2003 YAMAHA TMAX checking oil

PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ......................................................6-1
Periodic maintenance and lubrication chart ...........6-3
Removing and installing cowlings and panels .......6-6
Checking the spark plugs ......................................6-9
Engine oil and oil filter cartridge ...........................6-12
Chain drive oil ......................................................6-15
Coolant ................................................................6-17
Cleaning the air filter element ..............................6-19
Adjusting the carburetors .....................................6-21
Adjusting the engine idling speed ........................6-21
Adjusting the throttle cable free play ....................6-22
Adjusting the valve clearance ..............................6-22
Tires .....................................................................6-23
Cast wheels .........................................................6-25
Front and rear brake levers .................................6-25
Checking the front and rear brake pads ..............6-26
Checking the brake fluid level ..............................6-27
Changing the brake fluid ......................................6-28
Checking and lubricating the throttle grip
and cable ...........................................................6-29
Lubricating the front and rear brake levers ..........6-29
Checking and lubricating the centerstand and
sidestand ...........................................................6-29
Checking the front fork .........................................6-30Checking the steering ..........................................6-31
Checking the wheel bearings ...............................6-31
Battery .................................................................6-32
Replacing the fuses .............................................6-34
Replacing a headlight bulb ..................................6-35
Troubleshooting ...................................................6-36
Troubleshooting charts ........................................6-37
6
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6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
6 5. Place the spark plug cover in the
original position as shown, and
then install the cowling.
1
1. Spark plug cover
2. Start the engine, warm it up for
two minutes, and then turn it off.
3. Wait two minutes until the oil set-
tles, and then check the oil level
through the check window locat-
ed at the bottom-left side of the
crankcase.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
1
32
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
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Engine oil and oil filter
cartridge
Engine oil and oil filter cartridge
The engine oil level should be
checked before each ride. In addition,
the oil must be changed and the oil
filter cartridge replaced at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
To check the engine oil level
1. Place the scooter on the center-
stand.
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The engine must be cold before
proceeding with the oil level
check, otherwise the check will
result in a false reading.
NOTE:
Make sure that the scooter is posi-
tioned straight up when checking the
oil level. A slight tilt to the side can
result in a false reading.
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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
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8
8
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of
a higher quality than specified.
In addition, do not use oils
labeled “ENERGY CONSERV-
ING
II” or higher.
8 8
Make 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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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
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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
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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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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w
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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INDEX
F
Front and rear brake levers ..................6-25
Front and rear brake pads, checking ....6-26
Front fork, checking ..............................6-30
Fuel ......................................................3-10
Fuel consumption, tips for reducing .......5-3
Fuel gauge .............................................3-4
Fuel tank cap ..........................................3-9
Fuses, replacing ...................................6-34
H
Handlebar switches ................................3-6
Dimmer switch .....................................3-6
Engine stop switch ...............................3-7
Hazard switch ......................................3-7
Horn switch ..........................................3-7
Pass switch ..........................................3-6
Start switch ..........................................3-7
Turn signal switch ................................3-7
Headlight bulb, replacing ......................6-35
Headlight variations ................................3-8
Helmet holder .......................................3-13
I
Identification numbers ............................9-1
Ignition circuit cut-off system ................3-15
Indicator lights ........................................3-2
High beam indicator light .....................3-3
Oil change indicator light .....................3-2
Turn signal indicator lights ...................3-3
V-belt replacement indicator light ........3-3K
Key identification number .......................9-1
M
Main switch/steering lock .......................3-1
Model label .............................................9-2
P
Parking ...................................................5-4
Part locations ..........................................2-1
Periodic maintenance and lubrication
chart .....................................................6-3
Pre-operation check list ..........................4-1
R
Rider backrest, adjusting ......................3-12
S
Safe-riding points ...................................1-2
Seat ......................................................3-11
Self-diagnosis device .............................3-6
Sidestand .............................................3-14
Spark plugs, checking ............................6-9
Specifications .........................................8-1
Speedometer unit ...................................3-4
Starting off ..............................................5-2
Starting the engine .................................5-1
Steering, checking ................................6-31
Storage ...................................................7-4
Storage compartments .........................3-14A
Acceleration and deceleration ................5-2
Air filter element, cleaning ....................6-19
Anti-theft alarm (optional) .......................3-6
B
Battery ..................................................6-32
Brake fluid level, checking ....................6-27
Brake fluid, changing ............................6-28
Brake lever, front ....................................3-9
Brake lever, rear .....................................3-9
Brake levers, lubricating .......................6-29
Braking ...................................................5-3
C
Carburetors, adjusting ..........................6-21
Care ........................................................7-1
Centerstand and sidestand, checking and
lubricating ..........................................6-29
Chain drive oil .......................................6-15
Clock ......................................................3-5
Conversion table ....................................8-5
Coolant ..................................................6-17
Coolant temperature gauge ....................3-5
Cowlings and panels, removing and
installing ...............................................6-6
E
Engine break-in ......................................5-4
Engine idling speed ..............................6-21
Engine oil and oil filter cartridge ...........6-12
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