2006 YAMAHA TMAX Owners Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
2
3
4
5
67
8
9

EAU18712
Removing and installing
cowlings and panels
The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
a cowling or panel needs to be re-
moved and installed.
EAU33422
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 in-
stalling the nuts.
Cowling B
To remove the cowling1. Remove panels C and E. (See
page 6-7.)

1. Panel A
2. Panel B
3. Panel C
4. Cowling A
1
23
4
5

1. Panel D
2. Cowling B
3. Panel E
4. Cowling C
5. Panel F
4
3
1 2

1. Screw
2. Nut
2(×4)
1
2

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
1
2
3
4
5
6
7
8
9
2. Remove the cowling screws and
bolts.
3. Unhook the cowling from the hold-
er at the bottom.
4. Unhook the front of the cowling by
pushing it up, and then pull the
cowling out.
To install the cowling
1. Place the cowling in the original
position, and then install the
screws and bolts.2. Install panels C and E.
Cowling C
To remove the cowling
1. Remove the battery cover by re-
moving the screws.2. Remove the cowling bolts, and
then pull the cowling off.
To install the cowling
1. Place the cowling in the original
position, and then install the bolts.
2. Install the battery cover by install-
ing the screws.

EAU33431
Panels A and D
To remove one of the panels
1. Remove panel C (right side) or
panel E (left side).

1. Bolt
2. Screw
1(×2)2(×2)

1. Bolt
2. Screw
1
2

1. Screw
1(x6)
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
2
3
4
5
67
8
9
2. Remove the panel screws.
3. Pull outward on the front of the
panel.
To install the panel
Place the panel in the original position,
and then install the screws.
Panel B
To remove the panelRemove the panel screws, and then
pull outward on the areas shown.To install the panel
Place the panel in the original position,
and then install the screws.
Panels C and E
To remove one of the panelsPull the floorboard mat off, and then re-
move the panel screws.To install the panel
Place the panel in the original position,
install the screws, and then place the
floorboard mat back.
Panel F
To remove the panelRemove the panel screws.

1. Screw1
1

1. Screw
1(×4)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
1
2
3
4
5
6
7
8
9
To install the panel
Place the panel in the original position,
and then install the screws.

EAU19592
Checking the spark plugs
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 mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
To remove a spark plug
1. Remove cowling B. (See
page 6-6.)
2. Remove the spark plug cover by
pulling it out as shown.3. Remove the spark plug cap.
4. Remove the spark plug as shown
with the spark plug wrench includ-
ed in the owner’s tool kit.
1. Screw
1

1. Spark plug cover
1

1. Spark plug cap
1. Spark plug wrench
11

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
2
3
4
5
67
8
9 To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medi-
um-to-light tan (the ideal color
when the vehicle is ridden normal-
ly).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:

If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the vehicle.
3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-tion.
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:

If a torque wrench is not available wheninstalling 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 speci-
fied torque as soon as possible.
4. Install the spark plug cap.
5. Place the spark plug cover in the
original position as shown, and
then install the cowling.
Specified spark plug:
NGK/CR7E
1. Spark plug gap
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9 ft·lbf)
1

1. Spark plug cover
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
1
2
3
4
5
6
7
8
9

EAU19853
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 car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the vehicle on the center-
stand.
CAUTION:

ECA11290
The engine must be cold before pro-
ceeding with the oil level check, oth-
erwise the check will result in a false
reading.
NOTE:

Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
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 located
at the bottom-left side of the crank-
case.
NOTE:

The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
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.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1
32

1. Engine oil filler cap
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
2
3
4
5
67
8
9
NOTE:

Skip steps 4–6 if the oil filter cartridge is
not being replaced.
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 car-
tridge.
NOTE:

Make sure that the O-ring is properly
seated.
6. Install the new oil filter cartridge,
and then tighten it to the specified
torque with a torque wrench.7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
8. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
1. Engine oil drain bolt
1

1. Oil filter wrench
2. Oil filter cartridge
2
1

1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12.3 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31.1 ft·lbf)
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
1
2
3
4
5
6
7
8
9
CAUTION:

ECA11620

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 speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Make sure that no foreign mate-
rial 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, im-
mediately 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.
11. Reset the oil change indicator ac-
cording to the following procedure.
To reset the oil change indicator
1. Turn the key to “ON”.
2. Hold the “OIL CHANGE” button
pushed for two to eight seconds.
3. Release the “OIL CHANGE” but-
ton, and the oil change indicator
will go off.
NOTE:

If the engine oil is changed before the
oil change indicator comes on (i.e. be-
fore the periodic oil change interval hasbeen reached), the indicator must be
reset after the oil change for the next
periodic oil change to be indicated at
the correct time. To reset the oil change
indicator before the periodic oil change
interval has been reached, follow the
above procedure, but note that the indi-
cator will come on for 1.4 seconds after
releasing the “OIL CHANGE” button,
otherwise repeat the procedure.
Recommended engine oil:
SAE 10W-30 or SAE 10W-40(API
SE, SF, SG or higher)
Oil quantity:
Without oil filter cartridge replace-
ment:
2.80 L (2.96 US qt) (2.46 Imp.qt)
With oil filter cartridge replacement:
2.90 L (3.07 US qt) (2.55 Imp.qt)
1. “OIL CHANGE” button
1