check engine YAMAHA TMAX 2005 User Guide

OPERATION AND IMPORTANT RIDING POINTS
5-2
2
3
4
56
7
8
9
CAUTION:

ECA11040
For maximum engine life, never ac-
celerate hard when the engine is
cold!
EAU16760
Starting off
NOTE:

Before starting off, allow the engine to
warm up.
1. While pulling the rear brake lever
with your left hand and holding the
grab bar with your right hand, push
the scooter off the centerstand.
2. Sit astride the seat, and then ad-
just the rear view mirrors.
3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip (on
the right) in order to take off.
5. Switch the turn signal off.
EAU16780
Acceleration and deceleration
The speed can be adjusted by opening
and closing the throttle. To increase the
speed, turn the throttle grip in direction
(a). To reduce the speed, turn the throt-
tle grip in direction (b).
1. Grab bar1
(a)(b)

OPERATION AND IMPORTANT RIDING POINTS
5-4
2
3
4
56
7
8
9

EAU16820
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Avoid high engine speeds during
acceleration.

Avoid high engine speeds with no
load on the engine.

Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU36530
0–1000 km (0–600 mi)
Avoid prolonged operation above
4000 r/min.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above
6000 r/min.
CAUTION:

ECA11281
After 1000 km (600 mi) of operation,the engine oil must be changed, and
the oil filter cartridge or element re-
placed.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
CAUTION:

ECA10310

Keep the engine speed out of
the tachometer red zone.

If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.

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

10

*
Brake hoses

Check for cracks or damage.
√√√√ √

Replace. Every 4 years
11

*
Wheels

Check runout and for damage.
√√√√
12

*
Tires

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
√√√√ √
13

*
Wheel bearings

Check bearing for looseness or damage.
√√√√
14

*
Steering bearings

Check bearing play and steering for roughness.
√√√√√

Lubricate with lithium-soap-based grease. Every 20000 km
15

*
Chassis fasteners

Make sure that all nuts, bolts and screws are properly
tightened.
√√√√ √
16

Sidestand, centerstand

Check operation.

Lubricate.
√√√√ √
17

*
Sidestand switch

Check operation.
√√√√√ √
18

*
Front fork

Check operation and for oil leakage.
√√√√
19

*
Shock absorber assem-
bly

Check operation and shock absorber for oil leakage.
√√√√
20

*
Electronic fuel injection

Adjust engine idling speed and synchronization.
√√√√√ √
21

Engine oil

Change. (See pages 3-5 and 6-10.)
√
When the oil change indicator flashes
(every 5000 km)

Check oil level and vehicle for oil leakage. Every 5000 km
√
22

Engine oil filter cartridge

Replace.
√√√
23

*
Cooling system

Check coolant level and vehicle for coolant leakage.
√√√√ √

Change. Every 3 years
24

Chain drive oil

Check vehicle for oil leakage.

Change.
√√√√
25

*
V-belt

Replace.When the V-belt replacement indicator flashes
(every 20000 km)
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040

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

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.
To check the spark plugs
1. Check that the porcelain insulatoraround 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.
1. Spark plug cover
1

1. Spark plug cap
1. Spark plug wrench
11

Specified spark plug:
NGK/CR7E

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
1
2
3
4
5
6
7
8
9
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.
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-
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
2
3
4
5
67
8
9
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.
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.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1
32

1. Engine oil filler cap
1

1. Engine oil drain bolt
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
1
2
3
4
5
6
7
8
9
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.
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
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
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)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
2
3
4
5
67
8
9
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 has
been 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.
EAU19993
Chain drive oil
The chain drive oil should be changed
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Remove panel F. (See page 6-6.)
2. Place an oil pan under the chain
drive case to collect the used oil.
3. Remove the oil filler cap and drain
bolt to drain the oil from the chain
drive case.
4. Install the chain drive oil drain bolt,
and then tighten it to the specified
torque.
1. “OIL CHANGE” button
1

1. Chain drive oil filler cap
2. Chain drive oil drain bolt
1
2

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
2
3
4
5
67
8
9

EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU20122
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:


The coolant level must be checked
on a cold engine since the level
varies with engine temperature.

Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Remove the coolant reservoir cov-
er by removing the screw.3. Check the coolant level in the cool-
ant reservoir.
NOTE:

The coolant should be between the
minimum and maximum level marks.4. If the coolant is at or below the
minimum level mark, open the res-
ervoir cap, add coolant to the max-
imum level mark, and then close
the reservoir cap.
1. Coolant reservoir cover
2. Screw
1
2
1. Maximum level mark
2. Minimum level mark
12

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
1
2
3
4
5
6
7
8
9
CAUTION:

ECA10470

If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.

If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protectedagainst frost and corrosion.

If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
WARNING

EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
5. Install the coolant reservoir cover
by installing the screw.
NOTE:


The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.

If the engine overheats, see page
6-33 for further instructions.
EAU21120
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove cowling A. (See
page 6-6.)
2. Remove the windshield by remov-
ing the screws.
3. Remove the air filter case cover by
removing the screws, and then pull
the air filter element out.
1. Coolant reservoir cap
Coolant reservoir capacity (up to the
maximum level mark):
0.35 L (0.37 US qt) (0.31 Imp.qt)
1

1. Screw
1
1(×5)