2003 YAMAHA TMAX maintenance

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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.
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If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
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Checking the front forkFront fork, checking
The 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
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Securely 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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Checking the steeringSteering, checking
Worn 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.
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Securely support the scooter so
that there is no danger of it falling
over.
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Checking the wheel bearingsWheel bearings, checking
The 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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BatteryBattery
This scooter is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There
is no need to check the electrolyte or
to add distilled water.
To charge the battery
Have a Yamaha dealer charge the
battery as soon as possible if it
seems to have discharged. Keep in
mind that the battery tends to dis-
charge more quickly if the scooter is
equipped with optional electrical
accessories.
1
1. Battery
To access the battery
1. Open the seat. (See page 3-11
for seat opening and closing pro-
cedures.)
2. Remove the battery cover by
removing the screws.
1
2
1. Screw (×3)
2. Battery cover
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8 8
Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-
tact with skin, eyes or clothing
and always shield your eyes
when working near batteries.
In case of contact, administer
the following FIRST AID.
9EXTERNAL: Flush with plen-
ty of water.
9INTERNAL: Drink large quan-
tities of water or milk and
immediately call a physician.
9EYES: Flush with water for
15 minutes and seek prompt
medical attention.
8 8
Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes,
etc., away from the battery and
provide sufficient ventilation
when charging it in an
enclosed space.8 8
KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
To store the battery
1. If the scooter will not be used for
more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check it
at least once a month and fully
charge it if necessary.
3. Fully charge the battery before
installation.
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8
8
Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
8 8
To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is
required. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery charger, have a
Yamaha dealer charge your
battery.
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Replacing the fusesFuses, replacing
The main fuse box is located beside
the battery and can be accessed as
follows:
1. Open the seat. (See page 3-11
for seat opening and closing pro-
cedures.)
2. Remove the battery cover. (See
page 6-32 for battery cover
removal procedures.)
1
1. Battery
If a fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn
off the electrical circuit in ques-
tion.
2. Remove the blown fuse, and
then install a new fuse of the
specified amperage.
7
1
2
3
4
5
6
1. Signaling system fuse
2. Headlight fuse
3. Ignition fuse
4. Radiator fan fuse
5. Hazard fuse
6. Clock fuse (backup fuse)
7. Spare fuse (×2)
3. Disconnect the negative battery
lead, and then lift the battery as
shown.
The fuse box, which contains the
fuses for the individual circuits, is
located under the battery cover and
can be accessed as follows.
1. Open the seat. (See page 3-11
for seat opening and closing pro-
cedures.)
2. Remove the battery cover.
12
3
1. Negative battery lead
2. Main fuse box
3. Fuse box
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Do not use a fuse of a higher
amperage rating than recommend-
ed to avoid causing extensive
damage to the electrical system
and possibly a fire.
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.2. Unhook the headlight bulb holder
as shown, and then remove the
defective bulb.
a
1
1. Headlight bulb holder
a. Unhook.
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Replacing a headlight bulbHeadlight bulb, replacing
This scooter is equipped with quartz
bulb headlights. If a headlight bulb
burns out, replace it as follows.
1. Disconnect the headlight cou-
pler, and then remove the head-
light bulb cover.
1
2
1. Headlight coupler
2. Headlight bulb cover
Specified fuses:
Main fuse: 30 A
Headlight fuse: 15 A
Signaling system fuse: 15 A
Ignition fuse: 10 A
Radiator fan fuse: 15 A
Hazard fuse: 10 A
Clock fuse (backup fuse): 10 A
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Headlight bulbs get very hot.
Therefore, keep flammable prod-
ucts away from a lit headlight bulb,
and do not touch the bulb until it
has cooled down.
3. Place a new bulb into position,
and then secure it with the bulb
holder.
a
a. Do not touch the glass part of the bulb.
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TroubleshootingTroubleshooting
Although Yamaha scooters receive a
thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition sys-
tems, for example, can cause poor
starting and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your scooter
require any repair, take it to a
Yamaha dealer, whose skilled techni-
cians have the necessary tools,
experience, and know-how to service
the scooter properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life
and can lead to expensive repair
bills.
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Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the
bulb, and the bulb life will be
adversely affected. Thoroughly
clean off any dirt and fingerprints
on the headlight bulb using a cloth
moistened with alcohol or thinner.
4. Install the bulb cover, and then
connect the coupler.
5. Have a Yamaha dealer adjust
the headlight beam if necessary.
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Troubleshooting chartsTroubleshooting charts
Starting problems or poor engine performanceEW000125
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Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.
1. FuelThere 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. CompressionThere 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. IgnitionWipe 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.
The engine does not start.
Check the battery.
Operate the electric starter.
4. BatteryThe engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
Dry
WetOpen the throttle halfway and operate
the electric starter.
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