2003 YAMAHA TMAX belt

1-1
EAU00021
Q Q
GIVE SAFETY THE RIGHT OF WAY
1Scooters are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom.
However, they also impose certain limits, which you must accept; even the best scooter does not
ignore the laws of physics.
Regular care and maintenance are essential for preserving value and operating condition of your
scooter. Moreover, what is true for the scooter is also true for the rider: good performance depends on
being in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of
the question. Scooter riders—more than car drivers—must always be at their mental and physical
best. Under the influence of even small amounts of alcohol, there is a tendency to take dangerous
risks.
Protective clothing is as essential for the scooter rider as seat belts are for car drivers and passen-
gers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic
materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum pro-
tective wear, however, should not encourage carelessness. Although full-coverage helmets and suits,
in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable.
Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is
even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensive-
ly—avoiding all dangers, including those caused by others.
Enjoy your ride!
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EAU00026
DESCRIPTION
2
1. Fuel tank cap (page 3-9)
2. Rear storage compartment (page 3-14)
3. Helmet holder (page 3-13)
4. Grab bar (page 5-2)
5. Chain drive oil filler cap (page 6-15)
6. Engine oil filler cap (page 6-13)7. V-belt air filter element (left)
8. Engine oil drain bolt (page 6-13)
9. Engine oil level check window (page 6-12)
10. Oil filter cartridge (page 6-13)
1234
9876510
Part locations
Left view
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2-2
DESCRIPTION
2
11. Battery, Fuses (page 6-32, 6-34)
12. Owner’s tool kit (page 6-1)
13. Front storage compartment (page 3-14)
14. Windshield
15. Air filter element (page 6-19)16. Radiator
17. Coolant level check window (page 6-17)
18. V-belt air filter element (right)
19. Centerstand (page 6-29)
20. Passenger footrest
1112131415
1817161920
Right view
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3-2
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU03733.(Parking)
The steering is locked, and the tail-
light, license light and auxiliary light
are on, but all other electrical sys-
tems are off. The key can be
removed.
To turn the main switch to “
.”:
1. Turn the key to “LOCK”.
2. Slightly turn the key counter-
clockwise until it stops.
3. While still turning the key coun-
terclockwise, push it in until it
snaps into place.
ECA00043
cC
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
If the engine oil is changed before the
oil change indicator light comes on
(i.e. before the periodic oil change
interval has been reached), the indi-
cator light must be reset after the oil
change for the next periodic oil
change to be indicated at the correct
time. (See page 6-15 for the resetting
procedure.)
The electrical circuit of the indicator
light can be checked according to the
following procedure.
1. Set the engine stop switch to “#”
and turn the key to “ON”.
2. Check that the indicator comes
on for a few seconds and then
goes off.
3. If the indicator light does not
come on, have a Yamaha dealer
check the electrical circuit.
EAU00056
Indicator lightsIndicator lights
EAU03797
Oil change indicator light “7”Oil change indicator light
This indicator light comes on at the
initial 1,000 km, then at 5,000 km and
every 5,000 km thereafter to indicate
that the engine oil should be
changed.
After changing the engine oil, reset
the oil change indicator light. (See
page 6-15 for the resetting proce-
dure.)
1234
1. Oil change indicator light “7”
2. V-belt replacement indicator light “V-BELT”
3. High beam indicator light “&”
4. Turn signal indicator lights “4” and “6”
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3-3
NOTE:
The oil change indicator light may
flash when the engine is revved with
the scooter on the centerstand, but
this does not indicate a malfunction.
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU04424
V-belt replacement indicator light
“V-BELT”
V-belt replacement indicator light
This indicator light comes on every
20,000 km when the V-belt needs to
be replaced.
The electrical circuit of the indicator
light can be checked according to the
following procedure.
1. Turn the key to “ON” and make
sure that the engine stop switch
is set to “#”.
2. If the indicator light does not
come on, have a Yamaha dealer
check the electrical circuit.
1234
1. Oil change indicator light “7”
2. V-belt replacement indicator light “V-BELT”
3. High beam indicator light “&”
4. Turn signal indicator lights “4” and “6”
EAU00063
High beam indicator light “&”High beam indicator light
This indicator light comes on when
the high beam of the headlight is
switched on.
EAU04121
Turn signal indicator lights “4”
and “6”
Turn signal indicator lights
The corresponding indicator light
flashes when the turn signal switch is
pushed to the left or right.
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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03685
Periodic maintenance and lubrication chartPeriodic maintenance and lubrication chart
NOTE:
8 8
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line•Check fuel hoses and vacuum hose for cracks or damage.√√√√ √
2
*Fuel filter•Check condition.√√
3 Spark plugs•Check condition.
•Clean and regap.√√
•Replace.√√
4
*Valves•Check valve clearance.
•Adjust.Every 40,000 km
5 Air filter element•Clean.√√
•Replace.√√
6
*V-belt case air filter
elements•Clean.√√
•Replace.√√
7
*Front brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
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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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8-2
SPECIFICATIONS
8
Radiator capacity
(including all routes)1.5 L
Air filterDry element
Fuel
Type REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity 14 L
Carburetor
Manufacturer MIKUNI
Model × quantity BS30 × 2
Spark plug
Manufacturer/model × quantity NGK/CR7E × 2
Spark plug gap 0.7–0.8 mm
Clutch typeWet, multiple-disc automatic
Transmission
Primary reduction system Helical gear/spur gear
Primary reduction ratio 52/32 ×36/22 (2.659)
Secondary reduction system Chain drive
Secondary reduction ratio 41/25 ×40/29 (2.262)
Transmission type V-belt automatic
Operation Centrifugal automatic typeChassis
Frame type Diamond
Caster angle 28°
Trail 95 mm
Tires
Front
Type Tubeless
Size 120/70-14M/C 55S
Manufacturer/ DUNLOP/D305FA
model BRIDGESTONE/HOOP B03
Rear
Type Tubeless
Size 150/70-14M/C 66S
Manufacturer/ DUNLOP/D305
model BRIDGESTONE/HOOP B02
Maximum load* 183 kg
Air pressure (cold tire)
up to 90 kg load*
Front200 kPa (2.00 kgf/cm
2, 2.00 bar)
Rear 225 kPa (2.25 kgf/cm
2, 2.25 bar)
90 kg load–maximum
load*
Front225 kPa (2.25 kgf/cm
2, 2.25 bar)
Rear 250 kPa (2.50 kgf/cm
2, 2.50 bar)
* Total weight of rider, passenger, cargo and accessories
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