2003 YAMAHA TMAX oil level

2-1
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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4-1
EAU01114
PRE-OPERATION CHECKS
4The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
Pre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-4,3-9–3-11
Engine oil•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-12–6-15
Coolant•Check coolant level in reservoir.
•If necessary, add recommended coolant to specified level.
•Check cooling system for leakage.6-17–6-18
Front brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-9, 6-25–6-28
Rear brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-9, 6-25–6-28
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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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6-4
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
1 10203040
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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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6-12
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
EAU04621
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.
ECA00081
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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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6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
64. If the engine oil is below the min-
imum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
2
1
3
1. Maximum level mark
2. Minimum level mark
3. Engine oil drain bolt
4. Remove the oil filter cartridge
with an oil filter wrench.
NOTE:
An oil filter wrench is available at a
Yamaha dealer.
5. Apply a thin coat of engine oil to
the O-ring of the new oil filter
cartridge.
NOTE:
Make sure that the O-ring is properly
seated.
2
1
1. Oil filter wrench
2. Oil filter cartridge
To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the
engine to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil
from the crankcase.
NOTE:
Skip steps 4–6 if the oil filter cartridge
is not being replaced.
1
1. Engine oil filler cap
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6-14
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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cC
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
5GJ-28199-E2 9/9/02 9:15 AM Page 57