YAMAHA TMAX 2003 Manual PDF

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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03938
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear
without having to disassemble the
brake. To check the brake pad wear,
check the wear indicator grooves. If a
brake pad has worn to the point that
the wear indicator grooves have
almost disappeared, have a Yamaha
dealer replace the brake pads as a
set.
1 11 1
1. Brake pad wear indicator groove (×3)
EAU00721
Checking the front and rear
brake pads
Front and rear brake pads, checking
The front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.
REARFRONT
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Rear brake pads
1. Remove the rear brake caliper
by removing the bolts.
2. Check each rear brake pad for
damage and measure the lining
thickness. If a brake pad is dam-
aged or if the lining thickness is
less than 0.8 mm, have a
Yamaha dealer replace the
brake pads as a set.
3. Install the rear brake caliper by
installing the bolts, then tighten-
ing them to the specified torque.
a1
1. Bolt (×2)
a. Brake pad wear limit
EAU04856
Checking the brake fluid
level
Brake fluid level, checking
Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low
brake fluid level may indicate worn
brake pads and/or brake system
leakage. If the brake fluid level is low,
be sure to check the brake pads for
wear and the brake system for leak-
age.
1
1. Minimum level mark
REARFRONTTightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf)
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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
EAU03976
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
EAU04034
Checking and lubricating the
throttle grip and cable
Throttle grip and cable, checking and lubricating
The operation of the throttle grip
should be checked before each ride.
In addition, the cable should be lubri-
cated or replaced at the intervals
specified in the periodic maintenance
chart.
EAU03371
Checking and lubricating the
centerstand and sidestand
Centerstand and sidestand, checking and lubricating
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-
to-metal contact surfaces should be
lubricated if necessary.
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If the centerstand or sidestand
does not move up and down
smoothly, have a Yamaha dealer
check or repair it.
EAU03118
Lubricating the front and
rear brake levers
Brake levers, lubricating
The pivoting points of the front and
rear brake levers must be lubricated
at the intervals specified in the peri-
odic maintenance and lubrication
chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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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.
EC000098
cC
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU02939
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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6
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Checking the steeringSteering, checking
Worn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
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Securely support the scooter so
that there is no danger of it falling
over.
EAU01144
Checking the wheel bearingsWheel bearings, checking
The front and rear wheel bearings
must be checked at the intervals
specified in the periodic maintenance
and lubrication chart. If there is play
in the wheel hub or if the wheel does
not turn smoothly, have a Yamaha
dealer check the wheel bearings.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any
free play can be felt, have a
Yamaha dealer check or repair
the steering.
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BatteryBattery
This scooter is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There
is no need to check the electrolyte or
to add distilled water.
To charge the battery
Have a Yamaha dealer charge the
battery as soon as possible if it
seems to have discharged. Keep in
mind that the battery tends to dis-
charge more quickly if the scooter is
equipped with optional electrical
accessories.
1
1. Battery
To access the battery
1. Open the seat. (See page 3-11
for seat opening and closing pro-
cedures.)
2. Remove the battery cover by
removing the screws.
1
2
1. Screw (×3)
2. Battery cover
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6
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8 8
Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-
tact with skin, eyes or clothing
and always shield your eyes
when working near batteries.
In case of contact, administer
the following FIRST AID.
9EXTERNAL: Flush with plen-
ty of water.
9INTERNAL: Drink large quan-
tities of water or milk and
immediately call a physician.
9EYES: Flush with water for
15 minutes and seek prompt
medical attention.
8 8
Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes,
etc., away from the battery and
provide sufficient ventilation
when charging it in an
enclosed space.8 8
KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
To store the battery
1. If the scooter will not be used for
more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check it
at least once a month and fully
charge it if necessary.
3. Fully charge the battery before
installation.
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8
8
Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
8 8
To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is
required. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery charger, have a
Yamaha dealer charge your
battery.
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Replacing the fusesFuses, replacing
The main fuse box is located beside
the battery and can be accessed as
follows:
1. Open the seat. (See page 3-11
for seat opening and closing pro-
cedures.)
2. Remove the battery cover. (See
page 6-32 for battery cover
removal procedures.)
1
1. Battery
If a fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn
off the electrical circuit in ques-
tion.
2. Remove the blown fuse, and
then install a new fuse of the
specified amperage.
7
1
2
3
4
5
6
1. Signaling system fuse
2. Headlight fuse
3. Ignition fuse
4. Radiator fan fuse
5. Hazard fuse
6. Clock fuse (backup fuse)
7. Spare fuse (×2)
3. Disconnect the negative battery
lead, and then lift the battery as
shown.
The fuse box, which contains the
fuses for the individual circuits, is
located under the battery cover and
can be accessed as follows.
1. Open the seat. (See page 3-11
for seat opening and closing pro-
cedures.)
2. Remove the battery cover.
12
3
1. Negative battery lead
2. Main fuse box
3. Fuse box
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Do not use a fuse of a higher
amperage rating than recommend-
ed to avoid causing extensive
damage to the electrical system
and possibly a fire.
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.2. Unhook the headlight bulb holder
as shown, and then remove the
defective bulb.
a
1
1. Headlight bulb holder
a. Unhook.
EAU03874
Replacing a headlight bulbHeadlight bulb, replacing
This scooter is equipped with quartz
bulb headlights. If a headlight bulb
burns out, replace it as follows.
1. Disconnect the headlight cou-
pler, and then remove the head-
light bulb cover.
1
2
1. Headlight coupler
2. Headlight bulb cover
Specified fuses:
Main fuse: 30 A
Headlight fuse: 15 A
Signaling system fuse: 15 A
Ignition fuse: 10 A
Radiator fan fuse: 15 A
Hazard fuse: 10 A
Clock fuse (backup fuse): 10 A
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