oil YAMAHA TMAX 2003 User Guide

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
5GJ-28199-E2 9/9/02 9:15 AM Page 56

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
ECA00133
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

6-15
PERIODIC MAINTENANCE AND MINOR REPAIR
6To reset the oil change indicator
light
1. Turn the key to “ON”.
2. Hold the reset button pushed for
two to five seconds.
3. Release the reset button, and
the oil change indicator light will
go off.
1
1. Reset button “Oil Change”
EAU04253
Chain drive oilChain drive oil
The chain drive oil should be
changed as follows at the intervals
specified in the periodic maintenance
and lubrication chart.
1. Remove panel F. (See page 6-8
for panel removal and installation
procedures.)
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.
1
2
1. Chain drive oil filler cap
2. Chain drive oil drain bolt
NOTE:
If the engine oil is changed before the
oil change indicator light comes on
(i.e. before the periodic oil change
interval has been reached), the indi-
cator light 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
light before the periodic oil change
interval has been reached, follow the
above procedure, but note that the
indicator light will come on for
1.4 seconds after releasing the reset
button, otherwise repeat the proce-
dure.
5GJ-28199-E2 9/9/02 9:15 AM Page 58

6-16
PERIODIC MAINTENANCE AND MINOR REPAIR
6 4. Install the chain drive oil drain
bolt, and then tighten it to the
specified torque.
5. Add the specified amount of the
recommended oil.
6. Wipe the dipstick clean, insert it
into the oil filler hole (without
screwing it in), and then remove
it to check the oil level.
ECA00078
cC
Make sure that no foreign material
enters the chain drive case.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
7. 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.
8. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
1
2
1. Maximum level mark
2. Minimum level mark
Tightening torque:
Chain drive oil drain bolt:
20 Nm (2.0 m·kgf)
Recommended chain drive oil:
See page 8-1.
Oil quantity:
0.7 L
5GJ-28199-E2 9/9/02 9:15 AM Page 59

6-28
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
5GJ-28199-E2 9/9/02 9:15 AM Page 71

6-30
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
EW000115
w
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)
5GJ-28199-E2 9/9/02 9:15 AM Page 73

6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EW000119
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.
EAU03087
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.
EC000105
cC
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.
5GJ-28199-E2 9/9/02 9:15 AM Page 79

7-1
EAU03873
SCOOTER CARE AND STORAGE
7
CareCare
While the open design of a scooter
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go
unnoticed on a car, however, it
detracts from the overall appearance
of a scooter. Frequent and proper
care does not only comply with the
terms of the warranty, but it will also
keep your scooter looking good,
extend its life and optimize its perfor-
mance.Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and cov-
ers as well as all electrical cou-
plers and connectors, including
the spark plug cap, are tightly
installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such
products onto seals, gaskets and
wheel axles. Always rinse the dirt
and degreaser off with water.CleaningECA00011
cC
8
8
Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If such prod-
ucts are used on hard-to-
remove dirt, do not leave the
cleaner on the affected area
any longer than instructed.
Also, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection spray.
8 8
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent
and water to clean plastic.
5GJ-28199-E2 9/9/02 9:15 AM Page 84

7-3
SCOOTER CARE AND STORAGE
7After cleaning
1. Dry the scooter with a chamois
or an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, includ-
ing chrome- and nickel-plated,
surfaces.
4. Use spray oil as a universal
cleaner to remove any remaining
dirt.
5. Touch up minor paint damage
caused by stones, etc.6. Wax all painted surfaces.
7. Let the scooter dry completely
before storing or covering it.
EWA00002
w
8 8
Make sure that there is no oil
or wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
8 8
Before operating the scooter
test its braking performance
and cornering behavior.
ECA00013
cC
8
8
Apply spray oil and wax spar-
ingly and make sure to wipe
off any excess.
8 8
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
8 8
Avoid using abrasive polish-
ing compounds as they will
wear away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
5GJ-28199-E2 9/9/02 9:15 AM Page 86

7-4
SCOOTER CARE AND STORAGE
7
Storage
Storage
Short-term
Always store your scooter in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00015
cC
8
8
Storing the scooter in a poorly
ventilated room or covering it
with a tarp, while it is still wet,
will allow water and humidity
to seep in and cause rust.
8 8
To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your scooter for sever-
al months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Drain the carburetor float cham-
bers by loosening the drain bolts;
this will prevent fuel deposits
from building up. Pour the
drained fuel into the fuel tank.
3. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
4. Perform the following steps to
protect the cylinders, piston
rings, etc. from corrosion.a. Remove the spark plug caps
and the spark plugs.
b. Pour a teaspoonful of engine
oil into the spark plug bores.
c. Install the spark plug caps
onto the spark plugs, and then
place the spark plugs on the
cylinder head so that the elec-
trodes are grounded. (This will
limit sparking during the next
step.)
d. Turn the engine over several
times with the starter. (This
will coat the cylinder walls with
oil.)
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
EWA00003
w
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turn-
ing the engine over.
5GJ-28199-E2 9/9/02 9:15 AM Page 87