attempt to remove the radia-
tor cap when the engine is hot.5. Install the coolant reservoir cover
by installing the screw.NOTE:
The radiator fan is automatically
switched on or off according to the
coolant temperature in the radiator. If
the engine overheats, see page 6-38
for further instructions.
EC000080
cC8If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
8If water has been used instead
of coolant, replace it with
coolant as soon as possible,
otherwise the engine may not
be sufficiently cooled and the
cooling system will not be pro-
tected against frost and corro-
sion.
8If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be
reduced.
Coolant reservoir capacity:
0.6 L
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6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00630
Adjusting the carburetorsCarburetors, adjustingThe carburetors are important parts
of the engine and require very
sophisticated adjustment. Therefore,
most carburetor adjustments should
be left to a Yamaha dealer, who has
the necessary professional knowl-
edge and experience. The adjust-
ment described in the following sec-
tion, however, may be serviced by
the owner as part of routine mainte-
nance.
EC000095
cCThe carburetors have been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine.
NOTE:
The engine is warm when it quickly
responds to the throttle.4. Check the engine idling speed
and, if necessary, adjust it to
specification by turning the throt-
tle stop screw. To increase the
engine idling speed, turn the
screw in direction a. To
decrease the engine idling
speed, turn the screw in direction
b.
1a
b
1. Throttle stop screw
EAU03821
Adjusting the engine idling
speedEngine idling speedThe engine idling speed must be
checked and, if necessary, adjusted
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.NOTE:
A diagnostic tachometer is needed to
make this adjustment.1. Remove panel B. (See page 6-7
for panel removal and installation
procedures.)
2. Attach the tachometer to the
spark plug lead.
3. Start the engine and warm it up
for several minutes at 1,000–
2,000 r/min while occasionally
revving it to 4,000–5,000 r/min.
Engine idling speed:
1,150–1,200 r/min
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6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
If the specified idling speed cannot
be obtained as described above,
have a Yamaha dealer make the
adjustment.5. Install the panel.
EAU00637
Adjusting the valve
clearanceValve clearance, adjustingThe valve clearance changes with
use, resulting in improper air-fuel mix-
ture and/or engine noise. To prevent
this from occurring, the valve clear-
ance must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
EAU00635
Adjusting the throttle cable
free playThrottle cable free play, adjustingThe throttle cable free play should
measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
a
a. Throttle cable free play
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6-31
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00794
Checking the steeringSteering, checkingWorn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
wSecurely support the scooter so
that there is no danger of it falling
over.
EAU01144
Checking the wheel bearingsWheel bearings, checkingThe front and rear wheel bearings
must be checked at the intervals
specified in the periodic maintenance
and lubrication chart. If there is play
in the wheel hub or if the wheel does
not turn smoothly, have a Yamaha
dealer check the wheel bearings.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any
free play can be felt, have a
Yamaha dealer check or repair
the steering.
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6-37
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU02990
Troubleshooting chartsTroubleshooting chartsStarting problems or poor engine performance
EW000125
wKeep away open flames and do not smoke while checking or working on the fuel system.Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.DryWet
The engine does not start.
Check the battery.Open the throttle halfway and operate
the electric starter.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
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