2003 YAMAHA TMAX maintenance

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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.
4. Install the panel.
EAU00637
Adjusting the valve
clearance
Valve clearance, adjusting
The 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 play
Throttle cable free play, adjusting
The 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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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04403
TiresTires
To maximize the performance, dura-
bility, and safe operation of your
scooter, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
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8 8
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the tempera-
ture of the tires equals the
ambient temperature).
8 8
The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passen-
ger, cargo, and accessories
approved for this model.
sories does not exceed the
specified maximum load for
the vehicle.
8 8
Do not carry along loosely
packed items, which can shift
during a ride.
8 8
Securely pack the heaviest
items close to the center of the
scooter and distribute the
weight evenly on both sides.
8 8
Adjust the tire air pressure
with regard to the load.
8 8
Check the tire condition and
air pressure before each ride.
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Because loading has an enormous
impact on the handling, braking,
performance and safety character-
istics of your scooter, you should
keep the following precautions in
mind.
8 8
NEVER OVERLOAD THE
SCOOTER! Operation of an
overloaded scooter may result
in tire damage, loss of control,
or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and acces-
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg
200 kPa
(2.00 kgf/cm2,
2.00 bar)225 kPa
(2.25 kgf/cm2,
2.25 bar)
90 kg–maximum225 kPa
(2.25 kgf/cm2,
2.25 bar)250 kPa
(2.50 kgf/cm2,
2.50 bar)
Maximum load* 183 kg
* Total weight of rider, passenger, cargo and
accessories
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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.
1a
1. Tire sidewall
a. Tire tread depth
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8 8
Have 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.
8 8
The 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.
Tire information
This scooter is equipped with cast
wheels and tubeless tires.
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8 8
The front and rear tires should
be of the same make and
design, otherwise the handling
characteristics of the scooter
cannot be guaranteed.
8 8
After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor Co., Ltd.
Minimum tire tread depth
(front and rear)1.6 mm
FRONT
Manufacturer Size Model
DUNLOP 120/70-14M/C 55S D305FA
BRIDGESTONE120/70-14M/C 55S HOOP B03
REAR
Manufacturer Size Model
DUNLOP 150/70-14M/C 66S D305
BRIDGESTONE150/70-14M/C 66S HOOP B02
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03773
Cast wheelsWheels
To 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.
EAU03851
Front and rear brake levers
There should be no free play at the
brake lever ends. If there is free play,
have a Yamaha dealer inspect the
brake system.
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.FRONT
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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)
EAU00721
Checking the front and rear
brake pads
Front and rear brake pads, checking
The front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.
REARFRONT
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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
EAU04856
Checking the brake fluid
level
Brake fluid level, checking
Insufficient 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 fluid level is low,
be sure to check the brake pads for
wear and the brake system for leak-
age.
1
1. Minimum level mark
REARFRONTTightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf)
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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, changing
Have 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.
REAR
Recommended brake fluid:
DOT 4
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04034
Checking and lubricating the
throttle grip and cable
Throttle grip and cable, checking and lubricating
The 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 sidestand
Centerstand and sidestand, checking and lubricating
The 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.
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If 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 levers
Brake levers, lubricating
The 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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