2003 YAMAHA TMAX Owners Manual

6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
8*Rear brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
9
*Brake hoses•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-5.)Every 4 years
10
*Wheels•Check runout and for damage.√√√√
11
*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
12
*Wheel bearings•Check bearing for looseness or damage.√√√√
13
*Steering bearings•Check bearing play and steering for roughness.√√√√√
•Lubricate with lithium-soap-based grease.Every 20,000 km
14
*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
15 Sidestand, centerstand•Check operation.
•Lubricate.√√√√ √
16
*Sidestand switch•Check operation.√√√√√ √
17
*Front fork•Check operation and for oil leakage.√√√√
18
*Shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√
19
*Carburetors•Adjust engine idling speed and synchronization.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
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6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03884
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.
20 Engine oil•Change. (See page 3-2 and 6-15 for more information
about the oil change indicator light.)√4,000 km after initial 1,000 km
When the oil change indicator light comes on
(every 5,000 km)
•Check oil level and vehicle for oil leakage.Every 5,000 km√
21 Engine oil filter cartridge•Replace.√√√
22
*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change.Every 3 years
23 Chain drive oil•Check vehicle for oil leakage.
•Change.√√√√
24
*V-belt•Replace.When the V-belt replacement indicator light comes on
(every 20,000 km)
25
*Front and rear brake
switches•Check operation.√√√√√ √
26 Moving parts and cables•Lubricate.√√√√ √
27
*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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6-6
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01139
Removing and installing
cowlings and panels
Cowlings and panels, removing and installing
The cowlings and panels shown
above need to be removed to per-
form some of the maintenance jobs
described in this chapter. Refer to
this section each time a cowling or
panel needs to be removed and
installed.
4
3
1 2
1. Panel A
2. Panel B
3. Panel C
4. Cowling A
EAU03878
Panels A and D
To remove one of the panels
1. Remove panel C (right side) or
panel E (left side).
2. Remove the panel screws.
3. Pull outward on the front of the
panel.
1
1. Screw (×3)
1
23
4
5
1. Panel D
2. Cowling B
3. Panel E
4. Cowling C
5. Panel F
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6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
6To install the panel
Place the panel in the original posi-
tion, and then install the screws.
Panels C and E
To remove one of the panels
Pull the floorboard mat off, and then
remove the panel screws.
To install the panel
Place the panel in the original posi-
tion, install the screws, and then
place the floorboard mat back.
1
1. Screw (×4)
Panel B
To remove the panel
Remove the panel screws, and then
pull outward on the areas shown.
To install the panel
Place the panel in the original posi-
tion, and then install the screws.
1
1
1. Screw (×3)
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6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
6 Cowling A
To remove the cowling
1. Remove the rear view mirrors by
removing the nuts.
2. Remove the cowling screws.
To install the cowling
1. Place the cowling in the original
position, and then install the
screws.
2. Install the rear view mirrors by
installing the nuts.
21
2
1. Screw (×2)
2. Nut (×4)
Cowling B
To remove the cowling
1. Remove panels C and E.
2. Remove the cowling screws and
bolts.
3. Unhook the cowling from the
holder at the bottom.
4. Unhook the front of the cowling
by pushing it up, and then pull
the cowling out.
1
2
1. Bolt (×2)
2. Screw (×2)
Panel F
To remove the panel
Remove the panel screws.
To install the panel
1. Place the panel in the original
position, and then install the
screws.
1
1. Screw (×2)
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6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
6To install the cowling
1. Place the cowling in the original
position, and then install the
screws and bolts.
2. Install panels C and E.
EAU03816
Checking the spark plugsSpark plugs, checking
The spark plugs are important engine
components, which are easy to
check. Since heat and deposits will
cause any spark plug to slowly erode,
the spark plugs should be removed
and checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plugs can reveal the condition
of the engine. Cowling C
To remove the cowling
1. Remove the cowling bolts.
2. Remove the battery cover by
removing the screws.
3. Pull the cowling off.
To install the cowling
1. Install the battery cover by
installing the screws.
2. Place the cowling in the original
position, and then install the
bolts.
1
2
1. Bolt (×2)
2. Screw (×3)
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6-10
PERIODIC MAINTENANCE AND MINOR REPAIR
6 To remove a spark plug
1. Remove cowling B. (See page
6-8 for cowling removal and
installation procedures.)
2. Remove the spark plug cover by
pulling it out as shown.
1
1. Spark plug cover
4. Remove the spark plug as
shown with the spark plug
wrench included in the owner’s
tool kit.
1
1. Spark plug wrench
3. Remove the spark plug cap.
1
1. Spark plug cap
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6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
6To check the spark plugs
1. Check that the porcelain insula-
tor around the center electrode
on each spark plug is a medium-
to-light tan (the ideal color when
the scooter is ridden normally).
2. Check that all spark plugs
installed in the engine have the
same color.
NOTE:
If any spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead,
have a Yamaha dealer check the
scooter.
3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and
replace it if necessary.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4–1/2 turn past finger tight.
However, the spark plug should be
tightened to the specified torque as
soon as possible.
4. Install the spark plug cap. To install a spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
a
a. Spark plug gap
Specified spark plug:
CR7E (NGK)
Spark plug gap:
0.7–0.8 mm
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf)
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